Abstract: A brush holder assembly for an electric motor and a method of making it. The assembly comprises a unitary structure formed of a molded plastic housing in which a stamped and formed metal circuit plate is encapsulated. Separate circuit strips are formed by punching circuit bridges out of the plate after it is encapsulated. The separate circuit strips are embedded in one face of a web spanning the housing. On the opposite face of the web, brush holder channels are molded. The separate circuit strips each have a terminal formed unitarily with them, the terminals being embedded in a socket extending radially, outward from the web through a skirt encircling the web.

Abstract: An injection molded housing for thick film ignition circuitry used in conjunction with automobile or other vehicle engines includes an integral lead frame for providing electrical connections between the circuitry and engine sensors and ignition components. To provide protection against lead frame failure as a result of vibration and thermal stresses encountered in the engine environment, residual stress cracking caused by varying flexure of the lead frame during the manufacturing process is prevented by utilizing a pre-mold base in which the lead frame is placed prior to subsequent encapsulating of both the lead frame and the pre-molded base. The result is a lead-frame housing construction of greater reliability.