Abstract: A commutator is formed by providing an electrically insulating commutator body. First and second areas are defined on the commutator body covering a brush contact surface in an alternating manner. At least the surfaces of the first areas are formed of laser direct structured material. The first areas are treated by a laser to form metal particle layers. Conductive layers are formed on the metal particle layers by a plating process to form commutator segments. Terminals are connected to the conductive layers for connecting the commutator to rotor windings.

Abstract: A commutator includes a first body and a second body which are separately made of electrically insulating material, a plurality of commutator segments fixed on an outer surface of the first body and a plurality of commutator terminals. The first body is a hollow cylinder with two opposite ends. Each terminal has a contact area for contacting a corresponding one of the commutator segments. The second body has a base and a ring wall extending from the base, and one end of the first body is received in a space defined by the base and the ring wall, with the contact area of each terminal being in tight contact with the corresponding commutator segment at the inner side of the ring wall.

Abstract: A commutator (10, 40, 54, 60, 64, 70, 76, 78) for a brush motor includes a cylindrical insulating base (12), a plurality of segments (14) disposed on an outer surface (68) of the insulating base (12), circumferentially spaced from each other, and defining a plurality slots (42) between adjacent segments (14), and a plurality of insulating outgas elements (24) capable of releasing a gas having a lower conductivity than air and disposed on the outer surface (68) of the cylindrical insulating base (12). Each outgas element (24) is located between a corresponding pair of the plurality of segments (14), having a gas releasing surface (26) between the corresponding pair of segments (14) and lower than outer surfaces (28) of the corresponding pair of segments (14). A method for making a commutator is also provided.

Abstract: A commutator is formed by providing an electrically insulating commutator body. First and second areas are defined on the commutator body covering a brush contact surface in an alternating manner. At least the surfaces of the first areas are formed of laser direct structured material. The first areas are treated by a laser to form metal particle layers. Conductive layers are formed on the metal particle layers by a plating process to form commutator segments. Terminals are connected to the conductive layers for connecting the commutator to rotor windings.

Abstract: A commutator has a plurality of commutator segments fixed to an insulating support member. The commutator segments are formed by cold or hot forming a copper billet cut from a length of copper wire. Each billet has a volume approximately equal to the volume of one commutator segment. Each commutator segment has a main body and an anchor integrally formed with the main body. The commutator segments are spaced about a circle and then an insulating support member is molded to the commutator segments to fix the commutator segments to the support member.

Abstract: A commutator (10, 40, 54, 60, 64, 70, 76, 78) for a brush motor includes a cylindrical insulating base (12), a plurality of segments (14) disposed on an outer surface (68) of the insulating base (12), circumferentially spaced from each other, and defining a plurality slots (42) between adjacent segments (14), and a plurality of insulating outgas elements (24) capable of releasing a gas having a lower conductivity than air and disposed on the outer surface (68) of the cylindrical insulating base (12). Each outgas element (24) is located between a corresponding pair of the plurality of segments (14), having a gas releasing surface (26) between the corresponding pair of segments (14) and lower than outer surfaces (28) of the corresponding pair of segments (14). A method for making a commutator is also provided.

Abstract: A method of manufacturing a commutator. A connector plate is formed with a plurality of connectors arranged circumferentially about a central opening and interconnected by links, with each connector having a terminal portion, a segment portion and a number of anchors, with adjacent segment portions being separated circumferentially by slits. A conductive layer is fixed onto a first face of the segment portions to form a brush contacting surface. The connectors are separated by severing the links. The base is fixed to a second face of the connectors. Then the conductive layer is separated into circumferentially arranged segment parts by cutting radial slots through the conductive layer aligned with the slits, the width of the slots being narrower that the width of the slits to avoid cutting the connectors.

Abstract: A commutator includes a first body and a second body which are separately made of electrically insulating material, a plurality of commutator segments fixed on an outer surface of the first body and a plurality of commutator terminals. The first body is a hollow cylinder with two opposite ends. Each terminal has a contact area for contacting a corresponding one of the commutator segments. The second body has a base and a ring wall extending from the base, and one end of the first body is received in a space defined by the base and the ring wall, with the contact area of each terminal being in tight contact with the corresponding commutator segment at the inner side of the ring wall.

Abstract: A commutator has an electrically non-conductive base and a plurality of commutator segments fixed to the base. Each segment comprises an electrically conductive connector and a segment part, wherein the connector has a segment portion, a terminal portion and anchors all formed as a monolithic construction. The terminal and anchors extend from the segment portion at radial ends thereof. The anchors fix the connectors to the base by being embedded therein. The segment part is a part of an annular disc forming an electrically conductive brush-contacting layer fixed to a side of the segment portion remote from the base. The segment portions are circumferentially separated by slits into which the base extends and the segment parts are separated circumferentially by slots. The slots are aligned with the slits, are narrower than the slits and extend axially into the material of the base within the slits between adjacent connectors.

Abstract: A commutator has a plurality of commutator segments fixed to an insulating support member. The commutator segments are formed by cold or hot forming a copper billet cut from a length of copper wire. Each billet has a volume approximately equal to the volume of one commutator segment. Each commutator segment has a main body and an anchor integrally formed with the main body. The commutator segments are spaced about a circle and then an insulating support member is molded to the commutator segments to fix the commutator segments to the support member.

Abstract: A commutator has an electrically non-conductive base and a plurality of commutator segments fixed to the base. Each segment comprises an electrically conductive connector and a segment part, wherein the connector has a segment portion, a terminal portion and anchors all formed as a monolithic construction. The terminal and anchors extend from the segment portion at radial ends thereof. The anchors fix the connectors to the base by being embedded therein. The segment part is a part of an annular disc forming an electrically conductive brush-contacting layer fixed to a side of the segment portion remote from the base. The segment portions are circumferentially separated by slits into which the base extends and the segment parts are separated circumferentially by slots. The slots are aligned with the slits, are narrower than the slits and extend axially into the material of the base within the slits between adjacent connectors.

Abstract: A commutator comprises a commutator base of insulating material, a plurality of commutator terminals, each of which has a terminal portion and a contact portion, and a plurality of carbon segments formed on the base and over the contact portions, respectively, of the terminal. Each carbon segment has an inner portion of molded (unsintered) graphite material adjacent to the base and one or more outer exposed portions, containing or formed of sintered graphite.

Abstract: A commutator comprises a commutator base 10 of insulating material, a plurality of commutator terminals 20 each of which has a terminal portion 21 and a contact portion 22 and a plurality of carbon segments 30 formed on the base and over the contact portions, respectively, of the terminal. Each carbon segment has an inner portion 31 of molded graphite material adjacent to the base and one or more outer exposed portions 32 containing or formed of sintered graphite.