Abstract: An electric motor having an armature which includes a coating of thermally conductive plastic applied in a conventional injection molding process. The armature also includes a fan which is integrally formed from the thermally conductive plastic applied to the armature. The process of molding thermally conductive plastic around the armature and integrally forming a fan at one end of the armature completely eliminates the need to apply one or more coatings of a trickle resin to the armature. It also eliminates the need to separately form a fan and to secure the separately formed fan by a suitable adhesive to the armature, which together significantly simplify and reduce the manufacturing cost of the armature. The thermally conductive molded plastic coating also better fills the spaces between the magnet wires around the armature, thus promoting even more efficient cooling of the armature during use and better holding of the magnet wires stationary relative to one another.

Abstract: The invention concerns a method for producing a hook commutator for an electric motor with a metal layer (7). The metal layer (7) is applied to only one broad side (4) of a metal band (3) in a first step, so that the metal layer (7) is located on at least one interior side of the hook (20). A hook commutator is then produced in further steps. Production defects such as metal projections, metal in the commutator slit and corrosion no longer occur during production.

Abstract: A cutter mounting bar (18) is attached between both left and right side walls of an outer shield (16) in an armature winding apparatus to be swingably rotatable, and it is biased in a direction in which a movable blade (21) provided integrally with a tip end portion is away from an axis X by a compression spring (19). When an inner shield (15) is rotated, a cam surface presses an adjustment screw (23) outward to swing a cutter mounting bar (18) in a direction in which the movable blade (21) approaches the axis X. In this state, when an armature (1) is rotated and a wire (7) connecting a hook wire connection portion and a gripper (30) is inserted between the movable blade (21) and a backing blade (22) to advance the outer shield (16) rightward, the backing blade (22) abuts against a groove bottom surface of the inner shield (15) and stops, and only the movable blade (21) advances rightward and severs the wire (7) at a position close to the hook wire connection portion.

Abstract: A method of contouring a motor brush includes mounting a brush in a brush card and contouring the brush. The brushes are retracted and a contour wheel is placed proximate the brushes such that when the brushes are released, the brushes contact the contour wheel. The contour wheel includes an abrasive surface and when rotated the wheel wears-in the brushes. Accordingly, the brushes are worn-in to a commutator before the commutator is installed in the motor. Upon initial motor run, the contoured brushes allow the motor to run quieter than a motor without contoured brushes.

Abstract: A planar carbon segment commutator assembly made by forming an annular conductor substrate with an annular front projection extending integrally and axially from a front surface of the substrate. An annular carbon disk is formed on the conductor substrate by overmolding a carbon compound onto the front surface of the conductor substrate and around the annular front projection. The conductor substrate is mounted on an insulating hub. Electrically isolated, circumferentially-spaced commutator segments and corresponding mechanically interlocked conductor sections are formed by making radial cuts through the annular carbon disk and the metal substrate, respectively. According to one embodiment, each of the front projections has a greater cross-sectional area at a distal end than at a base end to mechanically lock the commutator segments onto the conductor sections.

Abstract: A dynamo-electric machine includes a commutator secured around a rotatable shaft and a plurality of carbon brushes placed in sliding contact with the commutator. The commutator has a sliding contact surface placed in sliding contact with the carbon brushes. The sliding contact surface of the commutator has a plurality of peaks and valleys that are substantially regularly and alternately arranged in both axial and circumferential directions of the commutator.

Abstract: A metallic ring 45 molded by punching a copper plate having hooks 43, etc., and a carbon member 46 are brazed to each other by a brazing material having a higher melting point than the temperature for connecting a coil to conductive members 52, that is, a brazing material containing, for example, nickel and chromium. Next, resin is filled up inside the metallic ring 45 and carbon member 46 to form a resin substrate 48. Next, slits 50 are formed at the metallic ring 45 and the carbon member 46 in the radial direction, so that generally fan-shaped segments 51 insulated from each other and conductive members 52 are formed. Next, a coil is connected to hooks 43 of the conductive members 52 by soldering, welding, etc.

Abstract: A process for fixing a rotor winding, which is hooked to connection lugs of commutator lamellas of a commutator in the vicinity between the connection lugs and winding heads that are embodied on the end face of the rotor body. In order to simplify the process, a shrink sleeve is placed over the commutator of the completed rotor and is slid onto the winding heads until the connection lugs and the connection wires of the rotor winding that extend to the connection lugs are covered. The mechanically fixed shrink sleeve is homogeneously heated with hot air while the rotor rotates so that after cooling, the shrink sleeve shrinks onto the connection lugs and connection wires as well as onto parts of the winding heads.

Abstract: A planar carbon segment commutator assembly made by forming an annular conductor substrate with an annular front projection extending integrally and axially from a front surface of the substrate. An annular carbon disk is formed on the conductor substrate by overmolding a carbon compound onto the front surface of the conductor substrate and around the annular front projection. The conductor substrate is mounted on an insulating hub. Electrically isolated, circumferentially-spaced commutator segments and corresponding mechanically interlocked conductor sections are formed by making radial cuts through the annular carbon disk and the metal substrate, respectively. According to one embodiment, each of the front projections has a greater cross-sectional area at a distal end than at a base end to mechanically lock the commutator segments onto the conductor sections.

Abstract: A combination brush retainer/spring assembly for use in a DC motor includes a retaining ring and a conical spring connected together as a single unit. The retaining ring portion is designed to fit in a center hole of a brush holder to retain a plurality of spring-loaded brushes against their spring bias so that an armature shaft and commutator can pass through the center hole without obstruction. When the commutator passes through the center hole, it pushes the retaining ring free, allowing the brushes to spring back toward the center hole to contact the commutator. The spring portion of the assembly has an end that engages with a ball bearing on the armature shaft with enough force to ensure that the armature shaft and ball bearing rotate at the same angular velocity and without slippage.

Abstract: A method of manufacturing a stator of a rotary electric machine is comprised of the following steps: providing a plurality of U-shaped basic conductor segments and a plurality of U-shaped connection conductor segments; forming the U-turn portions and straight portions into crossover portions, inserting the pair of straight portions of the basic and connection conductor segments into prescribed two slots of a stator core from one end thereof to extend from the other end, bending one of the pair of straight portions in the direction opposite to the other of the pair of extended straight portions so that the edges of straight portions extending from the prescribed slots can adjoin each other, connecting the adjoining edges to form a plurality of phase coils, and removing the U-turn portion of the connection conductor segments to form terminals of the phase coils.

Abstract: A rotor for a commutator machine, having a rotor shaft, a rotor body containing a rotor winding, and a commutator, which has an insulation material body non-rotatably supported on the rotor shaft and has a number of commutator lamellas that are disposed on the insulation material body. Connection lugs that are bent away from the commutator lamellas for connecting connection wires of the rotor winding, in order to use the advantageous ultrasonic torsion welding process to mechanically and electrically connect connection lugs and connection wires without changing the rotor geometry, the insulation material body, is axially supported against the end face of the rotor body oriented toward the end face.

Abstract: A small-sized motor includes an insulation holder (16) which is integrally molded from a synthetic resin. The insulation holder (16) includes a cover portion (13) for-covering the casing cover (5) from the outside thereof, and a pair of brush holders (12) which project from the cover portion (13) into the interior of the motor, while passing through cut portions formed in the casing cover (5). Each of the brush holder (12) supports a brush arm (17) and an input terminal (11) connected thereto. The brush arm (17) supports a brush (18). Bearings (3) and (6) for the shaft are respectively supported at the center of the bottom portion of the casing (2) and at the center of the casing cover (5). Thus, it becomes possible to realize stable bearing alignment and to provide insulation outside the motor to thereby enable attachment of an electrical element to the motor without use of any additional insulation means.

Abstract: In a wrapped ring manufacturing process for slip ring assemblies, the assembly is heated to expand a gap between ends of the slip ring. A conductive material is then used to fill the expanded gap, to assure compression of the conductive material and to eliminate cracks therein. The filled gap is electroplated with a precious metal to form a layer of material of uniform hardness, wear resistance, electrical conductivity and environmental resistance around the entire perimeter of the slip ring.

Abstract: In rotors for electric motors, it is usual to fix the commutator on the rotor shaft by a press fit. In the present invention, the rotor shaft, with the rotor core fixed thereon, is electrostatically coated with an epoxy layer on opposite portions of the rotor shaft and in the winding slots, and is then heated to the plasticizing and curing temperature of the epoxy. After that, by a sliding tool, the commutator, whose inner bore has a clearance fit relative to the rotor shaft, is slipped onto the rotor shaft in a terminal position, in the process the still-viscous epoxy is pushed backward and is deposited radially on a connecting end face, forming a bead, and penetrates the annular gap between the inner bore and the rotor shaft. Once the epoxy layer has cooled, the commutator is fixed against rotation and displacement on the rotor shaft. The rotor is suitable for electric motors of various types.

Abstract: The present invention advantageously provides a cost effective flat rotor for a pancake type slip ring. A flat copper coil sheet is stamped into a corrugated shape having concentric V-ring grooves. The corrugated stamped copper foil sheet is bonded using a bonding agent to a dielectric layer. Multiple concentric V-grooves are formed by separating the grooves, for example, by machining the grooves at an apex thereof in order to form separate electrical circuits. A corresponding plurality of holes extend through each concentric ring and through the dielectric layer from the first side through the second side. A conductive material is placed in each of the plurality of holes to electrically connect each concentric ring to the second side.

Abstract: Commutators for electro-dynamic machines such as electric motors comprise a cylindrical shell of insulated commutators bars, each of which has an outer layer with tangs extending from the outer layer and an inner layer with anchoring tabs extending therefrom. The commutating bars are typically produced from two strips of copper or other conductive metal. The inner layer may be formed of a thinner but stronger material, even of a non-conductive material, but is normally preferable to use two strips of copper to facilitate fusion of the materials together. The first strip, which is typically somewhat thicker than the second, is formed by punching so that partially formed tangs extend laterally from the side of the strip. The second strip is formed in a similar process to provide anchoring tabs extending from the sides of the second strip. These commutators can be produced economically and efficiently and can be adapted to a wide variety of applications and requirements.

Abstract: Addressed herein are commutators and methods of manufacturing them. The methods permit the carbonaceous material and core of a commutator to be molded simultaneously, rather than in a two-step process, and can eliminate one of two curing procedures used in connection with other manufacturing techniques. The necessity of machining the inner surface of the commutator shell to remove undesired excess phenolic or other material additionally is avoided by use of the techniques detailed herein. Commutators formed according to these methods may have increased useful lives and provide better performance than others presently available.

Abstract: A method is disclosed for manufacturing a commutator adapted to be mounted on a shaft of an electric motor for cooperation with electrical contacts of the motor, wherein a support member is molded from an electrically insulating material, the support member having a major outer surface portion divided into subsections of lesser area by a plurality of rib members extending upwardly from the outer surface portion. A sheet of electrically conductive material with minimum waste, is cut into commutator segments of predetermined shape and dimensions preferably by a stamping process for attachment to the outer surface portions of the subsections. The commutator segments are then adhesively attached to the outer surface portions of the subsections such that the segments form commutator surfaces interrupted by the rib members, with the upper surface of each segment being slightly higher than the upper surface of each of the adjacent rib members.

Abstract: The present invention advantageously provides a cost effective flat rotor for a pancake type slip ring. A flat copper coil sheet is stamped into a corrugated shape having concentric V-ring grooves. The corrugated stamped copper foil sheet is bonded using a bonding agent to a dielectric layer. Multiple concentric V-grooves are formed by separating the grooves, for example, by machining the grooves at an apex thereof in order to form separate electrical circuits. A corresponding plurality of holes extend through each concentric ring and through the dielectric layer from the first side through the second side. A conductive material is placed in each of the plurality of holes to electrically connect each concentric ring to the second side.

Abstract: The carbon commutator of the present invention comprises a plurality of segments having ends which are sliding members on a brush and the other ends to which conductive terminal members are attached, wherein the segments are arranged in a circumferential direction on an insulating boss member and are insulated from each other, carbon layers being formed on the sliding member sides of the segments, metal layers being formed between the carbon layers and the conductive terminal members by sintering a first material of a principal component of the conductive terminal member with a second material which can alloy with the first material.

Abstract: A method is disclosed for manufacturing a commutator adapted to be mounted on a shaft of an electric motor for cooperation with electrical contacts of the motor, wherein a support member is molded from an electrically insulating material, the support member having a major outer surface portion divided into subsections of lesser area by a plurality of rib members extending upwardly from the outer surface portion. A sheet of electrically conductive material with minimum waste, is cut into commutator segments of predetermined shape and dimensions preferably by a stamping process for attachment to the outer surface portions of the subsections. The commutator segments are then adhesively attached to the outer surface portions of the subsections such that the segments form commutator surfaces interrupted by the rib members, with the upper surface of each segment being slightly higher than the upper surface of each of the adjacent rib members.

Abstract: When a magnet cover 21 is press-fitted into the inner peripheral surfaces of magnets 18 annularly arranged on the inner peripheral surface of a hollow cylindrical yoke 11 having at an end thereof a closure wall 12, the magnets 18 are arranged peripherally at regular intervals on the outer peripheral surface of the magnet cover 21 that is supported by the lower die 34. The yoke 11 is held by the upper die 31 and arranged coaxially relative to the magnet cover 21 with open end 14 directed to the magnet cover 21. As the upper die 31 and the lower die 34 are closed relative to each other, the magnets 18 and the magnet cover 21 are press-fitted into the yoke 11 as the outer peripheral surfaces 19 of the magnets 18 are pressed by the inner peripheral surface of the yoke 11. Thus, the magnets 18 are rigidly secured to the yoke 11 without arranging a through hole in the closure wall 12 of the yoke.

Abstract: Through-holes 14 are formed in an armature core 11, and engaging portions 21 are formed in an commutator unit 15 at positions corresponding to the through-holes 14. Positioning pins 23 are inserted into the through-holes 14 and the engaging portion 21 to exactly position the armature core 11 to the commutator unit 15. The coil terminals are soldered to risers 18 in a state that the under side of the risers 18 are supported by the tips 35 of legs 36 standing erect on a support tool 34, inserted through the open slots 33.

Abstract: Disclosed are methods of making dynamoelectric machines which include use of two sheet metal cup-shaped members to form a housing that completely surrounds and encloses the stator. The stator is assembled with a can in such a manner that the core of the stator is completely contained within the can. Thereafter, a cap is positioned at the exposed face of the stator and the cap and can are joined together by a sheet metal fastening technique which displaces material from one superposed sheet into a second sheet of material. The can and cap are precision formed so that they will have precision sized and located bearing receivers and core retention regions. Both the cap and the can are provided with multiple flange locations which are utilized for fastening the can and cap together during the assembly process.

Abstract: A method for manufacturing a commutator adapted to be mounted on a shaft of an electric motor for cooperation with electrical contacts of the motor, wherein a support member is molded from an electrically insulating material, the support member having a major outer surface portion divided into subsections of lesser area by a plurality of rib members extending upwardly from the outer surface portion. A sheet of electrically conductive material with minimum waste, is cut into commutator segments of predetermined shape and dimensions preferably by a stamping process for attachment to the outer surface portions of the subsections. The commutator segments are then adhesively attached to the outer surface portions of the subsections such that the segments form commutator surfaces interrupted by the rib members, with the upper surface of each segment being slightly higher than the upper surface of each of the adjacent rib members.

Abstract: An electric motor according to the principles of the present invention includes a stator or stationary part of the motor and an armature. The armature includes a shaft having a rotation axis and a commutator subassembly fixed symmetrically to the shaft that includes an insulating body surrounding the shaft and a plurality of circumferentially spaced, carbon-based material segments surrounding the shaft. The carbon segments are held to the body and each segment has a brush contacting surface. An equal plurality of metallic commutator members have at least a part located and molded within the corresponding carbon segment for providing good mechanical and electrical connection between the carbon segment and metallic commutator member and to isolate the metallic part within the carbon segment from harmful external environments such as described above.

Abstract: In a production method of a rotor, a lower layer slot insulator is held at a slot insulator holding portion of a combining jig. A lower layer coil bar is inserted into a coil inserting path of the combining jig and is combined integrally with the lower layer slot insulator by being pushed together. Thereafter, the combined set is set in a coil integrating path of a coil holding member. The coil holding member is attached to a coil inserting device along with an armature core. The lower layer slot insulator and a lower coil trunk are integrally inserted into a slot of the armature core by pushing the lower layer coil bar in the coil integrating path. The lower layer coil trunk and an upper layer coil trunk may be formed integrally with respective coil arms as a single coil bar.

Abstract: A winding apparatus comprises a core jig having a circular outer circumference, plate-shaped stator core jigs designed to have a shape corresponding to stator cores, and holding jigs to be detachably installed to the outer circumference of the core jig for holding the stator core jigs. Accordingly, the plurality of divided stator cores can be subjected to winding quickly and easily. It is possible to perform an efficient winding operation.

Abstract: The lead portions have oval cross sections such that the dimensions of the cross sections of the lead portions parallel to the circumference of the armature are smaller than those of the straight portions parallel to the circumference of the armature are. Preferably, the cross-sectional area of the lead portions may be substantially equal to that of the straight portions. The lead portions may have circular cross sections such that the cross-sectional diameter of the lead portions is smaller than that of the straight portions. The method of manufacture for an armature coil conductor comprises the steps of working, which may be ironing preferably, the ends of the straight portions so that the lead portions have oval cross sections.

Abstract: A process for manufacturing collectors, in particular flat collectors for electric machines. The individual connection elements (2) are at first directly shaped by crowding in a substantially non-machined raw conductive material (1) with their final contour and size and in their final ductile state. For that purpose, a warm forming process is used. The raw material (1) is warmed before the connection elements (2) are formed so that it does not significantly consolidate while the connection elements (2) are formed by crowding, and forming is then carried out in the warm state. In addition, a pot-shaped blank (3) may be shaped, preferably in a cold forming step, for example with inner shaped anchoring elements (6) for an insulating lining. Recesses (9) may be shaped by crowding on the cylindrical envelope (4) of the pot-shaped blank (3). These recesses are associated to the segment divisions and extend almost down to the bottom (5) of the pot-shaped blank (3).

Abstract: An electric motor of outer-rotor type includes: an inner stator mounted on a stator holder, an outer rotor rotatably circumferentially disposed around the inner stator, a shaft coaxially secured with the outer rotor, and a housing combined with the stator holder for encasing the outer rotor and the inner stator within the housing; with the inner stator including an annular core made of magnetic conductor, a plurality of fin arrays made of magnetic conductors and formed as a fin array assembly concentrically wrapped on the annular core, and a plurality of insulating coil bobbins each coil bobbin pre-wound with the coil windings thereon and jacketed on each fin array, thereby forming an inner stator having a stable construction, a higher winding capacity, higher magnetic flux density and higher output power, as well as a lower production cost.

Abstract: A combined armature and commutator assembly for an electric motor is disclosed wherein an armature core is formed of a plurality of laminate plate members defining a central opening and having armature windings wound around the armature core. A disc-shaped commutator is provided and adapted for contact by electrically conductive brushes of the motor for conducting electrical current to the armature windings. The commutator is positioned within the generally central opening of the armature and is attached to the armature core by an interference fit relation to rotatability support the armature core on a rotor shaft of the electric motor thereby transmitting all torque directly from the armature core to the commutator and thereby to the rotor shaft. The combined armature and commutator may be incorporated into a single speed or a multiple speed motor.

Abstract: Armature start and finish wires are trimmed after connection to their associated commutator tang by use of a knife edge carried by an otherwise conventional lead guide mechanism. The lead guide mechanism moves the knife edge into position against the coil lead, and the coil lead is drawn across the knife edge by pivotal movement of a wire gripper holding the lead. The knife edge preferably comprises a blade removably secured to a portion of the lead guide mechanism, but the knife edge may alternatively be formed, by machining for example, on a part of the lead guide mechanism itself.

Abstract: A commutator for a dynamo-electric machine according to the present invention comprises a cylindrical commutator main body provided with a plurality of commutator segments disposed around the circumference thereof, an equalizer assembly disposed inside the commutator main body provided with equalizer segments electrically connecting commutator segments which are to have the same electric potential, and an insulating resin portion disposed within the space inside the commutator main body integrating the commutator main body and the equalizer assembly.

Abstract: These and other objects of the present invention are achieved by inserting electrically conductive rings and a bearing into a mold before a slip ring body is injection molded. During the injection molding process, the rings and the bearing are partially encapsulated by the injected plastic and retained. Plastic is prevented from entering the race of the bearing by using a pair of additional plastic inserts which prevent plastic from entering the bearing race. When the injected plastic cools, the plastic shrinks and compresses the bearing thereby preventing axial movement. Wires attached to the rings are also encapsulated by the plastic material during the injection molding process.

Abstract: An apparatus for producing magnetically-permeable cores for use in electromechanical machines, such as electric motors. The apparatus includes a plurality of welding arbors adapted to support a stack of core laminations. A storage structure defines a plurality of arbor storage locations at which respective welding arbors are maintained. A transporter device is operative to individually move the welding arbors to and from a respective arbor storage location. A welding device is operative to weld the stack of core laminations together. A conveyor assembly is also provided for moving the welding arbors between the welding device and the transporter device.

Abstract: A dynamo-electric machine comprises: a shaft; a core secured to the shaft having slots formed therein extending in the axial direction; a winding composed of a wire or wires wound by a lap winding method through the slots; a commutator having commutator segments being disposed at one end of the core and secured to the shaft; and equalizing connectors electrically connecting commutator segments which should have the same electric potential; wherein one end portion of each of the equalizing connectors is connected to one of the commutator segments and the other end portion of each of the equalizing connectors passes through the slots and is connected to the other of the commutator segments.

Abstract: A method of manufacturing a flat commutator comprising the steps of providing a support member having segment carrier parts; forming identical grooves in one side of said support member extending radially from the center of the support member, moulding a hub around the grooved support member with moulding compound entering the grooves; reducing the thickness of the support member from the ungrooved or abutment side of the support member until the support member is divided into a plurality of electrically isolated segment carrier parts with the moulding compound exposed in each groove; bonding an annular disc of carbon to the segment carrier parts and dividing said disc into a plurality of commutator segments.

Abstract: For producing a collector ring arrangement with a low radial thickness, a longitudinal portion of a shaft is coated with an insulating layer, than an electrically conductive layer is applied on the insulating layer, and the collector ring is fitted on the electrically conductive layer so as to be connected with the latter in an electrically conductive manner, for example by soldering. The length of the electrically conductive layer can be smaller than the length of the insulating layer. The process and the new collector ring arrangement reduce the material and time consumption during the manufacture and/or use the collector ring arrangement.

Abstract: An electric motor according to the principles of the present invention includes a stator or stationary part of the motor and an armature. The armature includes a shaft having a rotation axis and a commutator subassembly fixed symmetrically to the shaft that includes an insulating body surrounding the shaft and a plurality of circumferentially spaced, carbon-based material segments surrounding the shaft. The carbon segments are held to the body and each segment has a brush contacting surface. An equal plurality of metallic commutator members have at least a part located and molded within the corresponding carbon segment for providing good mechanical and electrical connection between the carbon segment and metallic commutator member and to isolate the metallic part within the carbon segment from harmful external environments such as described above.

Abstract: The process comprises forming a tube (1) of an electrically conductive material having on its inner surface axial grooves (2) and axial projecting portions (3) between the latter, injecting a hardenable insulating material (4) into the tube (1) so as to fill the latter, this material penetrating the grooves and surrounding the projecting portions, and removing the outer portion of the tube (1) after the hardening of the insulating material so as to reveal the insulating material of the grooves (2) and form between the latter commutator segments which are insulated from one another. The tube (1) is formed by the extrusion of two complementary half-tube shells (1a, 1b) and the assembly of the latter one against the other on an axial joint plane (A--A).

Abstract: A pallet and system for transporting armatures along an armature manufacturing line, where the armatures may change in configuration at different stations of the manufacturing line, accommodates the various configurations without requiring a change of pallets at a station at which a configuration change occurs. The pallet has multiple sets of seats, each set corresponding to one of the configurations that the armature may assume during processing. Whenever the configuration of the armature changes from a first configuration to a second configuration, the armature, having been removed from a set of seats that accommodates the first configuration, is replaced in a set of seats accommodating the second configuration. One way of accomplishing the transfer is, after lifting the armature from the first set of seats, allowing the pallet to advance by the distance separating the first and second sets of seats.

Abstract: A flat commutator for an electric motor of a vehicle fuel pump. The commutator, is made with a one-piece carbon ring having a flat outer face, a one-piece conductor ring underlying the outer face of and embedded in the carbon ring, and a housing of a plastic insulating material molded on the rear face and the inner and outer edges of the carbon ring and adapted to mount the commutator on a motor armature. A plurality of circumferentially spaced apart grooves extend radially and axially completely through both the carbon ring and the conductor ring to provide a plurality of individual sintered carbon segments each with a separate conductor for electrically connecting the segments with armature coils.

Abstract: In a plane carbon commutator which is formed by fixing a plurality of metal segments to a commutator main body made of a resin and by integrally fixing a carbon to each of these segments, engagement projections provided in the carbon are engaged with engagement holes provided in the segments for a mutually fixed integration. Accordingly, it is possible to effectively utilize the characteristics of the carbon which has been burned at a high temperature in advance.

Abstract: A carbon-segment face commutator assembly for an electric motor includes an annular array of copper conductor sections stamped from a single copper blank. The annular array is overmolded with an electrical-conducting resin-bonded carbon composition which mechanically interlocks the conductor sections and defines a circular commutating surface. During overmolding, radial grooves are formed in a bottom surface of the carbon overmold opposite the commutating surface. An annular hub is then formed by overmolding an insulator material around and under the carbon overmold and the conductor section array. The hub insulator material flows into the radial grooves of the carbon overmold and leaves only the circular commutating surface exposed. The carbon overmold is formed into an annular array of eight electrically-isolated carbon segments by machining radial slots inward from the commutating surface of the carbon overmold to the underlying radial grooves.

Abstract: A method of manufacturing a flat, composite ("pancake") slip ring is described. An assembly of slip rings of conductive material are formed by photo etching or the like into a plurality of annular, concentric conductive rings, the inner and outer diameters of the rings being connected by alignment tabs. A surface of the rings may be masked prior to plating a precious metal on the opposing surface. The slip ring assembly is aligned with the base and bonded to it prior to removing the alignment tabs.

Abstract: A direct current (DC) brushless motor for automotive and HVAC applications utilizes a single angular contact bearing assembly to rotatably couple an exterior rotor to an interior stator. The single angular contact bearing assembly can be a double horizontal row ball bearing, a four point contact bearing, and a crossed cylindrical roller bearing. The rotor is staked to the bearing assembly by a hub-shaft. A cooling fan is disposed on the top of the rotor to cool internal control circuitry within the motor. The stator includes a winding set connector which is slideably engaged within a cavity of a deep draw support member.

Abstract: Carbon segments (7) of a planar commutator are molded over contact members (5). Anchor means (8), integral with each carbon segment (7) have an interlocking part (11) engaging the rear surface (6) of the contact member (5) and fit into a first blind hole (4) in the form of a recess of uniform transverse cross-section extending rearwardly of the front end (3) of a molded plastic base member (1). The contact members (5) are each attached to the base member (1) by means of locking portions (15) which project into second blind holes (14) having internal surfaces which grip the locking portions (15).

Abstract: A method of making a carbon commutator is provided. The method includes the steps of providing a planar substrate having a series of current-carrying regions; providing a carbon base having a brush-contacting surface and a second opposite surface; substantially covering the second surface of the carbon base with a conductive plating to form an unslotted commutator body; applying a conductive bonding layer to the conductive plating; bonding the unslotted commutator body to the substrate; and cutting corresponding slots in the commutator body to form a series of commutator segments.