Metal-carbonaceous brush and method of manufacturing the same

• US 10,199,789 B2
• Filed: 10/01/2014
• Issued: 02/05/2019
• Est. Priority Date: 10/02/2013
• Status: Active Grant

• Current Assignee: Totan Kako Co., Ltd. (TOYO Tanso Company Limited)
• Original Assignee: Totan Kako Co., Ltd. (TOYO Tanso Company Limited)
• Inventors: Hozumi, Fumihiro
• Primary Examiner(s): Desai, Naishadh
• Application Number:
  US15/026,784
• Publication Number:
  US 20160240989A1
• Time in Patent Office: 1,588 Days
• Field of Search: 310220-239
• CPC Class Codes: C04B 2235/3262 Manganese oxides, manganates, rhenium oxides or oxide-forming salts thereof, e.g. MnO
• CPC Class Codes: C04B 2235/407 Copper
• CPC Class Codes: C04B 2235/425 Graphite
• CPC Class Codes: C04B 2235/446 Sulfides, tellurides or selenides
• CPC Class Codes: C04B 2235/48 Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
• CPC Class Codes: C04B 2235/5436 micrometer sized, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/604 Pressing at temperatures other than sintering temperatures
• CPC Class Codes: C04B 35/522 Graphite C04B35/536 takes precedence
• CPC Class Codes: C04B 35/532 containing a carbonisable binder
• CPC Class Codes: C22C 1/05 Mixtures of metal powder with non-metallic powder C22C1/08 takes precedence
• CPC Class Codes: H01R 39/20 characterised by the material thereof
• CPC Class Codes: H01R 39/22 incorporating lubricating or polishing ingredient
• CPC Class Codes: H01R 39/26 Solid sliding contacts, e.g. carbon brush
• CPC Class Codes: H01R 43/12 Manufacture of brushes

Abstract

A carbonaceous material is fabricated by a mixture of carbon powder and a binder. 10% by weight or more and 60% by weight or less of metal powder to the fabricated carbonaceous material is mixed. The mixed carbonaceous material and metal powder are pressurized and formed. A brush base material is fabricated by burning of the pressurized and formed carbonaceous material and metal powder. The fabricated brush base material is impregnated with oil. An impregnation rate of the oil to the mixed carbonaceous material and metal powder may be 0.5% by weight or more, for example.

Claims

1. A metal-carbonaceous brush including:

a carbonaceous material made of a plurality of carbonaceous particles;

metal mixed with the carbonaceous material; and

oil with which the carbonaceous material is impregnated, wherein

a ratio of the metal mixed with the carbonaceous material to the carbonaceous material is 10% by weight or more and 60% by weight or less and the oil is a mixed oil of 90% by weight or more and 99% by weight or less of a petroleum hydrocarbon oil and 1 by weight or more and 10% by weight or less of a silicone oil, or the oil is a mixed oil of 90% by weight or more and 99.5°

/o by weight or less of the petroleum hydrocarbon oil and 0.5% by weight or more and 10% by weight or less of a dimethyl silicone oil.

2. The metal-carbonaceous brush according to claim 1, wherein

an impregnation rate of the oil to the mixed carbonaceous material and metal is 0.5% by weight or more.

3. The metal-carbonaceous brush according to claim 1, wherein

a decrease of an impregnation ratio of the oil is 1% or less in 400 hours in an atmosphere having a temperature of 120°

C.

4. The metal-carbonaceous brush according to claim 1, wherein

the oil includes a synthetic hydrocarbon oil, an ester oil, a mineral oil or a petroleum hydrocarbon oil, or a mixed oil of these.

5. The metal-carbonaceous brush according to claim 4, wherein

the oil is a mixed oil of 90% by weight or more and 99% by weight or less of the synthetic hydrocarbon oil and 1% by weight or more and 10% by weight or less of a silicone oil.

6. The metal-carbonaceous brush according to claim 4, wherein

the oil is a mixed oil of 90% by weight or more and 99.5% by weight or less of the synthetic hydrocarbon oil and 0.5% by weight or more and 10% by weight or less of a dimethyl silicone oil.

7. The metal-carbonaceous brush according to claim 1, wherein

the metal includes electrolytic copper powder.

8. A method of manufacturing a metal-carbonaceous brush including the steps of:

fabricating a carbonaceous material by mixing carbon powder and a binder;

mixing 10% by weight or more and 60% by weight or less of metal to the fabricated carbonaceous material;

forming the mixed carbonaceous material and metal;

thermally processing the formed carbonaceous material and metal; and

impregnating the thermally processed carbonaceous material with oil.

9. The method of manufacturing the metal-carbonaceous brush according to claim 8, wherein

the step of forming the carbonaceous material and metal includes pressurizing the carbonaceous material and metal such that the carbonaceous material and metal have a specific gravity of 2.26 g/cm³ or less.

10. The method of manufacturing the metal-carbonaceous brush according to claim 8, wherein

the step of impregnation with oil includes immersing the carbonaceous material and metal in oil having a temperature of 80°

C. or more and 120°

C. or less.

11. The method of manufacturing the metal-carbonaceous brush according to claim 10, wherein

the step of impregnation with oil includes immersing the carbonaceous material and metal in oil having a temperature of 90°

C. or more and 110°

C. or less.