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Drum commutator and method for producing the same

  • US 20040100160A1
  • Filed: 09/26/2003
  • Published: 05/27/2004
  • Est. Priority Date: 03/29/2001
  • Status: Active Grant
First Claim
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1. A method for producing a drum commutator comprising a barrel-shaped support body (1) made of insulating compression-molding material, a plurality of metal conductor segments (3, 3

  • ) and an equal number of carbon segments (4), which are joined to the conductor segments (3, 3

    ) in electrically conductive relationship, comprising the following steps;

    producing a metal conductor blank comprising a plurality of conductor segments, each two of which adjacent to one another are joined to one another via a bridge part (20), the distance from the radial inside faces of the bridge parts (20) to the commutator axis (2) corresponding substantially to the distance from the radial outside faces of the conductor segments (3, 3

    ) to the commutator axis (2);

    producing a carbon shell with a substantially regular cylindrical outside face (26), at least the radial inside face and one axial end face of the carbon shell being metallized;

    joining the conductor blank together with the carbon shell in axial direction to form electrically conductive contact zones (17) between the conductor segments (3, 3

    ) and the metallized end face of the carbon shell;

    injection molding of a support body (1) made of insulating compression-molding material onto the composite part comprising the conductor blank and the carbon shell in an injection-molding die, the metallized radial inside face of the carbon shell being covered with compression-molding material;

    removing the bridge parts (20) with formation of an annular, closed, substantially regular cylindrical surface (19) with alternating zones of compression-molding material and metal;

    forming the carbon segments (4) by incising the carbon shell by axial cuts (16) extending in radial direction as far as the support body (1) and running in axial planes disposed between each two conductor segments (3, 3

    ), the annular, closed, substantially regular cylindrical surface (19) with alternating zones of compression-molding material and metal being at least partly preserved.

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