Armature having a flat disk type commutator

• US 5,245,240 A
• Filed: 07/16/1992
• Issued: 09/14/1993
• Est. Priority Date: 07/17/1991
• Status: Expired due to Term

• Current Assignee: Junichi Takasaki
• Original Assignee: Junichi Takasaki
• Inventors: Takasaki, Junichi
• Primary Examiner(s): Skudy, R.
• Application Number:
  US07/914,889
• Time in Patent Office: 425 Days
• Field of Search: 310/42, 310/43, 310/233, 310/235, 310/234, 310/45, 310/195, 310/237, 310/208, 29/597, 219/56.1, 219/56.22, 417/366
• US Class Current: 310/237
• CPC Class Codes: H01R 39/06 other than with external cylindrical contact surface, e.g. flat commutators
• CPC Class Codes: H01R 39/32 Connections of conductor to commutator segment
• CPC Class Codes: H02K 13/04 Connections between commutator segments and windings

Abstract

In an armature wherein a plurality of base metals 15 electrically insulated from one another are solidly secured to the surface of a boss portion 10, carbon protective members 18 are jointed to the surfaces of the base metals 15, respectively, through a solder layer 19 and coil ends 5 of an armature core are jointed to the risers, an auxiliary electrode portion 17 is formed integrally with the riser 12 on each of the base metals 15.

Claims

1. An armature having a flat disk type commutator, comprising:

a plurality of segments each of which includes an electrically conductive base metal having an upper and lower substantially flat surface and extending radially from a central axis;

each of said segments being circumaxially disposed about said central axis and electrically insulated from one another, said electrically conductive base metal being solidly secured to a boss portion, said boss portion being formed from synthetic resin and integrally with each of said base metals, said boss portion further having a circular outer peripheral surface, said base metal further comprising a riser defining a main electrode portion and an auxiliary electrode portion, said main electrode portion and said auxiliary electrode portion being formed integrally on said base metal and each having outwardly facing surfaces, said main and auxiliary electrode portions being disposed side-by-side one another circumferentially and along said circular outer peripheral surface of said boss portion;

each of said segments further comprising a protective member bonded to the upper substantially flat surface of said base metal by means of an electrically conductive and hot-melt bonding material, said protective member having a shape and size substantially equal to the upper substantially flat surface of said base metal;

said riser forming a support and guide for welding a wire end of an armature coil thereto during a fusing treatment wherein a main electrode is brought into contact with said main electrode portion of said base metal and an auxiliary electrode is brought into contact with said auxiliary electrode portion of said base metal so that during the fusing treatment electrical current flows through the main electrode to the main electrode portion circumferentially through the base metal through the auxiliary electrode portion to the auxiliary electrode without passing through the bonding material during the fusing treatment.

2. The armature as set forth in claim 1, wherein said riser and said auxiliary electrode portion are formed by press-molding said base metal.

3. The armature as set forth in claim 1, wherein said riser and said auxiliary electrode portion are formed adjacent said circular outer peripheral surface of said boss portion and are integral with the upper and lower surface of said base metal so that the lower substantially flat surface of said base metal forming said auxiliary electrode portion is in facing relationship with said circular outer peripheral surface of said boss.

4. The armature as set forth in claim 1, wherein said base metal is copper.

5. The armature as set forth in claim 1, wherein said base metal is a copper alloy.

6. The armature as set forth in claim 3, wherein said riser is generally U-shaped for holding the wire end of said armature coil.

7. The armature as set forth in claim 1, wherein said electrically conductive and hot-melt bonding material comprises a solder layer.

8. An armature having a flat disk type commutator, comprising:

a plurality of segments each of which include an electrically conductive base metal having an upper and lower substantially flat surface and extending radially from a central axis;

each of said segments being circumaxially disposed about said central axis and electrically insulated from one another, said electrically conductive base metal being solidly secured to a boss portion, said boss portion being formed from synthetic resin and integrally with each of said base metals, said boss portion further having a circular outer peripheral surface, said base metal further including a pawl means insert--molded with said boss portion, a riser defining a main electrode portion and an auxiliary electrode portion;

each of said segments further comprising a protective member bonded to the upper substantially flat surface of said base metal by means of an electrically conductive and hot-melt bonding material, said protective member having a shape and size substantially equal to the upper substantially flat surface of said base metal;

said riser forming a support and guide for welding a wire end of an armature coil thereto during a fusing treatment wherein a main electrode is brought into contact with said main electrode portion of said base metal and an auxiliary electrode is brought into contact with said auxiliary electrode portion of said base metal so that during the fusing treatment electrical current flows through the main electrode to the main electrode portion through the base metal through the auxiliary electrode portion to the auxiliary electrode without passing through the bonding material during the fusing treatment.