Method of making a motor actuator

• US 5,937,507 A
• Filed: 08/21/1997
• Issued: 08/17/1999
• Est. Priority Date: 06/24/1994
• Status: Expired due to Term

• Current Assignee: ASMO Company Limited (DENSO Corporation)
• Original Assignee: ASMO Company Limited (DENSO Corporation)
• Inventors: Asakura, Yasunori, Kujira, Yukinobu
• Primary Examiner(s): Hall, Carl E.
• Application Number:
  US08/916,008
• Time in Patent Office: 726 Days
• Field of Search: 29/596, 29/883, 29/884, 310/42, 310/43, 310/68 R
• US Class Current: 29/596
• CPC Class Codes: H02K 11/21 Devices for sensing speed or position, or actuated thereby specially adapted for machines having non-mechanical commutating devices H02K29/06, H02K29/14
• CPC Class Codes: H02K 11/40 Structural association with grounding devices
• CPC Class Codes: H02K 2211/03 Machines characterised by circuit boards, e.g. pcb
• CPC Class Codes: H02K 5/225 Terminal boxes or connection arrangements specially adapted for submersible motors H02K5/132
• CPC Class Codes: H02K 7/1166 comprising worm and worm-wheel structural association with bearings specially adapted for worm gear drives H02K7/081
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/4922 with molding of insulation
• CPC Class Codes: Y10T 29/49222 forming array of contacts or terminals

Abstract

A motor actuator has a housing, an output gearwheel rotated by a motor, a pattern board provided on one side of the output gearwheel, and a conducting unit. The conducting unit is formed integrally with brushes contacting the pattern board and connector pins corresponding to each of the brushes and electrically connecting the brushes to other electrical components. The brushes and connector pins are fixed by an insulating resin so as to maintain the structure when link portions unneeded for electrical connection are cut.

Claims

1. A method of manufacturing a motor actuator having an output gearwheel rotated by a motor, a pattern conductor provided on one side of said output gearwheel, a plurality of brushes contacting said pattern conductor, a plurality of connectors corresponding to respective of said brushes, a housing containing said connectors, and said connectors electrically connecting said brushes to electrical components, said method comprising the steps of:

integrally and simultaneously forming said brushes and connectors partially connected by electrical link portions from a unitary conductive material;

integrally fixing together said connectors by an insulating resin;

cutting only unnecessary link portions of said electrical link portions so as to form a desired electric circuit having at least one link portion between said connectors after fixing said connectors by said insulating resin; and

mounting said connectors in said housing after cutting said unnecessary link portions of said electrical link portions.

2. A method of manufacturing a motor actuator having an output gearwheel rotated by a motor, a pattern conductor provided on one side of said output gearwheel, a plurality of brushes contacting said pattern conductor, a plurality of connectors corresponding to respective of said brushes, a housing containing said connectors, and said connectors electrically connecting said brushes to electrical components, wherein said pattern conductor comprises a conducting portion formed circumferentially around an axis of said output gearwheel, and an insulating portion insulating said conducting portion, wherein said conducting portion and insulating portion are concentric with said axis and offset by a predetermined angle, and wherein at least one of said brushes avoids said insulating portion and conducts with said conducting portion, and at least one of said brushes slides on said pattern conductor in a circumferential direction, said method comprising the steps of:

integrally and simultaneously forming said brushes and connectors partially connected by electrical link portions from a unitary conductive material;

integrally fixing together said connectors by an insulating resin;

cutting only unnecessary link portions of said electrical link portions so as to form a desired electric circuit having at least one link portion between said connectors after fixing said connectors by said insulating resin; and

mounting said connectors in said housing after cutting said unnecessary link portions of said electrical link portions.

3. A method of manufacturing a motor actuator having an output gearwheel rotated by a motor, a pattern conductor provided on one side of said output gearwheel, a plurality of brushes contacting said pattern conductor, a plurality of connectors corresponding to respective of said brushes, a housing containing said connectors, and said connectors electrically connecting said brushes to electrical components, wherein said pattern conductor comprises a resistor portion having a predetermined resistivity and formed in an arc around an axis of said output gearwheel, and a conducting portion electrically connected to one end of said resistor portion, and wherein at least one of said brushes contacts and conducts with said conducting portion, and at least one of said brushes contacts and conducts with said resistor portion, said method comprising the steps of:

integrally and simultaneously forming said brushes and connectors partially connected by electrical link portions from a unitary conductive material;

integrally fixing together said connectors by an insulating resin;

cutting only unnecessary link portions of said electrical link portions so as to form a desired electric circuit having at least one link portion between said connectors after fixing said connectors by said insulating resin; and

mounting said connectors in said housing after cutting said unnecessary link portions of said electrical link portions.

4. A method of manufacturing a motor actuator having an output gearwheel rotated by a motor, a pattern conductor provided on one side of said output gearwheel, a plurality of brushes contacting said pattern conductor, a plurality of connectors corresponding to respective of said brushes, a housing containing said connectors, and said connectors electrically connecting said brushes to electrical components, wherein said insulating resin fixes said connectors and forms a connecting portion which connects with an external plug, said method comprising the steps of:

integrally and simultaneously forming said brushes and connectors partially connected by electrical link portions from a unitary conductive material;

integrally fixing together said connectors by an insulating resin so as to form a fixing portion and a connecting portion;

cutting only unnecessary link portions of said electrical link portions so as to form a desired electric circuit having at least one link portion between said connectors after fixing said connectors by said insulating resin; and

mounting said connectors in said housing after cutting said unnecessary link portions of said electrical link portions.

5. A method of manufacturing a motor actuator having an output gearwheel rotated by a motor, a pattern conductor provided on one side of said output gearwheel, a plurality of brushes contacting said pattern conductor, a plurality of connectors corresponding to respective of said brushes, a housing containing said connectors, and said connectors electrically connecting said brushes to any electrical components, wherein said pattern conductor comprises a conducting portion formed circumferentially around an axis of said output gearwheel, and an insulating portion insulating said conducting portion, wherein said conducting portion and insulating portion are concentric with said axis and offset by a predetermined angle, wherein at least one of said brushes avoids said insulating portion and conducts with said conducting portion, and at least one of said brushes slides on said pattern conductor in a circumferential direction, and wherein said insulating resin fixes said connectors and forms a connecting portion which connects with an external plug, said method comprising the steps of:

integrally and simultaneously forming said brushes and connectors partially connected by electrical link portions from a unitary conductive material;

integrally fixing together said connectors by an insulating resin so as to form a fixing portion and a connecting portion;

cutting only unnecessary link portions of said electrical link portions so as to form a desired electric circuit having at least one link portion between said connectors after fixing said connectors by said insulating resin; and

mounting said connectors in said housing after cutting said unnecessary link portions of said electrical link portions.

6. A method of manufacturing a motor actuator having an output gearwheel rotated by a motor, a pattern conductor provided on one side of said output gearwheel, a plurality of brushes contacting said pattern conductor, a plurality of connectors corresponding to respective of said brushes, a housing containing said connectors, and said connectors electrically connecting said brushes to electrical components, wherein said pattern conductor comprises a resistor portion having a predetermined resistivity and formed in an arc around an axis of said output gearwheel, and a conducting portion electrically connected to one end of said resistor portion, wherein at least one of said brushes contacts and conducts with said conducting portion, and at least one of said brushes contacts and conducts with said resistor portion, and wherein said insulating resin fixes said connectors and forms a connecting portion which connects with an external plug, said method comprising the steps of:

integrally and simultaneously forming said brushes and connectors partially connected by electrical link portions from a unitary conductive material;

integrally fixing together said connectors by an insulating re sin so as to form a fixing portion and a connecting portion;

cutting unnecessary link portions of said electrical link portions so as to form a desired electric circuit having at least one link portion between said connectors after fixing said connectors by said insulating resin; and

mounting said connectors in said housing after cutting said unnecessary ink portions of said electrical link portions.