Plane commutator and method of manufacturing the same

• US 6,525,445 B2
• Filed: 04/03/2001
• Issued: 02/25/2003
• Est. Priority Date: 04/13/2000
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Oi, Kiyotoshi, Ebihara, Yoshio, Kiyose, Kenzo
• Primary Examiner(s): Ramirez, Nestor
• Assistant Examiner(s): GONZALEZ, JULIO C
• Application Number:
  US09/823,745
• Publication Number:
  US 20010030485A1
• Time in Patent Office: 693 Days
• Field of Search: 310/235, 310/233, 310/234, 310/236, 310/237
• US Class Current: 310/233
• CPC Class Codes: H01R 39/045 the commutators being made of carbon
• CPC Class Codes: H01R 39/06 other than with external cylindrical contact surface, e.g. flat commutators
• CPC Class Codes: H01R 43/08 in which segments are not separated until after assembly
• CPC Class Codes: H02K 13/04 Connections between commutator segments and windings

Abstract

A plane commutator includes a plurality of commutator segments made of carbon compound, a resinous boss member having a body portion supporting a base portion of the commutator segments and an outer peripheral portion supporting an outer periphery of the same and a plurality of metal base plates. Each metal base plate has a contact portion in contact with the base portion of the commutator segment, an axial portion extending along a peripheral portion of the boss member and a terminal portion. The axial portion of the metal base plates is disposed on an outer periphery of the plane commutator in parallel with the outer peripheral portions of the boss member to separate the outer peripheral portion from the body portion. The outer peripheral portion moves freely from the body portion as the metal base plates thermally expand.

Claims

1. A plane commutator comprising:

a plurality of commutator segments made of carbon compound and having a commutator surface at one end thereof, a commutator segment outer periphery at an outer side thereof, and a base portion at the other end thereof;

a resinous boss member having a first support portion supporting said base portion of said plurality of commutator segments, a second support portion supporting said outer periphery of said plurality of commutator segments, and a plurality of bridge portions connecting said first and second support portions; and

a plurality of metal base plates, each said base plate having a contact portion in contact with said base portion of a respective one of said commutator segments, an axial portion extending from said contact portion along an outer peripheral portion of said first support portion, an opening in which one of said bridge portions is filled between said first and second support portions and a terminal portion extending radially outwardly from said axial portion;

wherein

said axial portion is disposed in parallel to said commutator outer periphery and adjacent said second support portion so that said axial portion and said second support portion define respective portions of an outer peripheral surface of the plane commutator, and wherein said first support portion and said second support portion are separated from each other throughout an extent of said outer peripheral surface of the plane commutator by said axial portion.

2. The plane commutator as claimed in claim 1, wherein said axial portions of said metal base plates are supported by said boss member so that said axial portions can move in a direction away from said commutator surface.

3. The plane commutator as claimed in claim 1, wherein said first support portion of said boss member comprises a portion engaging said terminal portion.

4. The plane commutator as in claim 1, wherein said plurality of commutator segments are circumferentially separated by a plurality of face slits that extend axially through said second support member and between the respective circumferentially adjacent metal base plates, to said first support member.

5. The plane commutator as in claim 1, wherein said second support portion is in contact with said axial portion of said metal base plates.

6. The plane commutator as in claim 1, wherein said opening through said metal base plate is defined in plural stages of differing diameter.

7. The plane commutator as in claim 1, wherein said first support portion and second support portion are connected solely by said bridge portions.