JP2002017072A - Commutator and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a commutator capable of preventing formation of burrs. SOLUTION: This commutator 1 is provided with a roughly cylindrical insulating material 2, and a plurality of commutator segments 3 which are disposed on the outer periphery of the insulating material 2 and each of which has a wire connecting claw 4 so as to protrude from the circumferential center of one end surface 3a. The one end surface 3a of the commutator segment 3 has an isolating surface 3c isolating the root 4a of the wire connecting claw 4 from the inner surface of the commutator segment 3 to the radial outside. During a manufacture process of bringing a die 7 into pressure contact with the one end surface of the commutator segment 3 including the isolating surface 3c from its axial direction, and charging the melted and softened insulating material as an insulator to be formed after curing into the commutator segment 3, the insulating material is difficult to leak along the root 4a of the wire connecting claw 4. It is thus possible to prevent formation of burrs along the root 4a of the wire connecting claw 4.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a commutator and a method for manufacturing the same.

[0002]

2. Description of the Related Art As a conventional commutator, as shown in FIG. 8, a substantially cylindrical insulator 51 made of resin and a plurality of commutator segments 52 arranged on the outer periphery of the insulator 51 are provided. There are things. A connection claw 53 extends from a part of one end face 52 a in the axial direction of each commutator segment 52. The connection claw 53 includes a base end portion 53a slightly extending in the axial direction from one end face 52a of the commutator segment 52, and a connection portion 53b bent radially outward from the distal end of the base end portion 53a. The connection claw 53 has the same thickness as that of the commutator segment 52, and the inner surface 53 c of the base end portion 53 a (the surface on the axial center side of the insulator 51) is in line with the inner surface of the commutator segment 52. It is continuous in the direction.

The commutator as described above is manufactured as follows. As shown in FIG. 10, by rolling a predetermined segment plate material, a plurality of the connection claws 5 are cut from one end face 54 a.
3 form a substantially cylindrical segment tubular member 54 extended.

[0004] The inside of the segment tubular member 54 is filled with an insulating material (a material to be the insulator 51). At this time, the one end surface 54a side of the segment tubular member 54 is
Seal with 5. More specifically, the mold 55 is formed in a substantially disk shape, and its outer diameter is set to be the same as the outer diameter of the segment tubular member 54. In the outer edge of the mold 55, grooves 55a corresponding to the base ends 53a of the connection claws 53 are formed at predetermined angular intervals. Then, the mold 55 is moved in the axial direction, and the outer edge where the groove portion 55a is not formed is pressed against the one end face 54a of the segment cylindrical member 54 to seal.

[0005] Next, after the insulating material is cured, the segment tubular member 54 is cut at predetermined angular intervals to form a plurality of commutator segments 52 as shown in FIG. This completes the manufacture of the commutator.

[0006]

However, in the above-described method for manufacturing a commutator, the proximal end 53 of the connection claw 53 is not provided.
The seal becomes insufficient at the position of the inner side surface 53c of FIG. Because, at the location of the inner side surface 53c of the base end portion 53a, as shown in FIG. 9, the direction in which the mold 55 (groove 55a) contacts the inner side surface 53c is in the pressing direction (axial direction) A of the mold 55. This is because the directions are orthogonal to each other.

Therefore, when the resin material is filled, there is a problem that the insulating material leaks along the inner side surface 53c of the base end portion 53a and burrs are generated. This makes the step of removing burrs (shot blast or the like) indispensable, and causes an increase in commutator manufacturing costs.

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and an object of the present invention is to provide a commutator capable of preventing generation of burrs and a method of manufacturing the same.

[0009]

According to a first aspect of the present invention, a substantially cylindrical insulator, a plurality of insulators are arranged on the outer periphery of the insulator, and connection claws extend from a part of one end face. In a commutator including a commutator segment, an isolating surface is formed on one end surface of the commutator segment to isolate a base end of the connection hook radially outward from an inner surface of the commutator segment. And

According to a second aspect of the present invention, in the commutator according to the first aspect, a protruding portion that protrudes radially inward is formed at a position corresponding to the connection hook of the commutator segment. The gist of the present invention is that one end surface of the overhang portion is the isolation surface.

According to a third aspect of the present invention, in the commutator according to the second aspect, the circumferential width of the projecting portion is wider than the circumferential width of the connection claw, and both sides of one end face thereof are provided. The gist of the present invention is that the portion is continuous with the one end face of the commutator segment formed in the circumferential direction of the connection claw.

According to a fourth aspect of the present invention, in the commutator according to the second aspect, the circumferential width of the projecting portion is substantially the same as the circumferential width of the connection hook. An R-shaped portion is formed radially outward on both sides in the circumferential direction, and extends in the circumferential direction toward the outside in the radial direction, and one end surface of the R-shaped portion extends one end surface of the projecting portion in the circumferential direction of the connection claw. The gist of the present invention is that the commutator segments are formed so as to be continuous with one end surface of the commutator segment.

[0013] The invention according to claim 5 is the invention according to claims 2 to 4.
In the commutator according to any one of the above, the gist is characterized in that a locking claw that radially engages with the insulator is formed on the overhanging portion.

According to a sixth aspect of the present invention, there is provided the commutator according to the first aspect, wherein a radially inner side of one end face of the commutator segment is formed in an arc shape, and the thickness of the connection claw is adjusted by the straightening. The connecting claws are formed radially outward from a radially inner end of one end face of the commutator segment, and the one end face radially inner than the connecting claws is isolated. The point is that it is a surface.

[0015] The invention according to claim 7 is the invention according to claims 1 to 6.
In the commutator according to any one of the above, the distance between the circumferential end of the commutator segment and the circumferential end of the commutator segment decreases toward the other end surface of the commutator segment. The gist of the present invention is that the inclined surface is formed as described above.

According to the present invention, the base end of the connecting claw is attached to the inner surface of the segment cylindrical member on one end surface of a substantially cylindrical segment cylindrical member having a plurality of connecting claws extending therefrom. Forming an isolation surface radially outward from the cylindrical member, and pressing the mold in axial contact with an annular one end surface of the segment cylinder member including the isolation surface, and filling the inside of the segment cylinder member with an insulating material. Then, after the insulating material is cured, the segment tubular member is cut at predetermined angular intervals to form a plurality of commutator segments.

(Operation) According to the first aspect of the present invention,
An isolation surface is formed on one end surface of the commutator segment to isolate the proximal end of the connection claw from the inner surface of the commutator segment radially outward. Therefore, when the mold is pressed into contact with one end face of the commutator segment including the isolation surface from the axial direction, and the inside of the commutator segment is filled with a melted and softened insulating material that cures and becomes an insulator, Is difficult to leak along the base end of the connection nail. This prevents the occurrence of burrs along the base end of the connection claw.

According to the second aspect of the present invention, the commutator segments are formed at the positions corresponding to the connection claws with a projecting portion projecting radially inward, and one end face of the projecting portion is formed as the separating surface. Is done.

According to the third aspect of the present invention, the circumferential width of the projecting portion is wider than the circumferential width of the connection hook, and both end portions of the one end face are formed in the circumferential direction of the connection hook. And one end surface of the commutator segment.

According to the fourth aspect of the present invention, the circumferential width of the projecting portion is substantially the same as the circumferential width of the connection claw, and the circumferential width of the projecting portion is radially outward on both sides in the circumferential direction. An R-shaped portion that expands in the circumferential direction toward the outside in the radial direction is formed. And R
One end surface of the protruding portion is formed as a surface continuous with the one end surface of the commutator segment formed in the circumferential direction of the connection claw by the one end surface of the shape portion.

According to the fifth aspect of the present invention, the protruding portion is formed with a locking claw that radially engages with the insulator. Therefore, the commutator segments are firmly fixed to the insulator.
Moreover, the overhanging portion has both the separating surface and the locking claw. This allows the commutator segment to have a simple shape,
Separation surfaces and locking claws can be obtained.

According to the sixth aspect of the invention, the radially inner side of one end face of the commutator segment is formed in an arc shape, and the radial thickness of the connection claw is smaller than the radial thickness of the commutator segment. Is done. The connection claw is formed radially outside the one end face of the commutator segment in the radial direction, and the one end face radially inside the connection claw is the isolation surface.

According to the seventh aspect of the present invention, the distance from the circumferential end of one end face of the commutator segment to the circumferential end of the commutator segment increases toward the other end face of the commutator segment. Is formed so as to approach.

According to the eighth aspect of the present invention, the base end of the connection claw is attached to one end surface of the substantially cylindrical segment cylinder member having a plurality of connection claws extending therefrom. An isolation surface is formed to isolate radially outward from the inner surface. Then, the mold is pressed into contact with the annular one end surface of the segment tubular member including the separating surface from the axial direction, and the inside of the segment tubular member is filled with the insulating material. A plurality of commutator segments are cut at predetermined angular intervals. As described above, the insulating surface is pressed against the mold, so that the insulating material is less likely to leak along the base end of the connection claw. This prevents the occurrence of burrs along the base end of the connection claw.

[0025]

(First Embodiment) A first embodiment of the present invention will be described below with reference to FIGS. 1 and 2. FIG. As shown in FIG. 1, the commutator 1 includes a substantially cylindrical insulator 2 made of resin, and a plurality of commutator segments 3 arranged on the outer periphery of the insulator 2. In this embodiment, eight commutator segments 3 are arranged at equal angular intervals.

Each commutator segment 3 is formed in a shape obtained by partially cutting a substantially cylindrical shape at a predetermined angle. The commutator segment 3 has a connection claw 4 extending from one end face (one end face in the axial direction of the insulator 2) 3a. The connection claw 4 of the present embodiment extends from the center in the circumferential direction of the one end face 3a. The connection claws 4 are provided on one end face 3 of the commutator segment 3.
a proximal end 4a extending slightly in the axial direction from the base end 4a;
a of the connecting portion 4b bent radially outward from the tip of the connecting portion 4a. The connecting claws 4 are set to have the same thickness (the radial thickness of the commutator 1) as the thickness L1 of the commutator segments 3. The connection claw 4 is provided on the outer surface (the insulator 2) of the base end 4a.
4c) is continuous with the outer side surface 3b of the commutator segment 3 in the axial direction.

On one end face 3a of the commutator segment 3, an isolation for isolating the base end 4a of the connection claw 4 radially outward from the inner face (the face fixed to the insulator 2) of the commutator segment 3. The surface 3c is formed.

More specifically, a protruding portion 5 is formed inside each commutator segment 3 so as to be embedded in the insulator 2 and protrude radially inward of the insulator 2 (see FIG. 2).
The overhang portion 5 is formed from one end of the commutator segment 3 in the axial direction to the other end. The overhang portion 5 is formed at the center of the commutator segment 3 in the circumferential direction, corresponding to the connection hook 4. The circumferential width M1 of the overhang portion 5 of the present embodiment is set to be wider than the circumferential width N1 of the connection hook 4. Then, one end surface of the overhang portion 5 (one end surface of the insulator 2 in the axial direction)
Are formed on both sides thereof as isolation surfaces 3c that are coplanar and continuous with one end surfaces 3a of the commutator segments 3 formed in the circumferential direction of the connection claws 4.

A locking claw 5a extending in the circumferential direction of the insulator 2 is formed on both sides of the tip end (radially inner end of the insulator 2) of the overhang portion 5 (see FIG. 2). The locking claw 5a is radially engaged with the insulator 2.

Next, a method of manufacturing the commutator 1 configured as described above will be described. First, as shown in FIG. 2, a predetermined segment plate material formed in advance is rolled to form a substantially cylindrical segment tube member 6 having a plurality of connection claws 4 extending from one end face 6a. The segment tubular member 6 has a shape in which the eight adjacent commutator segments 3 are connected to each other.
Are formed. In this embodiment, for the sake of convenience of explanation, the same shape as the commutator segment 3 (connection claw 4, separation surface 3c, etc.) even in the state of the segment cylindrical member 6 is used.
Are denoted by the same reference numerals, and description thereof is omitted.

Next, the inside of the segment cylindrical member 6 is filled with a molten and softened insulating material (a material to be the insulator 2). At this time, the one end surface 6a side of the segment tubular member 6 is sealed with a mold 7 in advance. More specifically, the mold 7 is formed in a substantially disk shape, and the outer diameter thereof is set to be the same as the outer diameter of the segment cylindrical member 6. At the outer edge of the mold 7, eight grooves 7a corresponding to the base ends 4a of the connection claws 4 are formed at predetermined angular intervals. The radial length (depth from the outer edge) P1 of the groove 7a is the radial length (thickness) of the base end 4a of the connection claw 4, that is, the commutator segment 3 (segment tubular member 6). It is longer than the radial length (thickness) L1 and extends from the outer side surface 3b of the commutator segment 3.
Is set to be shorter than the length (thickness) Q1 up to the distal end surface 5b. The circumferential width S1 of the groove portion 7a is set to be larger than the circumferential width N1 of the connection claw 4 and smaller than the circumferential width M1 of the overhang portion 5. Then, the mold 7 is moved in the axial direction so that the connection claws 4 are fitted into the groove portions 7a, and the annular one end surface 6 of the segment cylindrical member 6 including the separating surface 3c.
a to make a seal by pressing. The outer diameter of the mold 7 is
It is larger than the inner diameter of the segment cylindrical member 6, that is, the mold 7
It is sufficient if the lower surface is set to a size such that the annular one end surface 6a of the segment cylindrical member 6 abuts.

Next, after the insulating material is cured, the segment cylindrical member 6 is cut at predetermined angular intervals, and as shown in FIG.
A plurality of commutator segments 3 are formed. Specifically, after the insulating material is hardened, the mold 7 is separated, and a groove 8 (see FIG. 1) extending from the outer peripheral side of the cylindrical member 6 for the segment to the hardened insulating material (insulator) is formed by cutting. Formed along. Thereby, the insulator 2 and the plurality of commutator segments 3 are formed, and the manufacture of the commutator 1 is completed.

Next, the characteristic effects of the first embodiment will be described below. (1) On one end surface 3a of the commutator segment 3, an isolation surface 3c for isolating the base end 4a of the connection claw 4 from the inner surface of the commutator segment 3 to the outside in the radial direction is formed. More specifically, a protruding portion 5 whose circumferential width M1 is larger than the circumferential width N1 of the connection claw 4 is formed at a position corresponding to the connection claw 4 inside the commutator segment 3. Then, one end surface of the overhang portion 5 is connected to the commutator segment 3 formed in the circumferential direction of the connection claw 4.
Is formed as an isolating surface 3c which continues in the same plane as the one end surface 3a.

When the insulating material is filled at the time of manufacture, the mold 7 is pressed against the annular one end face 6a of the segment cylinder member 6 including the separating surface 3c, and the entire circumference is sufficiently sealed. This makes it difficult for the insulating material to leak along the base end 4a of the connection claw 4. This prevents generation of burrs along the base end 4a of the connection claw 4. as a result,
The commutator 1 can be manufactured at low cost without the need for a step of removing burrs (shot blasting or the like) during manufacturing.

(2) A locking claw 5a is formed on the overhang portion 5 to engage with the insulator 2 in the radial direction. Therefore, the commutator segments 3 are firmly fixed to the insulator 2. Moreover, the overhang portion 5
Has both the separating surface 3c and the locking claw 5a. Thereby, it is possible to obtain the separating surface 3c and the locking claw 5a while keeping the commutator segment 3 in a simple shape.

(Second Embodiment) Hereinafter, a second embodiment of the present invention will be described with reference to FIGS. As shown in FIG. 3, the commutator 11 includes a substantially cylindrical insulator 12 made of resin, and a plurality of commutator segments 13 arranged on the outer periphery of the insulator 12. Note that the commutator segments 13 of the present embodiment have eight angular intervals.
It is arranged individually.

Each commutator segment 13 is formed in a shape obtained by partially cutting a substantially cylindrical shape at a predetermined angle. The commutator segment 13 has a connection claw 14 extending from one end face (one end face in the axial direction of the insulator 2) 13a.
The connection claws 14 of the present embodiment extend from the center in the circumferential direction of the one end face 13a. The connection claw 14 includes a base end portion 14a slightly extending in the axial direction from one end surface 13a of the commutator segment 13, and a connection portion 14b bent radially outward from the distal end of the base end portion 14a.

On one end face 13a of the commutator segment 13, the base end 14a of the connection claw 14 is attached.
An isolation surface 13b is formed radially outward from the inner side surface (the surface fixed to the insulator 12).

More specifically, the thickness U of the connection claw 14 is set smaller than the thickness L2 of the commutator segment 3. The connection claw 14 is provided on the outer surface (the insulator 12) of the base end portion 14a.
14c is the commutator segment 13
Is continuous with the outer side surface 13c in the axial direction. That is, the thickness U of the proximal end portion 14a of the connection claw 14 is made smaller than the thickness L2 of the commutator segment 3, and the proximal end portion 14a is radially outward from the radially inner end of the one end surface 13a of the commutator segment 13. , The one end surface 13a formed radially inward from the base end portion 14a serves as the isolation surface 13b.

Inside each commutator segment 13 is formed a projecting portion 15 projecting radially inward of the insulator 12 so as to be embedded in the insulator 12 (see FIG. 4). The overhang portion 15 is provided at an axially intermediate portion of the commutator segment 13,
It is formed to extend along the axial direction. Locking claws 15a extending in the circumferential direction of the insulator 12 are formed on both sides of the distal end portion (radially inner end portion of the insulator 12) of the overhang portion 15 (see FIG. 4). It is radially engaged with the insulator 12.

Next, the commutator 11 configured as described above is used.
Will be described. First, as shown in FIG. 4, a predetermined segment plate material formed in advance is rounded to form a substantially cylindrical segment tube member 16 having a plurality of the connection claws 14 extending from one end face 16a. The segment tube member 16 has a shape in which the eight adjacent commutator segments 13 are connected, and the separating surface 13b is formed on one end surface 16a. In the present embodiment, for the sake of convenience of explanation, even in the state of the segment tubular member 16, those having the same shape as the commutator segment 13 (the connection claw 14, the separation surface 13 b, etc.) are given the same reference numerals, and Description is omitted.

Next, the inside of the segment cylindrical member 16 is filled with a melted and softened insulating material (a material to be the insulator 12). At this time, one end face 16 of the segment tubular member 16 is
The a side is sealed with a mold 17. In detail, mold 1
Numeral 7 is formed in a disk shape, the outer diameter V of which is larger than the inner diameter W of the segment cylindrical member 16, and the eight connecting claws 1.
4 is set to be smaller than the diameter X of the circle connecting the inner side surfaces (the surface fixed to the insulator 12) 14d. Then, the mold 17 is moved in the axial direction, and its outer edge is
b, annular one end surface 16a of the cylindrical member 16 for the segment
To make sealing.

Next, after the insulating material is cured, the segment cylindrical member 16 is cut at a predetermined angular interval to form a plurality of commutator segments 13 as shown in FIG. More specifically, after the insulating material is hardened, the mold 17 is separated, and a groove 18 is cut from the outer circumferential side of the segment cylindrical member 16 to the hardened insulating material (insulator) (see FIG. 3).
Are formed along the axial direction. Thereby, the insulator 12
And a plurality of commutator segments 13 are formed.
1 is completed.

Next, the characteristic effects of the second embodiment will be described below. (1) On one end surface 13a of the commutator segment 13, an isolation surface 13b that separates the base end 14a of the connection claw 14 from the inner surface of the commutator segment 13 to the outside in the radial direction is formed. More specifically, the thickness U of the proximal end 14a of the connection claw 14 is smaller than the thickness L2 of the commutator segment 3, and the proximal end 14a is larger than the radially inner end of the one end face 13a of the commutator segment 13. The one end surface 13a formed radially inward from the base end portion 14a by being formed outward in the direction is the isolation surface 13b.

When the insulating material is filled at the time of manufacture, the mold 17 is pressed against and brought into contact with the annular one end face 16a of the segment cylindrical member 16 including the separating surface 13b, so that the entire circumference is sufficiently sealed. The insulating material is connected
4 hardly leaks along the base end 14a. This allows
The occurrence of burrs along the base end 14a of the connection claw 14 is prevented. As a result, the commutator 11 can be manufactured at low cost without the need for a burr removal step (shot blasting or the like) at the time of manufacture.

(2) One end face 13 of the commutator segment 13
a is formed into an arc shape in the radial direction, and the base end portion 14 of the connection claw 14
a is formed radially outward from the radially inner end of one end face 13a of the commutator segment 13 so that the base end 14a
Since the separating surface 13b is formed more inward in the radial direction, the annular one end surface 1 of the segment cylindrical member 16 including the separating surface 13b is formed.
6a becomes a perfect circle. Therefore, the mold 17 can be formed in a simple disk shape.

The above embodiment may be modified and implemented as follows. The overhang portion 5 of the first embodiment is formed so that one end surface thereof serves as an isolation surface for isolating the base end portion 4a of the connection claw 4 from the inner surface of the commutator segment 3 to the outside in the radial direction. Any other shape may be used.

For example, the overhang portion 5 of the first embodiment is
You may change to the overhang part 21 shown in FIG. Overhang 21
Is set such that its circumferential width M2 is the same as the circumferential width N2 of the connection hook 4. An R-shaped portion 21a is formed radially outward on both sides in the circumferential direction of the overhang portion 21 so as to expand in the circumferential direction toward the outside in the radial direction. Then, one end surface of the overhang portion 21 including one end surface of the R-shaped portion 21a is separated from the separation surface 2.
1b. The separation surface 21b is formed in the same plane as the one end surface 3a of the commutator segment 3 formed in the circumferential direction of the connection claw 4. In addition, locking claws 21 c extending in the circumferential direction of the insulator 2 are formed on both sides of the distal end portion of the overhang portion 21. Even in this case, the same effect as that of the first embodiment can be obtained. In this case, it is necessary to appropriately change the shape of the mold 7.

The commutator 11 of the second embodiment is
You may change to the commutator 31 of the type as shown in FIG. The structure of the commutator 31 will be described only for a portion different from the commutator 11. As shown in FIG. 6, the circumferential end portions of one end face 13 a of the commutator segment 13 include:
Inclined surface 13 that is inclined such that the distance from circumferential end 13d decreases toward the other end surface of commutator segment 13
A step surface 13f having a step with the center in the circumferential direction is formed via e.

The method of manufacturing the commutator 31 is the same as the method of manufacturing the commutator 11, except that the shape of the segment tubular member 32 and the mold 33 are different only. I do.

As shown in FIG. 7, the segment cylindrical member 3
2 is only that a step surface 32a is formed between two adjacent connection claws 14 as compared with the segment cylinder member 16 via two inclined surfaces 13e whose intervals become narrower toward the other end surface. different.

The mold 33 includes the separating surface 13b, the inclined surface 1
3e, it is formed so as to be in contact with the annular one end surface 32b of the segment cylindrical member 32 including the step surface 32a. More specifically, the mold 33 is formed in a substantially disc shape, and the outer diameter thereof is set to be the same as the outer diameter of the segment tubular member 32. At the outer edge of the mold 33, the base end portion 14 of the connection claw 14 is provided.
Eight groove portions 33a corresponding to a are formed at predetermined angular intervals. Radial length of groove 33a (depth from outer edge)
P2 is set to be longer than the radial length (thickness) U of the base end portion 14a of the connection claw 14, and shorter than the radial length (thickness) L2 of the commutator segment 13. Groove 3
The circumferential width S2 of 3a is the circumferential width N2 of the connection claw 14.
It is set to be larger and smaller than the circumferential width Y of the one end face 32b near the connection hook 14. In the outer edge of the mold 33, a convex portion 33b projecting in the axial direction is formed between the adjacent groove portions 33a. The circumferential side surface of the protruding portion 33b is inclined so that the interval becomes narrower toward the tip. The circumferential dimension of the inner surface and the circumferential size of the outer surface of the projection 33b are set corresponding to the inclined surface 13e. More specifically, since the segment tubular member 32 is obtained by rolling a plate-shaped segment plate material, the interval between the pair of substantially facing inclined surfaces 13e varies for each segment tubular member 32. The circumferential dimension Z1 of the inner surface of the convex portion 33b is set to be slightly larger than the maximum value (maximum value within the variation) of the inner surface side interval Z2 between the pair of inclined surfaces 13e. The circumferential dimension Z3 of the outer surface of the projection 33b is set to be slightly smaller than the minimum value (minimum value within the variation) of the distance Z4 on the outer surface side between the pair of inclined surfaces 13e. That is, the convex portion 33b is
When fitted between the pair of inclined surfaces 13e, the inner surface side of the circumferential side surface is the pair of inclined surfaces 1 regardless of the variation.
It is set so as to come into contact with the inner surface side of 3e with a strong pressing force.

Even in this case, when the insulating material is filled at the time of manufacture, the annular one end surface 32b (the inclined surface 13b) of the segment cylindrical member 32 including the separating surface 13b and the inclined surface 13e is provided.
e, only the inner surface side is pressed against the mold 33 to seal it, so that the entire circumference is sufficiently sealed, and the insulating material is less likely to leak along the base end portion 14a of the connection claw 14 and is inclined. It becomes difficult to leak along the surface 13e. This prevents burrs along the base end 14a of the connection claw 14 and burrs along the inclined surface 13e. As a result, the commutator 31 can be manufactured at low cost without the need for a burr removal step during manufacture.

The inclined surface 13e of the commutator segment 13 of the commutator 31 (see FIG. 6) is
May be changed to the type formed up to the circumferential end portion 13d (the step surface 13f is not formed). In this case, for example, a V-shaped groove is formed on the segment cylindrical member 32 by a pair of inclined surfaces 13e, and the convex portion 33b of the mold 33 is changed to a shape corresponding to the V-shaped groove. Even in this case, generation of burrs can be prevented, and a commutator can be manufactured at low cost without requiring a step of removing burrs at the time of manufacture.

In the above embodiments, the separation surfaces 3c, 1
3b is continuous with one end surfaces 3a and 13a of the commutator segments 3 and 13 formed in the circumferential direction of the connection claws 4 and 14, however, the base ends 4a and 1 of the connection claws 4 and 14 are formed.
It is sufficient that the separation surface 4a can be radially outwardly separated from the inner surfaces of the commutator segments 3, 13, and the separation surfaces 3c, 13b may be formed to be inclined. In this case, it is necessary to appropriately change the shapes of the molds 7 and 17 so as to have contact surfaces along the slope.

In the first embodiment, the engaging claw 5a is formed on the overhang portion 5, but the engaging claw 5a may not be formed. Even in this case, the same effect as the effect (1) of the first embodiment can be obtained.

In each of the above-described embodiments, the commutator segments 11 are provided with eight commutator segments 3 and 13. However, the number of commutator segments may be changed as appropriate. The technical ideas other than those described in the claims that can be grasped from the above embodiment will be described below together with their effects.

(A) In the commutator according to claim 7,
A step surface (13f) having a step with the circumferential center of the one end surface is formed at both ends in the circumferential direction of one end surface (13a) of the commutator segment (13) via the inclined surface (13e). A commutator characterized by the following. Even in this case, the mold is pressed into contact with one end surface of the commutator segment including the separating surface and the inclined surface from the axial direction, and is melted to cure and become an insulator.
During the manufacturing of filling the inside of the commutator segment with the softened insulating material, the insulating material does not easily leak from the inside of the commutator segment, and the generation of burrs is prevented.

[0059]

As described in detail above, according to the first to seventh aspects of the present invention, it is possible to provide a commutator capable of preventing the occurrence of burrs.

According to the eighth aspect of the present invention, it is possible to provide a method of manufacturing a commutator capable of preventing the occurrence of burrs.

[Brief description of the drawings]

FIG. 1 is a perspective view illustrating a commutator according to a first embodiment.

FIG. 2 is an explanatory diagram for explaining a method for manufacturing the commutator according to the first embodiment.

FIG. 3 is a perspective view illustrating a commutator according to a second embodiment.

FIG. 4 is an explanatory diagram illustrating a method for manufacturing a commutator according to a second embodiment.

FIG. 5 is a perspective view for explaining another example of a commutator.

FIG. 6 is a perspective view for explaining another example of a commutator.

FIG. 7 is an explanatory diagram for explaining a method of manufacturing another example of a commutator.

FIG. 8 is a perspective view illustrating a commutator according to the related art.

FIG. 9 is an explanatory diagram for explaining a conventional method for manufacturing a commutator.

FIG. 10 is an explanatory view for explaining a conventional method for manufacturing a commutator.

[Explanation of symbols]

2,12 ... insulator, 3,13 ... commutator segment, 4,
Reference numeral 14: connection claw, 5, 21: projecting portion, 6, 16: tubular member for segment, 7, 17, 33: mold (mold), 3a, 13
a: One end face of the commutator segment, 3c, 13b, 21b
... Separation surface, 4a, 14a ... Base end of connection nail, 5a, 21
c: locking claw, 6, 16a: one end face of the segment cylindrical member, 13e: inclined surface, 21a: R-shaped part, L2: radial thickness of the commutator segment, M1, M2: circumference of the overhanging part Direction width, N1, N2 ... width in the circumferential direction of the connection nail, U ... thickness of the connection nail.

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 5H613 AA01 BB04 BB08 BB11 GA05 GB01 GB17 KK03 PP08 5H615 AA01 BB04 BB14 PP26 SS03 SS13 SS44 TT03

Claims (8)

[Claims] An insulator (2, 12) having a substantially cylindrical shape, and a plurality of insulators (2, 12) arranged on the outer periphery of the insulator (2, 12). 14), and a commutator segment (3, 13) extending therefrom, wherein one end face (3a, 1) of the commutator segment (3, 13) is provided.
3a), the base end (4a, 1) of the connection claw (4, 14).
4a) separating the commutator segments (3, 13) radially outward from the inner surfaces of the commutator segments (3, 13).
A commutator, wherein b) is formed. 2. The commutator according to claim 1, wherein the commutator segments (3) have radially inwardly extending projections (5, 2) at positions corresponding to the connection claws (4).
A commutator characterized in that 1) is formed and one end surface of the overhang portion (5, 21) is the isolation surface (3c, 21b). 3. The commutator according to claim 2, wherein a circumferential width (M1) of the projecting portion (5) is wider than a circumferential width (N1) of the connection hook (4). A commutator characterized in that both end portions of the one end face (3c) are continuous with one end face of the commutator segment (3) formed in the circumferential direction of the connection hook (4) in the same plane. 4. The commutator according to claim 2, wherein a circumferential width (M2) of the projecting portion (21) is substantially the same as a circumferential width (N2) of the connection hook (4). An R-shaped portion (21a) is formed radially outward on both sides in the circumferential direction of the overhanging portion (21) so as to expand in the circumferential direction toward the outside in the radial direction, and one end surface of the R-shaped portion (21a) forms A commutator characterized in that one end surface (21b) of the overhang portion is continuous with the one end surface of the commutator segment (3) formed in the circumferential direction of the connection hook (4). 5. The commutator according to claim 2, wherein the protrusion (5, 21) has a locking claw that radially engages the insulator (2). 5a, 21c). 6. The commutator according to claim 1, wherein a radially inner side of one end face (13a) of the commutator segment (13) is formed in an arc shape, and a thickness of the connection nail (14) is formed. U) is made thinner than the radial thickness (L2) of the commutator segment (13), and the connection claws (14) are made closer to the radially inner end of one end face (13a) of the commutator segment (13). A commutator formed radially outward, wherein one end face radially inward of the connection claw (14) is the isolation surface (13b). 7. The commutator according to claim 1, wherein one end face (13a) of the commutator segment (13) is provided on both sides in the circumferential direction of the commutator segment (13). A commutator characterized in that an inclined surface (13e) is formed such that the distance from the circumferential end of the commutator segment (13) decreases toward the end face side. 8. An end portion (6, 16a, 32b) of a substantially cylindrical segment tubular member (6, 16, 32) having a plurality of connecting claws (4, 14) extended therefrom, said connecting claws (6, 16a, 32b). 4,1
Forming a separation surface (3c, 13b, 21b) for separating the base end (4a, 14a) of (4) radially outward from the inner surface of the segment tubular member (6, 16, 32); One end surface (6a, 16a, 32b) of an annular end of the segment tubular member including (3c, 13b, 21b)
The mold (7, 17, 33) is brought into pressure contact with the
An insulating material is filled into the inside of the segment tubular member (6, 16, 32), and after the insulating material is cured, the segment tubular member (6, 16, 32) is cut at predetermined angular intervals to form a plurality of segments. A method for manufacturing a commutator, comprising a commutator segment (3, 13).