JP2007312495A - Assembled commutator and manufacturing method therefor - Google Patents

Assembled commutator and manufacturing method therefor Download PDF

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Publication number
JP2007312495A
JP2007312495A JP2006138358A JP2006138358A JP2007312495A JP 2007312495 A JP2007312495 A JP 2007312495A JP 2006138358 A JP2006138358 A JP 2006138358A JP 2006138358 A JP2006138358 A JP 2006138358A JP 2007312495 A JP2007312495 A JP 2007312495A
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commutator
riser
insulating base
groove
washer
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Minekazu Moriyama
峯和 森山
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NANSHIN SEIKI SEISAKUSHO KK
Nanshin Seiki Seisakusho KK
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NANSHIN SEIKI SEISAKUSHO KK
Nanshin Seiki Seisakusho KK
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Abstract

<P>PROBLEM TO BE SOLVED: To provide an assembled commutator and a manufacturing method therefor wherein multiple commutator pieces can be firmly disposed and fixed on the outer circumferential surface of an insulating substrate. <P>SOLUTION: Multiple commutator pieces 21 having a riser portion 22 are disposed and fixed on the outer circumferential surface of the insulating substrate 10 formed in a cylindrical shape with a slit 23 provided between the individual commutator pieces 21. Washers 30 are fit onto the periphery of the commutator pieces 21 to press and fix them against the outer circumferential surface of the insulating substrate 10. In a flange portion 12 provided at the base end of the insulating substrate 10, there are formed grooves 15 for fitting the base parts of the riser portions 22. A protrusion 14a protruded toward the riser portion 22 is formed on the opening side of each groove 15, and the protrusions 14a are swelled toward the grooves 15 by plastic deformation to fix the base parts of the riser portions 22 in the grooves 15. When fit, the washers 30 cover the swelled portions 15a and press the commutator pieces 21 against the insulating substrate 10. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

本発明は、小型モータ等の回転電機に取り付けられる組立式整流子及びその製造方法に関するものである。   The present invention relates to an assembly type commutator attached to a rotary electric machine such as a small motor and a method for manufacturing the same.

小型モータは、音響・映像機器や光学精密機器など様々な分野で広く使用されており、近年、軽量薄型化、高性能化が進んでいる。小型モータは、ケーシングの内部に永久磁石が装着され、軸受によって回転自在に支持された回転子が前記永久磁石に対向して配設されている。回転子には整流子片を有する整流子ユニットが設けられており、ケーシング内に設置された刷子が整流子ユニットと摺接することにより回転子の電機子巻線に給電している。   Small motors are widely used in various fields such as audio / video equipment and optical precision equipment, and in recent years, light weight, thinning, and high performance are progressing. In the small motor, a permanent magnet is mounted inside a casing, and a rotor that is rotatably supported by a bearing is disposed to face the permanent magnet. The rotor is provided with a commutator unit having a commutator piece, and a brush installed in the casing is in sliding contact with the commutator unit to supply power to the rotor armature winding.

整流子ユニットには、熱硬化性樹脂により全体を一体化したモールド式と、絶縁部分に熱可塑性樹脂を用いた組立式との2種類に大別されるが、電流や発熱量が比較的少ない小型モータには、組立式整流子ユニットが多く用いられている。   There are two types of commutator units: a mold type that integrates the whole with a thermosetting resin and an assembly type that uses a thermoplastic resin for the insulating part, but it has relatively little current and heat generation. Assembling type commutator units are often used for small motors.

組立式整流子ユニットは、一般的には例えば特開2000−92793号公報(特許文献1)に開示された構成が知られている。すなわち、図9は従来の組立式の整流子ユニットを示す分解斜視図で、図10はその断面を示す断面図である。整流子ユニットは、円筒部2の一端にフランジ部3が形成された絶縁基体1と、この絶縁基体1に取り付けられた導電性金属からなる3個の整流子片4と、整流子片4の外周に嵌入されて整流子片4を絶縁基体1の外周面に押圧固定するワッシャー5とを備えている。上記整流子片4は、円弧状に湾曲形成され、図示しない小型モータの刷子と摺接する整流子部4aと、この整流子部4aの一端側から放射状に連設したライザ部4bを有している。このライザ部4bには図示しない電機子巻線の端部が接続される。   The assembly type commutator unit is generally known to have a configuration disclosed in, for example, Japanese Patent Application Laid-Open No. 2000-92793 (Patent Document 1). 9 is an exploded perspective view showing a conventional assembly type commutator unit, and FIG. 10 is a cross-sectional view showing a cross section thereof. The commutator unit includes an insulating base 1 in which a flange portion 3 is formed at one end of a cylindrical portion 2, three commutator pieces 4 made of a conductive metal attached to the insulating base 1, and a commutator piece 4. A washer 5 is provided which is fitted on the outer periphery and presses and fixes the commutator piece 4 to the outer peripheral surface of the insulating substrate 1. The commutator piece 4 is curved in an arc shape, and has a commutator portion 4a that is in sliding contact with a brush of a small motor (not shown), and a riser portion 4b that is radially connected from one end side of the commutator portion 4a. Yes. An end portion of an armature winding (not shown) is connected to the riser portion 4b.

上記ワッシャー5は、通常、紙などの繊維質からなる電気的絶縁機能を有する素材が使用されている。そして、上記ワッシャー5は、3個の整流子片4を絶縁基体1の外周面に装着した後に、図示上方の先端側から嵌挿して各整流子片4を絶縁基体1の外周面に押圧した状態で固定するようにしている。ところが、このようなワッシャー5の寸法が変化した場合には、各整流子片4の押圧力に変化が生じ、振動や衝撃によって絶縁基体1から整流子片4から抜け出してしまう問題が発生することがあった。   The washer 5 is usually made of a material having an electrical insulating function made of a fibrous material such as paper. The washer 5 is fitted with the three commutator pieces 4 on the outer peripheral surface of the insulating base 1 and then inserted from the upper end side in the figure to press the commutator pieces 4 against the outer peripheral surface of the insulating base 1. It is fixed in the state. However, when the dimensions of the washer 5 are changed, the pressing force of each commutator piece 4 is changed, and there arises a problem that the commutator piece 4 comes out of the insulating base body 1 due to vibration or impact. was there.

上述したようなワッシャーによる固定手段の問題を回避するために、ワッシャーを使用することなく、絶縁基体への整流子片の固着強度を増大させる手段が特開平8−149760号公報(特許公報2)に開示されている。すなわち、組立式整流子は、円筒部に形成されたフランジ部の側面に外方に向けた複数の凹溝が形成され、この凹溝には、導電性の3個の整流子片から外方に向けて折曲形成された電機子巻線結線用の端子部が収納される。そして、凹溝の側壁と端子部には凸部が設けられ、端子部が凹溝内に圧入されたとき、凸部と側壁が変形した状態で端子部を係止するように構成されている。   In order to avoid the problem of the fixing means by the washer as described above, a means for increasing the fixing strength of the commutator piece to the insulating base without using a washer is disclosed in Japanese Patent Application Laid-Open No. 8-149760 (Patent Publication 2). Is disclosed. In other words, the assembly type commutator is formed with a plurality of outwardly recessed grooves on the side surface of the flange portion formed in the cylindrical portion, and the recessed grooves are formed outwardly from the three conductive commutator pieces. The terminal part for armature winding connection bent toward is stored. And the convex part is provided in the side wall and terminal part of a ditch | groove, and when a terminal part is press-fitted in a ditch | groove, it is comprised so that a terminal part may be latched in the state which the convex part and the side wall deform | transformed. .

特開2000−92793号公報JP 2000-92793 A 特開平8−149760号公報JP-A-8-149760

このような特許文献2に開示された組立式整流子によれば、整流子片の端子部をフランジ部に形成された凹溝内に圧入するので、前述したワッシャーを省略することが可能となる。ところが、フランジ部の側面に形成した凹溝と整流子片の端子部との寸法精度にばらつきがあることから圧入強度が小さいものがあり、小型モータが回転するときに発生する振動や落下等による衝撃によって整流子片が抜け出してしまう重大な問題が発生することがある。特に、円筒部の外周に装着された整流子片の外径寸法が3mm以下の超小型整流子の場合には、凹溝と整流子片の端子部の寸法が小さいことから、必要な圧入強度が得られない問題があり、しかも、寸法のばらつきによる圧入強度のばらつきが大きくなる問題があることから、結果的に超小型の組立式整流子には使用できなかった。   According to the assembly-type commutator disclosed in Patent Document 2, the terminal portion of the commutator piece is press-fitted into the recessed groove formed in the flange portion, so that the above-described washer can be omitted. . However, due to variations in dimensional accuracy between the groove formed on the side surface of the flange portion and the terminal portion of the commutator piece, there are those with low press-fitting strength, which may be caused by vibration or dropping that occurs when a small motor rotates. There may be a serious problem that the commutator piece is pulled out by impact. In particular, in the case of an ultra-small commutator with an outer diameter of 3 mm or less attached to the outer periphery of the cylindrical part, the required press-fit strength is small because the dimensions of the concave groove and the terminal part of the commutator piece are small. As a result, there has been a problem that variation in press-fit strength due to dimensional variation becomes large, and as a result, it cannot be used for an ultra-small assembly type commutator.

そこで、本発明の課題は、簡易な構成により、複数個の整流子片を絶縁基体の外周面に強固に配設固定することが可能な組立式整流子及びその製造方法を提供することにある。   Accordingly, an object of the present invention is to provide an assembly type commutator capable of firmly arranging and fixing a plurality of commutator pieces on the outer peripheral surface of an insulating base with a simple configuration, and a method for manufacturing the commutator. .

上記の課題を解決するために、請求項1の発明にかかる組立式整流子の製造方法は、円弧状に形成した整流子部および該整流子部に連設したライザ部を有する複数の整流子片を円筒状に形成された絶縁基体の外周面にスリットを設けて配置し、上記整流子片の外周にワッシャーを嵌入して上記絶縁基体の外周面に押圧固定する組立式整流子であり、上記絶縁基体は熱可塑性を有する合成樹脂により形成され、基端側に設けられたフランジ部には上記ライザ部の基部を嵌合する溝部が形成され、上記溝部の開口側には上記ライザ部方向に突出させた突起部が形成されている。この突起部は加熱手段により塑性変形させて上記溝部方向に膨出させ、上記ライザ部の基部を上記溝部内に固定する。そして、上記整流子片の外周に上記ワッシャーを嵌入することにより上記 膨出部を被覆すると共に上記整流子片を上記絶縁基体に押圧したことを要旨としている。   In order to solve the above-mentioned problem, a manufacturing method of an assembly type commutator according to the invention of claim 1 includes a plurality of commutators having a commutator portion formed in an arc shape and a riser portion connected to the commutator portion. An assembling type commutator in which a piece is provided with a slit on an outer peripheral surface of a cylindrical insulating base, and a washer is fitted on the outer periphery of the commutator piece to press and fix the outer peripheral surface of the insulating base. The insulating base is formed of a synthetic resin having thermoplasticity, and a flange portion provided on the base end side is formed with a groove portion for fitting the base portion of the riser portion, and the opening side of the groove portion is in the direction of the riser portion. The protrusion part protruded in this is formed. This protrusion is plastically deformed by a heating means and bulges in the direction of the groove, thereby fixing the base of the riser part in the groove. Then, the gist is that the bulging portion is covered by fitting the washer into the outer periphery of the commutator piece and the commutator piece is pressed against the insulating base.

また、請求項2に記載の発明は、上記ワッシャーはリング状に形成され、外径が上記 膨出部を被覆する大きさに形成され、内径が絶縁基体の外周面に配置した上記整流子片を押圧する大きさに形成されたことを要旨としている。   According to a second aspect of the present invention, in the commutator piece, the washer is formed in a ring shape, an outer diameter is formed to cover the bulging portion, and an inner diameter is disposed on the outer peripheral surface of the insulating base. The gist is that it is formed in a size to press.

さらに、請求項3に記載の発明は、円弧状に形成した整流子部および該整流子部に連設したライザ部を有する複数の整流子片を円筒状に形成された絶縁基体の外周面に対して、各整流子片間にスリットを設けて配置した後、上記整流子片の外周にワッシャーを嵌入して上記絶縁基体の外周面に押圧固定してなる組立式整流子の製造方法であり、熱可塑性を有する合成樹脂により形成された上記絶縁基体の基端側に設けられたフランジ部の溝部に上記ライザ部の基部を嵌合し、上記溝部の開口側に突出形成された突起部を塑性変形によって上記溝部方向に膨出させて膨出部を形成することにより上記ライザ部を上記溝部内に固定し、上記ワッシャーを上記整流子片の外周に嵌入して上記整流子片を上記絶縁基体に押圧固定すると共に上記 膨出部を被覆したことを要旨としている。   Further, according to the third aspect of the present invention, a plurality of commutator pieces having a commutator portion formed in an arc shape and a riser portion connected to the commutator portion are provided on the outer peripheral surface of the insulating base formed in a cylindrical shape. On the other hand, it is a method of manufacturing an assembling type commutator in which a slit is provided between each commutator piece and then a washer is fitted to the outer periphery of the commutator piece and pressed and fixed to the outer peripheral surface of the insulating base. The base portion of the riser portion is fitted into the groove portion of the flange portion provided on the base end side of the insulating base formed of a synthetic resin having thermoplasticity, and the protrusion portion formed to protrude to the opening side of the groove portion is provided. The riser part is fixed in the groove part by bulging in the groove part direction by plastic deformation, and the washer is fitted to the outer periphery of the commutator piece to insulate the commutator piece. While pressing and fixing to the base, the bulge The gist is that it is coated.

さらにまた、請求項4に記載の発明は、上記突起部は加熱手段により加熱された押圧工具によって上記ライザ部方向に塑性変形させて膨出し、 膨出部により上記ライザ部の基部を上記溝部内に固定した後、上記ワッシャーを上記整流子片の外周に嵌入して上記 膨出部を被覆することを要旨としている。   Furthermore, in the invention described in claim 4, the protrusion is bulged by being plastically deformed in the direction of the riser by a pressing tool heated by a heating means, and the base of the riser is inserted into the groove by the bulge. The gist is that the washer is fitted into the outer periphery of the commutator piece and covers the bulging portion.

本発明にかかるに組立式整流子によれば、円筒状に形成された絶縁基体の外周面に配置固定される複数の整流子片のライザ部が、絶縁基体のフランジ部に形成された溝部内に嵌合され、このライザ部が溝部の開口側の突出形成した突起部を塑性変形させて膨出させることにより押圧するので、絶縁基体の外周面に各整流子片を強固に固定することができる。さらに、ワッシャーが各整流子片を絶縁基体の外周面に押圧固定するので、各整流子片が回転時の遠心力等によりラジアル方向へ離脱することを未然に防止することができる。しかも、絶縁基体に形成された突起部の塑性変形によって固定するので、例え整流子片のライザ部や絶縁基体の溝部の寸法にばらつきがあっても、整流子片を確実に固定することが可能となる。また、ワッシャーが 膨出部を被覆しているので、上記突起部を加熱して塑性変形した後に糸引き現象(misting)によって糸状のひげが生じても、ワッシャーによりひげが押圧され、整流子片への突出や飛散を未然に防止することができる。   According to the assembly type commutator according to the present invention, the riser portion of the plurality of commutator pieces arranged and fixed on the outer peripheral surface of the cylindrical insulating base is formed in the groove formed in the flange portion of the insulating base. Since the riser portion is pressed by plastically deforming and projecting the protrusion formed on the opening side of the groove portion, each commutator piece can be firmly fixed to the outer peripheral surface of the insulating base. it can. Further, since the washer presses and fixes each commutator piece to the outer peripheral surface of the insulating base, it is possible to prevent the commutator pieces from separating in the radial direction due to centrifugal force during rotation. Moreover, since the protrusions formed on the insulating base are fixed by plastic deformation, the commutator pieces can be securely fixed even if the riser portion of the commutator pieces and the groove portions of the insulating base are uneven. It becomes. In addition, since the washer covers the bulging portion, even if a thread-like whisker occurs due to the stringing phenomenon (misting) after the protrusion is heated and plastically deformed, the whisker is pressed by the washer, and the commutator piece It is possible to prevent protrusions and splashes.

また、請求項2に記載の発明によれば、リング状に形成したワッシャーの外径を 膨出部を被覆する大きさに形成し、内径を絶縁基体の外周面に配置した整流子片を押圧する大きさに形成しているので、糸状のひげが整流子片側に生じても、ワッシャーを整流子片に軽圧入的に嵌入するのでひげが絶縁基体側に戻されることから、整流子片への突出や飛散を防止することができる。   According to the invention described in claim 2, the outer diameter of the washer formed in a ring shape is formed so as to cover the bulging portion, and the inner diameter is pressed on the outer peripheral surface of the insulating base. Since the washer is lightly press-fitted into the commutator piece even if thread-like whiskers occur on the commutator piece side, the whiskers are returned to the insulating substrate side. Can be prevented from protruding and scattering.

本発明にかかるに組立式整流子の製造方法によれば、絶縁基体のフランジ部に形成された溝部内に複数の整流子片のライザ部を嵌合した後、突起部を塑性変形によって各整流子片を容易に固定することができる。さらに、ワッシャーを各整流子片の外周面に嵌入することで、絶縁基体の外周面への各整流子片の固定と、糸状のひげの押圧による突出や飛散防止を同時に行うことができる。   According to the manufacturing method of the assembly-type commutator according to the present invention, after the riser portions of the plurality of commutator pieces are fitted into the groove portions formed in the flange portion of the insulating base, the protrusions are rectified by plastic deformation. The child piece can be easily fixed. Furthermore, by inserting the washer into the outer peripheral surface of each commutator piece, it is possible to fix each commutator piece to the outer peripheral surface of the insulating base and to prevent protrusion and scattering due to the pressing of the thread-like whiskers.

また、請求項4に記載の発明によれば、加熱手段により加熱された押圧工具によって突起部を塑性変形させて膨出する簡易な方法によりライザ部の基部を溝部内に固定することができる。しかも、ワッシャーを整流子片の外周に嵌入すると共に 膨出部を被覆するので、簡易な手段によって整流子片の外周方向への離脱と糸状のひげの押圧による突出や飛散防止を同時に行うことができる。   According to the invention described in claim 4, the base portion of the riser portion can be fixed in the groove portion by a simple method in which the protruding portion is plastically deformed and bulged by the pressing tool heated by the heating means. Moreover, since the washer is fitted to the outer periphery of the commutator piece and covers the bulging portion, it is possible to simultaneously prevent the commutator piece from detaching in the outer peripheral direction and preventing protrusion and scattering by pressing the filamentous whisker. it can.

組立式整流子は、円弧状に形成した整流子部および該整流子部に連設したライザ部を有する複数の整流子片を円筒状に形成された絶縁基体の外周面に対して、各整流子片間にスリットを設けて配置固定され、さらに、上記整流子片の外周にワッシャーを嵌入して上記絶縁基体の外周面に押圧固定されている。この組立式整流子において、上記絶縁基体の基端側に設けられたフランジ部には、上記ライザ部の基部を嵌合する溝部が形成され、この溝部の開口側には上記ライザ部方向に突起部が突出形成されている。この突起部は塑性変形可能であり、突起部を塑性変形させて上記溝部方向に膨出し、この 膨出部によって上記ライザ部の基部を上記溝部内に固定する。さらに、上記ワッシャーを上記整流子片の外周に嵌入する。そして、上記整流子片の外周に上記ワッシャーを嵌入することにより上記膨出部を被覆すると共に上記整流子片を上記絶縁基体に押圧する。   The assembly type commutator is configured such that a plurality of commutator pieces each having a commutator portion formed in an arc shape and a riser portion connected to the commutator portion are rectified with respect to the outer peripheral surface of the insulating base formed in a cylindrical shape. A slit is provided between the element pieces and fixed. Further, a washer is fitted on the outer periphery of the commutator piece and is fixed to the outer peripheral surface of the insulating base. In this assembly type commutator, a groove portion that fits the base portion of the riser portion is formed in the flange portion provided on the base end side of the insulating base, and the groove portion projects toward the riser portion on the opening side. The part is formed to protrude. The protruding portion can be plastically deformed, and the protruding portion is plastically deformed to bulge in the direction of the groove portion, and the base portion of the riser portion is fixed in the groove portion by the bulging portion. Further, the washer is fitted on the outer periphery of the commutator piece. Then, the washer is fitted on the outer periphery of the commutator piece to cover the bulging portion and press the commutator piece against the insulating base.

図1は本発明の実施形態にかかる組立式整流子の平面図、図2は同整流子の断面図、図3は分解斜視図、図4(A)(B)は整流子片のライザ部を固定する工程を示す説明図である。図1乃至図3に示すように、組立式整流子は、円筒状に形成した例えば熱可塑性樹脂等の可塑性を有する樹脂からなる電気的絶縁材料によって形成された絶縁基体10と、導電性金属からなり、絶縁基体10の外周に取り付けられた複数個の整流子片21からなる整流子部20と、整流子片21の外周に配設されて整流子片21を絶縁基体1の外周面に押圧固定するワッシャー30とによって構成されている。   1 is a plan view of an assembly type commutator according to an embodiment of the present invention, FIG. 2 is a sectional view of the commutator, FIG. 3 is an exploded perspective view, and FIGS. 4A and 4B are riser portions of commutator pieces. It is explanatory drawing which shows the process of fixing. As shown in FIGS. 1 to 3, the assembly type commutator includes an insulating base 10 formed of an electrically insulating material made of a resin having plasticity such as a thermoplastic resin formed in a cylindrical shape, and a conductive metal. The commutator portion 20 is composed of a plurality of commutator pieces 21 attached to the outer periphery of the insulating base 10 and the commutator piece 21 is disposed on the outer periphery of the commutator piece 21 and presses the commutator piece 21 against the outer peripheral surface of the insulating base 1. And a washer 30 to be fixed.

上記絶縁基体10は、後述するように、加熱によって塑性変形し、しかも熱膨張率や経時変化が小さいエンジニアリングプラスチック、例えば、ポリアミド9T樹脂、ポリブチレンテレフタレート(PBT)などの合成樹脂が採用される。絶縁基体10は、これらの樹脂を使用して、所定のモールド金型によって例えば射出成形等成型手段によって形成される。   As will be described later, the insulating base 10 is made of an engineering plastic that is plastically deformed by heating and has a small coefficient of thermal expansion and change with time, such as a synthetic resin such as polyamide 9T resin and polybutylene terephthalate (PBT). The insulating substrate 10 is formed by a molding means such as injection molding using a predetermined mold using these resins.

そして、絶縁基体10は、円筒部11とその基端側に円筒部11よりも大径のフランジ部12とが一体的に成形され、中央の貫通孔13には図示しないモータ等の回転軸が嵌入される。フランジ部12の端面には円環状の突堤部14が形成され、この突堤部14には整流子片21のライザ部22を嵌合するための溝部15が周方向に約120度毎の等間隔で3箇所形成されている。この溝部15の深さは、ライザ部22の板厚寸法よりもおよそ2倍乃至5倍程度の寸法に設定され、溝部15の幅はライザ部22の嵌合を許容する寸法に設定されている。   The insulating base 10 is integrally formed with a cylindrical portion 11 and a flange portion 12 having a diameter larger than that of the cylindrical portion 11 on the base end side, and a rotation shaft such as a motor (not shown) is provided in the central through hole 13. Inserted. An annular jetty portion 14 is formed on the end surface of the flange portion 12, and a groove portion 15 for fitting the riser portion 22 of the commutator piece 21 is equidistantly spaced about every 120 degrees in the circumferential direction. In three places. The depth of the groove portion 15 is set to a dimension that is approximately two to five times the plate thickness dimension of the riser portion 22, and the width of the groove portion 15 is set to a dimension that allows the riser portion 22 to be fitted. .

また、図3に示すように、絶縁基体10の円筒部11の基端近傍に位置する突堤部14には、上記溝部15の両側に各々突起部14aが一体に突出形成されている。この突起部14aは、図示のように円錐状に形状に形成され、加熱することにより塑性変形させることができる。なお、突起部14aは、円錐状の他に、円柱状、角柱状または半球状等の適宜な形状に形成しても良い。そして、個々の突起部14aの体積は、好ましくは、上記溝部15にライザ部22を嵌合したときに形成される開口側空間の容積の2分の1程度に設定される。   Further, as shown in FIG. 3, protrusions 14 a are integrally formed on both sides of the groove portion 15 on the jetty portion 14 located near the base end of the cylindrical portion 11 of the insulating base 10. This protrusion 14a is formed in a conical shape as shown, and can be plastically deformed by heating. In addition to the conical shape, the protruding portion 14a may be formed in an appropriate shape such as a columnar shape, a prismatic shape, or a hemispherical shape. And the volume of each protrusion part 14a is preferably set to about one half of the volume of the opening side space formed when the riser part 22 is fitted to the groove part 15.

さらに、突堤部14よりも内側で円筒部11との付け根の部分には整流子片21の下端部を受け入れるための円弧状溝17が各溝部15と繋がって形成されている。これらの円弧状溝17は、円筒部11の外周面から半径方向外側に膨出した凸部16によって周方向に隔てられている。凸部16は、周方向に約120度毎の等間隔で3箇所形成され、それぞれの両側面に整流子片21の側面が当接することにより、スリット23の幅Sを一定に保つように機能している。   Further, an arc-shaped groove 17 for receiving the lower end portion of the commutator piece 21 is formed in the base portion with the cylindrical portion 11 inside the jetty portion 14 so as to be connected to each groove portion 15. These arc-shaped grooves 17 are separated in the circumferential direction by convex portions 16 bulging radially outward from the outer peripheral surface of the cylindrical portion 11. The convex portions 16 are formed at three locations at regular intervals of about 120 degrees in the circumferential direction, and function to keep the width S of the slit 23 constant by contacting the side surfaces of the commutator piece 21 with both side surfaces. is doing.

整流子片21は、図示しない小型モータ等の回転電機に配設された刷子と摺接する円弧状に形成された整流子部20と、この整流子部20の一端側から半径方向外側に向けて屈曲形成されたライザ部22とを有している。上記整流子片21の素材は、銅を基材とし、刷子と摺接する個所にAg−Cuなどの薄い接点材料を埋め込んだクラッド材が用いられている。さらに、整流子片21は、絶縁基体10の円筒部11の外周面に合った曲率半径を有し、その幅は絶縁基体10に取り付けたとき、隣接する各整流子片21の間に所定の幅Sのスリット23が形成されるすように設定されている。なお、ライザ部22には図示しない電機子巻線が接続される。   The commutator piece 21 has a commutator portion 20 formed in an arc shape that is in sliding contact with a brush disposed in a rotating electric machine such as a small motor (not shown), and is directed radially outward from one end side of the commutator portion 20. And a riser portion 22 that is bent. The commutator piece 21 is made of a clad material in which copper is used as a base material and a thin contact material such as Ag-Cu is embedded in a portion in sliding contact with the brush. Further, the commutator piece 21 has a radius of curvature that matches the outer peripheral surface of the cylindrical portion 11 of the insulating base 10, and its width is a predetermined distance between adjacent commutator pieces 21 when attached to the insulating base 10. A slit 23 having a width S is set to be formed. Note that an armature winding (not shown) is connected to the riser unit 22.

また、突堤部14の円筒部11側面には、整流子片21の外周に嵌入されたワッシャー30が当接されている。このワッシャー30はリング状に形成され、紙、合成樹脂、或いは、バリスタなどの電気的絶縁機能または半導体機能を有する素材が使用されている。さらに、ワッシャー30は、内径寸法が整流子片21を絶縁基体1の外周面に押圧固定する大きさに設定され、外径寸法が突起部14aを塑性変形させることによって形成された膨出部を被覆する大きさに形成されている。そして、上記ワッシャー30は、3個の整流子片21を絶縁基体10の外周面に装着した後に、図示上方の先端側から嵌入して各整流子片21を絶縁基体10の外周面に押圧した状態で固定するようにしている。   Further, a washer 30 fitted on the outer periphery of the commutator piece 21 is in contact with the side surface of the cylindrical portion 11 of the jetty portion 14. The washer 30 is formed in a ring shape, and a material having an electrical insulating function or a semiconductor function such as paper, synthetic resin, or varistor is used. Furthermore, the washer 30 has an inner diameter dimension set to a size that presses and fixes the commutator piece 21 to the outer peripheral surface of the insulating base 1, and an outer diameter dimension is a bulging portion formed by plastic deformation of the protrusion 14a. It is formed in the size to cover. The washer 30 is attached to the outer peripheral surface of the insulating base 10 with the three commutator pieces 21 and then fitted from the upper end side in the drawing to press the commutator pieces 21 against the outer peripheral surface of the insulating base 10. It is fixed in the state.

次に、本発明からなる組立式整流子の製造方法について説明する。まず、図3に示すように、3個の整流子片21を矢示の方向に向けて各々絶縁基体10の円筒部11の外周面に添設する。このとき、整流子片21のライザ部22を溝部15に嵌合するとともに、円筒部11の付け根部分に形成された円弧状溝17に整流子片21の下端部を挿入し、側面を凸部16に当接させる。この結果、整流子片21はスリット23の幅Sを一定に保ちながら所定の位置に添設される。   Next, the manufacturing method of the assembly type commutator which consists of this invention is demonstrated. First, as shown in FIG. 3, the three commutator pieces 21 are attached to the outer peripheral surface of the cylindrical portion 11 of the insulating base 10 in the direction indicated by the arrow. At this time, the riser portion 22 of the commutator piece 21 is fitted into the groove portion 15, the lower end portion of the commutator piece 21 is inserted into the arc-shaped groove 17 formed at the base portion of the cylindrical portion 11, and the side surface is convex. 16 is contacted. As a result, the commutator piece 21 is attached at a predetermined position while keeping the width S of the slit 23 constant.

このように、整流子片21を絶縁基体10の円筒部11の外周面に添設したときには、図4(A)に示すように、整流子片21のライザ部22が溝部15の底面に当接するまで嵌合する。上述したように、溝部15の深さをライザ部22の板厚寸法よりも大きく形成しているので、ライザ部22の上面と溝部15の開口端との間は離間し、そこに空間が形成されている。   In this way, when the commutator piece 21 is attached to the outer peripheral surface of the cylindrical portion 11 of the insulating base 10, the riser portion 22 of the commutator piece 21 contacts the bottom surface of the groove portion 15 as shown in FIG. Fit until contacted. As described above, since the depth of the groove portion 15 is formed larger than the plate thickness dimension of the riser portion 22, the upper surface of the riser portion 22 and the opening end of the groove portion 15 are separated from each other, and a space is formed there. Has been.

3個の整流子片20のライザ部22を溝部15に嵌合した状態から、押圧工具40の押圧により突起部14aを塑性変形する。押圧工具40は、例えば電熱ヒーターによって所定の温度に加熱されている。このように、加熱された押圧工具40を突起部14aに向けて押圧すると、図4(B)に示すように、突起部14aは塑性変形し、突起部14aの樹脂は、特に流動負荷が小さな上記溝部15の開口側空間内に移動して溝部15内には膨出部15aが膨出形成される。この結果、溝部15内に嵌合したライザ部22の基部は、膨出部15aによって押圧されて溝部15内に固着される。このとき、図示のように、膨出部15aは互いに接近するように溝部15の空間内に膨出され、図6に示すように、突堤部14の上面が平坦に形成されると共に、両側の膨出部15a間にはギャップが形成されるが、両側の膨出部15aを接合するまで膨出させ、この膨出部15aが突堤部14の上面よりやや突出させても良い。   From the state in which the riser portions 22 of the three commutator pieces 20 are fitted in the groove portions 15, the protrusion portions 14 a are plastically deformed by pressing the pressing tool 40. The pressing tool 40 is heated to a predetermined temperature by, for example, an electric heater. Thus, when the heated pressing tool 40 is pressed toward the protrusion 14a, the protrusion 14a is plastically deformed as shown in FIG. 4B, and the resin of the protrusion 14a has a particularly small flow load. A bulging portion 15 a bulges in the groove portion 15 by moving into the opening side space of the groove portion 15. As a result, the base portion of the riser portion 22 fitted in the groove portion 15 is pressed by the bulging portion 15 a and fixed in the groove portion 15. At this time, as shown in the figure, the bulging portion 15a bulges into the space of the groove portion 15 so as to approach each other, and the upper surface of the jetty portion 14 is formed flat as shown in FIG. Although a gap is formed between the bulging portions 15 a, the bulging portions 15 a on both sides may be bulged until they are joined, and the bulging portions 15 a may slightly protrude from the upper surface of the jetty portion 14.

なお、超音波加熱手段やレーザー加熱手段等により突起部14aを塑性変形可能な温度に加熱しながら押圧工具40を押圧し、突起部14aの樹脂を溝部15内に移動させて膨出部15aを形成することによってライザ部22を固定するようにしても良い。   The pressing tool 40 is pressed while the projection 14a is heated to a temperature at which plastic deformation can be performed by ultrasonic heating means, laser heating means, or the like, and the resin of the projection 14a is moved into the groove 15 so that the bulge 15a is moved. The riser part 22 may be fixed by forming.

このように、突起部14aを押圧して塑性変形するとき、図5に示すように、突起部14aの樹脂は溝部15内に移動するとともに、整流子部21の外周面方向に移動する。この結果、整流子片21は絶縁基体10の円筒部11の外周面に圧接されることから、3個の整流子片20はライザ部22とともに強固に固定される。従って、整流子片21は、ワッシャー30による押圧固定と、突起部14aの塑性変形による外周側からの押圧固定、および、ライザ部22の固定により確実に固定される。   Thus, when the protrusion 14a is pressed and plastically deformed, the resin of the protrusion 14a moves into the groove 15 and moves toward the outer peripheral surface of the commutator 21 as shown in FIG. As a result, since the commutator piece 21 is pressed against the outer peripheral surface of the cylindrical portion 11 of the insulating base 10, the three commutator pieces 20 are firmly fixed together with the riser portion 22. Therefore, the commutator piece 21 is securely fixed by pressing and fixing by the washer 30, pressing and fixing from the outer peripheral side by plastic deformation of the protrusion 14 a, and fixing of the riser portion 22.

ところで、溝部15の幅はライザ部22が嵌合できるように設定されているが、溝部15とライザ部22の幅は寸法のばらつきを有していて、溝部15内にライザ部22が緩く嵌合する場合がある。しかし、上述したように、溝部15内に嵌合したライザ部22を、塑性変形によって形成された膨出部15aにより押圧して固定するので、溝部15とライザ部22の幅にばらつきがあったとしても所定の強度によって固定することができる。特に、整流子部の外径寸法が3mm以下の超小型整流子の場合には、溝部15とライザ部22の幅が0.5mm以下の寸法になることから、両者間の嵌合状態が大きくばらつくことがある。しかし、このような極小寸法の超小型組立式整流子であっても、ライザ部22を、塑性変形によって形成された膨出部15aにより固定するので、固定に関して寸法のばらつきは無視することが可能となる。   By the way, the width of the groove portion 15 is set so that the riser portion 22 can be fitted, but the width of the groove portion 15 and the riser portion 22 varies in size, and the riser portion 22 fits loosely in the groove portion 15. May match. However, as described above, since the riser portion 22 fitted in the groove portion 15 is pressed and fixed by the bulging portion 15a formed by plastic deformation, the width of the groove portion 15 and the riser portion 22 varies. Can be fixed with a predetermined strength. In particular, in the case of an ultra-compact commutator having an outer diameter of the commutator portion of 3 mm or less, since the width of the groove portion 15 and the riser portion 22 is 0.5 mm or less, the fitting state between the two is large. May vary. However, even in such a very small size ultra-compact assembly type commutator, the riser portion 22 is fixed by the bulging portion 15a formed by plastic deformation, so that the variation in size with respect to fixing can be ignored. It becomes.

次に、上記ワッシャー30を整流子片21の図示上方の先端側から軽圧入状態で突起部14aに当接するまで嵌入し、3個の整流子片20を絶縁基体10の円筒部11の外周面に押圧固定すると共に、膨出部15aを被覆する。これにより、組立式整流子が製造される。   Next, the washer 30 is inserted from the upper end side of the commutator piece 21 in the illustrated state until it comes into contact with the protrusion 14a in a light press-fit state, and the three commutator pieces 20 are attached to the outer peripheral surface of the cylindrical portion 11 of the insulating base 10. And the bulging portion 15a is covered. Thereby, an assembly-type commutator is manufactured.

上述したように、所定の温度に加熱された押圧工具40の押圧により突起部14aを塑性変形させて押圧した後、押圧工具40を引き上げるときに、図7に示すように、膨出部15aに糸引き現象(misting)によって糸状のひげ50が生ずることがある。このひげ50は、小型モータ等の回転電機に配設したときに飛散して整流子部20に付着することがある。ひげ50電気的に絶縁体のため、刷子が付着したひげ50に乗り上げたときに通電が停止する事故が発生する。   As described above, when the protrusion 14a is plastically deformed and pressed by pressing the pressing tool 40 heated to a predetermined temperature, when the pressing tool 40 is pulled up, as shown in FIG. A thread-like whisker 50 may occur due to misting. The whiskers 50 may scatter and adhere to the commutator 20 when disposed in a rotating electric machine such as a small motor. The whisker 50 is an electrically insulating material, and there is an accident in which energization stops when the brush 50 rides on the beard 50 with the brush attached.

ところが、ワッシャー30を膨出部15aに当接するまで嵌入すると、ワッシャー30の押圧力によって、図8に示すように、ひげ50を圧潰すると共に、膨出部15aを被覆する。この結果、ひげ50は膨出部15aとワッシャー30の間に挟持され、さらに、ワッシャー30の内周面と整流子片21との間には隙間がないので、整流子片21側を経由することも阻止されることから、整流子部20への付着や、モータ内への飛散が防止される。   However, when the washer 30 is inserted until it comes into contact with the bulging portion 15a, the pressing force of the washer 30 compresses the whisker 50 and covers the bulging portion 15a as shown in FIG. As a result, the whisker 50 is sandwiched between the bulging portion 15a and the washer 30, and there is no gap between the inner peripheral surface of the washer 30 and the commutator piece 21, so that it passes through the commutator piece 21 side. Since this is also prevented, adhesion to the commutator 20 and scattering into the motor are prevented.

以上のように、円筒状に形成された絶縁基体10の外周面に配置固定される複数の整流子片20のライザ部22が、絶縁基体10のフランジ部12に形成された溝部15内に嵌合され、さらに、溝部15の開口側に形成した突起部14aを押圧工具40の押圧により塑性変形させてライザ部22の基部を固定するので、簡易な構成によって絶縁基体10の外周面に各整流子片20を強固に配設固定することができる。また、突起部14aの塑性変形によって固定するので、例え整流子片のライザ部や絶縁基体の溝部の寸法にばらつきがあっても、整流子片を確実に固定することが可能となる。さらに、ワッシャーが 膨出部を被覆しているので、上記突起部を加熱して塑性変形した後に糸引き現象によって糸状のひげが生じても、ワッシャーによりひげが押圧され、整流子片への突出や飛散を未然に防止することができる。   As described above, the riser portions 22 of the plurality of commutator pieces 20 arranged and fixed on the outer peripheral surface of the insulating base 10 formed in a cylindrical shape are fitted in the grooves 15 formed in the flange portion 12 of the insulating base 10. In addition, since the protrusion 14a formed on the opening side of the groove 15 is plastically deformed by the pressing of the pressing tool 40 and the base of the riser 22 is fixed, each rectification is performed on the outer peripheral surface of the insulating base 10 with a simple configuration. The child piece 20 can be firmly disposed and fixed. Further, since the protrusion 14a is fixed by plastic deformation, the commutator piece can be reliably fixed even if the dimensions of the riser portion of the commutator piece and the groove portion of the insulating base vary. In addition, since the washer covers the bulging portion, even if a thread-like whisker occurs due to the thread pulling phenomenon after the protrusion is heated and plastically deformed, the whisker is pressed by the washer and protrudes into the commutator piece. And scattering can be prevented.

以上、本発明を実施例に基づいて具体的に説明したが、本発明は上記実施例に限定されるものではなく、その要旨を逸脱しない範囲内で種々変更可能であることは言うまでもない。例えば、上述した実施例は、溝部の開口側を塑性変形させてライザ部を左右一対の膨出部によって固定しているが、溝部の開口側の一方に突起部を形成し、この1個の突起部を塑性変形させて、1つの膨出部によって固定するようにしても良い。また、整流子片をに数は3個に限らず、2個以上の任意の数に変更しても良く、各整流子片の開角度は、等角度に限らず、異なった角度に設定しても良い。この場合には、上記突起部の配置角度も異なった角度に設定される。さらに、溝部の開口側の形状は、上述した実施例の形状に限らず、開口側の塑性変形により溝部内に膨出部を膨出できる樹脂の量が確保できれば、任意の形状に形成しても良い。   Although the present invention has been specifically described above based on the embodiments, it is needless to say that the present invention is not limited to the above embodiments and can be variously modified without departing from the gist thereof. For example, in the above-described embodiment, the opening side of the groove portion is plastically deformed and the riser portion is fixed by a pair of left and right bulging portions, but a protrusion is formed on one of the opening sides of the groove portion, and this one piece The protruding portion may be plastically deformed and fixed by one bulging portion. Further, the number of commutator pieces is not limited to three, and may be changed to an arbitrary number of two or more. The open angle of each commutator piece is not limited to an equal angle, and is set to a different angle. May be. In this case, the arrangement angle of the protrusion is also set to a different angle. Furthermore, the shape of the groove side on the opening side is not limited to the shape of the above-described embodiment, and any shape can be used as long as the amount of resin that can bulge the bulging portion in the groove portion can be secured by plastic deformation on the opening side. Also good.

本発明にかかる組立式整流子の平面図である。It is a top view of the assembly-type commutator concerning this invention. 図1における断面図である。It is sectional drawing in FIG. 本発明にかかる組立式整流子の分解斜視図である。It is a disassembled perspective view of the assembly-type commutator concerning this invention. (A)(B)は、本発明にかかる組立式整流子のライザ部を固定する工程を示す説明図である。(A) (B) is explanatory drawing which shows the process of fixing the riser part of the assembly-type commutator concerning this invention. 本発明にかかる組立式整流子のライザ部を固定した状態を示す拡大断面図である。It is an expanded sectional view showing the state where the riser part of the assembly type commutator concerning the present invention was fixed. 本発明にかかる組立式整流子の斜視図である。It is a perspective view of the assembly-type commutator concerning this invention. 膨出部にひげが生じた状態を示す断面図である。It is sectional drawing which shows the state in which the beard produced in the bulging part. 膨出部に生じたひげをワッシャーにより押圧した状態を示す断面図である。It is sectional drawing which shows the state which pressed the whisker produced in the bulging part with the washer. 従来の組立式整流子の構成を示した分解斜視図である。It is the disassembled perspective view which showed the structure of the conventional assembly type commutator. 従来の組立式整流子の構成を示した断面図である。It is sectional drawing which showed the structure of the conventional assembly type commutator.

符号の説明Explanation of symbols

10 絶縁基体
11 円筒部
12 フランジ部
14a 突起部
15 溝部
15a 膨出部
20 整流子片
21 整流子部
22 ライザ部
23 スリット
30 ワッシャー
40 押圧工具
50 ひげ
DESCRIPTION OF SYMBOLS 10 Insulation base | substrate 11 Cylindrical part 12 Flange part 14a Protrusion part 15 Groove part 15a Expansion part 20 Commutator piece 21 Commutator part 22 Riser part 23 Slit 30 Washer 40 Press tool 50 Whisk

Claims (4)

円弧状に形成した整流子部および該整流子部に連設したライザ部を有する複数の整流子片を円筒状に形成された絶縁基体の外周面に対して、各整流子片間にスリットを設けて配置し、上記整流子片の外周にワッシャーを嵌入して上記絶縁基体の外周面に押圧固定してなる組立式整流子において、
上記絶縁基体は熱可塑性を有する合成樹脂により形成され、基端側に設けられたフランジ部には上記ライザ部の基部を嵌合する溝部が形成され、
上記溝部の開口側には上記ライザ部方向に突出させた突起部が形成され、
上記ライザ部の基部は上記突起部の塑性変形によって上記溝部方向に膨出させた膨出部により上記溝部内に固定され、
上記ワッシャーは、上記整流子片の外周に嵌入して上記整流子片を上記絶縁基体に押圧固定すると共に、上記膨出部分を被覆したことを特徴とする組立式整流子。
A plurality of commutator pieces having a commutator portion formed in an arc shape and a riser portion connected to the commutator portion are formed with slits between the respective commutator pieces on the outer peripheral surface of the cylindrical insulating base. In the assembly type commutator formed by placing and arranging a washer on the outer periphery of the commutator piece and pressing and fixing to the outer peripheral surface of the insulating base,
The insulating base is formed of a synthetic resin having thermoplasticity, and a groove portion for fitting the base portion of the riser portion is formed in the flange portion provided on the base end side,
On the opening side of the groove is formed a protrusion protruding in the riser direction,
The base part of the riser part is fixed in the groove part by a bulging part bulged in the groove part direction by plastic deformation of the protrusion part,
The assembly type commutator, wherein the washer is fitted on an outer periphery of the commutator piece, presses and fixes the commutator piece to the insulating base, and covers the bulging portion.
上記ワッシャーはリング状に形成され、外径が上記膨出部分を被覆する大きさに形成され、内径が絶縁基体の外周面に配置した上記整流子片を押圧する大きさに形成された請求項1に記載の組立式整流子。   The washer is formed in a ring shape, an outer diameter is formed to cover the bulging portion, and an inner diameter is formed to press the commutator piece disposed on the outer peripheral surface of the insulating base. The assembly type commutator according to 1. 円弧状に形成した整流子部および該整流子部に連設したライザ部を有する複数の整流子片を円筒状に形成された絶縁基体の外周面に対して、各整流子片間にスリットを設けて配置した後、上記整流子片の外周にワッシャーを嵌入して上記絶縁基体の外周面に押圧固定してなる組立式整流子の製造方法において、
熱可塑性を有する合成樹脂により形成された上記絶縁基体の基端側に設けられたフランジ部の溝部に上記ライザ部の基部を嵌合し、
上記溝部の開口側に突出形成された突起部を塑性変形によって上記溝部方向に膨出させて膨出部を形成することにより上記ライザ部を上記溝部内に固定し、
上記ワッシャーを上記整流子片の外周に嵌入して上記整流子片を上記絶縁基体に押圧固定すると共に、上記膨出部分を被覆したことを特徴とする組立式整流子の製造方法。
A plurality of commutator pieces having a commutator portion formed in an arc shape and a riser portion connected to the commutator portion are formed with slits between the respective commutator pieces on the outer peripheral surface of the cylindrical insulating base. After providing and arranging, in the manufacturing method of the assembly type commutator formed by inserting a washer into the outer periphery of the commutator piece and pressing and fixing to the outer peripheral surface of the insulating base,
The base portion of the riser portion is fitted into the groove portion of the flange portion provided on the base end side of the insulating base formed of a synthetic resin having thermoplasticity,
The riser portion is fixed in the groove portion by forming a bulge portion by bulging the protrusion portion formed on the opening side of the groove portion in the direction of the groove portion by plastic deformation,
A method of manufacturing an assembly-type commutator, wherein the washer is fitted on an outer periphery of the commutator piece to press-fix the commutator piece to the insulating base and cover the bulging portion.
上記突起部は加熱手段により加熱された押圧工具によって上記ライザ部方向に塑性変形させて膨出し、膨出部分により上記ライザ部の基部を上記溝部内に固定した後、上記ワッシャーを上記整流子片の外周に嵌入して上記膨出部分を被覆する請求項3に記載の組立式整流子の製造方法。

The protrusion is bulged by plastic deformation in the direction of the riser by a pressing tool heated by a heating means, and the base of the riser is fixed in the groove by the bulge, and then the washer is fixed to the commutator piece. The manufacturing method of the assembly type commutator according to claim 3, wherein the bulging portion is covered by being fitted on an outer periphery of the commutator.

JP2006138358A 2006-05-17 2006-05-17 Assembled commutator and manufacturing method therefor Pending JP2007312495A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110350727A (en) * 2019-08-12 2019-10-18 宁波市鸿林自动化机械有限公司 A kind of automatic assembly equipment of miniature DC motor

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110350727A (en) * 2019-08-12 2019-10-18 宁波市鸿林自动化机械有限公司 A kind of automatic assembly equipment of miniature DC motor
CN110350727B (en) * 2019-08-12 2021-06-11 宁波市鸿林自动化机械有限公司 Automatic assembling equipment for miniature direct current motor

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