JP2009027791A - Carbon commutator - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a carbon commutator configured so that separation between a riser and a segment is prevented and compaction is not impaired. <P>SOLUTION: The riser 4 constituting the commutator 1 comprises a segment joining portion 4a connecting to the segment 3 and a coil connecting portion 4b extending from the segment joining portion 4a and allowing a coil 5 to be fused, and is configured so that first and second bulging pieces 4f, 4g bulging in both directions around the circumference of a second bent piece 4c are formed on a first bent piece 4c bent along the external circumference of a boss 2 of the coil connecting portion 4b and any of the pieces 4f, 4g is used as an electrode portion in fusing processing. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention belongs to the technical field of carbon commutators constituting rotating electrical machines used for in-tank fuel pumps and the like.

  Generally, in an in-tank type fuel pump mounted on a vehicle, the fuel pump itself is immersed (immersed) in the fuel. Therefore, the inside of the housing constituting the fuel pump is a fuel flow path. On the other hand, in recent years, from the viewpoint of environmental protection, it has been attempted to use alcohol (methanol, ethanol, etc.) or a mixed fuel containing alcohol as a fuel. In this case, the commutator is not eroded by alcohol. It is proposed to use a segment composed of the above, a riser metal composed of, for example, copper as a conductive terminal member, and a boss composed of an insulating resin material. In this structure, the riser metal is composed of a segment joint portion that is electrically joined to the segment by soldering or the like, and a coil connection portion that is coiled to be electrically connected (fusing treatment). However, when fusing a coil to the coil connection part, the fusing process is performed by pressing the electrode from the outer diameter side to the coil connection part and segment of the riser metal as the main and sub-electrodes and energizing between them. As a result, the joint between the riser metal and the segment becomes hot and the solder is eluted, and there is a problem that they are peeled off.

As this improvement measure, in the coil connecting portion constituted by the first bent piece bent along the outer peripheral surface of the boss and the second bent piece folded back on the outer diameter side of the first bent piece, A bulging piece that bulges in the circumferential direction is formed at the extending base end portion of the first bent piece that extends from the segment joining portion, and the bulging piece serves as a sub-electrode portion, while the coil connecting portion As a configuration in which the second bent piece is used as the main electrode portion, the current between the segment and the riser metal is not directly energized to reduce the heat acting on the solder, and the segment and the riser metal are separated. Something to prevent is proposed.
Japanese Patent No. 2651963

  By the way, in the said conventional thing, when bending the 1st, 2nd bending piece of a coil connection part, the 1st, 2nd bending piece is the cylinder length of a boss so that the outer periphery of a boss may be followed beforehand. In this state, the second bent piece is folded back to the other in the tube length direction and processed so as to be positioned on the outer diameter side of the first bent piece. The sub electrode part formed in the extended base end part of the first bent piece is formed in a state of bulging toward one side in the circumferential direction of the first bent piece. For this reason, the bending load when the second bent piece is folded back with respect to the first bent piece bent along the outer periphery of the boss is the extended base end portion of the first bent piece. Does not act uniformly on the side, acts largely on the other part in the circumferential direction opposite to the bulging direction of the sub-electrode part, and the part moves from the state along the outer peripheral surface of the boss to the outer diameter side. The first bent piece may not be in a uniform curved shape because it tends to be in a floating state. In this case, the outer diameter of the commutator becomes large, which not only impairs downsizing, but also has a problem that it may adversely affect the fusing state of the coil at the coil connection portion. There are issues to be solved.

The present invention has been created in view of the above-described circumstances and has been created for the purpose of solving these problems. The invention of claim 1 includes a segment composed of a carbon base material and a joint to the segment. A riser metal comprising: a segment joint, a riser metal having a coil connection portion extending from the segment joint and fusing a coil; and a carbon commutator comprising an insulating boss that embeds the segment and the segment joint. The coil connecting portion is composed of a first bent piece that is bent along the outer peripheral surface of the boss, and a second bent piece that is folded back to the outer diameter side of the first bent piece, This is a carbon commutator in which first and second bulging pieces that bulge in both directions in the circumferential direction of the second bent piece are formed on the piece.
The invention according to claim 2 is that the bulge area of the first bulge piece is larger than the bulge area of the second bulge piece, and the coil suspended around the coil connecting portion is connected to the first bulge piece and the first bulge piece. The carbon commutator according to claim 1, wherein the two folded pieces are used as a main and sub-electrode portion for fusing treatment.

According to the invention of claim 1, a highly reliable commutator is provided that prevents the riser metal from rising from the outer peripheral surface of the boss while preventing the joint portion between the segment and the riser metal from peeling off. Can be provided.
According to the invention of claim 2, even if the commutator is made compact, it is possible to manufacture a highly reliable commutator with high workability without fear of peeling between the riser metal and the segment.

Next, a first embodiment of the present invention will be described with reference to the drawings.
In the drawings, reference numeral 1 denotes a commutator that is integrally fitted to a motor shaft of an electric motor (not shown). The commutator 1 is made of an insulating resin material and has a through hole 2a through which the motor shaft passes in a non-rotating manner. The opened cylindrical boss 2, a plurality of circumferentially extending (six in this embodiment) segments 3, and electrical connection is made to each of these segments 3, and projecting in the outer diameter direction of the boss 2 And a riser metal 4 disposed on the base, and these basic configurations are the same as before.

  The plurality of segments 3 in the circumferential direction are formed in a shape that is long in the axial direction (cylinder hole direction) of the boss 2, the inner diameter side portion is embedded in the boss 2, and the outer diameter side surface is the exposed surface 3 a. It is configured so that it is flush with the outer peripheral surface of the boss 2 and a brush (not shown) slides on the exposed surface 3a. An insulating groove (slit) H for breaking the electrical connection between the segments 3 adjacent in the circumferential direction is formed to a depth reaching the boss 2.

On the other hand, the riser metal 4 is formed by extending a segment joint portion 4a connected to one end in the longitudinal direction of each segment 3 embedded in the boss 2, and extending from the segment joint portion 4a. And a coil connecting portion 4b provided outside. And the coil connection part 4b is the 1st bending piece (extension of this invention) bent toward the cylinder length direction one side (motor core arrangement | positioning side not shown) of the boss 2 along the outer peripheral surface of the boss | hub 2. 4c (corresponding to the base end portion) and the first bent piece 4c so that the first bent piece 4c is folded back to the other side in the cylinder length direction of the boss 2 and located on the outer diameter side of the first bent piece 4c. The coil 5 is hung around a hook-shaped bent portion between the first and second bent pieces 4c and 4d and subjected to a fusing process. Is set to
A locking claw 4e is bent toward one side in the cylinder length direction of the boss 2 on the inner diameter side of the segment joint portion 4a of each riser metal 4, and the boss 2 is embedded in the boss 2. It is configured to realize a strong integration with.

The first bent piece 4c of each coil connecting portion 4b includes first and second bulging pieces 4f that bulge in both directions in the circumferential direction at the proximal end portion extending from the segment joint portion 4a. 4g is formed, and these first and second bulging pieces 4f and 4g are formed in a circumferential direction with respect to the extended tip portion 4h of the first bent piece 4c and the second bent piece 4d. Widely formed. Further, the second bent piece 4d is folded back so as to face the outer diameter side of the extended tip end portion 4h of the first bent piece 4c, so that when the commutator 1 is faced from the outer diameter direction, The first and second bulging pieces 4f and 4g are set so as to be positioned at positions shifted in the circumferential direction and the cylinder length direction of the boss 2 with respect to the second bent piece 4d. And when fusing the coil 5 hung around the bending part of the extended front-end | tip part 4h of the 1st bending piece 4c and the 2nd bending piece 4d, the 2nd bending piece 4d is made into a main electrode part. On the other hand, the first or second bulging piece 4f or 4g, which is displaced from the second bent piece 4d, is set so that the fusing process can be performed using the sub-electrode portion. As a result, the solder between the segment 3 and the segment joint 4a is not energized by the fusing process, and the segment 3 and the riser metal 4 are prevented from being peeled off.
Here, the first and second bulging pieces 4f and 4g are dimensioned to bulge in the circumferential direction within a range not interfering with the second and first bulging pieces 4f and 4g of the adjacent riser metal 4. Yes.

  Furthermore, in the present embodiment, the extended distal end portion 4h of the first bent piece 4c has a circumferential direction one side with respect to the extended base end portion where the first and second bulged pieces 4f and 4g are integrally formed. It is formed so as to be in a state of being biased to. As a result, the first bulging piece 4g has a larger bulging amount than the second bulging piece 4g, and the bulging area facing the outer diameter direction of the first bulging piece 4g is the bulging of the second bulging piece 4g. It is set to be larger than the area. Thus, by using the first bulging piece 4f as a sub-electrode portion, the fusing process can be performed more reliably and easily.

Next, a procedure for forming the commutator 1 will be briefly described.
A cylindrical carbon base material (not shown) as a constituent member of the segment 3 and a metal plate 6 formed by punching a copper plate material (conductive member) shown in FIG. 2 as a constituent member of the riser metal 4 are prepared. At this time, the metal plate 6 includes a segment joint portion equivalent portion 6a connected in a ring shape and a plurality of coil connection portion equivalent portions 6b that are located at predetermined circumferential positions and extend in the outer diameter direction. The outer diameter side end portions of the plurality of coil connecting portion equivalent portions 6b are connected and integrated by an integrated portion 6c. 6d and 6e are first and second bulging piece equivalent portions formed in each coil connection portion corresponding portion 6b, and form the first and second bulging pieces 4f and 4g of the riser metal 4. Is set to

  The metal plate 6 thus formed is integrated with the carbon base material in such a state that solder is applied between the segment joint portion equivalent portion 6a and one cylindrical end of the carbon base material and electrical connection is possible. By molding a resin material on the joined body, only the coil connection portion equivalent portion 6b of the metal plate 6 is exposed to the outside, and the other portion is embedded in the resin material. Mold. Thereafter, the integrated portion 6c of the metal plate 6 is cut off, and the cutting process for exposing the outer peripheral surface of the carbon base material to the outside, the carbon base material and the segment joint corresponding portion 6a of the metal plate 6 are provided at six locations in the circumferential direction. The insulating groove H having a depth reaching the resin material is cut to form a segment 3 and a riser metal 4 that are insulated from each other, and a bending process for bending the coil connection portion 4c of the riser metal 4 in an appropriate order. The commutator 1 is formed by carrying out.

  In the bending process of the riser metal 4, first and second bulging pieces 4f and 4g are formed at the extended base end portion of the first bent piece 4c. From the second bent piece 4d, The second bent piece 4d having a narrow width and the extended tip end 4h of the first bent piece 4c are formed with first and second bulged pieces 4f and 4g. The first bent piece 4c is formed so as to be located in the circumferential direction intermediate portion of the extending base end portion. For this reason, when the second bent piece 4d is folded back with respect to the first bent piece 4c, the bending load based on the bending operation is the first and second bulging pieces 4f, 4g. Thus, the first bent piece 4c is configured so as not to cause a problem that the first bent piece 4c is lifted from the outer peripheral surface of the boss 2.

In the present embodiment configured as described, in the commutator 1 including the segment 3 composed of the carbon base material, when the coil 5 is subjected to the fusing process on the coil connection portion 4c of the riser metal 4, the second bent piece 4d is used. Is formed in the first bent piece 4c, and the first bulge is in a state of being displaced with respect to the second bent piece 4d in the circumferential direction and in the cylinder length direction of the boss 2 respectively. The fusing process of the coil 5 can be performed by using the piece 4f as a sub-electrode part and pressing the pair of electrodes against the electrode parts from the outer diameter side. As a result, the fusing process energizes the second bent piece 4d, which is the coil connecting portion 4c of the riser metal 4, and the first bulging piece 4f, but in order to join the segment 3 and the riser metal 4 together. The applied solder portion is not directly energized, and the solder portion is prevented from being heated to a high temperature, thereby preventing a problem that the joint portion between the segment 3 and the riser metal 4 is peeled off. .
In addition, in this case, the first and second bulging portions 4f and 4g are formed on both sides in the circumferential direction of the first bent piece 4c, so that the second bent piece 4d is connected to the first bent piece 4c. In the case of performing the bending process of folding back to the outer diameter side, the bending load is not biased and acts on the first bending piece unlike the conventional one. Therefore, the commutator 1 can be provided with the fusing portion of the coil 5 with high reliability without being reduced in the compactness of the commutator 1.

  Further, in the embodiment of the present invention, first and second bulging pieces 4f and 4g are formed on the extended base end portion of the first bent piece 4c, and the second bent piece 4d is formed. The bending load when bending is applied to the extended base end of the first bent piece 4c evenly, but the outer diameter of the first bulging piece 4f serving as the sub-electrode portion Since the bulge area facing the side is set to be larger than the bulge area of the second bulge piece 4g, the outer diameter of the commutator 1 is small and the shape of the riser metal 4 itself cannot be increased. Even in such a case, there is no fear of the riser metal 4 and the segment 3 being peeled off, and the operation of applying the electrode in the fusing work is easy, and the shape of the first bent piece 4c is uniform. The commutator 1 that can be in a state and is highly reliable can be manufactured with good workability. Kill.

1A and 1B are a side view and a side cross-sectional view of the commutator, respectively. 2A and 2B are a front view of the riser metal and a partially enlarged view of FIG.

Explanation of symbols

Reference Signs List 1 commutator 2 boss 3 segment 4 riser metal 4a segment joint 4b coil connection 4c first bent piece 4f first bulge 4g second bulge

Claims (2)

  A riser metal having a segment composed of a carbon base material, a segment joint part joined to the segment, a coil connection part extending from the segment joint part and fusing the coil, and the segment and the segment joint part are embedded. In the carbon commutator provided with an insulating boss, the coil connecting portion of the riser metal is folded back along the outer peripheral surface of the boss and the outer diameter side of the first folded piece. A carbon commutator configured with a second bent piece, wherein the first bent piece is formed with first and second bulged pieces that bulge in both circumferential directions of the second bent piece.   The bulge area of the first bulge piece is larger than the bulge area of the second bulge piece, and the coil hanged around the coil connection portion is mainly composed of the first bulge piece and the second bent piece. The carbon commutator according to claim 1, wherein the carbon commutator is configured to perform a fusing treatment as a sub-electrode part.

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