JPH0286081A - Two-layer brush and manufacture thereof - Google Patents
Two-layer brush and manufacture thereofInfo
- Publication number
- JPH0286081A JPH0286081A JP23727788A JP23727788A JPH0286081A JP H0286081 A JPH0286081 A JP H0286081A JP 23727788 A JP23727788 A JP 23727788A JP 23727788 A JP23727788 A JP 23727788A JP H0286081 A JPH0286081 A JP H0286081A
- Authority
- JP
- Japan
- Prior art keywords
- layer
- brush
- laminated
- brushes
- lamination
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 9
- 238000003475 lamination Methods 0.000 claims abstract description 13
- 239000000843 powder Substances 0.000 claims description 14
- 239000002994 raw material Substances 0.000 claims description 10
- WABPQHHGFIMREM-UHFFFAOYSA-N lead(0) Chemical compound [Pb] WABPQHHGFIMREM-UHFFFAOYSA-N 0.000 claims description 4
- 238000000034 method Methods 0.000 claims description 4
- 238000000465 moulding Methods 0.000 claims description 2
- 230000000149 penetrating effect Effects 0.000 claims description 2
- 230000008878 coupling Effects 0.000 abstract 1
- 238000010168 coupling process Methods 0.000 abstract 1
- 238000005859 coupling reaction Methods 0.000 abstract 1
- 238000010008 shearing Methods 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 59
- 238000010304 firing Methods 0.000 description 4
- 238000003825 pressing Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
Landscapes
- Manufacturing Of Electrical Connectors (AREA)
- Motor Or Generator Current Collectors (AREA)
Abstract
Description
【発明の詳細な説明】
【産業上の利用分野］
本発明は２つの異種ブラシを積層した２層ブラシ、さら
に詳しくは自動車、電動工具、クリーナ、ミキサー等に
使用される電動パワーモータ用の２層の積層ブラシに関
する。
〔従来の技術〕
従来、直流モータ用として一般的に用いられている第４
図（ａ）の単層ブラシ３０は整流性を良くすると接触抵
抗が高くなり、又、接触抵抗を低くすると整流性が悪く
なる欠点があった。そのため、第４図（ｂ）及び（Ｃ）
に示すような低抵抗層３１と高抵抗層３２の異種ブラシ
を積層した２層の積層ブラシ（第４図（ｃ）は同図（ｂ
）の底面図である。
）又は第４図（ｄ）及び（ｅ）に示すような３層の積層
ブラシを整流子３の接線方向に配列したブラシが注目さ
れていた。
これらの多層積層ブラシは異種材料、例えば銀−黒鉛系
ブラシと銅−黒鉛系ブラシを積層するため、積層境界面
近傍において、圧粉成形時の内部歪みや、焼成時に収縮
係数の差による内部歪み等が生じ、そのため積層境界面
から異種材料が剥離しやすい欠点がある。そこで、積層
境界面を第４図（Ｃ）、（ｅ）に示すように凹凸係合さ
せて係合強度を高めた積層ブラシが考えられている。又
、その製造方法の一例としては、特公昭５９−５１１１
８号に示されるように、積層境界面に凹凸部を形成し、
上記の問題を解決することができる２層ブラシの製造方
法が知られている。
（発明が解決しようとする課題〕
第４図の】〜（ｅ）に示される上記従来の２層又は多層
積層ブラシにおいては、積層境界面の凹凸により境界面
を剥離しようとする応力を分散させて剥離を防ぐ効果は
ある。しかし、第５図（ａ）に示すように、凹凸の大き
さが小さいと境界面（ニ）では剥離を生じないものの、
剪断応力に対する強度の高い層（イ）と強度の低い層（
ロ）とが積層されている場合、強度の低い層（ロ）側の
谷（もしくは山）の面（ハ）で剪断破壊が生じやすく、
又、第５図（ｂ）に示すように、凹凸の大きさが大きい
と境界面（ホ）で剥離を生しやすい欠点を有し、そのた
め積層ブラシの材料選択、凹凸形状の設計、焼成条件等
の管理が複雑かつ困難をきわめた。
本発明は上記従来の欠点を解消した２層ブラシ及びその
製造方法を提供するものである。
〔課題を解決するための手段〕
本発明は、２つの異種ブラシを積層した２層ブラシにお
いて、第１の層はその一部が積層境界面から第２の層の
方向に凸部を有し、かつ、該凸部は第２の層を貫通して
いることを特徴とする２層ブラシである。又その製造方
法は、第１の圧粉成形用ダイスの成形型内に第２の層の
原料粉末を充填し、これを成形品に貫通孔を形成すべく
構成された上・下ポンチで押圧して貫通孔を有する第２
の層の異種ブラシを成形した後、第２の圧粉成形用ダイ
スの成形型内に第１の層の原料粉末、該第２の層の異種
ブラシの順で入れて上・下ポンチで押圧し、積層面を凹
凸係合させて一体化することを特徴とするものである。
〔実施例〕
以下、本発明を実施例に基づき説明する。第１図（ａ）
は本発明の２層ブラシの側面図、第１図（ｂｌはその正
面図である。１は第１の層、２は第２の層、３は整流子
、Ａは整流子の回転方向、４は整流子の回転方向に平行
な凹凸部、５はブラシを整流子４に圧接するためのコイ
ルバネ、１１は第１の層の凸部、２６は積層ブラシであ
る。凸部１１は円柱状の形状を有し第１の層１と一体構
造をなし、第２の層２を貫通している。
しかしその形状は円柱状に限られず三角柱ないし四角柱
でもよく、又その大きさも特に限定はない。又、凸部は
複数個あってもよい。第１の層ｌと第２の層２は互いに
ほぼ直角方向にある積層境界６及び積層境界７を介して
係合されている。積層境界７で仮に剪断応力Ｂが発生し
ても積層境界７の面上には凸部１１が存在するのでその
応力は分散され第１の層１と第２の層２が剥離すること
はない、特に、第２の層２の焼成収縮率が第１の層１の
ものより大きい場合は積層境界６における係合がより強
くなるのでなお一層強固な積層ブラシとなる。
第２図（ａ）は本発明の積層ブラシにリード線を取り付
けた側面図であり、第２図℃）はその正面図である。１
２はリード線、その他の番号は第１図に示したものと同
じである。従来の積層ブラシにおいては、例えば２層ブ
ラシの場合、一方のブラシ層をあらかじめ所定の形状に
仮成形した後、他方の層の仮成形物又は原料粉末と係合
させるため、積層境界を貫通してリード線を取り付ける
ことは製造技術上困難であった。
しかし、本発明は第１の層１は第２の層２を貫通してい
る凸部１１と一体構造を有しているので、リード＄４１
２は第１の層１及び凸部１１の内部に保持されて積層境
界７の面より深く取り付けることが可能となる。
第３図（ａ）〜（ハ）は本発明の２層ブラシの製造方法
を図示したものである。１３は第１の圧粉成形用ダイス
、１４はその成形型内部、１５は第２の層の原料粉末、
１６・１７はそれぞれ上ポンチ・下ポンチ、１８は上ポ
ンチ１６に設けられた孔、１９は下ポンチ１７に設けら
れた貫通孔形成のためのビンであり、原料粉末１５を成
形型内１４に充填する（第３図（ａＪ）、次に上下ポン
チ１６・１７を所定圧により押圧して第２の層の異種ブ
ラシ２を仮成形する。このとき孔１日は下降してピン１
９にそって移動するので成形物に貫通孔を形成する（第
３図（ｂ））、異種ブラシ２は、下ポンチ１７を上昇さ
せて取り出すことができる（第３図（Ｃ））。
その形状は第３図（ｄ）に示すとおり貫通孔２２を有す
る。次に第２の圧粉成形用ダイス２０の成形型内２１に
第１の層の原料粉末２３を入れ（第３図（ｅ））、その
後、その上に上記の異種ブラシ２をおとし入れる（第３
図（ｆ））。ダイス２０の大きさが異種ブラシ２より適
宜大きくなっていればよい。
原料粉末２３は、貫通孔２２の内部に流動するが、上下
ポンチ２４・２５で押圧することにより完全に上ポンチ
２４の押圧面まで充填することができ、かつ第１の層１
と第２の層（異種ブラシ）２を凹凸保合することが可能
となる（第３図（ｇ））、下ポンチ２５を上昇させて一
体成形された積層ブラシ２６を取り出しく第３図（ハ）
）、これを所定の焼成工程により焼結させて２層の積層
ブラシを製造する。
〔発明の効果〕
本発明は上記のような構成を有する２層ブラシであるの
で上記従来の欠点が解消され、積層面において強度な保
合が得られる。又、リード線の取り付けが容易かつ強固
になるなど２層ブラシの設計上従来にない効果を有する
。Detailed Description of the Invention [Industrial Application Field] The present invention relates to a two-layer brush in which two different types of brushes are stacked, more specifically, a two-layer brush for electric power motors used in automobiles, power tools, cleaners, mixers, etc. Concerning layer laminated brushes. [Prior art] Conventionally, the fourth type
The single-layer brush 30 shown in FIG. 3(a) has the disadvantage that when the rectification property is improved, the contact resistance becomes high, and when the contact resistance is made low, the rectification property becomes poor. Therefore, Fig. 4(b) and (C)
A two-layer laminated brush consisting of a laminated brush of different types including a low resistance layer 31 and a high resistance layer 32 as shown in FIG.
) is a bottom view. ) or a brush in which three layers of laminated brushes are arranged in the tangential direction of the commutator 3 as shown in FIGS. 4(d) and 4(e) has attracted attention. These multi-layer laminated brushes are made by laminating different materials, such as silver-graphite brushes and copper-graphite brushes, so near the interface between the laminated layers, internal distortions may occur during powder compaction or due to differences in shrinkage coefficients during firing. etc., resulting in the disadvantage that different materials tend to peel off from the laminated interface. Therefore, a laminated brush has been considered in which the laminated boundary surface is engaged with the concave and convex portions as shown in FIGS. 4(C) and (e) to increase the engagement strength. In addition, as an example of the manufacturing method, there is
As shown in No. 8, an uneven part is formed on the laminated boundary surface,
A method of manufacturing a two-layer brush is known that can solve the above problems. (Problems to be Solved by the Invention) In the conventional two-layer or multi-layer laminated brush shown in FIGS. However, as shown in Figure 5(a), if the size of the unevenness is small, no peeling will occur at the interface (d).
A layer with high strength against shear stress (A) and a layer with low strength (A)
When layers (b) and (b) are laminated, shear failure is likely to occur on the valley (or mountain) face (c) of the lower strength layer (b).
In addition, as shown in Figure 5(b), if the size of the unevenness is large, it has the disadvantage that peeling easily occurs at the interface (e), so the material selection of the laminated brush, the design of the uneven shape, and the firing conditions are difficult. Management of such matters was extremely complex and difficult. The present invention provides a two-layer brush that eliminates the above-mentioned conventional drawbacks and a method for manufacturing the same. [Means for Solving the Problems] The present invention provides a two-layer brush in which two different types of brushes are laminated, in which a part of the first layer has a convex portion in a direction from the lamination boundary surface to the second layer. , and the brush is a two-layer brush characterized in that the convex portion penetrates the second layer. The manufacturing method includes filling the mold of the first powder compacting die with raw material powder for the second layer, and pressing it with upper and lower punches configured to form through holes in the molded product. and a second hole having a through hole.
After molding the layers of different types of brushes, the raw material powder for the first layer and the different types of brushes for the second layer are placed in the mold of a second compacting die in this order and pressed with upper and lower punches. It is characterized in that the laminated surfaces are integrated by engaging the concave and convex surfaces. [Examples] The present invention will be described below based on Examples. Figure 1(a)
is a side view of the two-layer brush of the present invention, FIG. 4 is an uneven portion parallel to the rotation direction of the commutator, 5 is a coil spring for pressing the brush against the commutator 4, 11 is a convex portion of the first layer, and 26 is a laminated brush.The convex portion 11 has a cylindrical shape. It has the shape of an integral structure with the first layer 1 and penetrates the second layer 2. However, its shape is not limited to a cylinder, but may be a triangular prism or a square prism, and its size is not particularly limited. In addition, there may be a plurality of convex portions.The first layer 1 and the second layer 2 are engaged with each other via a lamination boundary 6 and a lamination boundary 7 that are substantially perpendicular to each other.Lamination boundary Even if shear stress B occurs in 7, since the convex portion 11 exists on the surface of the lamination boundary 7, the stress will be dispersed and the first layer 1 and the second layer 2 will not separate, especially If the firing shrinkage rate of the second layer 2 is larger than that of the first layer 1, the engagement at the lamination boundary 6 will be stronger, resulting in an even stronger laminated brush. FIG. 2 is a side view of the laminated brush of the invention with a lead wire attached thereto, and FIG. 2C) is a front view thereof. 1
2 is a lead wire, and the other numbers are the same as those shown in FIG. In conventional laminated brushes, for example, in the case of a two-layer brush, one brush layer is pre-formed into a predetermined shape, and then the layer is penetrated through the laminated boundary in order to engage with the temporarily formed product or raw material powder of the other layer. It was difficult due to manufacturing technology to attach the lead wires. However, in the present invention, since the first layer 1 has an integral structure with the convex portion 11 penetrating the second layer 2, the lead is $41.
2 is held inside the first layer 1 and the convex portion 11 and can be attached deeper than the surface of the lamination boundary 7. FIGS. 3(a) to 3(c) illustrate the method for manufacturing the two-layer brush of the present invention. 13 is the first compacting die, 14 is the inside of the mold, 15 is the raw material powder for the second layer,
16 and 17 are upper and lower punches, 18 is a hole provided in the upper punch 16, and 19 is a bottle provided in the lower punch 17 for forming a through hole. Filling (Fig. 3 (aJ)) Next, the upper and lower punches 16 and 17 are pressed with a predetermined pressure to temporarily form the second layer of different types of brushes 2. At this time, the hole 1 is lowered and the pin 1
9 to form a through hole in the molded product (FIG. 3(b)). The dissimilar brush 2 can be taken out by raising the lower punch 17 (FIG. 3(C)). Its shape has a through hole 22 as shown in FIG. 3(d). Next, the raw material powder 23 for the first layer is put into the mold 21 of the second powder compacting die 20 (FIG. 3(e)), and then the dissimilar brush 2 is placed thereon ( Third
Figure (f)). It is sufficient that the size of the dice 20 is appropriately larger than the different type of brush 2. The raw material powder 23 flows into the through hole 22, but by pressing it with the upper and lower punches 24 and 25, it can be completely filled up to the pressing surface of the upper punch 24, and the first layer 1
This makes it possible to maintain the unevenness of the second layer (different types of brushes) 2 (Fig. 3 (g)). C)
), this is sintered through a predetermined firing process to produce a two-layer laminated brush. [Effects of the Invention] Since the present invention is a two-layer brush having the above-mentioned configuration, the above-mentioned conventional drawbacks are eliminated and strong retention can be obtained on the laminated surface. Furthermore, the two-layer brush has unprecedented effects in terms of design, such as easier and stronger attachment of lead wires.
第１図（ａ）・ら）は本発明の２層ブラシを示す図、第
２図（ａ）・（ｂ）は本発明の他の実施例を示す図、第
３図（ａｌ〜（社）は本発明の２層ブラシの製造方法を
説明する図、第４図・第５図はいずれも従来品の説明図
である。
ｌは第１の層、２は第２の層、６．７は積層境界面、１
１は凸部、１ｚはリード線、１３は第１の圧粉成形用ダ
イス、１４はその成形型内、１５は第２の層の原料粉末
、１６・２４は上ポンチ、１７・２５は下ポンチ、２０
は第２の圧粉成形用ダイス、２１はその成形型内、２２
は貫通孔、２３は第１の層の原料粉末。
第４図
（ＣＩ）
（ｂ）
（ｄ）Figures 1(a) and 1) are views showing a two-layer brush of the present invention, Figures 2(a) and (b) are views showing other embodiments of the present invention, and Figures 3 (al~(company)) are views showing a two-layer brush of the present invention. ) is a diagram explaining the manufacturing method of the two-layer brush of the present invention, and FIGS. 4 and 5 are explanatory diagrams of conventional products. 1 is the first layer, 2 is the second layer, 6. 7 is the lamination interface, 1
1 is a convex part, 1z is a lead wire, 13 is a first compacting die, 14 is inside the mold, 15 is raw material powder for the second layer, 16 and 24 are upper punches, and 17 and 25 are lower parts. Punch, 20
is the second compacting die, 21 is inside the mold, 22
23 is a through hole, and 23 is a raw material powder for the first layer. Figure 4 (CI) (b) (d)
Claims (3)
、第１の層はその一部が積層境界面から第２の層の方向
に凸部を有し、かつ、該凸部は第２の層を貫通している
ことを特徴とする２層ブラシ。(1) In a two-layer brush in which two different types of brushes are stacked, a part of the first layer has a convex portion in the direction from the lamination boundary surface to the second layer, and the convex portion is in the direction of the second layer. A two-layer brush that is characterized by penetrating the layers.
れており、該凸部の内部及び第１の層の内部に保持され
ている請求項（１）記載の２層ブラシ。(2) The two-layer brush according to claim 1, wherein the lead wire is inserted from the second layer to the first layer and is held inside the convex portion and inside the first layer. .
原料粉末を充填し、これを成形品に貫通孔を形成すべく
構成された上・下ポンチで押圧して貫通孔を有する第２
の層の異種ブラシを成形した後、第２の圧粉成形用ダイ
スの成形型内に第１の層の原料粉末、該第２の層の異種
ブラシの順で入れて上・下ポンチで押圧し、積層面を凹
凸係合させて一体化することを特徴とする請求項（１）
記載の２層ブラシの製造方法。(3) Fill the mold of the first powder compacting die with the raw material powder for the second layer, and press it with upper and lower punches configured to form a through hole in the molded product to penetrate it. second with hole
After molding the layers of different types of brushes, the raw material powder for the first layer and the different types of brushes for the second layer are placed in the mold of a second compacting die in this order and pressed with upper and lower punches. Claim (1) characterized in that the laminated surfaces are integrated by engaging the concave and convex surfaces.
The method for manufacturing the two-layer brush described above.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP63237277A JP2788456B2 (en) | 1988-09-21 | 1988-09-21 | 2-layer brush |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP63237277A JP2788456B2 (en) | 1988-09-21 | 1988-09-21 | 2-layer brush |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH0286081A true JPH0286081A (en) | 1990-03-27 |
| JP2788456B2 JP2788456B2 (en) | 1998-08-20 |
Family
ID=17013006
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP63237277A Expired - Fee Related JP2788456B2 (en) | 1988-09-21 | 1988-09-21 | 2-layer brush |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP2788456B2 (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0658586U (en) * | 1993-01-14 | 1994-08-12 | 日電アネルバ株式会社 | High frequency power transmission equipment |
| JPH06303743A (en) * | 1993-04-13 | 1994-10-28 | Toraisu Kk | Laminated brush and its manufacture |
| US5712522A (en) * | 1995-05-26 | 1998-01-27 | Nippondenso Co., Ltd. | Starter with multi-layered brush structure |
| US6898839B2 (en) | 2000-02-22 | 2005-05-31 | Denso Corporation | Multi-layered brush of rotary electric machine and method of manufacturing the same |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS56153674A (en) * | 1980-04-30 | 1981-11-27 | Oopatsuku Kk | Method of manufacturing two-layer brush |
| JPS6268463U (en) * | 1985-10-19 | 1987-04-28 |
-
1988
- 1988-09-21 JP JP63237277A patent/JP2788456B2/en not_active Expired - Fee Related
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS56153674A (en) * | 1980-04-30 | 1981-11-27 | Oopatsuku Kk | Method of manufacturing two-layer brush |
| JPS6268463U (en) * | 1985-10-19 | 1987-04-28 |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0658586U (en) * | 1993-01-14 | 1994-08-12 | 日電アネルバ株式会社 | High frequency power transmission equipment |
| JPH06303743A (en) * | 1993-04-13 | 1994-10-28 | Toraisu Kk | Laminated brush and its manufacture |
| US5712522A (en) * | 1995-05-26 | 1998-01-27 | Nippondenso Co., Ltd. | Starter with multi-layered brush structure |
| US6898839B2 (en) | 2000-02-22 | 2005-05-31 | Denso Corporation | Multi-layered brush of rotary electric machine and method of manufacturing the same |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2788456B2 (en) | 1998-08-20 |
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