US2400590A - Method of making commutators - Google Patents
Method of making commutators Download PDFInfo
- Publication number
- US2400590A US2400590A US536079A US53607944A US2400590A US 2400590 A US2400590 A US 2400590A US 536079 A US536079 A US 536079A US 53607944 A US53607944 A US 53607944A US 2400590 A US2400590 A US 2400590A
- Authority
- US
- United States
- Prior art keywords
- cylinder
- tabs
- commutator
- blank
- commutators
- 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.)
- Expired - Lifetime
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/06—Manufacture of commutators
- H01R43/08—Manufacture of commutators in which segments are not separated until after assembly
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49009—Dynamoelectric machine
- Y10T29/49011—Commutator or slip ring assembly
Definitions
- This invention relates to improvements in the construction of commutators for electric motors and generators.
- the. invention relates to an improved commutator for use with relatively small, high speed motors, and allords means whereby a commutator having a high degree of perfection of finish and balance may be made by massproduction methods, with relatively unskilled labor.
- Commutators for relatively small-size motors are presently made by placing within a tubular blank of copper having interiorly directed fingers or tabs, a mass of moldable insulation material, curing said material in situ and then slitting the cylinder according to the number of poles of the varmature with which the commutator is tovbe used.
- a second presently known method ot manufacture resides in rolling a strip of copper, congurated to provide a plurality of fingers or soldering lugs, into cylindrical form, iiliing the cylinder with insulation material as aforesaid, and slitting the cylinder as aforesaid.
- nat blank of soft or semi-soft copper is drawn, in the cold
- a light anneal slightly softens the metal to protect against breakage of the tabs upon the bending thereof; successive cold-working stages provide Ztl-155.54
- a commutator blank of work-hardened copper The blank may subsequently be provided with a core of phenolic condensation material or the like, slotted to provide the requisite poles, and
- Fig, 1 is a plan view of a soft copper sheet, l
- Fig,I 2 is a side elevation of the same
- Fig. 3 is a side elevation, in section, oi the nrst clipping stage of the copper sheet;
- Fig. 4 is an end elevation of the same
- Fig. 5 is a front view of the commutator blank at a successive stage of manufacture
- Fig. 6 is a side elevation, in section, of the commutator blank of Fig. 5;
- Fig. 7 is a side elevation, in section, of the commutator blank, showing the bending of the terminal and anchoring tabs;
- Fis. 8 is a rear elevation of the commutator blank ol Fig. 7;
- Fig. 9 illustrates the next forming stage of the commutator blank
- Fig. l0 depicts the tinned commutator blank of Fig. 9, prior to the stage oi the insertion of dielectric material therein;
- Fig, 11 shows, in section, a commutator blank complete as respects the core of dielectric material therein;
- Fig. l2 is asection on lines it-ii of Fig. ll, after the slitting operation.
- a blank l@ is stamped from copper sheet. Extensions il, l2, ultimately provide soldering tabs and anchoring lugs, respectively.
- the blank is placed in a conventional cupping or draw press and is drawn to produce a com mutator shell lila, in which the respective tabs il, l2 are axially disposed.
- the drawing oper ation affords a symmetrical, closed-ended cylin der, preferably .005 inch oversize.
- the closed end i3 of the shell lila is blanked out to provide a plurality of anchoring lugs lil.
- the commutator ⁇ shell now desigfnated lb, may be given a light anneal which conditions the copper so that the soldering tabs Il and the anchoring lugs I2 may be angularly struck, see Fig. 7. without danger of fracture.
- the respective anchoring lugs i2 and I4 are directed inwardly of the shell, identified Ilic, as shown in Fig. 9.
- the initial oversize dimension Illa may be reucked as desired.
- the respective anchors i2 and I4 are equal in .number and are substantially oi equal weight.
- the disposition of the anchors I2 and Il is such as to provide clear areas Ila adjacent each soldering tab Il, along which the slitting saw may pass ina later stage.
- the shell Ic is then plated with a thin coating Il of tin.
- the shell luc is disposed concentrically about a bushing It, the inside diameter of which is suitable to engage tightly the shaft of the armature with which the commutator is to be used, and the annular space about said shell is filled with a thermo-setting plastic material I1 such as "Bakelite” or thelike, whereupon the plastic material is cured, bonding with the sleeve Il, and completely enveloping and engaging the anchors I2 and il.
- the thus-formed shell ild is disposed on a suitabe slit-ting machine (not shown) and is subdivided into mutually insulated commutator segments I8, symmetrical and concentric with respect to the bushing Il, and each embodying a soldering tab Il and anchor means i2 and il. Each segment is therefore of substantially uniform weight and the dynamic balance f the commutator is preserved.
- one of the anchoring tabs may be omitted from each segment, although there is little advantage gained from so doing.
- the commutator is then placed on the previously trued armature shaft, for secdrement thereto, and the leads to the respective pole windings of the armature soldered to the soldering tabs Il.
- the tin coating on the tabs Il simplies the soldering step.
- the thus-mounted commutator is then ground to remove the sur plus tin coating and to polish the surface of the respective segments. It will be apparent that with the commutator mounted upon the previously trued armature shaft, the symmetry of position of the segments with respect to the shafts is insured.
- a method of manufacturing commutators which includes the steps of: drawing an initially circular blank having a plurality of pairs of radial extensions. into closed-ended cylindrical form having a diameter larger than the final commutator diameter, saidcylindrical form having said extensions projecting axially thereof; blanking out the said closed end to provide thereat, a plurality of tabs equal in number to one half of the said pairs of extensions; cold working said cylinder to reduce the diameter thereof while bending one extension of each of said pairs of extensions angularly inwardly of the cylinder and bending the remaining extension angularly outwardly; bending the said tabs angularly inwardly of said cylinder; disposing within said cylinder a mass of insulation material in bonded relationship with said inwardly directed elements; slitting the cylinder longitudinally adjacent each of the said outwardly directed extensions to subivide the cylinder into a plurality of equal, electrically insulated segments of the said cylinder; and sub sequently smoothing the surface of the said segments.
- a method of manufacturing commutators which includes the steps of drawing a blank of metal having a plurality of pairs of radial extensions, into closedended cylinder form; blanking out the said closed end to provide a plurality of tabs equal in number to one half of the said pairs of extensions; annealing the said cylinder to soften the same; cold-working the cylinder to reduce the diameter thereof, while displacing one of each of said pairs of extensions angularly inwardly of the cylinder; displacing the tabs formed at the initially closed end of said cylinder angularly inwardly thereof; disposing within the said cylinder a sleeve of less diameter than the cylinder; disposing and curing within said cylinder and about said sleeve a mass of thermo-setting insulating material in bonded relationship with the inwardly projecting tabs and with the exterior wall of said sleeve; slitting said cylinder axially throughout its length at equi-distant locations without slitting the said tabs or extensions
- the method of manufacturing commutators which includes the steps of cold-working an initially fiat blank of metal into a cylinder having ⁇ a plurality of equi-angularly spaced tabs extending outwardly therefrom at one end thereof and a plurality of adjacent tabs extending angularly inwardly of said cylinder; tin plating the said cylinder and the outwardly extending tabs thereof; disposing within said cylinder a mass of insulation material; bonding the said mass of material to the inner wall of said cylinder and to the said inwardly directed tabs, and subdividing said cylinder into a plurality of individual segments of equal area and substantially equal weight and removing the tin plating from the surface of said segments by grinding the segments to produce a smooth surface thereon, while leaving the tin plating on the said tabs.
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Manufacturing Of Electrical Connectors (AREA)
- Manufacture Of Motors, Generators (AREA)
Description
METHOD OF MAKING COMMUTATORS Filed May 18, 1944 IN VEN TOR.
' Patented May 21, 1 946 YMETHOD F MAKING COMMUTATORS Carl it. Meyerhoefer, Brooklyn, N. Y., asslgnor to E. A. Laboratories, Inc., Brooklyn, N. Y., a corporation of New York AppllcationMay 18, 1944, Serial No. 536,079
3 Claims.
This invention relates to improvements in the construction of commutators for electric motors and generators.
In particular, the. invention relates to an improved commutator for use with relatively small, high speed motors, and allords means whereby a commutator having a high degree of perfection of finish and balance may be made by massproduction methods, with relatively unskilled labor.
It is an object oi! the invention to provide an improved means of manufacturing commutators for electric motors or generators.
It is an object of the invention to provide a method of manufacturing commutators, which will afford a low-cost, high quality product.
It is an object of the invention to provide a' method of manufacturing commutatore by the cold working of sheet copper, whereupon the iinished product is work-hardened and therefore of increased durability.
Commutators for relatively small-size motors are presently made by placing within a tubular blank of copper having interiorly directed fingers or tabs, a mass of moldable insulation material, curing said material in situ and then slitting the cylinder according to the number of poles of the varmature with which the commutator is tovbe used. i
A second presently known method ot manufacture resides in rolling a strip of copper, congurated to provide a plurality of fingers or soldering lugs, into cylindrical form, iiliing the cylinder with insulation material as aforesaid, and slitting the cylinder as aforesaid.
Disadvantages in. the said methods reside in the necessity of using relatively soft copper stock to. insure that the fingers and lugs do not break or fracture during the bending thereof; in manuiacturingaccording to the rolled-strip method,
. it is diflicult to attain an initial cylinder which is truly concentric, necessitating grinding or turnn ing operations which result in portions which are relatively thinner than others. In high speed motors, in which 12,500 R. P. M. is not an unusual speed, 'an unbalanced condition, such as will result from non-uniform weight distribution, is detrimental to operative life.
Pursuant to the present invention, a nat blank of soft or semi-soft copper is drawn, in the cold,
into cup shape, slightly oversize, and having a,
plurality of axial tabs at itsopen end, A light anneal slightly softens the metal to protect against breakage of the tabs upon the bending thereof; successive cold-working stages provide Ztl-155.54
a commutator blank of work-hardened copper. The blank may subsequently be provided with a core of phenolic condensation material or the like, slotted to provide the requisite poles, and
mounted on its armature shaft for polishing.
During the cupping and drawing operations, the blank is maintained as a substantially true cylinder, and the grinding and polishing of the Fig, 1 is a plan view of a soft copper sheet, l
blanked to provide the terminal tabs and anchoring tabs of the completed commutator;
Fig,I 2 is a side elevation of the same;
Fig. 3 is a side elevation, in section, oi the nrst clipping stage of the copper sheet;
Fig. 4 is an end elevation of the same;
Fig. 5 is a front view of the commutator blank at a successive stage of manufacture;
Fig. 6 is a side elevation, in section, of the commutator blank of Fig. 5;
Fig. 7 ,is a side elevation, in section, of the commutator blank, showing the bending of the terminal and anchoring tabs;
Fis. 8 is a rear elevation of the commutator blank ol Fig. 7;
Fig. 9 illustrates the next forming stage of the commutator blank;
Fig. l0 depicts the tinned commutator blank of Fig. 9, prior to the stage oi the insertion of dielectric material therein;
Fig, 11 shows, in section, a commutator blank complete as respects the core of dielectric material therein; and
Fig. l2 is asection on lines it-ii of Fig. ll, after the slitting operation.
Referring to the drawing, a blank l@ is stamped from copper sheet. Extensions il, l2, ultimately provide soldering tabs and anchoring lugs, respectively.
The blank is placed in a conventional cupping or draw press and is drawn to produce a com mutator shell lila, in which the respective tabs il, l2 are axially disposed. The drawing oper ation affords a symmetrical, closed-ended cylin der, preferably .005 inch oversize.
The closed end i3 of the shell lila is blanked out to provide a plurality of anchoring lugs lil.
If desired, the commutator` shell, now desigfnated lb, may be given a light anneal which conditions the copper so that the soldering tabs Il and the anchoring lugs I2 may be angularly struck, see Fig. 7. without danger of fracture.
Subsequently, and preferably in a cold working drawing operation, the respective anchoring lugs i2 and I4 are directed inwardly of the shell, identified Ilic, as shown in Fig. 9. At this stage, the initial oversize dimension Illa may be re duced as desired. The respective anchors i2 and I4 are equal in .number and are substantially oi equal weight. As shown in Fig. 8, the disposition of the anchors I2 and Il is such as to provide clear areas Ila adjacent each soldering tab Il, along which the slitting saw may pass ina later stage.
The shell Ic is then plated with a thin coating Il of tin. In a suitable molding press (not shown) the shell luc is disposed concentrically about a bushing It, the inside diameter of which is suitable to engage tightly the shaft of the armature with which the commutator is to be used, and the annular space about said shell is filled with a thermo-setting plastic material I1 such as "Bakelite" or thelike, whereupon the plastic material is cured, bonding with the sleeve Il, and completely enveloping and engaging the anchors I2 and il.
The thus-formed shell ild is disposed on a suitabe slit-ting machine (not shown) and is subdivided into mutually insulated commutator segments I8, symmetrical and concentric with respect to the bushing Il, and each embodying a soldering tab Il and anchor means i2 and il. Each segment is therefore of substantially uniform weight and the dynamic balance f the commutator is preserved.
It will be understood that for smaller or lower speed motors, one of the anchoring tabs may be omitted from each segment, although there is little advantage gained from so doing.
It will be noted that at this stage, the tin plating Il remains on the commutator.
The commutator is then placed on the previously trued armature shaft, for secdrement thereto, and the leads to the respective pole windings of the armature soldered to the soldering tabs Il. The tin coating on the tabs Il simplies the soldering step. The thus-mounted commutator is then ground to remove the sur plus tin coating and to polish the surface of the respective segments. It will be apparent that with the commutator mounted upon the previously trued armature shaft, the symmetry of position of the segments with respect to the shafts is insured.
Whereas it is obvious that the several cbjects of the invention as specifically aforenoted are achieved, it 1s apparent that numerous changes in the manner of performing the steps of the method, and variations of the sequence of performance thereof might be resorted to without departing from the spirit of the invention as defined by the claims.
Iclaim:
1. A method of manufacturing commutators, which includes the steps of: drawing an initially circular blank having a plurality of pairs of radial extensions. into closed-ended cylindrical form having a diameter larger than the final commutator diameter, saidcylindrical form having said extensions projecting axially thereof; blanking out the said closed end to provide thereat, a plurality of tabs equal in number to one half of the said pairs of extensions; cold working said cylinder to reduce the diameter thereof while bending one extension of each of said pairs of extensions angularly inwardly of the cylinder and bending the remaining extension angularly outwardly; bending the said tabs angularly inwardly of said cylinder; disposing within said cylinder a mass of insulation material in bonded relationship with said inwardly directed elements; slitting the cylinder longitudinally adjacent each of the said outwardly directed extensions to subivide the cylinder into a plurality of equal, electrically insulated segments of the said cylinder; and sub sequently smoothing the surface of the said segments.
2. A method of manufacturing commutators which includes the steps of drawing a blank of metal having a plurality of pairs of radial extensions, into closedended cylinder form; blanking out the said closed end to provide a plurality of tabs equal in number to one half of the said pairs of extensions; annealing the said cylinder to soften the same; cold-working the cylinder to reduce the diameter thereof, while displacing one of each of said pairs of extensions angularly inwardly of the cylinder; displacing the tabs formed at the initially closed end of said cylinder angularly inwardly thereof; disposing within the said cylinder a sleeve of less diameter than the cylinder; disposing and curing within said cylinder and about said sleeve a mass of thermo-setting insulating material in bonded relationship with the inwardly projecting tabs and with the exterior wall of said sleeve; slitting said cylinder axially throughout its length at equi-distant locations without slitting the said tabs or extensions to subdivide the cylinder into a plurality of mutually insulated equi-angular segments; and smoothing the surface of the said segments.
3. The method of manufacturing commutators, which includes the steps of cold-working an initially fiat blank of metal into a cylinder having` a plurality of equi-angularly spaced tabs extending outwardly therefrom at one end thereof and a plurality of adjacent tabs extending angularly inwardly of said cylinder; tin plating the said cylinder and the outwardly extending tabs thereof; disposing within said cylinder a mass of insulation material; bonding the said mass of material to the inner wall of said cylinder and to the said inwardly directed tabs, and subdividing said cylinder into a plurality of individual segments of equal area and substantially equal weight and removing the tin plating from the surface of said segments by grinding the segments to produce a smooth surface thereon, while leaving the tin plating on the said tabs.
CARL E. MEYERHOEFER.
Priority Applications (1)
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---|---|---|---|
US536079A US2400590A (en) | 1944-05-18 | 1944-05-18 | Method of making commutators |
Applications Claiming Priority (1)
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US536079A US2400590A (en) | 1944-05-18 | 1944-05-18 | Method of making commutators |
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US2400590A true US2400590A (en) | 1946-05-21 |
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US536079A Expired - Lifetime US2400590A (en) | 1944-05-18 | 1944-05-18 | Method of making commutators |
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Cited By (21)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2477455A (en) * | 1946-04-11 | 1949-07-26 | Watliff Company Ltd | Electric commutator |
US2478536A (en) * | 1946-10-12 | 1949-08-09 | John C Koonz | Commutator construction for electric devices |
US2604502A (en) * | 1949-04-15 | 1952-07-22 | Mach Electrostatiques Sa Des | Commutator |
US2639396A (en) * | 1950-04-10 | 1953-05-19 | N T Kyle | Commutator, armature, and method of making the same |
US2658158A (en) * | 1950-08-03 | 1953-11-03 | Gen Ind Co | Commutator |
US2786985A (en) * | 1952-07-11 | 1957-03-26 | Breeze Corp | Miniature slip ring and process of making the same |
US2798210A (en) * | 1954-06-04 | 1957-07-02 | Baker & Co Inc | Miniature slip ring assembly |
DE1073080B (en) * | 1953-04-14 | 1960-01-14 | Hoover Limited, Penvale, Greenford, Middlesex (Großbritannien) | Process for the production of drum current inverters for dynamoelectric machines |
US2934813A (en) * | 1953-07-09 | 1960-05-03 | Nippert Electric Products Comp | Method for forming slip rings |
US3005920A (en) * | 1959-01-19 | 1961-10-24 | Fiat Spa | Commutator for dynamo electric machines and manufacturing method |
US3177562A (en) * | 1960-01-16 | 1965-04-13 | Kautt & Bux Kg | Method of producing commutators |
US3478421A (en) * | 1966-07-20 | 1969-11-18 | Lucas Industries Ltd | Method of manufacturing commutators |
US3781981A (en) * | 1972-02-28 | 1974-01-01 | Nippon Denko | Method for making armature-commutator assembly having armature winding of very small diameter |
US3812576A (en) * | 1971-10-25 | 1974-05-28 | Nippon Denso Co | Method of making commutator for revolving armature |
US3902241A (en) * | 1973-06-06 | 1975-09-02 | Krautt & Bux A G Fa | Method of manufacturing pressed material commutators |
US5440800A (en) * | 1990-06-26 | 1995-08-15 | Asmo Co. Ltd. | Method of pre-applying soldering material to a motor commutator |
WO1996033534A1 (en) * | 1995-04-21 | 1996-10-24 | Firma Anton Holzhauer Umformtechnik | Collector manufacturing process |
US6349458B1 (en) | 1999-08-27 | 2002-02-26 | Steven Al-Rawi | Burnishing apparatus |
US7009323B1 (en) * | 2004-12-06 | 2006-03-07 | Siemens Vdo Automotive Inc. | Robust commutator bar anchoring configuration with dove-tailed features |
US20080209974A1 (en) * | 2007-02-28 | 2008-09-04 | Shiloh Industries, Inc. | Metal Blank with Binder Trim Component and Method |
USD869332S1 (en) | 2017-12-19 | 2019-12-10 | Oshkosh Corporation | Vehicle |
-
1944
- 1944-05-18 US US536079A patent/US2400590A/en not_active Expired - Lifetime
Cited By (25)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2477455A (en) * | 1946-04-11 | 1949-07-26 | Watliff Company Ltd | Electric commutator |
US2478536A (en) * | 1946-10-12 | 1949-08-09 | John C Koonz | Commutator construction for electric devices |
US2604502A (en) * | 1949-04-15 | 1952-07-22 | Mach Electrostatiques Sa Des | Commutator |
US2639396A (en) * | 1950-04-10 | 1953-05-19 | N T Kyle | Commutator, armature, and method of making the same |
US2658158A (en) * | 1950-08-03 | 1953-11-03 | Gen Ind Co | Commutator |
US2786985A (en) * | 1952-07-11 | 1957-03-26 | Breeze Corp | Miniature slip ring and process of making the same |
DE1073080B (en) * | 1953-04-14 | 1960-01-14 | Hoover Limited, Penvale, Greenford, Middlesex (Großbritannien) | Process for the production of drum current inverters for dynamoelectric machines |
US2934813A (en) * | 1953-07-09 | 1960-05-03 | Nippert Electric Products Comp | Method for forming slip rings |
US2798210A (en) * | 1954-06-04 | 1957-07-02 | Baker & Co Inc | Miniature slip ring assembly |
US3005920A (en) * | 1959-01-19 | 1961-10-24 | Fiat Spa | Commutator for dynamo electric machines and manufacturing method |
US3177562A (en) * | 1960-01-16 | 1965-04-13 | Kautt & Bux Kg | Method of producing commutators |
US3478421A (en) * | 1966-07-20 | 1969-11-18 | Lucas Industries Ltd | Method of manufacturing commutators |
US3812576A (en) * | 1971-10-25 | 1974-05-28 | Nippon Denso Co | Method of making commutator for revolving armature |
US3781981A (en) * | 1972-02-28 | 1974-01-01 | Nippon Denko | Method for making armature-commutator assembly having armature winding of very small diameter |
US3902241A (en) * | 1973-06-06 | 1975-09-02 | Krautt & Bux A G Fa | Method of manufacturing pressed material commutators |
US5440800A (en) * | 1990-06-26 | 1995-08-15 | Asmo Co. Ltd. | Method of pre-applying soldering material to a motor commutator |
WO1996033534A1 (en) * | 1995-04-21 | 1996-10-24 | Firma Anton Holzhauer Umformtechnik | Collector manufacturing process |
AU722392B2 (en) * | 1995-04-21 | 2000-08-03 | Firma Anton Holzhauer Umformtechnik | Process for production of a commutator |
US6108898A (en) * | 1995-04-21 | 2000-08-29 | Firma Anton Holzhauer Umformtechnik | Commutator manufacturing process |
US6349458B1 (en) | 1999-08-27 | 2002-02-26 | Steven Al-Rawi | Burnishing apparatus |
US7009323B1 (en) * | 2004-12-06 | 2006-03-07 | Siemens Vdo Automotive Inc. | Robust commutator bar anchoring configuration with dove-tailed features |
US20080209974A1 (en) * | 2007-02-28 | 2008-09-04 | Shiloh Industries, Inc. | Metal Blank with Binder Trim Component and Method |
US8062763B2 (en) * | 2007-02-28 | 2011-11-22 | Shiloh Industries, Inc. | Metal blank with binder trim component |
US8573021B2 (en) | 2007-02-28 | 2013-11-05 | Shiloh Industries, Inc. | Metal blank with binder trim component and method |
USD869332S1 (en) | 2017-12-19 | 2019-12-10 | Oshkosh Corporation | Vehicle |
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