WO2003034574A1

WO2003034574A1 - Commutator and its manufacturing method

Info

Publication number: WO2003034574A1
Application number: PCT/JP2002/008965
Authority: WO
Inventors: Shinya Ashimura
Original assignee: Aupac Co., Ltd.
Priority date: 2001-10-12
Filing date: 2002-09-04
Publication date: 2003-04-24
Also published as: JP2003125556A

Abstract

A commutator wherein terminal pieces having winding connection terminals are insulated from one another and secured generally along the periphery of an insulating support, commutator pieces corresponding to the terminal pieces are insulated from one another and secured to the respective terminal pieces, for example, through-holes in the terminal pieces correspond to the holes in the commutator pieces, and connectors are engaged with the through holes in the terminal pieces and commutator pieces. The connectors are preferably formed of a conductive powder. The electrical connection between the commutator pieces and the terminal pieces can be more reliable and stable. The commutator can be produced and supplied in a simpler process and at low cost.

Description

Description Commutator and its manufacturing method

The present invention relates to a commutator mainly incorporated in a motor used for a fuel pump or the like, and a method for manufacturing the commutator. Background art

Conventionally, there is a flat commutator disclosed in Japanese Patent Application Laid-Open No. 2001-95206 as a known technique for improving the conductivity between a commutator piece and a terminal piece of a commutator. The flat commutator has good electric power by forming a fitting gap between the inner peripheral surface of the metal segment and the outer peripheral surface of the commutator segment, and fitting the paneling metal plate into the fitting gap. It realizes a dynamic connection.

Also, as another known technique, there is a flat commutator disclosed in Japanese Patent Application Laid-Open No. 200-95207. In the flat commutator, the inner peripheral surface of the commutator segment is fixed to a side surface of a shaft support portion protruding substantially at the center of the insulating support with a bonding material, and the bottom of the commutator segment is connected to the upper portion of the insulating support. The outer peripheral surface of the commutator segment is fixed to the inner peripheral surface of the metal segment with a conductive bonding material to obtain good electrical connection.

Also, as another known technique, there is a flat commutator disclosed in Japanese Patent Application Laid-Open No. 2001-190900. The flat rectifier is provided with a panel metal plate insulated from each other in contact with a metal piece and a commutator piece. Preferably, the panel metal plate is embedded in an insulating support. This is to improve the electrical connection of the pieces.

JP-A-2001-95206, JP-A-201-95207, JP-200

The flat type commutator disclosed in JP-A-1-1900900 can realize a somewhat good electrical connection between a commutator piece and a metal piece. No. JP 2000

In the flat type commutator of No. 1-191900, the contact of the panel-like metal plate with the metal piece or the commutator piece may be insufficient. The flat commutator of No. 5207 requires a large number of manufacturing steps for the joining material, and the soldering between the metal piece and the commutator piece. The electrical connection between the commutator piece and the metal piece may become insufficient due to the melting of the electrical bonding material. Therefore, the electrical connection between the commutator piece and the metal piece can be made more reliable and more stable, and furthermore, a commutator that can be manufactured and supplied in a simpler process and at lower cost is provided. It has been demanded.

The present invention has been made in view of the above problems, and is intended to provide a more reliable and highly stable electrical connection between a commutator piece and a terminal piece. It is an object of the present invention to provide a commutator that can be manufactured and supplied at a low cost and a method for manufacturing the same. Disclosure of the invention

In the commutator of the present invention, a plurality of terminal pieces having winding connection terminals are fixed along the substantially outer periphery of the insulating support so as to be insulated from each other, and a plurality of commutator pieces respectively corresponding to the terminal pieces are provided. Are fixedly insulated from each other, and a connecting body is provided in engagement with the corresponding terminal piece and commutator piece. For example, a connection body is engaged with and embedded in the corresponding terminal piece and commutator piece, respectively.

Further, in the commutator of the present invention, the through hole formed in the terminal piece and the hole formed in the commutator piece correspond to each other, and the commutator is connected to the through hole of the terminal piece and the hole of the commutator piece. The body is provided in engagement. It is preferable that the through hole of the terminal piece and the hole of the commutator piece correspond to each other at a contact surface between the terminal piece and the commutator piece or in a region including the contact portion.

Furthermore, the commutator of the present invention is characterized in that the connection body is provided so as to engage in a centripetal direction. For example, a commutator in which a connection body is buried from the outer peripheral surface of the terminal piece in the axial direction. By providing the connection body in the centripetal direction, it is possible to manufacture with a simpler process, and it is possible to improve the conductivity and the fixing strength.

Furthermore, the commutator of the present invention is characterized in that the connection body is a compact formed of conductive powder. By molding the conductive powder, the connection body can be provided in a simple process, and the connection body can be provided in the through hole of the terminal piece and the hole of the commutator piece with high consolidation force without any gap. A good electrical connection between the terminal piece and the commutator piece can be obtained. In particular, when calcined conductive powder is used as the conductive powder, It is preferable because the connector can solidify, the connecting body can exhibit a higher anchoring function, and the insulating support, the commutator piece and the terminal piece can be stably positioned with respect to each other, and the mechanical fixing strength of the three can be improved. . For example, calcined powder such as electrolytic powder such as electrolytic copper powder is formed by combining a number of particles to form a small group. Since they are combined with each other to form a large group, the strength of the green compact is dramatically increased.

Furthermore, in the commutator of the present invention, the conductive powder is mainly composed of one of Cu, Ag, Au, Ni, Sn, and Ag plating Cu or one of these metals. It is a composite powder. By using these powders, higher conductivity and higher consolidation force can be obtained.

Further, in the method for manufacturing a commutator according to the present invention, a plurality of terminals t having winding connection terminals are fixed along the substantially outer periphery of the insulating support so as to be insulated from each other, and correspond to the terminal pieces, respectively. A plurality of commutator pieces are fixedly insulated from each other, and a through hole formed in the terminal piece and a hole formed in the commutator piece correspond to each other. A method for manufacturing a commutator in which a connecting body is provided in engagement with one of the holes, wherein the annular commutator body is arranged in contact with an annular terminal body having a plurality of winding connection terminals, Fixing the terminal body and the commutator body to the formed insulating support by insert molding with an insulating resin; and forming the terminal body at a plurality of predetermined positions of the terminal body and the commutator body. And a hole is drilled, and a connecting body is engaged with the through hole of the terminal body and the hole of the commutator body. Forming a slit in the terminal body and the commutator body and dividing the terminal body into a plurality of mutually insulated terminal pieces and a plurality of mutually insulated commutator pieces. I do. According to the manufacturing method, for example, it is not necessary to align the through hole of the terminal body formed beforehand with the hole of the commutator body, and the manufacturing can be performed with simpler processes.

Further, in the method for manufacturing a commutator of the present invention, the connecting body may be provided by providing a conductive powder in a through hole of the terminal body and a hole of the commutator body, and pressing and molding the conductive powder. It is characterized by. By pressing and molding the conductive powder, the connection body can be provided in a simple process, and the connection body is provided with a high consolidation force without any gap between the through hole of the terminal piece and the hole of the commutator piece. Good between terminal strip and commutator strip It is possible to obtain an excellent electrical connection.

Since the commutator of the present invention and the method of manufacturing the same are configured as described above, the electrical connection between the commutator piece and the terminal piece of the commutator can be made more reliable and more stable, and more simple. It can be manufactured and supplied in a simple process and at low cost. In addition, since the connecting body penetrates the through hole of the terminal piece and is provided in engagement with the hole of the commutator piece, the connecting body exerts an impedance function, and the insulating support, the commutator piece, and the terminal. The pieces are stably positioned with respect to each other, and the mechanical fixing strength of the three is improved. BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a plan view showing a commutator according to a first embodiment of the present invention,

FIG. 2 is a front view showing the commutator of the first embodiment before bending the winding connection terminal, FIG. 3 is a longitudinal sectional view taken along line A-A of the commutator of the first embodiment,

FIG. 4 is a partial longitudinal sectional view showing a commutator of the first embodiment before forming a connection body, FIG. 5 is a partial longitudinal sectional view showing a modification of the commutator of the first embodiment,

FIG. 6 is a partial longitudinal sectional view showing a commutator according to a second embodiment of the present invention. BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, a commutator of the present invention and a method of manufacturing the same will be described based on a specific embodiment shown in the drawings. 1 to 4 relate to the commutator of the first embodiment, FIG. 1 is a plan view of the commutator, FIG. 2 is a front view showing the commutator before bending the winding connection terminal, and FIG. FIG. 4 is a partial vertical cross-sectional view of the commutator before forming a connection body.

The commutator 1 of the first embodiment is a flat commutator in which the brush sliding surface is perpendicular to the axial direction of the rotor, and as shown in FIGS. A plurality of metal terminal pieces 3 that are mutually insulated through slits 5 are fixed along the outer circumference, and each terminal piece 3 is connected to a winding connection terminal 3 that is connected to the winding of the rotor by hyging. 1 and a plurality of rectifier pieces 4 mainly composed of carbon mutually insulated through a slit 5 are provided in close contact with each corresponding terminal piece 3. Both are fixed to and integrated with the insulating support 2. Brush sliding surface of each commutator piece 4 4 1 is perpendicular to the axial direction of the rotor, the brush sliding surface 41 slides with the brush 100, and the winding is connected to the winding connection terminal 3 1 from the winding. The current is supplied to the wound rotor, and the rotor rotates. · The insulative support 2 is a substantially top shape formed by molding an insulating resin, with a shaft hole 21 for the rotor shaft formed at the center, and the rotor shaft of the motor inserted into the shaft hole 21. It is installed as Each of the terminal strips 3 has a substantially sector shape in which a winding connection terminal 31 bent outward in a hook shape is formed, and an inclined surface 3 2 that is inclined upward and outward is formed substantially at the upper inside. It is formed and is in close contact with the commutator piece 4 on the inclined surface 32, and is fixed by shape bonding on the contact surface with the insulating support 2 such as the inner peripheral surface 33 by insert molding with insulating resin. ing. Each terminal strip 3 has an outer peripheral surface 3 4 and an inner peripheral surface

A through hole 35 is formed in the centripetal direction through a part of 33 and a part of the inclined surface 32. Also, inside the terminal strip 3, anchors 36 are bent at both sides or one side of the winding connection terminal 31, and the anchors 36 are embedded in the insulating support 2 and The adhesion between the piece 3 and the insulating support 2 is enhanced.

The commutator piece 4 is substantially fan-shaped, with the upper surface being a brush sliding surface 41, and an inclined surface 42 inclined upward and outward is formed substantially below the outer periphery thereof. Is in close contact with the inclined surface 32, and is fixed by form-fitting at the contact surface with the insulating support 2 by insert molding with an insulating resin. On the inclined surface 42 of the commutator piece; a hole 43 not penetrating is formed in the centripetal direction at a position corresponding to the through hole 35 of the terminal piece 3. The main component of the commutator piece 4 is graphite or amorphous carbon or a mixture of both, and may be mixed with carbon fiber. Commutator pieces 4 other than the above can also be used.

The through hole 3 5 of the terminal piece 3 and the hole 43 of the commutator piece 4 are arranged at corresponding positions, and at least a part of the through hole 35 and the hole 43 having substantially the same diameter is connected. 3 5 hole

A connection body 6 is provided in engagement with 43. The connection body 6 is made of one of Cu, Ag, Au, Ni, Sn, Ag, and Cu, or a conductive powder such as a composite powder containing one of these metals as a main component or an electrolytic powder. The powder is formed by pressing, and the conductive powder or the connecting body 6 enters the through-holes 35 and 43 without any gap, and the formed connecting body 6 is solidified with high strength, and the through-hole is formed. Engage with 3 5 and hole 4 3. And connect In this configuration, reliable and stable conduction between the terminal piece 3 and the commutator piece 4 is obtained via the body 6.

When manufacturing the commutator 1 of the first embodiment, first, an annular commutator body is placed in contact with an annular terminal body having a plurality of winding connection terminals 31. In the above arrangement, the inclined surface 42 of the commutator body is arranged close to the inclined surface 32 of the terminal body. Then, if necessary, the anchor 36 of the terminal body 36 is bent inward and insert-molded with an insulating resin using a predetermined mold to form the insulating support 2 and align it with the terminal body. The sponge is fixed to the insulating support 2 by shape coupling. In a state where the terminal body and the commutator body are fixed to the insulating support 2, the close contact between the inclined surfaces 32 and 42 is maintained. Then, a hole is drilled in the centripetal direction from the position above the winding connection terminal 31 through the terminal body to penetrate from the outer peripheral surface 34 of the terminal body to the inclined surface 32 and the inner peripheral surface 33. A hole 35 is formed, a hole 43 that does not penetrate from the inclined surface 42 of the commutator body is formed, and a hole is formed between the through hole 35 and the hole 43 of the insulating support 2. As a result, the through-holes 35 and the holes 43 are connected in a hollow state, and in this example, between the through-holes 35 and the substantially lower portions of the holes 43, the insulating support 2 has holes of approximately the same diameter as these. Is partially formed, and a cavity is formed by the through hole 35 and the partial hole and the hole 43 of the insulating support 2.

Then, conductive powder is filled into the cavity of the through hole 35 of the terminal body and the hole 43 of the commutator body, or into the through hole 35 and the hole of the insulating support 2 and the cavity of the hole 43. Then, the conductive powder is pressed into the cavity by pressing the conductive powder or the like, thereby forming the connector 6. The connecting body 6 is formed by loading and squeezing the conductive powder into all or a part of the through-hole 35 of the cavity and squeezing it. The formed connecting body 6 is a through-hole. 35 and the hole 43, or the through hole 35 and the hole and the hole 43 of the insulating support 2. Therefore, the terminal piece 3 and the commutator piece 4 fixed to the insulating support 2 are engaged by the connecting body 6. Then, a slit 5 is formed on the terminal body and the commutator body and divided into a plurality of mutually insulated terminal pieces 3 and a plurality of mutually insulated commutator pieces 4 (see FIG. 2). The winding connection terminal 31 is bent into a hook shape to complete the commutator 1 of the first embodiment (see FIGS. 1 and 3).

The commutator 1 of the flat commutator according to the present invention is not limited to the above example, and may be, for example, the commutator 1 shown in FIG. The basic configuration of the commutator 1 in FIG. 5 is the same as in the first embodiment. However, the protrusion formed on the lower inside of the commutator piece 4 engages with the insulating support 2 to increase the fixing strength, and the outer peripheral surface 3 4 of the terminal strip 3 to the inner peripheral surface 3 A through hole 3 5 in the centripetal direction is formed on 3, and the inner peripheral surface 3 3 of the terminal strip 3 and the outer peripheral surface of the commutator strip 4 are in close contact with each other and correspond to the through hole 3 5 on the outer peripheral face of the commutator strip 4 A hole 43 in the centripetal direction is formed in the hole, and a connecting body 6 formed by loading and pressing conductive powder into the cavity of the continuous through hole 35 and the hole 43 is provided. .

Further, the commutator according to the present invention is not limited to a flat commutator, but may be any suitable such as a cylindrical commutator in which the brush sliding surface 41 is parallel to the axial direction of the rotor. For example, a cylindrical commutator shown in FIG. Commutator 1 may be used. The commutator 1 shown in FIG. 6 has a plurality of terminal pieces 3 fixedly insulated from each other on the lower outer periphery of a substantially cylindrical insulative support 2, and a plurality of commutators on the outer periphery extending from the upper portion to substantially the center. The child pieces 4 are insulated and fixed to each other. A substantially upper portion of the terminal strip 3 protrudes upward, and a through hole 35 in the centripetal direction is formed from the outer peripheral surface 3 4 to the inner peripheral surface 3 3 of the terminal strip 3. The outer peripheral surface of the commutator segment 4 is in close contact with the outer peripheral surface of the commutator segment 4, and a hole 43 in the centripetal direction is formed at a position corresponding to the through hole 35 on the outer peripheral surface of the commutator segment 4. A connection body 6 formed by loading and pressing a conductive powder into the cavity is provided by engaging.

Various conductive adhesives such as applying a conductive adhesive may be provided on the contact surface between the terminal piece 3 and the commutator piece 4. Further, the commutator of the present invention, for example, penetrates a plurality of holes 43 formed in an annular terminal body having a plurality of winding connection terminals and a plurality of through holes 35 formed therein. The terminal body and the rectifier body are fixedly mounted on the molded insulating support member by placing an annular commutator body in contact with the hole 35 and performing insert molding with an insulating resin. A connecting body is provided in the through-hole of the terminal body and the hole of the rectifier body, and a slit 5 is formed on the terminal body and the commutator body to be divided and insulated from each other. It can also be manufactured by a process of forming a plurality of commutator pieces 4 mutually insulated from the plurality of terminal pieces 3.

Claims

The scope of the claims

1. A plurality of terminal pieces having winding connection terminals are fixed along the substantially outer periphery of the insulating support so as to be insulated from each other, and a plurality of commutator pieces respectively corresponding to the terminal pieces are insulated from each other. A commutator, which is fixedly provided, and a connection body is provided so as to be engaged with the corresponding terminal piece and the commutator piece.

2. A through hole formed in the terminal piece and a hole formed in the commutator piece correspond to each other, and a connector is engaged with the through hole of the terminal piece and the hole of the commutator piece. The commutator according to claim 1, wherein the commutator is provided.

3. The commutator according to claim 1 or 2, wherein the connection body is provided so as to engage in a centripetal direction.

4. The commutator according to claim 1, wherein the connection body is a green compact of conductive powder.

5. The commutator according to claim 4, wherein the conductive powder is calcined.

6. The conductive powder is one of Cu, Ag, Au, Ni, Sn, and Ag Cu, or a composite powder containing one of these metals as a main component. The commutator according to claim 4, wherein:

7. A plurality of terminal strips having winding connection terminals are fixed along the substantially outer periphery of the insulated support so as to be insulated from each other, and a plurality of commutator strips respectively corresponding to the terminal strips are insulated from each other. A through hole formed in the terminal piece and a hole formed in the commutator piece correspond to each other, and a connector is engaged with the through hole of the terminal piece and the hole of the commutator piece. A method of manufacturing a commutator provided by mounting a ring-shaped commutator body in contact with a ring-shaped terminal body having a plurality of winding connection terminals, and performing insert molding with an insulating resin. Accordingly, a step of fixing the terminal body and the commutator body to the molded insulating support, and forming holes through the terminal body at predetermined plural positions of the terminal body and the commutator body. A connecting body is provided in the through hole of the terminal body and the hole of the commutator body so as to engage with each other, and the terminal body and the commutator body are slipped. A method for manufacturing a commutator, comprising: forming and dividing a plurality of terminal pieces into a plurality of mutually insulated terminal pieces and a plurality of mutually insulated commutator pieces.

8. The connection body is provided by providing a conductive powder in a through hole of the terminal body and a hole of the commutator body, and pressing and molding the conductive powder. A method for manufacturing the commutator according to the above.