WO2005077017A2 - Improved brush card apparatus and method - Google Patents
Improved brush card apparatus and method Download PDFInfo
- Publication number
- WO2005077017A2 WO2005077017A2 PCT/US2005/003906 US2005003906W WO2005077017A2 WO 2005077017 A2 WO2005077017 A2 WO 2005077017A2 US 2005003906 W US2005003906 W US 2005003906W WO 2005077017 A2 WO2005077017 A2 WO 2005077017A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- brush card
- lead frame
- brush
- molded
- plastic body
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims description 10
- 239000004033 plastic Substances 0.000 claims abstract description 15
- 239000003990 capacitor Substances 0.000 claims abstract description 12
- 239000002991 molded plastic Substances 0.000 claims abstract description 7
- 239000004020 conductor Substances 0.000 claims description 22
- 229910001369 Brass Inorganic materials 0.000 claims description 20
- 239000010951 brass Substances 0.000 claims description 20
- 238000000465 moulding Methods 0.000 claims description 5
- 239000002184 metal Substances 0.000 claims description 3
- WABPQHHGFIMREM-UHFFFAOYSA-N lead(0) Chemical compound [Pb] WABPQHHGFIMREM-UHFFFAOYSA-N 0.000 claims 1
- 238000007789 sealing Methods 0.000 claims 1
- 238000005266 casting Methods 0.000 abstract description 9
- 230000005540 biological transmission Effects 0.000 abstract description 2
- 238000001914 filtration Methods 0.000 abstract description 2
- 238000003466 welding Methods 0.000 description 6
- 238000002788 crimping Methods 0.000 description 4
- 238000005476 soldering Methods 0.000 description 4
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000013016 damping Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000002955 isolation Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000005058 metal casting Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000001629 suppression Effects 0.000 description 1
- 230000003685 thermal hair damage Effects 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
- H02K5/14—Means for supporting or protecting brushes or brush holders
- H02K5/143—Means for supporting or protecting brushes or brush holders for cooperation with commutators
- H02K5/148—Slidably supported brushes
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/02—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for suppression of electromagnetic interference
- H02K11/026—Suppressors associated with brushes, brush holders or their supports
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/20—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for measuring, monitoring, testing, protecting or switching
- H02K11/27—Devices for sensing current, or actuated thereby
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
- H02K5/10—Casings or enclosures characterised by the shape, form or construction thereof with arrangements for protection from ingress, e.g. water or fingers
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
- H02K5/22—Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes
- H02K5/225—Terminal boxes or connection arrangements
Definitions
- the present invention relates to permanent magnet DC brush motors, and more particularly, to brush cards used in such motors.
- Insert molding, integral connectors, and molded-in-place gaskets are common knowledge in the permanent magnet DC brush motor industry, and molded plastic brush cards with integral brush tubes are also commonly used.
- the brush cards have generally been encased and staked in a metal casting and a separate circuit breaker assembly mounted onto the brush card.
- the placement of the brush card in the casting and the staking of the brush card to the casting results in a direct mechanical fastening of the brush card to the motor housing providing an unimpeded path for the vibrations generated in the brush card to be passed to the motor housing. It can therefore be appreciated that a brush card which provides some mechanical isolation between the brush card and the motor housing, and in which a separate circuit breaker assembly can be eliminated is highly desirable.
- a molded plastic brush card for use in DC permanent magnet brush motors having an integral circuit breaker. Also described is the utilization of gaskets formed on the brush card to both seal the motor and to resiliently mount the brush card thereby providing sound and vibration damping. Further described is a brush card assembly incorporating the particular combination of features presented below.
- Fig. 1 is a perspective top view of the improved brush card of the present invention
- Fig. 2 is a perspective bottom view of the brush card assembly of the present invention
- Fig. 3 is a perspective exploded side view of the brush card, shell, & end frame
- Fig. 4 is a perspective bottom view of the assembled position of brush card, end-frame, & shell of Fig. 3
- Fig. 5 is a perspective top view of the brass conductor system used in the brush card of Fig. 1
- Fig. 6 is a perspective top view of the plastic molded around brass conductor system of Fig. 5
- Fig. 7 is a perspective bottom view of a portion of the brush card of Fig.
- Fig. 8 is a perspective top view of the circuit breaker blade shown in Fig. 1 ;
- Fig. 9 is a perspective top view of the brush attachment of the brush card of Fig. 1 ;
- Fig. 10 is a perspective top view of capacitor attachment of the brush card of Fig. 1 ;
- Fig. 11 is a perspective top view of the spring and retainer assembly together with the brush card of Fig. 1 ;
- Fig. 12 is a perspective side view of a portion of the brush card of Fig. 1 showing the circuit breaker blade and contact.
- the improved brush card of the present invention comprises a novel brush card design, wherein the cost associated with brush card assembly is reduced. Following is a description and drawings of this novel apparatus and method.
- the novel apparatus of the present invention comprises brush card 10 constructed of molded plastic with brush tubes 12 and a connector housing 14 molded as an integral part of the card.
- the embodiment further comprises a brass conductor system 16 (shown in Fig. 5) wherein the brass conductor system 16 is molded inside the brush card 10.
- the leads of the brushes 18 and RFI capacitor 20 may be connected to the brass conductor system 16 by soldering, resistance welding, ultrasonic welding, or crimping.
- the brush card of the present invention further comprises a circuit breaker 26 that is attached directly to the brass conductor system 16.
- An additional feature of the present invention is that the brush card 10 may be assembled into the motor without direct mechanical fastening. However, the brush card may also be attached to the motor by any suitable method, such as, riveting, screwing, or staking. Referring now to Figs. 3 and 4, the brush card 10 is positioned between the motor shell 28 and end-frame casting 30. The brush card 10 is placed into the end-frame casting 30, and is held in place radially by a thin wall feature of the end-plate casting 30 that extends part way up the side of the brush card.
- the brush card of the present invention is an insert- molded design.
- the first step in the manufacturing process is to stamp and form a brass conductor system 16, such as the one shown in Fig. 5.
- An electrical contact 32 is attached to the brass conductor system for later use as part of a circuit breaker.
- the second step in the process is to place the brass conductors in a mold and to mold plastic around the conductors.
- the brush tubes and a connector housing are molded as integral parts of the plastic card as shown in Fig. 6.
- the electrical contact 32 and certain areas of the brass conductors are left exposed for later attachment of components.
- the next step is to place the plastic card into another mold and to injection mold gaskets.
- the gasket material may be an injection-moldable elastomer.
- Fig. 7 shows a particular configuration for these gaskets. As shown in Fig.
- the circuit breaker 26 assembly comprises a current-carrying bi-metal blade 34 that is stamped and formed in such a way so as to "snap" from a concave shape to a convex shape at a temperature slightly below the safe thermal limits of the motor components.
- An electrical contact 36 may be welded or riveted to the blade.
- the blade 34 may be attached to the brass conductor system by welding or riveting. Additionally, the blade is positioned so the electrical contact 36 on the blade is centered, and in contact with the electrical contact 32 attached to the brass conductor system 16 as shown in Fig. 12. In operation, the current flowing to the motor goes through the circuit breaker blade 34 and contacts 32 and 36.
- the blade 34 snaps and the two electrical contacts 32 and 36 are pulled apart, opening the electric circuit and stopping current flow to the motor, protecting it from thermal damage.
- the blade 34 cools, it snaps back to the original operating position and automatically re-energizes the motor.
- the motor brushes 18 are attached to the card at two points 38 where the brass conductors were left exposed. These connections may be made by welding, crimping, or soldering.
- capacitor 20 is attached at two additional points 40 to the card, also by welding, crimping, or soldering.
- the RFI filter capacitor 20 is placed as near the point where the power conductors exit the motor shell as possible. Keeping the capacitor leads as short as possible serves to increase the filtering effectiveness of the capacitor.
- the capacitor is placed adjacent to the connector housing 14 and attached to the brass conductor system 16 by welding, crimping, or soldering.
- the brushes 18 are held against the commutator by spring pressure.
- brush springs 42 are inserted into the brush tubes 12 so as to press against the back of the brush 18.
- a plastic cap 44 snaps into place on the end of the brush tube 12 and retains the spring 42.
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Motor Or Generator Frames (AREA)
- Motor Or Generator Current Collectors (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US54238604P | 2004-02-06 | 2004-02-06 | |
US60/542,386 | 2004-02-06 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2005077017A2 true WO2005077017A2 (en) | 2005-08-25 |
WO2005077017A3 WO2005077017A3 (en) | 2005-11-10 |
Family
ID=34860301
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2005/003906 WO2005077017A2 (en) | 2004-02-06 | 2005-02-07 | Improved brush card apparatus and method |
Country Status (1)
Country | Link |
---|---|
WO (1) | WO2005077017A2 (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2011103947A3 (en) * | 2010-02-23 | 2012-01-12 | Brose Fahrzeugteile Gmbh & Co. Kg, Würzburg | Electric motor for driving a motor vehicle component |
ITTO20111158A1 (en) * | 2011-12-15 | 2013-06-16 | Gate Srl | BRUSH HOLDER FOR AN ELECTRIC MANIFOLD WITH A COLLECTOR, IN PARTICULAR FOR A DIRECT CURRENT MOTOR, AND A PROTECTION DEVICE FOR SUCH A BRUSH HOLDER. |
EP3163719A1 (en) * | 2015-10-26 | 2017-05-03 | LG Innotek Co., Ltd. | Sealing cover and actuator having same |
CN107147236A (en) * | 2017-07-14 | 2017-09-08 | 成都华川电装有限责任公司 | Motor brush rocker and brushed DC motor |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB9423900D0 (en) * | 1994-11-26 | 1995-01-11 | Pifco Ltd | Improvements to thick film elements |
JP3274072B2 (en) * | 1996-08-05 | 2002-04-15 | 株式会社ミツバ | Power supply structure in electric motor |
US6078117A (en) * | 1997-08-27 | 2000-06-20 | Nartron Corporation | End cap assembly and electrical motor utilizing same |
US6573625B2 (en) * | 2000-03-29 | 2003-06-03 | Asmo Co., Ltd. | Motor device having water-proof brush holder |
US6528922B2 (en) * | 2000-10-06 | 2003-03-04 | New Bright Industrial Co., Ltd. | Motor housing having simplified cover plate and brush base |
-
2005
- 2005-02-07 WO PCT/US2005/003906 patent/WO2005077017A2/en active Application Filing
Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102771036B (en) * | 2010-02-23 | 2015-01-21 | 博泽沃尔兹堡汽车零部件有限公司 | Electric motor for driving a motor vehicle component |
CN102771036A (en) * | 2010-02-23 | 2012-11-07 | 博泽沃尔兹堡汽车零部件有限公司 | Electric motor for driving a motor vehicle component |
EP2613428A2 (en) | 2010-02-23 | 2013-07-10 | Brose Fahrzeugteile GmbH & Co. Kommanditgesellschaft, Würzburg | Electric motor for driving a motor vehicle component |
EP2613427A2 (en) | 2010-02-23 | 2013-07-10 | Brose Fahrzeugteile GmbH & Co. Kommanditgesellschaft, Würzburg | Electric motor for driving a motor vehicle component |
US8633621B2 (en) | 2010-02-23 | 2014-01-21 | Brose Fahrzeugteile Gmbh & Co. Kommanditgesellschaft, Wuerzburg | Electric motor for driving a motor vehicle component |
WO2011103947A3 (en) * | 2010-02-23 | 2012-01-12 | Brose Fahrzeugteile Gmbh & Co. Kg, Würzburg | Electric motor for driving a motor vehicle component |
KR101506856B1 (en) * | 2010-02-23 | 2015-03-30 | 브로제 파르초이크타일레 게엠베하 운트 코. 카게, 뷔르츠부르크 | Electric motor for driving a motor vehicle component |
EP2613428A3 (en) * | 2010-02-23 | 2016-11-23 | Brose Fahrzeugteile GmbH & Co. Kommanditgesellschaft, Würzburg | Electric motor for driving a motor vehicle component |
EP2613427A3 (en) * | 2010-02-23 | 2016-11-23 | Brose Fahrzeugteile GmbH & Co. Kommanditgesellschaft, Würzburg | Electric motor for driving a motor vehicle component |
ITTO20111158A1 (en) * | 2011-12-15 | 2013-06-16 | Gate Srl | BRUSH HOLDER FOR AN ELECTRIC MANIFOLD WITH A COLLECTOR, IN PARTICULAR FOR A DIRECT CURRENT MOTOR, AND A PROTECTION DEVICE FOR SUCH A BRUSH HOLDER. |
EP3163719A1 (en) * | 2015-10-26 | 2017-05-03 | LG Innotek Co., Ltd. | Sealing cover and actuator having same |
US10431921B2 (en) | 2015-10-26 | 2019-10-01 | Lg Innotek Co., Ltd. | Sealing cover and actuator having same |
CN107147236A (en) * | 2017-07-14 | 2017-09-08 | 成都华川电装有限责任公司 | Motor brush rocker and brushed DC motor |
Also Published As
Publication number | Publication date |
---|---|
WO2005077017A3 (en) | 2005-11-10 |
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