JP3248142B2 - Commutator and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a commutator and a method of manufacturing the same, and more particularly, to a flat commutator in which segments are arranged at equal circumferential intervals on one end surface of a boss in an axial direction. The present invention relates to an in-tank type fuel supply pump integrated with a pump, which is effective.

[0002]

2. Description of the Related Art In general, as a fuel supply pump for supplying fuel for vehicles such as automobiles, there is an in-tank type in which a motor is integrated with a pump and installed inside a fuel tank. In this in-tank type fuel supply pump, a flat commutator may be used for the motor.

On the other hand, an in-tank type fuel supply pump is generally configured so that fuel is sent from the pump to the outside through a motor housing. In this case, the fuel comes into contact with the commutator of the motor.

By the way, when gasohol in which alcohol is mixed in gasoline is used as fuel,
When the commutator copper used in the fuel supply pump motor comes into contact with gasohol, the fuel is reformed,
It is known that copper is eroded. Therefore, as a commutator for countermeasures against gasohol, a protective piece made of carbon is applied by soldering to at least a surface of the copper base material of the segment (commutator piece) that contacts the brush, and at least the solder of the protective piece made of carbon is soldered. It is proposed that the attachment surface is subjected to nickel plating and copper plating.

[0005]

However, in the above-mentioned conventional commutator, the carbon protective piece is electrically and mechanically connected to the copper segment base material by soldering. When the armature coil is fused to the riser piece integrally projecting from the base material, there is a possibility that the soldering layer is melted and the carbon protection piece is separated from the segment base material.
For this reason, it is necessary to check whether the carbon protective piece is properly soldered to the segment base material, but this check is impossible or extremely difficult.
Therefore, it is confirmed whether or not the conduction between the carbon protective piece and the riser piece is ensured. In this method, the solder between the carbon protective piece and the segment base material is checked. Since the bonding state of the attachment layer cannot be confirmed, it cannot be confirmed whether the carbon protective piece is properly fixed to the segment base material.

[0006] Further, since the protection piece is plated with nickel and copper, not only the number of manufacturing steps increases, but also the number of manufacturing steps increases.
Manufacturing costs increase.

An object of the present invention is to provide a commutator capable of electrically connecting a riser piece to a carbon segment without soldering, and a method of manufacturing the same. A second object of the present invention is to provide a commutator that can omit nickel plating and a copper plating film in a segment, and a method of manufacturing the same.

[0008]

A commutator according to the present invention comprises: a boss portion integrally formed into a disk shape with a resin; and a boss portion provided at one axial end surface of the boss portion at circumferentially equal intervals and insulated from each other. a plurality of segments of fixed carbon, the commutator and a riser which are electrically connected to each segment, the recess above each <br/> segments are respectively deaths set , Said la
The Isa pieces are formed the coupled parts, respectively, wherein the coupled parts conductor powder filled in the concave portion is inserted into the recess of the respective segments or conductive each riser
It is characterized by being bonded by an adhesive .

Further, the commutator according to the present invention is provided with a boss integrally formed in a disk shape with resin, and is disposed at equal intervals in the circumferential direction on one axial end surface of the boss and is insulated and fixed to each other. In a commutator including a plurality of segments and a riser piece electrically connected to each segment, each of the segments is formed using carbon, and each carbon segment has a concave portion. One end of each conductive wire is electrically connected to each of the riser pieces, and the other end of each conductive wire is inserted into each segment, part of which is inserted into the recess. It is characterized by being connected by being connected.

Further, the method for manufacturing a commutator according to the present invention includes a boss portion integrally formed into a disc shape with a resin,
A commutator comprising a plurality of segments arranged at equal intervals in the circumferential direction on one end surface in the axial direction of the boss portion and insulated and fixed to each other, and a riser piece electrically connected to each segment. In the manufacturing method, a step of preparing a segment base plate in which carbon is used to form a disk shape and a plurality of concave portions are laid and disposed at equal intervals in a circumferential direction, and a plurality of riser pieces are annular A step of preparing riser piece base plates which are arranged and connected to each other by an annular ring-shaped portion, and a part of each riser piece or a part of a conductive wire connected to each riser piece in each recess of the segment base plate. The step of being inserted into the concave portion and being joined to each other, and a disk-shaped boss portion around the segment material to which each riser piece is fixed, and a state in which a part of each riser piece is projected from the boss portion, respectively. The step of forming, the ring-shaped part of the riser piece base plate is cut, and the step of bending each riser piece, and the slit is cut into the segment base plate between the riser pieces over the boss portion and each segment Is formed.

[0011]

According to the above-mentioned means, the riser piece or the conductive wire is electrically and mechanically connected to the carbon segment, so that the riser piece is electrically connected to the carbon segment. The formation can be omitted. Therefore, it is possible to avoid secondary adverse effects caused by melting of the soldering layer.

Further, since the riser piece is directly connected to the carbon segment or directly connected by a conductive wire, the segment base material made of copper is omitted by omitting the segment base material made of copper. Exposure can be avoided. As a result, a step for applying a nickel plating and a copper plating film on the surface of the segment base material can be omitted, and the cost can be reduced.

[0013]

1 shows a commutator according to an embodiment of the present invention. FIG. 1 (a) is a partially cutaway perspective view and FIG. 1 (b) is a plan view. FIG. 2 et seq. Are explanatory views showing respective steps of the method for manufacturing the commutator according to one embodiment of the present invention.

In this embodiment, the commutator according to the present invention has a flat structure and is used for a motor in an in-tank type fuel supply pump.

The flat commutator 1 according to this embodiment has a boss portion 16 formed of a thick, substantially disk-shaped member using an insulating resin, and a boss portion 16 formed of a substantially fan-shaped member. And a plurality of segments 21 radially arranged at substantially equal intervals on the surface of the segment, and a riser piece 4 electrically and mechanically connected to each of the segments 21.
And a slit 20 for making adjacent segments 21 electrically insulated from each other. A shaft hole 17 for inserting and fixing the motor rotation shaft is formed concentrically in the boss portion 16.

Each segment 21 is formed by baking carbon with a suitable binder, and a concave portion 11 is provided at the interface between each segment 21 and the boss 16. The riser pieces 4 are integrally connected to each other while being sandwiched between the segment 21 and the boss portion 16. The to-be-joined part 6 is formed to be bent at the inner end of the riser piece 4.
The connected portion 6 is inserted into the concave portion 11 of the segment 21 and is electrically and mechanically connected by a copper powder caulking portion 14 as a connecting portion. Therefore, the riser piece 4 is electrically and mechanically connected to the carbon segment 21.

Hereinafter, a method of manufacturing a commutator according to an embodiment of the present invention will be described with reference to a method of manufacturing the commutator 1 having the above-described configuration. With this description, the details of the configuration of the commutator 1 according to the above configuration will be clarified.

FIGS. 2A and 2B show a base plate of a riser piece used for manufacturing the commutator according to the above configuration, wherein FIG. 2A is a front sectional view and FIG. 2B is a bottom view.

In FIG. 2, the base plate 2 of the riser piece is integrally formed by pressing using a copper-based material (copper or copper alloy). The riser piece blank 2 is provided with a ring-shaped portion 3 as a connecting member for connecting the riser pieces during manufacturing, and the inner diameter of the ring-shaped portion 3 is larger than the outer diameter of the flat commutator 1. It is formed to be sufficiently large.

A plurality (eight in the illustrated example) of riser pieces 4 are arranged at equal intervals in the circumferential direction and radially project inward in the radial direction on the inner periphery of the ring-shaped portion 3. A wide portion 5 is integrally formed at the tip of the riser piece 4, and the wide portion 5 is formed in a substantially square shape with one of the corners cut out in a triangle. Further, each wide portion 5 is set to a size such that adjacent ones do not contact each other.
An L-shaped portion to be joined 6 is arranged at the inner end side of the wide portion 5 at a substantially central portion in the width direction, and extends toward one end surface on the side where the carbon segment is joined. It is bent integrally so as to protrude. The size of the joined portion 6 is set to a size that can be inserted into a concave portion described later in the carbon segment.

A pair of locking claws 7 forming an anchor for fixing the riser piece 4 to the boss portion are provided on both sides of the joined portion 6 on the inner end side of the wide portion 5. Each is bent so as to protrude to the end face opposite to the protruding side and to be tilted to the extent that the anchor effect can be exerted on the ring-shaped portion 3 side.

FIGS. 3A and 3B show a carbon plate which is a raw plate of carbon segments used for manufacturing the commutator according to the above configuration, wherein FIG. 3A is a plan view and FIG. 3B is a front sectional view.

In FIG. 3, a carbon plate 8 for forming a carbon segment is formed by integrally firing carbon with a suitable binder into a circular ring shape. The carbon plate 8 is formed in a substantially circular ring shape having a width equal to the radial dimension of the segment to be manufactured. That is, the large ring-shaped carbon plate 8 is formed such that its outer diameter is substantially equal to the outer diameter of the segment group, and its inner diameter is substantially equal to the inner diameter of the segment group. I have.

An inner engaging step 9 and an outer engaging step 10 are formed at a constant width and a constant height, respectively, on the inner peripheral surface and the outer peripheral surface of one end surface of the carbon plate 8. As will be described later, the two step portions 9 and 10 are engaged with a part of the boss portion after the boss portion is formed by resin molding, and the boss portion and each carbon segment are integrally connected by a shape coupling effect. The width and height are set to optimal values so as to be able to fulfill the role of

Both steps 9 and 1 of the carbon plate 8
On the end face opposite to the end face where 0 is formed, a plurality of recesses 11 for coupling riser pieces are arranged at equal intervals in the circumferential direction on a concentric circle passing through the center position in the radial direction and have a constant depth. Each is submerged in a circular hole shape. This recess 11
Is set to be large enough to accommodate the above-described coupled portion 6 of the riser piece, and is set so as to be able to fill an appropriate amount of copper powder 12 (see FIG. 3B) as conductor powder. I have.

FIG. 4 shows a joint structure in which the riser piece shown in FIG. 2 and the carbon plate shown in FIG. 3 are joined, (a) is a front sectional view,
(B) is a bottom view.

The joint structure 13 shown in FIG. 4 has a structure in which the carbon plate 8 is in contact with the end face of the riser piece plate 2 on the side where the part 6 to be joined protrudes. The coupling portion 6 is configured to be coupled to each recess 11 by so-called copper powder caulking. That is, the carbon plate 8 formed in a circular ring shape and the riser piece base plate 2 in which the plurality of riser pieces 4 are radially arranged and connected by the circular ring-shaped portion 3 are concentrically arranged. Contact. At this time, the coupled portion 6 of each riser piece 4
Are inserted into the respective concave portions 11 of the carbon plate 8. Then, the copper powder 12 filled in the concave portion 11 is compacted to form a copper powder caulking portion 14 as a conductor powder coupling portion. The joined portion 6 is firmly joined to the concave portion 11 by the copper powder caulking portion 14 by the anchoring effect, so that the riser piece 2 and the carbon plate 8 are joined, and the joint structure 13 is manufactured. It will be in the state that was done.

FIGS. 5A and 5B show the resin-integrated molded product after the boss portion is molded with resin. FIG. 5A is a front sectional view, and FIG. 5B is a bottom view.

In the resin integrated molded product 15 shown in FIG. 5, a boss 16 is provided on the end face of the carbon plate 8 on the side where the riser pieces 4 are joined, and a pressurization using an insulating resin is performed. It is integrally formed by a molding method (molding method). A shaft hole 17 is formed on the center line of the boss 16 by simultaneous molding into a cylindrical hole shape. The boss portion 16 has an inner engaging portion 18 and an outer engaging portion 19 formed inside and outside the carbon plate 8, respectively. The inner engaging portion 18 and the outer engaging portion 19
The inner engagement step 9 and the outer engagement step 10 formed on the carbon plate 8 are respectively shape-coupled. The carbon plate 8 is held by the boss portion 16 so as not to come off in the axial direction by the mutual shape coupling portion.

On the other hand, the riser piece 4 is in a state where a part of the wide portion 5 is implanted in the boss portion 16 at the interface with the carbon plate 8, and the pair of locking claws 7, 7 are inside the boss portion 16. It is in a state of being anchored in. Therefore, riser piece 4
Is securely fixed to the boss portion 16. As described above, the joined portion 6 of the riser piece 4 is securely connected to the concave portion 11 of the carbon plate 8 by the copper powder caulking portion 14, so that the carbon plate 8
Is more securely connected to the boss portion 16 via the riser piece 4. Thereafter, the ring-shaped portion 3 of the riser piece base plate 2 is cut off from each riser piece 4 and each riser piece 4 is folded back into a V-shape.

Thereafter, the carbon plate 8 and a part of the boss portion 16 are cut into slits, and the flat commutator 1 having the above-described configuration shown in FIG. 1 is manufactured. That is, a plurality of slits 20 are arranged in the carbon plate 8 and the boss portion 16 of the resin integrated molded product 15 at intermediate positions between the adjacent riser pieces 4 and 4, respectively, so that the cutting tool is aligned with the normal line. It is cut out by a suitable means such as cutting (not shown). The slit 20 separates the carbon plate 8 by cutting the carbon plate 8 to a depth reaching the boss portion 16, and each segment 2 in which adjacent ones are electrically independent.
1 is substantially constituted. That is, the segments 21 are formed of carbon plate pieces separated from each other by the slits 12, and the riser pieces 4 are electrically and mechanically connected by the copper powder caulking portion 14.

The flat commutator 1 manufactured and configured as described above is provided with a shaft hole 17 in the rotating shaft of the motor.
Are fitted and fixed, an armature coil (not shown) is entangled with each riser piece 4 and electrically connected by fusing processing. During the fusing process, the riser piece 4 is heated, but since the riser piece 4 is electrically and mechanically connected to the carbon segment 21 by the copper powder caulking portion 14, adverse effects due to heating are generated. Never. That is, by copper powder crimp 14 is melted, riser 4 and segment 2
There is no possibility that the connection with the first device will be damaged.

FIG. 6 is a partially cut perspective view showing a commutator according to another embodiment of the present invention.

Embodiment 2 is different from Embodiment 1 in that
One end of a conductive wire 22 made of a braided or stranded wire is connected to the inner end of the boss portion 16 of the riser piece 4A by spot welding, and the other end of the conductive wire 22 is connected to a carbon segment 21. Is connected by a copper powder caulking portion 14 to the inside of the concave portion 11.

Also in the second embodiment, the same effect as in the first embodiment can be obtained because the soldering portion is omitted in the electrical connection between the riser piece 4A and the carbon segment 21.

It is needless to say that the present invention is not limited to the above-described embodiment, but can be variously modified without departing from the gist thereof.

For example, the connection between the carbon segment and the riser piece is not limited to copper powder caulking, and a conductive adhesive may be used.

The ring-shaped portion of the riser base plate is not limited to the outer peripheral side of the riser piece but may be provided on the inner peripheral side.

Further, in the above embodiment, each segment 21 is electrically separated by the slit 20 cut between the adjacent segments 21, 21. May be arranged in a circular ring shape with an insulating gap therebetween, and insert-molded in the boss portion 16.

[0040]

As described above, according to the present invention,
It is possible to obtain a commutator capable of securely connecting the carbon segment and the riser piece with a simple configuration by omitting the soldering between the carbon segment and the riser piece, and easily realizing the manufacture thereof. be able to.

[Brief description of the drawings]

FIGS. 1A and 1B show a commutator according to an embodiment of the present invention, wherein FIG. 1A is a partially cut perspective view, and FIG.

FIGS. 2A and 2B show a riser piece used for manufacturing the commutator of FIG. 1, wherein FIG. 2A is a front sectional view and FIG. 2B is a bottom view.

3A and 3B show a carbon plate which is a raw plate of a carbon segment used for manufacturing the commutator of FIG. 1, wherein FIG. 3A is a plan view and FIG. 3B is a front sectional view.

FIGS. 4A and 4B show a joint structure in which the riser piece shown in FIG. 2 and the carbon plate shown in FIG. 3 are joined, FIG. 4A being a front sectional view, and FIG. Is a bottom view.

FIGS. 5A and 5B show a resin-integrated molded product after the boss portion is formed by resin molding, wherein FIG. 5A is a front sectional view and FIG. 5B is a bottom view.

FIG. 6 is a partially cutaway perspective view showing a commutator according to another embodiment of the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Flat commutator, 2 ... Riser piece plate, 3 ... Ring shape part, 4 and 4A ... Riser piece, 5 ... Wide part, 6 ... Coupled part, 7 ... Locking claw, 8 ... Carbon plate, 9 ... Inner engaging step, 10 ... outer engaging step, 11 ... recess, 12 ... copper powder (conductor powder), 13 ... joining structure, 14 ... copper powder caulking
Processed part (joining part) , 15: integrally molded resin, 16: boss, 17: shaft hole, 18: inner engaging part, 19: outer engaging part, 20: slit, 21: segment, 22: conductive wire .

Claims (3)

(57) [Claims] A boss portion integrally formed into a disk shape with a resin, and a plurality of carbon bosses arranged at one axial end surface of the boss portion at equal intervals in a circumferential direction and insulated and fixed to each other. and number of segments, the commutator and a riser which are electrically connected to each segment, the recess above each segment are respectively deaths set,
Each of the riser pieces has a portion to be joined,
The joined part of each riser piece is in front of each segment .
Conductor powder filled in the concave portion is inserted into the serial recess or
A commutator characterized by being connected by a conductive adhesive . 2. A boss portion integrally formed into a disk shape by a resin, a plurality of segments arranged at equal intervals in the circumferential direction on one axial end surface of the boss portion and insulated and fixed to each other; A commutator comprising a riser piece that is electrically connected to each of the segments, wherein each of the segments is formed using carbon, and each of the carbon segments has a recessed portion, One end of each conductive wire is electrically connected to each of the riser pieces, and the other end of each conductive wire is connected to each segment by inserting a part of the conductive wire into a concave portion and connecting the segments. A commutator characterized by being made. 3. A boss portion integrally formed into a disk shape with resin, a plurality of segments arranged at equal intervals in the circumferential direction on one end surface in the axial direction of the boss portion and fixed to each other insulated from each other. In a method of manufacturing a commutator comprising a riser piece electrically connected to each other, a disc is formed by using carbon, and a plurality of recesses are disposed at equal intervals in the circumferential direction and are submerged. A plurality of riser pieces are arranged in a ring, and a riser piece is connected to each other by an annular ring-shaped portion. A step in which each riser piece or a part of the conductive wire connected to each riser piece is inserted into the concave portion and respectively joined, and a disk-shaped boss is formed around the segment material to which each riser piece is fixed. A step of resin molding with a part of each riser piece protruding from the boss portion, a step of cutting the ring-shaped part of the riser piece base plate and bending each riser piece, and a segment base plate Wherein a slit is cut across the boss between the riser pieces to form each segment. A method for manufacturing a commutator, comprising: