Molded commutator and method of manufacture

Electrical generator or motor structure – Dynamoelectric – Rotary

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Details

310 43, 29597, H02K 1300

Patent

active

045594643

ABSTRACT:
A molded commutator has conductive segments circumferentially arranged about a central axis so that their outer surfaces form an overall structure of cylindrical shape as the outer surface of the commutator. Inside of this structure is an annular core to which each commutator segment is anchored by a tang formed on the inner surface of each segment, which is mechanically interlocked with a pair of tangs on the core. The tangs are shaped and configured such that, after assembly, each segment tang is interlocked between the core tangs in a dove-tail-like relationship. A nonconductive matrix is molded between the segments and the core. A method of making the commutator is to form an annular segment pack containing the conductive segments, with each segment having a segment tang formed on its inner surface, and an annular core having the core tang for one axial end of the commutator formed on its outer surface. The segment pack is then fitted over the outside of the core such that each of the core tangs is in interlocking engagement with one end of one of the segment tangs. The core tangs for the other axial end of the commutator are then mounted on the core such that each of them is in interlocking engagement with the other axial end of one of the segment tangs. To complete the structure, a nonconductive matrix is molded between the segment pack and the core.

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