JP2003259605A - Cylindrical commutator and method of manufacturing the same - Google Patents

Abstract

(57) [Problem] To provide good and stable electrical conductivity between a metal segment and a commutator segment of a cylindrical commutator. SOLUTION: A metal segment having a winding connection portion is pressed into a groove portion extending in the axial direction on a commutator segment, and the commutator segment and the metal segment are arranged corresponding to each other. It is a cylindrical commutator in which a commutator segment and a plurality of metal segments are arranged substantially along the outer periphery of an insulating support. For example, a convex portion is formed on the outer surface of a spring-like interior portion that is installed in a groove portion of a metal segment. Then, the protrusion is pressed against the groove by utilizing elasticity.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cylindrical commutator incorporated in a small motor mainly used for a fuel pump and the like and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, in a motor of a fuel pump used in gasoline or alcohol, it is known to use a cylindrical commutator as the commutator and copper or carbon as the material of the commutator. . In particular, a cylindrical commutator using a material whose main component is carbon for the commutator piece or its brush sliding surface is excellent in corrosion resistance and electrolysis resistance and is suitable as a commutator used in the motor.

Japanese Patent Laid-Open No. Sho 58-58, which is a related art of a cylindrical commutator.
In No. 207840, a copper collector having a connection hook and a carbon collector made of a sintered material containing carbon are provided around a plastic support, and a slit is cut in the copper collector and the carbon collector to form a segment. And a cylindrical commutator in which a solderable or weldable layer is provided on the mutually facing end faces of the copper collector and the carbon collector.

Another related technique, Japanese Patent Laid-Open No. Hei 5-23.
In No. 4653, a slot having a cross-shaped cross section extending in the axial direction is formed on the cylindrical outer surface of an insulating base member, a contact member having a terminal is housed in the slot, and a fixed piece integrally molded with a carbon segment is used as a contact. A cylindrical commutator is disclosed in which a slot portion where no member is present is filled with a hole of a contact member.

Another related technique, Japanese Patent Laid-Open No. 8-12.
In No. 6258, a plurality of conductive metal plates are respectively joined to a plurality of commutator pieces arranged through slits, and the conductive metal plates are connected to each other by a boss portion. Disclosed is a commutator having a sliding layer formed of carbon powder and a metal conductive layer formed of metal powder, the metal conductive layer being electrically joined to a metal plate by solder or a conductive adhesive. An example of the cylindrical commutator is shown in FIGS.

Further, another related technique, Japanese Patent Laid-Open No. 8-12.
In No. 6259, a plurality of commutator pieces arranged through slits are connected to each other by an electrically insulating boss portion, and the commutator pieces are formed of a sliding layer made of carbon powder and a metal powder. And a metal conductive layer
A commutator in which a metal conductive layer is integrally formed with a riser piece protruding from the outer periphery and a protrusion engaging with a boss is disclosed. FIGS. 5 and 6 show the commutator. Examples are given.

[0007] Another related technique is Japanese Patent Laid-Open No. 11-1.
No. 68859 is composed of a contact portion that slides with a brush and a support portion that supports the contact portion, and the contact portion is divided into segments electrically insulated from each other by a groove. A commutator in which a groove shallower than the thickness is formed is disclosed, and an embodiment of a cylindrical commutator is shown in FIGS. 10 and 11 thereof.

[0008] Another related art, US Pat. No. 542,
In No. 2528, a commutator plate whose surface is covered with a carbon material is formed with a lateral groove, and a radial opening is formed in the groove, and the carbon material is formed in the opening and the groove. A cylindrical commutator configured to be filled and integrated is disclosed.

[0009]

By the way, in the cylindrical commutator as described above, in order to stably drive a fuel pump or the like in which the cylindrical commutator is used, a metal segment having a winding connecting terminal is used. It is important to ensure good and stable electrical continuity with the commutator segment. However, although the above-mentioned related art discloses, for example, a configuration in which a metal segment and a commutator segment are joined by soldering, welding, or a conductive adhesive to improve conductivity, the present demand for a cylindrical commutator is present. It cannot be said that the level of continuity that it has is sufficient. Therefore, a commutator capable of achieving good and stable electrical continuity between the metal segment and the commutator segment has been desired.

The present invention has been made in view of the above problems, and provides a cylindrical commutator capable of realizing good and stable electrical continuity between a metal segment and a commutator segment, and a manufacturing method thereof. With the goal.

[0011]

In the cylindrical commutator of the present invention, a metal segment having a winding connecting portion is pressed into a groove extending in the axial direction of the commutator segment to press the commutator segment. And the metal segments are arranged correspondingly, and the plurality of commutator segments and the plurality of metal segments are arranged substantially along the outer periphery of the insulating support. For example, by pressing the metal segment in the groove on the inner peripheral surface of the commutator segment, reliable or uniform pressure contact between the metal segment and the commutator segment is possible, and good and stable contact between the metal segment and the commutator segment is possible. Conductivity can be obtained.
The winding connecting portion may be provided with a winding connecting terminal or may not be provided with a winding connecting terminal.

Further, the cylindrical commutator of the present invention is characterized in that a convex portion is formed on an outer surface of an interior portion of the metal segment which is accommodated in the groove portion, and the convex portion is pressed against the groove portion. The number of the protrusions may be one or more, and the shape of the protrusions is, for example, a mountain shape, a hemispherical shape, a trapezoidal protrusion, or a protrusion in the circumferential direction such as a pressure contact with the groove portion is suitable, Further, the configuration of the convex portion is, for example, a projection or a ridge provided on the flat outer surface of the interior portion, a projection or a ridge on the outer surface having irregularities of the interior portion, or a projection on the sawtooth or wavy outer surface of the interior portion. Alternatively, it may be a ridge or the like. By the pressure contact by the convex portion, it is possible to more surely secure good and stable conductivity. Further, the pressure contact of the convex portion can strengthen the adhesion between the metal segment and the commutator segment.

Further, the cylindrical commutator of the present invention is characterized in that an inner portion to be installed in the groove portion of the metal segment has a spring shape and is pressed against the inner portion by utilizing elasticity of the inner portion. By utilizing the elasticity of the interior portion having a spring property, the interior of the interior portion can ensure good and stable electrical continuity between the metal segment and the commutator segment, and can be easily manufactured. In particular, even in the case of a small-sized cylindrical commutator requiring labor and precision, it can be easily manufactured and the conductivity can be secured. Further, for example, a slit is formed in the interior portion to obtain the spring property, so that the contact can be performed with a stable contact pressure.

Further, in the cylindrical commutator of the present invention, a slit is formed in the interior portion of the metal segment which is installed in the groove portion, and a biasing member for biasing the interior portion outward is provided in the slit. It is characterized by By biasing the interior part outward by the biasing member provided in the slit, the pressure contact between the groove part and the interior part is made more reliable and more uniform, the contact pressure is strengthened, and the conductivity is secured more reliably. be able to. The urging member has, for example, a spring member or an elastic member installed in the slit, a protrusion, an unevenness or an inclination, and a locking portion (stopper), and the interior portion is outwardly fitted in conformity with the shape in the slit. It is appropriate as long as it can urge the interior portion outward, such as the expanding member that urges to the. Further, instead of the slit, it is possible to form a long hole or the like that is long in the axial direction.

Further, in the cylindrical commutator of the present invention, at least the pressure contact portion of the groove portion of the metal segment and the pressure contact portion of the inner portion of the commutator segment which is installed in the groove portion are plated. Is characterized by. For example, by plating the inner surface of the groove and the outer surface of the interior and plating the metal segment and the commutator segment where they come into contact with each other, the metal segment and the commutator segment are both pressed and plated. It is possible to further improve the conductivity with and to be stable. The plating is appropriate such as tin plating and nickel plating.

Further, the cylindrical commutator of the present invention is characterized in that at least a part of the groove portion of the commutator segment with which the metal segment is in pressure contact is filled with a conductive bonding material. By providing at least a part such as all or most of the groove portion with a conductive bonding material, both of the pressure welding and the conductive bonding material, or the pressure welding, the plating and the conductive bonding material, and the metal segment The conductivity with the commutator segment can be made even better and stable. The conductive bonding material is, for example, solder, brazing, conductive adhesive, or the like.

Further, according to the method for manufacturing a cylindrical commutator of the present invention, a metal segment having a winding connecting portion is press-contacted with a groove extending in the axial direction of the commutator segment, and the commutator segment is connected to the commutator segment. A method of manufacturing a cylindrical commutator, wherein the metal segments are arranged correspondingly to each other, and the plurality of commutator segments and the plurality of metal segments are arranged substantially along the outer periphery of an insulating support, A step of forming a substantially cylindrical commutator base material having a plurality of grooves extending in the axial direction, and a step of internally mounting the interior parts of the metal segments in the grooves and press-contacting the interior parts with the grooves It is characterized by having.

Further, according to the method of manufacturing a cylindrical commutator of the present invention, a metal segment having a winding connecting portion is press-contacted to a groove extending in the axial direction of the commutator segment to form the commutator segment. A method of manufacturing a cylindrical commutator, wherein the metal segments are arranged correspondingly to each other, and the plurality of commutator segments and the plurality of metal segments are arranged substantially along the outer periphery of an insulating support, A step of forming a commutator piece corresponding to one or a plurality of commutator segments having a groove part extending in the axial direction; and an interior part of a metal segment is internally provided in the groove part, and the interior part is It is characterized by having a step of press-contacting the groove. By using the commutator piece, for example, it becomes possible to easily carry out the work of mounting the inner portion of the metal segment in the groove portion of the inner peripheral surface and press-contacting it, and also easily filling the conductive bonding material and the like. Is possible.

Further, the method for manufacturing a cylindrical commutator of the present invention is characterized in that after the inner portion is pressed against the groove portion, at least a part of the groove portion is filled with a conductive bonding material. By providing a conductive bonding material such as solder, brazing, or a conductive adhesive after the pressure contact, it is possible to obtain better and stable conductivity and strong mechanical fixation.

[0020]

BEST MODE FOR CARRYING OUT THE INVENTION Next, embodiments of the cylindrical commutator and the manufacturing method thereof according to the present invention will be described. FIG. 1 is a plan view showing a cylindrical commutator of the first embodiment, and FIG. 2 is a vertical sectional view of the cylindrical commutator of FIG.

As shown in FIGS. 1 and 2, the cylindrical commutator 1 of the first embodiment includes a substantially cylindrical insulating support 2 having a shaft hole 21 for the rotor shaft at the center thereof. And a plurality of metal segments 3 along the substantially outer periphery of the insulating support 2.
Are arranged in a fixed state, and a plurality of commutator segments 4 are arranged in a fixed state. In this embodiment, six metal segments 3 and six commutator segments 4 are provided correspondingly. Has been. The insulating support 2
Is geometrically fixed to the metal segment 3 and the commutator segment 4 and is engaged at a predetermined position.

Each metal segment 3 has a groove 42 which will be described later.
As shown in FIGS. 1, 2 and 3, it has a first side wall 31 and a second side wall 32 that are arcuate in plan view and are parallel to the axial direction of the rotor. However, the first side wall 31 having a small thickness is integrally provided with the second side wall 32 having a larger thickness through a step. A slit 33 is formed in the axial direction from the upper end of the first side wall 31 in the center in a front view, and the anchors 34 are bent obliquely downward inward on the left and right sides of the slit 33 at the upper end of the first side wall 31, respectively. A plurality of chevron-shaped protrusions 35 are formed on both outer sides or both outer surfaces of the first side wall 31 in the width direction. Further, at the lower end of the second side wall 32, a hook-shaped winding connecting terminal 36 is formed at the center thereof so as to be bent obliquely outwardly upward, and on both left and right sides thereof is bent obliquely upward inwardly. Anchor 37 is formed. The anchor 34 and the anchor 37 bite into and engage with the insulating support 2 to strengthen the adhesion between the insulating support 2 and the metal segment 3.

Each commutator segment 4 has a substantially fan-shaped fan shape in plan view, and its arcuate outer peripheral surface is a brush sliding contact surface 41 parallel to the axial direction of the rotor and its inner peripheral surface. A groove 42 extends axially in the center of the surface. The groove 42 is substantially fan-shaped in plan view, and has a tapered side surface 421 and a bottom surface 422 that widen from the inner side to the outer side. Adjacent commutator segments 4 and 4 are insulated from each other by slits 5 formed by cutting into the insulating support 2. As the commutator segment 4,
For example, a mixture of carbon material powder such as natural graphite, artificial graphite, and amorphous carbon in an appropriate ratio, and a thermosetting resin added to the mixture, which has been subjected to powder compaction heating or molding, and pressure sintering method such as hot pressing. And those formed by other sintering methods, those obtained by adding a binder to carbon powder blended in an appropriate proportion, and firing the mold at a high temperature, for example, at 600 ° C. or higher to decompose the binder, and amorphous carbon. A carbon material having a composition in which several percent of carbon fibers having a length of 1 mm or less is added to the carbon material is suitable.

A concave groove 42 which is a groove portion of the commutator segment 4.
As shown in FIG. 3, the first side wall 31, which is the interior portion of the metal segment 3, is internally provided in the. Since the first side wall 31 has flexibility or spring property due to the slit 33, the portions of the first side wall 31 on both sides of the slit 33 are each provided with the concave groove 42.
When pushed inward by the side surface 421, the elastic portion or the restoring force urges it outward, and the convex portion 35 of the first side wall 31 is pressed against the side surface 421 of the concave groove 42. or,
Although not shown in the drawing, for example, the side surface 421 of the concave groove 421 or a portion such as the side surface 421 and the bottom surface 422 where the groove portion is pressed and the convex portion 35 of the first side wall 31 or the first side wall 3 is pressed.
Plating is applied to both the inner portion and the pressure-contacting portion such as 1.

In the cylindrical commutator 1 described above, the convex portion 35 of the first side wall 31 having the spring property is mainly the side surface 42 of the concave groove 42.
By press contacting with 1, the good and stable electrical conductivity between the corresponding metal segment 3 and commutator segment 4 can be obtained. Further, the convex portion 35 of the plated metal segment 3 and the side surface 421 of the concave groove 42 of the plated commutator segment 4 are pressed against each other, so that the corresponding metal segment 3 and commutator segment 4 Four
It is possible to further improve the conductivity with and to be stable.

Next, the manufacturing process of the cylindrical commutator 1 of the first embodiment will be described. FIG. 3 is a diagram showing a process of press-fitting a metal segment into a groove portion of a commutator base material, FIG. 4 is a diagram showing an example of the commutator base material, and FIGS. 5 and 6 are commutator pieces obtained by dividing the commutator base material. It is a top view which shows an example.

In the process of manufacturing the cylindrical commutator 1 of the first embodiment, first, the substantially cylindrical commutator base material 40 shown in FIG.
Is formed by, for example, compacting a material containing carbon as a main component, and then sintering the same, and in the process of forming, six recessed grooves 42 are formed at predetermined intervals in the circumferential direction. Also concave groove 4
2 is plated. On the other hand, the winding connecting terminal 36 is extended in the longitudinal direction, and the metal segment 3 in a state where it is not bent outward is formed by performing a predetermined process. Each of the metal segments 3 is provided with a first side wall 31, a second side wall 32, a slit 33, and a convex portion 35, and the anchors 34 and 37 thereof are bent inward obliquely downward or obliquely upward, respectively. ing. Further, the first side wall 31 or the convex portion 35 is plated.

After that, as shown in FIG. 3, the first side wall 31 of the metal segment 3 is inserted or press-fitted into the concave groove 42 of the commutator base material 40, and the first side wall 31 is installed inside the concave groove 42.
The metal segment 3 is press-fitted until the step between the first side wall 31 and the second side wall 32 contacts the lower end surface of the commutator base material 40. The press-fitted first side wall 31 is urged outward by its spring property, the convex portions 35 of the first side wall 31 are pressed against the side surfaces 421 of the concave grooves 42, and the respective metal segments 3 correspond to the corresponding concave grooves 42. It is attached by pressure welding to.

Instead of the substantially cylindrical commutator base material 40, for example, a substantially semi-cylindrical commutator piece 401 corresponding to three commutator segments 4 shown in FIG. 5 or a commutator shown in FIG. Corresponding to a plurality of or one commutator segment 4, such as a generally truncated fan-shaped commutator piece 402 corresponding to one child segment 4, and a number of concave grooves corresponding to the corresponding commutator segment 4. 42 is used for the commutator piece,
Insert or press fit the first side wall 31 of the metal segment 3 into the concave groove 42 of the commutator pieces 401, 402, etc.
1 may be installed in the groove 42 and press-contacted.
The commutator pieces 401, 402, etc. are divided by cutting the substantially cylindrical commutator base material 40 in the axial direction at a position corresponding to the position where the slit 5 is formed, or in advance.
It can be formed by molding into a shape such as 1, 402 or the like.

After that, the metal segment 3 and the commutator base material 40 (or commutator piece) are placed in a mold, and in that state, resin is poured and insert molding is performed to form the insulating support 2. The insulative support 2 is formed mainly on the substantially inner peripheral side of the commutator base material 40 (or the commutator piece), and if necessary, for example, the commutator base material 4 is formed.
0 (or commutator piece) is formed at the upper end, the lower end, a part of the outer periphery, or the like, and is filled in the concave groove 42. The formed insulating support body 2 is fixed to the metal segment 3 and the commutator base material 40 (or the commutator piece) in shape, and the pressure contact state between the metal segment 3 and the commutator base material 40 is fixed.
Further, by engaging a predetermined portion of the metal segment 4 such as the anchors 34 and 37 or a predetermined portion of the commutator base material 40 (or the commutator piece), the insulating support 2, the metal segment 3, the commutator base material. 40 (or commutator piece) are integrated.

After that, the outer peripheral surface of the commutator base material 40 (or commutator piece) is cut to form a brush sliding contact surface 41 parallel to the axial direction and having a predetermined radius of curvature for finishing, and at the same time, the commutator base material 40. A slit 5 is formed so that a part of it penetrates into the insulating support 2, and is divided into a plurality of (for example, 6) commutator segments 4, and adjacent commutator segments 4
The cylindrical commutator 1 according to the first embodiment is configured such that the winding connecting terminals 36 are bent outwardly and obliquely upward so that the windings can be welded by fusing while the wires 4 are separated and insulated from each other. Is completed. Even in the case of a commutator piece, in order to form a plurality (for example, six) of commutator segments 4, a slit is formed so that a part of the commutator segment 4 bites into the insulating support 2. By the manufacturing process described above, it is possible to efficiently perform the pressure contact, and the cylindrical commutator 1 can be easily manufactured.

Next, the cylindrical commutator 1 of the second embodiment will be described. FIG. 7 is a diagram for explaining the state of the metal segment installed in the groove portion of the commutator segment in the cylindrical commutator of the second embodiment.

In the cylindrical commutator 1 of the second embodiment, as shown in FIG. 7, the first side wall 31 of the metal segment 3 is provided in the concave groove 42 of the commutator segment 4, and the concave groove 4 is mainly formed.
In the state that the convex portion 35 of the metal segment 3 is pressed against the side surface 421 of the second side, the concave groove 42 is filled with the conductive bonding material 6 such as solder, braze or conductive adhesive. 1
Different from the cylindrical commutator 1 of the embodiment, other configurations are basically the same as the cylindrical commutator 1 of the first embodiment. With the above configuration, the pressure contact, the plating, and the conductive bonding material 6 can be combined to further improve the conductivity of the metal segment 3 and the commutator segment 4. Further, the adhesive strength between the metal segment 3 and the commutator segment 4 can be strengthened by the conductive bonding material 6.

When the cylindrical commutator 1 of the second embodiment is manufactured, the first side wall 31 of the metal segment 3 is connected to the commutator as described in the manufacturing process of the cylindrical commutator 1 of the first embodiment. By inserting or press-fitting into the concave groove 42 of the base material 40 (or commutator piece), the first side wall 31 is housed inside the concave groove 42 and the convex portion 35 is brought into pressure contact with the side surface 421 of the concave groove 42. After that, the groove 42 is filled with a conductive bonding material 6 such as solder, brazing, or a conductive adhesive, and then the resin is insert-molded to form the insulating support 2. The other manufacturing steps are basically the same as those for manufacturing the cylindrical commutator 1 of the first embodiment.

Next, the cylindrical commutator 1 of the third embodiment will be described. FIG. 8 is a partial front view for explaining the state of the metal segment housed in the groove of the commutator segment in the cylindrical commutator of the third embodiment.

In the cylindrical commutator 1 of the third embodiment, as shown in FIG. 8, a spring plate 71 having a corrugated shape in front view is installed as a biasing member in the slit 33 of the metal segment 3,
The first side wall 31 on which the spring plate 71 is installed is installed inside the concave groove 42 of the commutator segment 4. Portions of the first side wall 31 on both sides of the slit 33, which are pushed inward by the side surface 421 of the concave groove 42, are urged outward by a restoring force due to their springiness, and outwardly by springiness of the spring plate 71. The convex portions 35 of the first side wall 31 are each biased by the above-mentioned biasing.
The second side surface 421 is pressed. The other structure is basically the same as that of the cylindrical commutator 1 of the first embodiment. The spring plate 71, which is a biasing member, can stably and uniformly open both outer sides of the slit 33 of the first side wall 31. Further, by the pressure contact and plating by the both biases, the conductivity between the metal segment 3 and the commutator segment 4 can be further improved and stabilized.

When manufacturing the cylindrical commutator 1 of the third embodiment, the metal segment 3 is prepared and the metal segment 3 is prepared as described in the manufacturing process of the cylindrical commutator 1 of the first embodiment.
Of the first side wall 31 of the commutator base material 40 (or the commutator piece) is inserted or press-fitted, the first side wall 31 is housed in the concave groove 42, and the convex portion 35 is a side surface of the concave groove 42. 421
Put in pressure contact with. Then, the spring material 71 is installed in the slit 33 of the metal segment 3. The spring plate 71 urges the portions of the first side wall 31 on both sides of the slit 33 by the spring property, is attached by being sandwiched by the portions, and further strengthens and stabilizes the pressure contact. After that, the resin is insert-molded to form the insulating support 2. The other manufacturing steps are basically the same as those for manufacturing the cylindrical commutator 1 of the first embodiment.

Next, the cylindrical commutator 1 of the fourth embodiment will be described. FIG. 9A is a partial front view for explaining the state of the metal segment installed in the groove portion of the commutator segment in the cylindrical commutator of the fourth embodiment, and FIG. 9B is related to FIG. It is explanatory drawing explaining the abutting of protrusion parts. In FIG. 9, the anchor 34 of the metal segment 3,
The display of 37 and the winding connection terminal 36 is omitted.

In the cylindrical commutator 1 of the fourth embodiment, as shown in FIG. 9, substantially chevron-shaped protrusions 351 are formed on both outer sides or both outer sides of the first side wall 31 of the metal segment 3 in the width direction. A substantially trapezoidal or substantially rectangular parallelepiped projecting portion 331 is formed so as to project inward at a position corresponding to the convex portion 351 on the periphery of the slit 33 or on the peripheral surface, and the opening end of the slit 33 is formed. An engaging portion 332 is formed on the above portion so as to protrude further inward than the protruding portion 331. A spreading member 72 is installed in the slit 33 as a biasing member, and a substantially rectangular parallelepiped projecting portion 721 is formed on the spreading member 72 at a position corresponding to the projecting portion 331.
Butt against the protruding portion 331, and the portions of the first side walls 31 on both outer sides of the slit 33 are expanded outwardly by the butt. Further, the protruding portion 7 closest to the opening end of the slit 33
21 is locked to the locking portion 332.

In addition to the springiness of the first side wall 31 itself, the portions of the first side wall 31 on both outsides of the slit 33 are urged outward, and in addition, the protruding portion 721 of the expanding member 72 and the protrusion of the slit 33. Due to the abutment of the portions 331, the portions of the first side walls 31 on both outer sides are urged outward, and the convex portions 33 of the metal segment 3 housed in the concave grooves 42 are brought into pressure contact with the side surfaces 421 to expand the urging member. Both the outsides of the slit 33 of the first side wall 31 can be stably and uniformly spread by the opening member 72, and the conductivity between the metal segment 3 and the commutator segment 4 can be ensured by the pressure contact and plating by the both biases. It can be made better and more stable. Incidentally, the protruding portions 331, 7
The shape of 21 is appropriate as long as it can stably maintain the abutted state of the two, and for example, one can be a slightly gently recessed shape and the other can be a slightly gently protruding shape. The other structure is basically the same as that of the cylindrical commutator 1 of the first embodiment.

When manufacturing the cylindrical commutator 1 of the fourth embodiment, the metal segment 3 is prepared as described in the manufacturing process of the cylindrical commutator 1 of the fourth embodiment, and FIG. As shown in FIG. 7, the expanding member 72 is installed in the slit 33 of the metal segment 3 so that the protruding portion 721 of the expanding member 72 does not butt against the protruding portion 331 of the slit 33. Then, the first side wall 31 in which the expansion member 72 is installed is inserted or press-fitted into the concave groove 42 of the commutator base material 40 (or commutator piece), and the first side wall 31 is provided inside the concave groove 42. Then, the convex portion 35 is brought into pressure contact with the side surface 421 of the concave groove 42 by the spring property of the first side wall 31 itself.

Thereafter, the expanding member 72 is pulled toward the opening end of the slit 33 until the protruding portion 721 is locked by the locking portion 332, and the protruding portion 721 of the expanding member 72 is slit 3.
3 is abutted against the protruding portion 331, and the slit 33
The portions of the first side walls 31 on both outer sides are urged outward, and the portions of the expanding member 72 protruding outward from the open ends are removed by cutting or the like. In addition, in order to facilitate the removal, a cut or the like may be formed in advance at a portion where the protrusion from the opening end is expected to be outward. After that, the resin is insert-molded to form the insulating support 2. The other manufacturing steps are basically the same as those for manufacturing the cylindrical commutator 1 of the first embodiment.

The configuration of the cylindrical commutator 1 and the manufacturing process thereof in each of the above-described embodiments can be adopted by adding or changing it to the configuration of the cylindrical commutator 1 of the other embodiments and the manufacturing process thereof. Is.

[0044]

Since the cylindrical commutator and the method for manufacturing the same according to the present invention have the above-mentioned structure, the metal segment is surely pressed against the commutator segment, and good and stable conduction between the metal segment and the commutator segment is achieved. The effect that can realize the nature is exhibited. Therefore, it becomes possible to stably drive the fuel pump or the small motor thereof in which the cylindrical commutator is used.

[Brief description of drawings]

FIG. 1 is a plan view showing a cylindrical commutator of a first embodiment.

FIG. 2 is a longitudinal sectional view of the cylindrical commutator of FIG. 1 taken along the line AA.

FIG. 3 (a) is a partial front view showing a state immediately before press-fitting a metal segment into a groove of a commutator base material in a manufacturing process of the cylindrical commutator of the first embodiment. (B) Partial front view showing a state in which the metal segment is being press-fitted into the groove portion of the commutator base material in the manufacturing process of the cylindrical commutator of the first embodiment. (C) Partial front view showing a state immediately after the metal segment is press-fitted into the groove of the commutator base material in the manufacturing process of the cylindrical commutator of the first embodiment.

FIG. 4A is a plan view showing an example of a commutator base material used for manufacturing the cylindrical commutator of the first embodiment. (B) The front view of the commutator base material of the same figure (a).

FIG. 5 is a plan view showing an example of a commutator piece obtained by dividing a commutator base material.

FIG. 6 is a plan view showing another example of a commutator piece obtained by dividing a commutator base material.

FIG. 7 (a) is a partial front view illustrating a state of a metal segment installed in a groove portion of a commutator segment in the cylindrical commutator of the second embodiment. (B) The partial cross-sectional view of the same figure (a).

FIG. 8 is a partial front view illustrating a state of a metal segment installed in a groove portion of a commutator segment in a cylindrical commutator of a third embodiment.

FIG. 9 (a) is a partial front view for explaining a state of a metal segment installed in a groove portion of a commutator segment in the cylindrical commutator of the fourth embodiment. (B) Explanatory drawing explaining the abutting of protrusion parts with respect to the same figure (a).

[Explanation of symbols]

1 Cylindrical commutator 2 Insulating support 21 shaft hole 3 metal segments 31 First side wall 32 Second side wall 33 slits 331 protrusion 332 Locking part 34, 37 anchor 35, 351 convex part 36 winding connection terminal 4 commutator segment 40 Commutator base material 401, 402 commutator piece 41 Brush contact surface 42 groove 421 side 422 bottom 5 slits 6 Conductive bonding material 71 spring plate 72 Expansion member 721 Projection

   ─────────────────────────────────────────────────── ─── Continued front page    F-term (reference) 5H613 AA01 AA02 BB04 BB08 GA03                       GB05 GB09 GB12 GB13 KK03                       KK05 KK13 PP08                 5H615 AA01 BB04 PP26 SS12 SS19                       TT01 TT11 TT26

Claims (9)

[Claims] 1. A commutator segment and a metal segment having a winding connecting portion are pressed into contact with a groove extending in the axial direction to dispose the commutator segment and the metal segment in correspondence with each other. A cylindrical commutator characterized in that a plurality of the commutator segments and a plurality of the metal segments are arranged substantially along the outer circumference of an insulating support. 2. The cylindrical commutator according to claim 1, wherein a protrusion is formed on an outer surface of an interior portion of the metal segment which is internally provided in the groove, and the protrusion is pressed against the groove. 3. The cylindrical commutator according to claim 1, wherein an inner portion of the metal segment, which is to be installed in the groove portion, has a spring-like shape, and is pressed by utilizing elasticity of the inner portion. . 4. A slit is formed in an interior portion of the metal segment to be installed in the groove portion of the metal segment, and a biasing member for biasing the interior portion outward is provided in the slit. The cylindrical commutator according to 2 or 3. 5. The plating is applied to at least a pressure contact portion of the groove portion of the metal segment and a pressure contact portion of an inner portion of the commutator segment which is internally installed in the groove portion. 3. The cylindrical commutator according to 3 or 4. 6. The conductive bonding material is filled in at least a part of the groove portion of the commutator segment with which the metal segment is in pressure contact, and the groove is provided.
The cylindrical commutator according to 3, 4, or 5. 7. The commutator segment and the metal segment are arranged in correspondence with each other by press-contacting a metal segment having a winding connecting portion with a groove extending in the axial direction of the commutator segment. A method for manufacturing a cylindrical commutator in which a plurality of the commutator segments and a plurality of the metal segments are arranged along substantially the outer circumference of an insulating support, the method having a plurality of groove portions extending in the axial direction. A cylindrical commutator characterized by including a step of forming a substantially cylindrical commutator base material and a step of internally mounting the interior portion of the metal segment in the groove portion and press-contacting the interior portion with the groove portion. Production method. 8. A commutator segment and a metal segment having a winding connecting portion are pressed into contact with a groove extending in the axial direction to dispose the commutator segment and the metal segment in correspondence with each other. A method for manufacturing a cylindrical commutator in which a plurality of the commutator segments and a plurality of the metal segments are arranged along substantially the outer circumference of an insulating support, the method having a groove portion extending in the axial direction, A step of forming a commutator piece corresponding to one or a plurality of commutator segments; and a step of internally mounting an inner part of a metal segment in the groove part and press-contacting the inner part with the groove part. Manufacturing method of cylindrical commutator. 9. After press-contacting the interior portion with the groove,
9. The method for manufacturing a cylindrical commutator according to claim 7, wherein at least a part of the groove is filled with a conductive bonding material.