Patent EP0042600A2 successfully refreshed from Google Patents.
US3777367A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of fabricating a commutator
Assignee: Ametek Inc
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Filing: 1971-12-06
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Granted: 1973-12-11
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Expires: 1991-12-06
Abstract
Abstract In fabrication of commutators by applying a thin insulation coating on a cylindrical support and thereafter applying a thin conductive layer ultimately providing the conductive segments by plasma or flame spray techniques, a bonding layer is layed before the insulating layer; and further electrical connections for armature coil leads, either in the form of tangs or direct connections are provided by applying to the insulating layer either a tang-originating preform or the lead ends before flame spraying of a copper layer for the conductive bars or segments and thereafter slotting to define the tanged or lead-connected segments. Alternatively, bar defining slots can be produced by masking the insulation coated blank before the final layer flame spray, wholely or in part eliminating slotting operations. A dove tail interlock between the bars and core may be achieved by using a core with longitudinal trapezoidal section slots and carrying out the bar slotting centrally of each of the core slot locations.
Inventors
- 👤 M Kalagidis
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 23:01
CPC Classifications
H; H01; H01R; H01R43/00; H01R43/06; H01R39/00; H01R39/02; H01R39/32; H01R43/08; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49009; Y10T29/49011
Claims Analysis
Total Claims: 10
Claim 1
Independent Claim
78 words
A method of making a cylindrical metal-cored commutator, comprising the steps of: providing a generally circularly cylindrically surfaced metal core, and applying a boning layer on the cylindrical surface of said core; depositing a circumferentially continuous metal oxide insulating layer on the bonding layer, by particle spray fusion; forming a plurally axially interrupted conductive layer of sprayed-on molten conductive metal particles fused together and fused onto said insulating layer, thereby to provide a circumferential array of commutator bars.
Claim 2
Independent Claim
78 words
A method of making a cylindrical metal-cored commutator, comprising the steps of: providing a generally circularly cylindrically surfaced metal core, and applying a boning layer on the cylindrical surface of said core; depositing a circumferentially continuous metal oxide insulating layer on the bonding layer, by particle spray fusion; forming a plurally axially interrupted conductive layer of sprayed-on molten conductive metal particles fused together and fused onto said insulating layer, thereby to provide a circumferential array of commutator bars.
Claim 3
Dependent Claim
44 words
The method as described in claim 1, wherein said circumferential array is formed by masking said metal oxide layer with spaced thin longitudinally extending elements, then spraying on said molten particles, and removing said elements after solidification and cooling of the sprayed on material.
Claim 4
Dependent Claim
46 words
The method as described in claim 1, wherein said circumferential array is formed by spraying on said molten particles to form a circumferentially continuous outer layer, and thereafter axially plurally slotting the last said layer down to the said metal oxide layer at equi-angularly spaced locations.
Claim 5
Dependent Claim
27 words
The method as described in claim 3, including the further step of turning said outer layer to concentricity with a rotational axis of said core before slotting.
Claim 6
Dependent Claim
30 words
A method as described in claim 2, including the further step of turning said outer layer to concentricity with a rotational axis of said core before removal of said elements.
Claim 7
Dependent Claim
58 words
The method as described in claim 3, wherein as said core there is provided an aluminum cylinder; said bonding layer is applied by flame spray deposition of first a thin layer of nickel aluminide onto the surface of said core and then a layer of copper; said insulating layer is aluminum oxide; and said conductive layer is copper.
Claim 8
Dependent Claim
97 words
The method as described in claim 6, including a step of longitudinally dove-tail slotting said aluminum cylinder at equi-angularly spaced locations corresponding in number and spacing to desired commutator bars; before applying said bonding layer, said bonding layer carried continuously down into and out of the resultant dove-tail slots, said molten particles being applied to said insulating layer in said dove-tail slots to fill the dove-tail slots as well as to build up said circumferentially continuous outermost layer to a substantially cylindrical form; the plural slotting being carried out at the respective centers of the dove-tail slots.
Claim 9
Dependent Claim
163 words
The method as described in claim 6, including the further steps of forming an outwardly flanged copper collar having a cylindrical body with numerous generally uniformly distributed apertures therethrough, the body having a length appreciably less than half the length of said core and an inside diameter to closely fit on said core after said insulating layer is applied; fitting said collar, with flanged end trailing, onto one end of the insulated core with the flanged end slightly inboard of the core end face; then carrying out the forming of the plurally axially interrupted layer by first flame spraying molten copper particles on the exposed portions of the insulating layer and over the body of the collar thereby to embed the body leaving the flange projecting from said outer layer, and then carrying out said slotting through the entire collar as well as the outer layer to define, by the slotting of the projecting flange, coil lead attaching tangs for respective commutator bars.
Claim 10
Dependent Claim
90 words
The method as described in claim 2, wherein at least the step of forming the interrupted conductive layer is carried out with said core emplaced on a shaft carrying an armature stack; and including the steps of winding the armature coIls onto the armature stack, and placing the coil leads in equi-spaced locations to project over the said insulating layer at one end of the core, and thereafter spraying on molten copper particles as said conductive metal particles to mechanically and electrically connect said leads into the resultant commutator structure.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1976-12-10 | 1977-06-11 | 1977-12-11 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1980-12-10 | 1981-06-11 | 1981-12-11 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1984-12-10 | 1985-06-11 | 1985-12-11 | $7700.00 | Window Closed / Lapsed |