Method of manufacturing flat-type rotors

Claim 2

Method of manufacturing a rotor for a flat-type motor comprising steps of: winding a wire to make an armature coil in a flat cylindrical space, said flat cylindrical space being defined in part by one surface of a plate-shaped first mold on to which said wire is laid while being wound, said first mold having an interior configuration conforming to an outer configuration of a first portion of the rotor to be made, providing a shaft extending along the longitudinal axis of the cylindrical space, combining a second mold with said first mold to form a space between said first and second molds, said second mold having an interior configuration conforming to the outer configuration of a second portion of the rotor, and filling said space between said first and second molds with a resin material to provide an integrated unit having a predetermined mechanical strength, thereby forming said integrated unit which comprises said armature coil and said shaft.

Claim 3

Method of manufacturing a rotor for a flat-type motor as defined in claim 1 wherein a core cylinder is pressed on to the shaft before the shaft is provided in said cylindrical space.

Claim 4

Method of manufacturing a rotor for a flat-type motor comprising steps of: winding a wire to make an armature coil in a flat cylindrical space, said flat cylindrical space being defined in part by one surface of a plate-shaped first mold on to which said wire is laid while being wound, said first mold having an interior configuration conforming to an outer configuration of a first portion of the rotor to be made, providing a shaft extending along the longitudinal axis of said cylindrical space and a commutator adjacent to said shaft, connecting an end of said armature coil with the commutator, combining a second mold with said first mold to form a space between said first and second molds, said second mold having an interior configuration conforming to the outer configuration of a second portion of the rotor, and filling said space between said first and second molds to surround said armature coil and said shaft at the commutator with a resin material to provide an integrated unit having a predetermined mechanical strength, thereby forming said integrated unit which comprises said armature coil and said shaft.

Claim 5

Method of manufacturing a rotor for a flat-type motor comprising steps of: winding a wire to make an armature coil in a flat cylindrical space, said flat cylindrical space being defined in part by one surface of a plate-shaped first mold on to which said wire is laid while being wound, said first mold having an interior configuration conforming to an outer configuration of a first portion of the rotor to be made, providing a shaft extending along the longitudinal axis of said cylindrical space and a commutator adjacent to said shaft, connecting an end of said armature coil with the commutator, combining a second mold with said first mold to form a space between said first and second molds, said second mold having an interior configuration conforming to the outer configuration of a second portion of the rotor, and filling said space between said first and second molds to surround said armature coil and said shaft at the commutator with a resin material to provide an integrated unit having a predetermined mechanical strength, thereby forming said integrated unit which comprises said armature coil and said shaft.

Claim 6

Method of manufacturing a rotor for a flat-type motor comprising steps of: arranging a shaft at an opening in the center of a plate-shaped first mold having an interior configuration conforming to the outer configuration of a first portion of the rotor to be made, arranging a commutator adjacent central opening of said first mold, winding a wire to form an armature coil in a flat cylindrical space, said flat cylindrical space being defined in part by one surface of said first mold on to which said wire is laid while being wound and connecting an end of said wire to the commutator, combining a second mold with said first mold, said second mold having an interior configuration conforming to the outer configuration of a second portion of the rotor, and injecting a resin between the first and second molds to integrally combine the armature coil and the shaft to form a rotor.

Claim 7

Method of manufacturing a rotor for a flat-type motor comprising steps of: arranging a shaft at an opening in the center of a plate-shaped first mold having an interior configuration conforming to the outer configuration of a first portion of the rotor to be made, arranging a commutator adjacent central opening of said first mold, winding a wire to form an armature coil in a flat cylindrical space, said flat cylindrical space being defined in part by one surface of said first mold on to which said wire is laid while being wound and connecting an end of said wire to the commutator, combining a second mold with said first mold, said second mold having an interior configuration conforming to the outer configuration of a second portion of the rotor, and injecting a resin between the first and second molds to integrally combine the armature coil and the shaft to form a rotor.

Claim 8

Method of manufacturing a rotor for a flat-type motor comprising steps: inserting a shaft and a commutator into a first mold, said first mold having pins fixed thereto for winding coils therearound and having a surface to define the outer configuration of one side of the rotor to be made, winding wire about said pins and on to a flat surface of said first mold to form coils and connecting said coils to said commutator to form an armature coil, combining a second mold wiTh said first mold, said second mold having pin holes to be mated with said pins and having a space define the outer configuration of a second side of the rotor, said first and second molds being further provided with a space to retain the shaft and one of the molds being provided with a space to retain the commutator, and injecting a resin between the first and second molds to make an integrated unit of said coil, commutator and shaft to form a rotor.

Claim 9

Method of manufacturing a rotor for a flat-type motor comprising steps: inserting a shaft and a commutator into a first mold, said first mold having pins fixed thereto for winding coils therearound and having a surface to define the outer configuration of one side of the rotor to be made, winding wire about said pins and on to a flat surface of said first mold to form coils and connecting said coils to said commutator to form an armature coil, combining a second mold wiTh said first mold, said second mold having pin holes to be mated with said pins and having a space define the outer configuration of a second side of the rotor, said first and second molds being further provided with a space to retain the shaft and one of the molds being provided with a space to retain the commutator, and injecting a resin between the first and second molds to make an integrated unit of said coil, commutator and shaft to form a rotor.

Claim 10

Method of manufacturing a rotor for a flat-type motor as defined in claim 5 wherein a projection of small height is provided on each of the configuration defining surfaces of said first and second molds, whereby the armature coil can be located centrally between the first and second molds.

Claim 11

Method of manufacturing a rotor for a flat-type motor comprising the steps of: forming a relatively flat armature coil by winding wire about pins fixed to a disc-like jig, positioning a shaft along an axis normal to said flat armature coil, placing said armature coil and positioned shaft into a mold, and injecting a resinous material into said mold to integrally mold said armature coil and shaft to form a rotor, wherein said mold is formed of a first mold section and a second mold section, said first and second mold sections forming a cavity therebetween corresponding to the outer configuration of the rotor, and said first mold section serving as said disc-like jig.

Claim 12

Method of manufacturing a rotor for a flat-type motor comprising the steps of: forming a relatively flat armature coil by winding wire about pins fixed to a disc-like jig, positioning a shaft along an axis normal to said flat armature coil, placing said armature coil and positioned shaft into a mold, and injecting a resinous material into said mold to integrally mold said armature coil and shaft to form a rotor, wherein said mold is formed of a first mold section and a second mold section, said first and second mold sections forming a cavity therebetween corresponding to the outer configuration of the rotor, and said first mold section serving as said disc-like jig.

Claim 13

A method according to claim 7, wherein a commutator is fixed to said shaft prior to said positioning step.

Claim 14

A method according to claim 7, wherein said shaft is provided with a core cylinder.

Claim 15

A method according to claim 7, wherein said first and second mold sections are each formed with at least one projection on respective surfaces forming said cavity to space said armature coil from the surfaces of said first and second mold sections.