Rotor for miniature motors

Claim 2

A rotor for miniature motors having an annular spark-quenching element for suppressing electrical sparks generated between commutator segments and brushes, each said commutator segment being a one-piece structure comprising a commutating portion for contact with said brushes and a terminal portion with a neck portion bent through 180° and electrically connected to a lead wire of a rotor winding; said terminal portion having an element-retaining portion formed by bending said terminal portion to extend radially of the rotor axis; and being electrically connected to any one surface of said element-retaining portion thereby to hold said spark-quenching element in position thereon.

Claim 3

A rotor for miniature motors as claimed in claim 1 wherein said terminal portion is electrically connected to said rotor winding lead wire by resistance welding.

Claim 4

A rotor for miniature motors as claimed in claim 1 wherein said element-retaining portion and said terminal portion are subjected to pretreatment, by solder coating.

Claim 5

A rotor for miniature motors as claimed in claim 1 wherein an annular varistor is used as said spark-quenching element.

Claim 6

A rotor for miniature motors as claimed in claim 1 wherein a ring resistor is used as said spark-quenching element.

Claim 7

A rotor for miniature motors as claimed in claim 1 wherein a molded commutator is constructed by forming said commutator segments integrally with an insulating member made of a synthetic resin.

Claim 8

A rotor for miniature motors having an annular spark-quenching element for suppressing electrical sparks generated between motor commutator segments and motor brushes comprising: a motor shaft; a rotor core fitted on the motor shaft; an insulating cylinder fitted on the motor shaft adjacent the core, the cylinder being integrally formed with a radially extending flange and an axially extending supporting portion; each commutator segment being stamped and formed in one-piece from sheet material with a part cylindrical commutating portion, a terminal portion extending from one axial end of the commutating portion and an element retaining portion; the terminal portion having a first part stepped radially outwardly from the commutating portion and a second part extending axially away from the commutating part and being reversely bent through 180° at an axial end to provide a rotor winding lead wire connecting portion and the element retaining portion comprising a first tab portion extending laterally from the reversely bent second part and a second tab portion bent to extend perpendicularly of the first tab portion, radially outwardly of the motor shaft; an insulating washer seated against adjacent portions of the commutating portion and the first, stepped part of the terminal portion thereby fitting each commutator segment on the insulating cylinder with the commutating portion supported by the supporting portion and the stepped and axial ends extending respectively radially and axially across the radially extending flange; and, the annular spark-quenching element being electrically connected to the element retaining portion mounted thereon with a radially inner axially extending surface engaging the outer surface of the first, laterally extending tab portion and a radially extending surface engaging the second, radially outwardly extending tab portion.

Claim 9

A rotor for miniature motors having an annular spark-quenching element for suppressing electrical sparks generated between motor commutator segments and motor brushes comprising: a motor shaft; a rotor core fitted on the motor shaft; an insulating cylinder fitted on the motor shaft adjacent the core, the cylinder being integrally formed with a radially extending flange and an axially extending supporting portion; each commutator segment being stamped and formed in one-piece from sheet material with a part cylindrical commutating portion, a terminal portion extending from one axial end of the commutating portion and an element retaining portion; the terminal portion having a first part stepped radially outwardly from the commutating portion and a second part extending axially away from the commutating part and being reversely bent through 180° at an axial end to provide a rotor winding lead wire connecting portion and the element retaining portion comprising a first tab portion extending laterally from the reversely bent second part and a second tab portion bent to extend perpendicularly of the first tab portion, radially outwardly of the motor shaft; an insulating washer seated against adjacent portions of the commutating portion and the first, stepped part of the terminal portion thereby fitting each commutator segment on the insulating cylinder with the commutating portion supported by the supporting portion and the stepped and axial ends extending respectively radially and axially across the radially extending flange; and, the annular spark-quenching element being electrically connected to the element retaining portion mounted thereon with a radially inner axially extending surface engaging the outer surface of the first, laterally extending tab portion and a radially extending surface engaging the second, radially outwardly extending tab portion.

Claim 10

A rotor according to claim 7 wherein said element-retaining portion and said terminal portion have a pretreatment of solder coating.