End cap and brush box assembly

An end cap and brush box assembly for a mechanically commutated electric motor, comprising:

• an end cap;
• a two-piece brush box including a brush hood and a base plate, the brush hood having first and second legs, each of the first and second legs having at least one coupling tab extending therefrom through a corresponding coupling tab opening in the base plate, the coupling tabs bent against the base plate to secure the brush hood to the base plate;
• the base plate including first and second lock tabs for securing the base plate to the housing;
• and
• the base plate including a shunt welding plate and a connector.

A method for assembling an end cap and brush box assembly for a mechanically commutated electric motor, comprising:

• inserting a plurality of coupling tabs extending from a brush hood into a plurality of corresponding openings in a base plate;
• bending the coupling tabs such that the brush hood is coupled to the base plate, thereby resulting in a two-piece brush box;
• coining each coupling tab by stamping at least one indentation into each coupling tab causing each coupling tab to laterally expand, thereby tightly securing the brush hood to the base plate;
• and
• mounting the two piece brush box directly on an end cap of the end cap and brush box assembly.

A mechanically commutated electric motor comprising;

• a housing;
• an end cap and brush box coupled to the motor housing, the end cap assembly having an end cap made from a high temperature material;
• a two piece brush box mounted directly on the housing of the end cap assembly, the brush box including a first lock tab and a second lock tab for securing the two piece brush box to the end cap;
• and
• the brush box including a brush hood mounted to a base plate, the base plate having a shunt welding tab for attachment to an electrical shunt of a brush and a connector for attachment to an electrical lead coupled to a source of power.

An end cap and brush box assembly for a mechanically commutated motor, comprising:

• an end cap made from a high temperature material;
• a two piece brush box directly mounted on the housing, the two piece brush box including a brush hood having a first leg having at least one coupling tab extending therefrom and a second leg having at least one coupling tab extending therefrom;
• a base plate including a plurality of coupling tab openings and first and second lock tabs for securing the two piece brush box on the end cap, wherein each of the coupling tabs extends through a corresponding one of the coupling tab openings, is bent at approximately a 90° angle, and is coined with at least one stamped indentation to laterally displace at least a portion of each coupling tab, thereby tightly securing the brush hood to the base plate;
• the end cap having first and second retaining arms for retaining the first and second lock tabs when the two piece brush box is mounted on the end cap and first and second lock tab recesses into which the first and second lock tabs are bent when the two piece brush box is mounted on the end cap;
• the first and second lock tabs each including a relief formed in a distal end of the respective lock tabs, whereby when the two piece brush box is mounted on the end cap, the reliefs facilitate unbending the first and second lock tabs so that the two piece brush box can be removed from the end cap.

A brush box, comprising:

• a brush hood including a first leg having at least one coupling tab extending therefrom and a second leg having at least one coupling tab extending therefrom;
• and
• a base plate including a plurality of coupling tab openings, a first lock tab and a second lock tab;
• wherein each of the coupling tabs extends through a corresponding one of the coupling tab openings, is bent at approximately a 90° angle, and is coined with at least one stamped indentation to laterally displace at least a portion of each coupling tab, thereby tightly securing the brush hood to the base plate.