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US 2024/0305053 A1Published application
Brush holder assembly
AssigneeCutsforth, Inc.
InventorsROBERT S. CUTSFORTH, KURTIS JEREMY SCHULTZ
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Abstract
A brush assembly for use in a brush holder assembly of an electrical machine is disclosed. The brush assembly includes a carbon brush, an electrically conductive terminal and an electrically conductive lead assembly attached to both the carbon brush and the electrically conductive terminal. In some instances, the electrically conductive lead assembly includes a spliced union located between the electrically conductive terminal and the carbon brush and spaced away from both the electrically conductive terminal and the carbon brush. In some instances, the electrically conductive terminal includes an inner core layer positioned between a first conductive metal layer and a second conductive metal layer.
Claims18
A brush assembly, comprising:
- a carbon brush having an upper surface and a lower surface;
- a first lead wire including a first end region and a second end region, wherein the first lead wire extends continuously from the first end region of the first lead wire to the second end region of the first lead wire;
- a second lead wire including a first end region and a second end region, wherein the second lead wire extends continuously from the first end region of the second lead wire to the second end region of the second lead wire;
- a third lead wire including a first end region and a second end region, wherein the third lead wire extends continuously from the first end region of the third lead wire to the second end region of the third lead wire;
- and
- an electrically conductive terminal attached to the first lead wire with the first and second end regions of the first lead wire extending away from the electrically conductive terminal;
- wherein the first end region of the first lead wire is coupled to the first end region of the second lead wire at a spliced union;
- wherein the second end region of the first lead wire is coupled to the first end region of the third lead wire at the spliced union;
- wherein the second end region of the second lead wire and the second end region of the third lead wire are secured to the carbon brush;
- wherein the spliced union is located between the electrically conductive terminal and the carbon brush, and wherein the spliced union is spaced away from both the electrically conductive terminal and the carbon brush.
7 more elements
A brush assembly, comprising:
- a carbon brush having an upper surface and a lower surface;
- a first lead wire including a first end region and a second end region, wherein the first lead wire extends continuously from the first end region of the first lead wire to the second end region of the first lead wire;
- a second lead wire including a first end region and a second end region, wherein the second lead wire extends continuously from the first end region of the second lead wire to the second end region of the second lead wire, the second end region of the second lead wire secured to the carbon brush;
- a third lead wire including a first end region and a second end region, wherein the third lead wire extends continuously from the first end region of the third lead wire to the second end region of the third lead wire, the second end region of the third lead wire secured to the carbon brush;
- an electrically conductive terminal attached to a medial region of the first lead wire with the first and second end regions of the first lead wire extending away from the electrically conductive terminal;
- and
- a spliced union located between the electrically conductive terminal and the carbon brush, and wherein the spliced union is spaced away from both the electrically conductive terminal and the carbon brush;
- wherein the spliced union is formed by welding the first end region and the second end region of the first lead wire to the first end region of the second lead wire and the first end region of the third lead wire, with the medial region of the first lead wire forming a looped portion extending from the spliced union.
5 more elements
A method of manufacturing a brush assembly, the method including:
- welding a first end region of a first lead wire to a first end region of a second lead wire and welding a second end region of the first lead wire to a first end region of a third lead wire;
- wherein the first lead wire was previously secured to an electrically conductive terminal prior to the welding step;
- wherein the second lead wire was previously secured to a carbon brush prior to the welding step;
- wherein the third lead wire was previously secured to the carbon brush prior to the welding step;
- and
- wherein the welding forms a spliced union between the first lead wire, the second lead wire, and the third lead wire, the spliced union located at a location between and spaced away from the carbon brush and the electrically conductive terminal;
- wherein the spliced union is formed by welding the first end region and the second end region of the first lead wire to the first end region of the second lead wire and the first end region of the third lead wire.
4 more elements
Dependencies are inferred from the claim text.