Method of making a flat commutator

A method of making a flat commutator for an electric motor of a fuel pump comprising:

• providing a circumferentially continuous one-piece conductor ring of metal having a plurality of integral and circumferentially spaced apart connector tangs adjacent the periphery of the conductor ring and a plurality of integral and circumferentially spaced apart mounting tabs projecting from the conductor ring and disposed generally radially inwardly of the connector tangs, molding a circumferentially continuous one-piece ring of carbon having a substantially planar front face and a back face around the conductor ring with the conductor ring between and spaced from the front and back faces of the carbon ring so that the connector tangs are disposed adjacent the periphery of the carbon ring, sintering the carbon ring to form a subassembly of the carbon ring with the conductor ring embedded therein and bonded thereto, after forming the subassembly, molding on at least the back face of the carbon ring a housing of an insulating plastic material so that the housing underlies the carbon ring and secures and mounts the carbon ring on the housing with the mounting tabs of the conductor ring embedded in and interlocked with the housing, and after the housing is molded on the back of the sintered carbon ring cutting a plurality of grooves extending radially and axially through both the sintered carbon ring and the conductor ring and being circumferentially spaced apart to form a plurality of separate sintered carbon segments each with a separate electrical conductor and at least one mounting tab embedded in and interlocked with the housing.