Planar commutator segment attachment method and assembly

A method for making a planar carbon segment commutator that includes a plurality of metallic conductor sections supported in an annular circumferentially-spaced array on a hub comprising electrical insulating material, each conductor section including a first front projection integrally extending from a front surface of each conductor section and embedded in one of a plurality of carbon commutator segments, the commutator segments defining a flat composite annular front commutating surface;

• the method including the steps of:
• forming an annular conductor substrate with a first annular front projection extending integrally and axially from a front surface of the substrate;
• forming an annular carbon disk on the conductor substrate by overmolding a carbon compound onto the front surface of the conductor substrate and around the first annular front projection and allowing the compound to harden;
• providing an annular hub comprising an insulating material;
• connecting the conductor substrate to a front surface of the hub;
• and
• forming electrically isolated, circumferentially spaced commutator segments and corresponding mechanically interlocked conductor sections by forming radial cuts through the annular carbon disk and the metal substrate, respectively.