Method of making a carbon commutator assembly
OwnerWilliam E. Ziegler, William A. Bauerinventors
Life of this patent
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Abstract
A method for making a carbon commutator assembly by forming an annular carbon cylinder of a conductive carbon composition and metalizing an inner surface of the carbon cylinder by bonding a first layer of metallic material to the inner surface of the carbon cylinder. A metallic substrate is soldered to the metalized inner surface of the carbon cylinder and an insulator hub is disposed in a position supporting the metallic substrate and carbon cylinder. The carbon cylinder and substrate are then segmented by forming radial interstices through the carbon cylinder and the metallic substrate thus forming a carbon/metal commutator array comprising electrically isolated carbon/metal commutator sectors.
Claims18
A method for making a carbon commutator assembly, the method including the steps of:
- providing a metallic substrate;
- providing an annular carbon cylinder of a conductive carbon composition, the cylinder having an inner surface and an outer commutating surface;
- providing a tin-based metalization layer including a chemical reaction zone at the inner surface of the carbon cylinder by:
- forming a metallic powder mixture of tin with a transition metal;
- forming a metalization paste by mixing the metallic powder mixture with an organic binder;
- applying the metalization paste onto the base end surface;
- and
- firing the paste to 800-900° C. in an atmosphere including carbon monoxide;
- converting the metalization layer into a solder layer by reflowing a solder composition into the metalization layer;
- providing an insulator hub in a position supporting the metallic substrate and carbon cylinder;
- and
- segmenting the carbon cylinder by forming radial interstices through the carbon cylinder after providing the insulator hub, the metallic substrate being cut as each of the radial interstices is formed, thus forming a carbon/metal commutator array comprising electrically isolated carbon/metal commutator sectors.
A method for making a carbon commutator assembly, the method including the steps of:
- providing a metallic substrate;
- forming an annular carbon cylinder of a conductive carbon composition, the cylinder having an outer commutating surface disposed on an outer circumferential surface of the carbon cylinder and an inner surface disposed at an axial bottom end of the cylinder;
- metalizing the inner surface of the carbon cylinder by bonding a first layer of metallic material to the inner surface of the carbon cylinder;
- soldering the metallic substrate to the metalized inner surface of the carbon cylinder;
- providing an insulator hub in a position supporting the metallic substrate and carbon cylinder;
- segmenting the carbon cylinder by forming radial interstices through the carbon cylinder after providing the insulator hub, the metallic substrate being cut as each of the radial interstices is formed, thus forming a carbon/metal commutator array comprising electrically isolated carbon/metal commutator sectors;
- and
- overmolding insulator material onto the carbon cylinder and metallic substrate in an insert molding process to form the hub, the overmolding step including flowing insulator material into a retention groove provided in an axial top end of the cylinder.
Dependencies are inferred from the claim text.