Patent ID: 7043822
Filing Date: 2006-05-16
Classification: H01R,H02K,Y10S,Y10T

Abstract:
1. A method of manufacturing a commutator of a rotary electric machine which includes a plurality of commutator segments, a plurality of metal terminal members each of which has a nail to be connected to one of armature coils of the rotary electric machine, an insulating resinous member which supports the commutator segments and the metal terminal member, said method comprising: a step of forming a first unitary material having nail portions for the plurality of metal terminals and a plurality of arc-shaped members connecting the nail portions at radially inside portions thereof, said first unitary material being flat with the nails extending radially outward; a step of forming a second unitary material for the commutator segments; a step of fixing the first unitary material and the second unitary material together to form a pre-commutator unit so that the nails extend radially outward from the periphery of the pre-commutator unit; a step of inserting the pre-commutator unit between a pair of dies so that the dies hold the nails without a substantial gap; and a step of charging liquid resinous material into the radial inside of the arc-shaped members in the dies to mold the pre-commutator unit, whereby the arc-shaped members are disposed radially outside an outer periphery of the resinous material of the pre-commutator unit.