Patent ID: 6898839

Claim:
A method of manufacturing a brush element of a rotary electric machine to be brought by a spring in contact with a commutator, said method comprising the steps of: filling a first conduction powder into a female die to form a stairs shape having a higher step and a lower step; adding a second conduction powder that has lower conductivity than said first conduction powder to said lower step so that a surface of said second conduction powder can be flush with a surface of said first conduction powder thereby forming a layer of said second conduction powder having a thickness that corresponds to a difference between said higher step and said lower step; pressing and hardening said first and second conduction powders by a single punch to form a mold; and sintering said mold, wherein said step of filling said first conduction powder comprises a step of filling said first conduction powder flat into said female die and a step of scraping a surface portion of said first conduction powder by a movable member to form said step.