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Abstract

A method and product of making a motor armature that includes a carbon disk or carbon barrel commutator subassembly with the carbon layer soldered to the metal commutators. The novel method includes, while fusing the armature wire segment to each metal commutator, applying cooling liquid to the commutator segment being fused and/or the fusing electrode in order to remove or reduce heat transfer to the solder layer. This technique yields many benefits to the process and product, including (1) overheating, flow, and beading of the solder is avoided, (2) temperature rise of the electrode and fused joint can be better controlled, (3) application of power and power consumption can be more uniformly achieved, and (4) better repeatability, yield, and quality of product can be achieved.

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First Claim