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 Electric motor including unitary brush card bushing holder

Details
Inventors: Campbell, Robert; Bailey, Steve C.;
Assignee: Valeo Electrical Systems, Inc. (Auburn Hills, MI)
Primary Examiner: Ramirez; Nestor
Assistant Examiner: Gonzalez; Julio C.
Attorney, Agent or Firm: Lewis; J. Gordon

A vehicle blower motor includes a housing having a first bushing mounted at a first end about a shaft extending through the housing. A one-piece brush card bushing holder is mounted in the second end of the housing and carries a plurality of brushes engagable with a commutator mounted on the shaft. A second bushing is mounted in the brush card holder and disposed in engagement with the shaft. A portion of the brush card holder is formed as an end plate covering the second end of the housing.

DETAILED DESCRIPTION Referring now to FIGS.
2-7, there is depicted a motor 10 which is ideally suited for driving a fan or blower in a motor vehicle ventilation system, such as a heating and air-conditioning system, not shown.
As shown in detail in FIG.
2, the motor 10 includes a metal body or housing 12 of generally cylindrical form.
The housing 12 has a sidewall 14 extending between a first end 16 and an opposed second end 18.
The first end 16 has a raised boss or end plate 20.
The boss 20 defines an internal cavity within the housing 12 for receiving a first bearing or bushing 22.
An aperture is formed in the first end 16 to allow passage of a rotatable shaft 24 therethrough.
The second end 18 of the housing 12 is provided with a plurality of longitudinally inward extending notches or recesses 28.
A plurality of bendable tabs 13 project outward from the second end 18.
A pair of semi-circular magnets 32 are fixedly mounted to the inner surface of the sidewall 14 at diametrically opposed positions in the housing 12.
An armature 34 is rotatably disposed between the magnets 32.
The second end 18 of the housing 12 would normally be closed by a separate end plate, as in the prior art blower motor shown in FIG.
1.
In the present invention, an end plate, a second bushing retainer means and the holders for a plurality of brushes are integrated into a one-piece integral brush card bushing holder 30 which is shown in greater detail in FIGS.
3-7.
The integral brush card bushing holder 30, hereafter referred to as the "holder 30", also functions as an end cap in that it is fixedly joined to and spans the second end 18 of the housing 12.
A commutator 40 is fixed to the shaft 24 adjacent to one end of the lamination stack of the armature 34.
At least two brushes 42 and 44 are disposed in a position to contact the commutator 40 as the armature 34, including the shaft 24, rotate.
The brushes 42 and 44 are mounted in brush boxes 46 and 48, respectively, on the holder 30 as shown in FIGS.
5-7.
The holder 30 is formed of an integral, one-piece unitary member of a suitable insulating plastic, such as polybutylene terepthalate (PBT), polypropylene styrene (PPS), or polyphtalarnide (PPA), for example, as well as thermoset plastics



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