Method of forming a commutator
A commutator is formed by providing an electrically insulating commutator body. First and second areas are defined on the commutator body covering a brush contact surface in an alternating manner. At least the surfaces of the first areas are formed of laser direct structured material. The first areas are treated by a laser to form metal particle layers. Conductive layers are formed on the metal particle layers by a plating process to form commutator segments. Terminals are connected to the conductive layers for connecting the commutator to rotor windings.
1. A method of forming a commutator, comprising:
providing an electrically insulating commutator body having first areas and second areas being alternately distributed in a circular manner, at least surfaces of the first areas being formed of laser direct structuring material;
forming metal particle layers on the first areas by laser treating the laser direct structuring material; and
forming conductive layers on the metal particle layers, the conductive layers on adjacent first areas being electrically insulated from each other.
2. The method of claim 1 , wherein the conductive layers are formed by depositing metal material on the metal particle layers by an electroless plating process.
3. The method of claim 1 , wherein only a single conductive layer is formed on the metal particle layer on each of the first areas.
4. The method of claim 1 , further comprising forming second conductive layers on said conductive layers on the metal particle layers.
5. The method of claim 1 , wherein only the first areas of the commutator body have metal particle layers formed thereon.
6. The method of claim 1 , wherein the entire commutator body is formed of laser direct structuring material.
7. The method of claim 1 , comprising:
forming metal particle layers by a laser treatment process on both the first areas and the second areas of the commutator body;
forming the conductive layers on the metal particle layers; and
removing the conductive layers on the second areas.
8. The method of claim 1 , further comprising:
providing a plurality of conductive terminals; and
assembling the conductive terminals to the commutator body and electrically connecting the conductive terminals with the conductive layers on the first areas.
9. The method of claim 1 , further comprising:
providing terminal bases extending from the commutator body and having at least a surface formed of laser direct structuring material;
forming metal particle layers on the terminal bases integrally extending from the first areas of the commutator body by the laser treatment process; and
forming conductive layers on the metal particle layers on the terminal bases.