Appeal No. 2003-1407
Application No. 09/733,667
Hartzell discloses a process for manufacturing a commutator that comprises
molding a cylindrical support member from an electrically insulating phenolic
resinous material. (Col. 1, ll. 53-58). The support member has a major outer surface
portion divided into subsections of lesser area by a plurality of teeth or tongues (rib
members) extending upwardly from the outer surface. (Fig. 1, Col. 1, ll. 74-80).
Hartzell discloses cutting a sheet of electrically conductive material into commutator
segments of predetermined shape and dimensions for subsequent attachment to the
outer surface of the support member such that the segments form commutator
surfaces interrupted by the rib members. (Col. 1, ll. 80–108). Hartzell includes an
additional step wherein the final commutator is turned or ground to equalize the
ribs/teeth with the surfaces of the conductive plates. (Col. 2, ll. 21-26). Hartzell
does not disclose that the height of the ribs/teeth is lower than the conductive plates.
The Examiner asserts that Ito discloses forming a commutator wherein
intervening ribs/teeth have a thickness that is less than the conductive commutator
segments. (Answer, pp. 3-4). According to Ito, when the insulator ribs/teeth of a
commutator project above the conductive segments undesirable contact occurs
between the brush and the commutator producing noise and reduced performance.
(Col. 2, ll. 13-17).
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