Method for assembling and electrical connector assembly for a power tool

• US 20040171299A1
• Filed: 03/08/2004
• Published: 09/02/2004
• Est. Priority Date: 12/01/1999
• Status: Active Grant

• Current Assignee: Milwaukee Electric Tool Corporation (Techtronic Industries Company Limited)
• Original Assignee: Milwaukee Electric Tool Corporation (Techtronic Industries Company Limited)
• Inventors: Zeiler, Jeffrey M., Hessenberger, Jeffrey C.
• Granted Patent: US 6,927,512 B2
• Time in Patent Office: Days
• US Class Current: 439/577
• CPC Class Codes: B25F 5/02 Construction of casings, bodies or handles B25F5/006, B25F5/008 take precedence
• CPC Class Codes: C10M 101/02 Petroleum fractions
• CPC Class Codes: C10M 159/18 Complexes with metals
• CPC Class Codes: C10M 169/042 the additives being compounds of unknown or incompletely defined constitution only
• CPC Class Codes: C10M 2203/1006 used as base material
• CPC Class Codes: C10M 2203/1025 used as base material
• CPC Class Codes: C10M 2203/1045 used as base material
• CPC Class Codes: C10M 2203/1065 used as base material
• CPC Class Codes: C10M 2203/1085 used as base material
• CPC Class Codes: C10M 2219/068 Thiocarbamate metal salts
• CPC Class Codes: C10M 2223/045 Metal containing thio derivatives
• CPC Class Codes: C10M 2227/09 Complexes with metals
• CPC Class Codes: C10N 2010/12 Groups 6 or 16
• CPC Class Codes: C10N 2040/25 Internal-combustion engines
• CPC Class Codes: C10N 2040/251 Alcohol-fuelled engines
• CPC Class Codes: C10N 2040/255 Gasoline engines
• CPC Class Codes: C10N 2040/28 Rotary engines
• CPC Class Codes: H02K 2203/09 Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations
• CPC Class Codes: H02K 2211/03 Machines characterised by circuit boards, e.g. pcb
• CPC Class Codes: H02K 23/66 Structural association with auxiliary electric devices influencing the characteristic of, or controlling, the machine, e.g. with impedances or switches
• CPC Class Codes: H02K 3/522 : for generally annular cores with salient poles
• CPC Class Codes: H02K 5/148 : Slidably supported brushes
• CPC Class Codes: H02K 5/225 : Terminal boxes or connection arrangements specially adapted for submersible motors H02K5/132
• CPC Class Codes: Y10T 29/49009 : Dynamoelectric machine
• CPC Class Codes: Y10T 29/49117 : Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49121 : Beam lead frame or beam lead device
• CPC Class Codes: Y10T 29/49169 : Assembling electrical component directly to terminal or elongated conductor
• CPC Class Codes: Y10T 29/49174 : Assembling terminal to elongated conductor
• CPC Class Codes: Y10T 29/53143 : Motor or generator

Abstract

An electrical connector assembly for a power tool, a power tool and methods for assembling a power tool. A one-piece trace or spider terminal member assembly provides points of connection for the motor components, such as the field windings, the brushes and the switch. To assemble the motor, the terminal member assembly is positioned in the motor housing. To mount the terminal member assembly, the terminal member assembly is preferably co-molded with the housing or, alternatively, may snap-fit into connectors formed on the housing. The terminal member assembly and the housing are then preferably punched or stamped at points to provide the necessary number of electrically separated contact elements to connect the components of the motor. For example, the female ends or terminals of the field windings, the brushes and the switch are connected to the electrically separated contact elements to provide a suitable complete electrical circuit for the motor. Non-conducting members are positioned between adjacent ones of the electrically separated contact elements.

Claims

1. An assembly for use in manufacturing a power tool, the power tool including an electric motor, said assembly comprising:

a motor housing for supporting the motor; and

an electrical connector assembly provided by a method comprising the acts of

providing a terminal member assembly including a plurality of separable contact elements,

mounting said terminal member assembly to said motor housing, and

separating said terminal member assembly to provide at least a first electrically separated contact element and a second electrically separated contact element, said first electrically separated contact element and said second electrically separated contact element being electrically connectable to the motor to provide a complete electrical circuit for the motor.

2. The assembly, as recited in claim 1, wherein the housing is formed of a molded material, and wherein said act of mounting said terminal member assembly includes molding said terminal member assembly into said motor housing.

3. The assembly, as recited in claim 1, wherein said act of separating said terminal member assembly includes creating an opening between adjacent ones of said plurality of separable contact elements to provide said first electrically separated contact element and said second electrically separated contact element.

4. The assembly, as recited in claim 3, and further comprising a non-conducting element positioned between said first electrically separated contact element and said second electrically separated contact element.

5. The assembly, as recited in claim 3, further comprising a separate cover having a non-conducting element mounted thereon, said separate cover being positionable over said motor housing so that said non-conducting element is positioned between said first electrically separated contact element and said second electrically separated contact element.

6. The assembly, as recited in claim 3, wherein said act of creating an opening includes punching an opening between adjacent ones of said plurality of separable contact elements to provide to provide said first electrically separated contact element and said second electrically separated contact element.

7. The assembly, as recited in claim 6, wherein said act of punching provides a corresponding hole in said motor housing, said hole being substantially aligned with said opening.

8. The assembly, as recited in claim 7, wherein said opening is between said first electrically separated contact element and said second electrically separated contact element, and wherein said assembly further comprises a non-conducting element positioned in said opening between said first electrically separated contact element and said second electrically separated contact element, said non-conducting element being positioned in said opening through said hole.

9. A method for assembling a power tool, the power tool including a motor housing, and a motor supportable by the housing, the method comprising the acts of:

providing a terminal member assembly including a plurality of electrically separable contact elements;

mounting the terminal member assembly in the motor housing;

creating an opening in the terminal member assembly between adjacent ones of the plurality of electrically separable contact elements to provide a plurality of electrically separated contact elements;

positioning a non-conducting element in the opening between adjacent ones of the plurality of electrically separated contact elements;

supporting the motor in the motor housing; and

electrically connecting the plurality of electrically separated contact elements to the motor to provide a complete electrical circuit for the motor.

10. The method, as recited in claim 9, wherein the housing is formed of a molded material, and wherein the act of mounting the terminal member assembly includes molding the terminal member assembly as a unit with the motor housing.

11. The method, as recited in claim 9, wherein the act of positioning the non-conducting element includes providing a seal between adjacent ones of the plurality of electrically separated contact elements.

12. The method, as recited in claim 9, wherein the act of creating an opening includes punching an opening in the terminal member assembly between adjacent ones of the plurality of electrically separable contact elements to provide the plurality of electrically separated contact elements.

13. The method, as recited in claim 12, wherein the act of punching provides a corresponding hole in the motor housing substantially aligned with the opening between adjacent ones of the plurality of electrically separated contact elements.

14. The method, as recited in claim 13, further comprising the acts of:

providing a non-conducting element; and

positioning the non-conducting element in the opening between adjacent ones of the plurality of electrically separated contact elements through the corresponding hole in the motor housing.

15. The method, as recited in claim 9, further comprising the acts of:

providing a separate motor housing cover having a non-conducting element mounted thereon;

positioning the separate motor housing cover over the motor housing; and

positioning the non-conducting element in the opening between adjacent ones of the plurality of electrically separated contact elements.

16. The method, as recited in claim 9, wherein the motor includes a field having a plurality of field terminals, wherein each of the plurality of electrically separated contact elements has at least a first contact, wherein said act of supporting the motor includes supporting the field in the motor housing, and wherein said act of electrically connecting the plurality of electrically separated contact elements to the motor includes electrically connecting the first contact of a corresponding one of the plurality of electrically separated contact elements with one of the plurality of field terminals.

17. The method, as recited in claim 16, wherein said act of supporting the field occurs substantially simultaneously with said act of electrically connecting the first contact of the corresponding one of the plurality of electrically separated contact elements with the one of the plurality of field terminals.

18. The method, as recited in claim 9, wherein the motor includes a switch having a switch terminal, wherein at least one of the plurality of electrically separated contact elements has a first contact and a second contact, wherein said act of supporting the motor includes supporting the switch on the motor housing, and wherein said act of electrically connecting the plurality of electrically separated contact elements to the motor includes electrically connecting the switch terminal to the second contact of the at least one of the plurality of electrically separated contact elements.

19. The method, as recited in claim 9, wherein the motor further includes a braking circuit and switch assembly having a braking circuit electrically connected to a switch and a plurality of assembly terminals, wherein at least one of the plurality of electrically separated contact elements has a first contact and a second contact and at least another one of the plurality of electrically separated contact elements has a first contact, a second contact and a third contact, wherein said act of supporting the motor includes supporting the braking circuit and switch assembly on the motor housing, and wherein said act of electrically connecting the plurality of electrically separated contact elements to the motor includes electrically connecting one of the plurality of assembly terminals to the second contact of the at least one of the plurality of electrically separated contact elements and electrically connecting another of the plurality of assembly terminals to the third contact of the at least another one of the plurality of electrically separated contact elements.

20. The method, as recited in claim 9, wherein the motor includes a brush having a brush terminal, wherein at least one of the plurality of electrically separated contact elements has a first contact and a second contact, wherein said act of supporting the motor includes supporting the brush on the motor housing, and wherein said act of electrically connecting the plurality of electrically separated contact elements to the motor includes electrically connecting the brush terminal to the second contact of the at least one of the plurality of electrically separated contact elements.

21. The method as recited in claim 20, wherein said act of supporting the brush occurs substantially simultaneously with said act of electrically connecting the brush terminal to the second contact of the at least one of the plurality of electrically separated contact elements.

22. A method for assembling a power tool, the method comprising the acts of:

providing a motor and a terminal member for connecting the motor to a power source;

forming a motor housing of a moldable material, said act of forming including molding the terminal member with the moldable material of the housing;

supporting the motor in the motor housing; and

electrically connecting the terminal member and the motor to provide a complete electrical circuit for the motor.

23. The method, as recited in claim 22, wherein the terminal member includes a plurality of separable contact elements, wherein said method further comprises the act of separating the plurality of separable contact elements of the terminal member to provide a corresponding plurality of electrically separated contact elements, and wherein said act of electrically connecting the terminal member to the motor includes electrically connecting the plurality of electrically separated contact elements to the motor to provide a complete electrical circuit for the motor.

24. The method, as recited in claim 23, wherein the act of separating includes creating an opening in the terminal member assembly between adjacent ones of the plurality of electrically separable contact elements to provide the plurality of electrically separated contact elements.

25. The method, as recited in claim 24, further comprising the acts of:

providing a non-conducting element; and

positioning the non-conducting element in the opening between adjacent ones of the plurality of electrically separated contact elements.

26. The method, as recited in claim 25, wherein the act of positioning the non-conducting element includes providing a seal between adjacent ones of the plurality of electrically separated contact elements.

27. The method, as recited in claim 24, wherein the act of creating an opening includes punching an opening in the terminal member assembly between adjacent ones of the plurality of electrically separable contact elements to provide the plurality of electrically separated contact elements.

28. The method, as recited in claim 27, wherein the act of punching provides a corresponding hole in the motor housing substantially aligned with the opening between adjacent ones of the plurality of electrically separated contact elements.

29. The method, as recited in claim 28, further comprising the acts of:

providing a non-conducting element; and

positioning the non-conducting element in the opening between adjacent ones of the plurality of electrically separated contact elements through the corresponding hole in the motor housing.

30. The method, as recited in claim 24, further comprising the acts of:

providing a separate motor housing cover having a non-conducting element mounted thereon;

positioning the separate motor housing cover over the motor housing; and

positioning the non-conducting element in the opening between adjacent ones of the plurality of electrically separated contact elements.

31. The method, as recited in claim 23, wherein the motor includes a field having a plurality of field terminals, wherein each of the plurality of electrically separated contact elements has at least a first contact, wherein said act of supporting the motor includes supporting the field in the motor housing, and wherein said act of electrically connecting the plurality of electrically separated contact elements to the motor includes electrically connecting the first contact of a corresponding one of the plurality of electrically separated contact elements with one of the plurality of field terminals.

32. The method, as recited in claim 31, wherein said act of supporting the field occurs substantially simultaneously with said act of electrically connecting the first contact of the corresponding one of the plurality of electrically separated contact elements with the one of the plurality of field terminals.

33. The method, as recited in claim 23, wherein the motor includes a switch having a switch terminal, wherein at least one of the plurality of electrically separated contact elements has a first contact and a second contact, wherein said act of supporting the motor includes supporting the switch on the motor housing, and wherein said act of electrically connecting the plurality of electrically separated contact elements to the motor includes electrically connecting the switch terminal to the second contact of the at least one of the plurality of electrically separated contact elements.

34. The method, as recited in claim 23, wherein the motor further includes a braking circuit and switch assembly having a braking circuit electrically connected to a switch and a plurality of assembly terminals, wherein at least one of the plurality of electrically separated contact elements has a first contact and a second contact and at least another one of the plurality of electrically separated contact elements has a first contact, a second contact and a third contact, wherein said act of supporting the motor includes supporting the braking circuit and switch assembly on the motor housing, and wherein said act of electrically connecting the plurality of electrically separated contact elements to the motor includes electrically connecting one of the plurality of assembly terminals to the second contact of the at least one of the plurality of electrically separated contact elements and electrically connecting another of the plurality of assembly terminals to the third contact of the at least another one of the plurality of electrically separated contact elements.

35. The method, as recited in claim 23, wherein the motor includes a brush having a brush terminal, wherein at least one of the plurality of electrically separated contact elements has a first contact and a second contact, wherein said act of supporting the motor includes supporting the brush on the motor housing, and wherein said act of electrically connecting the plurality of electrically separated contact elements to the motor includes electrically connecting the brush terminal to the second contact of the at least one of the plurality of electrically separated contact elements.

36. The method as recited in claim 35, wherein said act of supporting the brush occurs substantially simultaneously with said act of electrically connecting the brush terminal to the second contact of the at least one of the plurality of electrically separated contact elements.

37. A method for assembling a power tool, the power tool having an electrical circuit, the method comprising the acts of:

providing a first electrical component and a second electrical component electrically connectable to the first electrical component;

providing a terminal member for electrically connecting the first electrical component to the second electrical component, the terminal member including a plurality of separable contact elements;

forming a power tool housing of a moldable material, said act of forming including molding the terminal member with the moldable material of the housing;

separating the plurality of separable contact elements of the terminal member to provide a corresponding plurality of electrically separated contact elements;

supporting the first electrical component and the second electrical component on the housing; and

electrically connecting the plurality of electrically separated contact elements to the first electrical component and to the second electrical component to provide a complete portion of the electrical circuit for the power tool.

38. The method, as recited in claim 37, wherein the act of separating includes creating an opening in the terminal member assembly between adjacent ones of the plurality of electrically separable contact elements to provide the plurality of electrically separated contact elements.

39. The method, as recited in claim 38, further comprising the acts of:

providing a non-conducting element; and

positioning the non-conducting element in the opening between adjacent ones of the plurality of electrically separated contact elements.

40. The method, as recited in claim 39, wherein the act of positioning the non-conducting element includes providing a seal between adjacent ones of the plurality of electrically separated contact elements.

41. The method, as recited in claim 38, wherein the act of creating an opening includes punching an opening in the terminal member assembly between adjacent ones of the plurality of electrically separable contact elements to provide the plurality of electrically separated contact elements.

42. The method, as recited in claim 41, wherein the act of punching provides a corresponding hole in the motor housing substantially aligned with the opening between adjacent ones of the plurality of electrically separated contact elements.

43. The method, as recited in claim 42, further comprising the acts of:

providing a non-conducting element; and

positioning the non-conducting element in the opening between adjacent ones of the plurality of electrically separated contact elements through the corresponding hole in the motor housing.

44. The method, as recited in claim 38, further comprising the acts of:

providing a separate motor housing cover having a non-conducting element mounted thereon;

positioning the separate motor housing cover over the motor housing; and

positioning the non-conducting element in the opening between adjacent ones of the plurality of electrically separated contact elements.

45. A method of assembling a power tool, the method comprising the acts of:

providing a motor housing;

providing an electric motor supportable by the housing and electrically connectable with a power source, the electrical motor including a field, a brush, and a switch; and

providing an electrical circuit assembly provided by a method including the acts of

providing a terminal member assembly including a plurality of separable contact elements,

mounting the terminal member assembly to the housing, and

separating the plurality of electrically separable contact elements of the terminal member assembly to provide at least a first electrically separated contact element and a second electrically separated contact element; and

electrically connecting the first electrically separated contact element between the field and the switch and the second electrically separated contact element between the field and the brush to provide a complete electrical circuit for the motor.

46. The method, as recited in claim 45, wherein the housing is formed of a molded material, and wherein said act of mounting the terminal member assembly includes molding the terminal member assembly into the housing.

47. The method, as recited in claim 45, wherein said act of separating the terminal member assembly includes creating an opening between adjacent ones of the plurality of electrically separable contact elements to provide the first electrically separated contact element and the second electrically separated contact element.

48. The method, as recited in claim 47, further comprising the act of positioning a non-conducting element in the opening between the first electrically separated contact element and the second electrically separated contact element.

49. The method, as recited in claim 47, further comprising the acts of:

providing a separate cover having a non-conducting element mounted thereon;

positioning the separate cover over the motor housing; and

positioning the non-conducting element in the opening between the first electrically separated contact element and the second electrically separated contact element.

50. The method, as recited in claim 47, wherein the act of creating an opening includes punching an opening in the terminal member assembly between adjacent ones of the plurality of separable electrically contact elements to provide the first electrically separated contact element and the second electrically separated contact element.

51. The method, as recited in claim 50, wherein said act of punching includes providing a corresponding hole in the housing, the hole being substantially aligned with the opening.

52. The method, as recited in claim 51, further comprising the act of positioning a non-conducting element in the hole and in the opening between the first electrically separated contact element and the second electrically separated contact element.

53. The method, as recited in claim 52, wherein said act of positioning the non-conducting element includes providing a seal between the first electrically separated contact element and the second electrically separated contact element.

54. The method, as recited in claim 45, wherein said act of separating the terminal member includes providing a first electrically separated contact element, a second electrically separated contact element, a third electrically separated contact element, and a fourth electrically separated contact element, wherein said method further comprises the acts of:

providing a member supporting a first non-conducting element, a second non-conducting element, and a third non-conducting element;

supporting the member on the motor housing;

positioning the first non-conducting element between the first electrically separated contact element and the second electrically separated contact element;

positioning the second non-conducting element between the second electrically separated contact element and the third electrically separated contact element; and

positioning the third non-conducting element between the third electrically separated contact element and the fourth electrically separated contact element.

55. The method, as recited in claim 54, wherein said act of providing a member includes supporting a fourth non-conducting element, wherein said method further comprises the act of positioning the fourth non-conducting element between the first electrically separated contact element and the fourth electrically separated contact element.

56. The method, as recited in claim 45, further comprising the act of supporting the field in the housing simultaneously with said electrically connecting act.

57. The method, as recited in claim 45, wherein the first electrically separated contact element has a first contact, wherein the field has a plurality of field terminals, and wherein said electrically connecting act includes connecting the first contact of the first electrically separated contact element with one of the plurality of field terminals on the field.

58. The method, as recited in claim 45, wherein the first electrically separated contact element has a first contact, wherein the switch has a switch terminal, and wherein said electrically connecting act includes connecting the first contact of the first electrically separated contact element with the switch terminal on said switch.

59. The method, as recited in claim 45, further comprising the act of providing a switch assembly having a braking circuit electrically connected to the switch and a plurality of assembly terminals, wherein said electrically connecting act includes connecting one of the plurality of assembly terminals to a second contact of the first electrically separated contact elements and electrically connecting another of the plurality of assembly terminals to a third contact of the second electrically separated contact elements.

60. The method, as recited in claim 45, wherein said electrically connecting act includes connecting a first contact of the second electrically separated contact element with a brush terminal of the brush simultaneously with supporting the brush on the motor housing.