Method for assembling a power tool

• US 6,701,604 B2
• Filed: 05/21/2002
• Issued: 03/09/2004
• Est. Priority Date: 12/01/1999
• Status: Expired due to Term

• 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.
• Primary Examiner(s): Arbes, Carl J.
• Assistant Examiner(s): Phan, T. D.
• Application Number:
  US10/152,138
• Publication Number:
  US 20020133932A1
• Time in Patent Office: 658 Days
• Field of Search: 295/96, 297/32, 298/25, 298/27, 298/54, 298/57, 310/71, 310/50, 310/42, 174/52.3
• US Class Current: 29/596
• 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 fueled 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. 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.

2. The method, as recited in claim 1, 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.

3. The method, as recited in claim 2, 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.

4. The method, as recited in claim 3, 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.

5. The method, as recited in claim 4, 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.

6. The method, as recited in claim 2, 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.

7. The method, as recited in claim 6, 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.

8. The method, as recited in claim 2, 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.

9. The method, as recited in claim 2, 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.

10. The method as recited in claim 9, 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.

11. 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;

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;

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;

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.

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

13. 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;

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;

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;

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;

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;

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.

14. 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;

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;

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;

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.

15. 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;

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;

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.