Patent ID: 7685697
Filing Date: 2010-03-30
Classification: H01R,H02K,Y10T

Abstract:
1. A method for forming a power tool, comprising: forming an armature by placing an electrically insulative sleeve on an armature shaft; after the electrically insulative sleeve has been placed on the armature shaft, securing a lamination stack having slots therein on the armature shaft with the insulative sleeve disposed therebetween and securing a commutator on one end of the armature shaft without the insulative sleeve disposed therebetween; winding magnet wires in the slots in the lamination stack and securing ends of the magnet wires to the commutator; and after the magnet wires have been wound in the slots in the lamination stack and ends of the magnet wires secured to the commutator, molding thermally conductive plastic to at least partially encase the magnet wires in plastic and preventing any of the thermally conductive plastic from flowing into any gap between the commutator and an end of the insulative sleeve during molding of the thermally conductive plastic; after molding the thermally conductive plastic, disposing the armature in a stator to form an electric motor; and disposing the electric motor in the power tool.