Abstract:
A switch assembly usable in a food waste disposer is disclosed having several improvements over the prior art. The switch assembly positively retains an overload switch, making assembly of the switch into the disposer easier. The switch assembly includes terminals, which attach to the start and run windings of the disposer. The terminals are arranged in a uniform direction along a single side of the switch assembly. This arrangement allows a single, integrated connector of winding leads to be easily connected to the switch assembly, facilitating assembly and reducing the possibility of incorrectly wiring the disposer during construction.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application is concurrently filed with U.S. Design patent application Ser. No.______, which is entitled “Switch Assembly” and contains subject matter related to that disclosed herein. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates generally to food waste disposers and, more particularly to a switch assembly for use in a food waste disposer.  
         BACKGROUND OF THE INVENTION  
         [0003]    Referring to FIG. 1, a portion of a conventional food waste disposer  10  is illustrated in a cross-sectional view. The conventional disposer  10  includes an upper food conveying section (not shown), a lower motor section  30 , and a central grinding section  20  disposed between the food conveying section and the motor section  30 . The food conveying section conveys food waste and water to the central grinding section  20 . The central grinding section  20  includes a grinding plate  22  containing grinding lugs  24 .  
           [0004]    The motor section  30  includes an induction motor  40 , enclosed within a motor housing  32  having an upper end frame  34  and a lower end frame  36 . The motor  40  includes a stator  42  and a rotor  46 . The stator  42  includes windings  44 . The rotor  46  is disposed on a motor shaft  48 . The motor  40  imparts rotational movement to the motor shaft  48 , which turns the grinding plate  22  of the grinding section  20 .  
           [0005]    The motor shaft  48  includes a mechanical or centrifugal actuator  50  disposed adjacent the lower end frame  36 . The centrifugal actuator  50  includes a body  52  attached to the motor shaft  48 . Two weights  54  are pivotably connected to the body  52  and are biased together by one or more springs  56 . The spring-loaded weights  54  move a movable plate  58  disposed about the motor shaft  48 , as will be explained in more detail later.  
           [0006]    A switch assembly  60  is attached to the lower end frame  36  adjacent the motor shaft  48  and centrifugal actuator  50 . In particular, tabs  63  on the switch assembly  60  are press fit through apertures defined in the lower end frame  36 . The switch assembly  60  includes an internal switch having a lever arm or blade  66  in contact with the movable plate  58  of the centrifugal actuator  50 . When a certain rotational speed is reached by the motor  40 , the spring-loaded weights  54  of the centrifugal actuator  50  move apart due to centrifugal force. The separation of the weights  54  causes the movable plate  58  to lift. In contact with the movable plate  58 , the lever arm or blade  66  moves upward and an electrical connection is broken within the internal switch of the switch assembly  60 . Typically, the electrical connection is broken when the motor reaches approximately 1500 to 1600 r.p.m. for 60 Hz. Motors or 1300 to 1400 r.p.m. for 50 Hz. motors and may occur within about 0.3 seconds from start-up. As will be discussed in more detail below, the internal switch, lever arm or blade  66 , and centrifugal actuator  50  work in conjunction to control power to the windings  44  of the motor  40 .  
           [0007]    The switch assembly  60  houses an overload switch  70 , which is typically a separately manufactured component. The overload switch  70  is used to cut power to the motor  40  under certain conditions. The overload switch  70  includes a reset button  72  disposed through an aperture  38  in the lower end frame  36 . The reset button  72  allows a user to reset the overload switch  70  from outside the disposer  10 .  
           [0008]    Referring to FIGS.  2 A-B, top views of two switch assemblies  60   a  and  60   b  according to the prior art are illustrated for use with the conventional disposer  10 . In FIG. 2A, the switch assembly  60   a  represents a start switch used in a food waste disposer produced by In-Sink-Erator®, a division of Emerson Electric Co. In FIG. 2B, the switch assembly  60   b  represents a start switch produced by Whiterock Corporation of China.  
           [0009]    The switch assembly  60   a  or  60   b  includes a body  62  that attaches to the lower end frame with retainers or tabs  63 . The body  62  includes a contact switch  64   a  or  64   b  and houses the overload switch  70 . The overload switch  70  may be, for example, a switch manufactured by Thermodisc Incorporated, a subsidiary of Emerson Electric Co., having a type 30M frame style. The overload switch  70  includes a terminal  81  and a connection point  85 .  
           [0010]    In the switch assembly  60   a  of FIG. 2A, the contact switch  64   a  includes a plastic lever arm  66   a  pivotally connected to the body  62  and biased open by a spring (not shown). As described above in FIG. 1, the plastic lever arm  66   a  moves with the movable plate  58  of the centrifugal actuator  50 . A flexible, conductive blade  68   a  is connected to and movable with the lever arm  66   a . The blade  68   a  is electrically connected to the terminals  82  and  84 . In contrast to the switch assembly  60   a  of FIG. 2A, the lever arm  66   b  and flexible blade  68   b  of the contact switch  60   b  in FIG. 2B are an integral conductive piece. Despite this difference, the contact switch  64   b  operates in a substantially similar fashion to the contact switch  64   a  of FIG. 2A.  
           [0011]    Referring to FIG. 2C, an electrical schematic of a switch assembly  60  according to the prior art such as assembly  60   a  or  60   b , is illustrated. The switch assembly  60  is connected to leads L 1 -L 3  from the motor of the disposer. The motor has run windings  44 R and start windings  44 S. The switch assembly  60  is also connected to leads L 4 -L 5  from a power supply V.  
           [0012]    The terminal  81  of the overload switch  70  connects in parallel to the windings  44 S and  44 R, and the connection point  85  connects to the power source V. Thus, the overload switch  70  can cut power to the windings  44 S and  44 R in case of a power overload. The terminal  82  is connected to the lead L 2  from the run windings  44 R. The terminal  83  is connected to the lead L 3  from the start windings  44 S. The terminal  84  is connected to the lead L 4  from the power source V.  
           [0013]    The contact switch  64  of the switch assembly  60  is used to control activation of the start windings  44 S. At initial start-up of the motor  40 , the contact switch  64  is closed so that the start and run windings  44 S and  44 R are both engaged. The start windings  44 S are initially used in combination with the run windings  44 R to overcome inertial forces of the rotor, shaft, and grinding plate of the disposer, in addition to other forces. After a certain point and in response to movement of the movable plate  58  of the centrifugal actuator  50 , the contact switch  64  interrupts electrical connection between the power source V connected to terminal  84  and the start windings  44 S connected to terminal  83 , effectively shutting off the start windings  44 S.  
           [0014]    Although the switch assemblies  60   a  and  60   b  of FIGS.  2 A-B operate efficiently and effectively, manufacturers continually strive to improve the efficiency of, and hence reduce the cost of, the manufacture and assembly of such switches and of the disposers in which they are contained. Unfortunately, the prior art switch assemblies have some drawbacks, which prevent these goals from being reached.  
           [0015]    For example, the switch assemblies  60   a  and  60   b  according to the prior art are relatively difficult to install in the disposer  10 . As noted above in FIG. 1, the switch assembly  60   a  or  60   b  includes tabs  63  that press fit into slots defined in the lower end frame  36 . The overload switch  70  includes a reset button  72  that extends from the bottom of the switch assembly  60   a  or  60   b  and is disposed through the hole  38  in the lower end frame  36 . During assembly, an operator manually positions the overload switch  70  within the housing  62  before attaching the assembly  60   a  or  60   b  to the lower end frame  36 . However, the switch assembly  60   a  or  60   b  does not positively retain the overload switch  70 . Consequently, the operator must hold the overload switch  70  in the assembly  60   a  or  60   b  while simultaneously pushing the tabs  63  into the slots defined in the lower end frame  36  and disposing the reset button  72  in the hole  38 . Thus, the attachment of the assembly  60   a  or  60   b  to the lower end frame  36  requires manual dexterity from the operators, making the assembly process difficult.  
           [0016]    In another drawback, the connection of leads to the switch assembly  60   a  or  60   b  offers further challenges to the assembly of the disposer. As shown in FIG. 2C, the switch assembly  60   a  or  60   b  has five terminals ( 81 - 85 ) that must be connected to the leads L 1 -L 5  from the power source and motor. An operator typically performs some of these connections manually by press fitting a terminal connector connected to each lead onto the relevant terminal.  
           [0017]    For example, for the switch  60   a  depicted in FIG. 2A, the terminals  81 - 83  extend in three different directions. The terminals  81 - 83  receive separate terminal connectors  91 - 93  connected to leads L 1 -L 3  in three mating operations. In general, there is no guidance or built-in system for determining or indicating what lead attaches to which terminal. Consequently, the possibility of incorrectly wiring the leads to the switch assembly  60   a  is increased. Furthermore, the operator must attach each lead one at a time. Such difficult or time-consuming operations complicate the assembly of the disposer. Moreover, the terminals  81 - 83  in the prior art configurations of FIGS. 2A and 2B appear on different sides of their switch assemblies, making automated assembly difficult The present invention is directed to overcoming, or at least reducing the effects of, one or more of the problems set forth above.  
         SUMMARY OF THE INVENTION  
         [0018]    A switch assembly usable in a food waste disposer is disclosed having several improvements over the prior art. The switch assembly positively retains an overload switch, making assembly of the switch into the disposer easier. The switch assembly includes terminals, which attach to the start and run windings of the disposer. The terminals are arranged in a uniform direction along a single side of the switch assembly. This arrangement allows a single, integrated connector of winding leads to be easily connected to the switch assembly, facilitating assembly and reducing the possibility of incorrectly wiring the disposer during construction. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]    The forgoing summary, a preferred embodiment, and other aspects of the present invention will be best understood with reference to the following detailed description of specific embodiments of the invention when read in conjunction with the accompanying drawings, in which:  
         [0020]    [0020]FIG. 1 illustrates a cross-sectional view of part of a conventional food waste disposer.  
         [0021]    [0021]FIG. 2A illustrates a top view of a switch assembly according to the prior art.  
         [0022]    [0022]FIG. 2B illustrates a top view of another switch assembly according to the prior art.  
         [0023]    [0023]FIG. 2C illustrates an electrical schematic of the prior art switch assemblies of FIGS.  2 A-B.  
         [0024]    [0024]FIG. 3 illustrates an embodiment of a switch assembly according to the present invention.  
         [0025]    FIGS.  4 A-C illustrate various views of the switch assembly of FIG. 3 having an overload switch disposed therein.  
         [0026]    [0026]FIG. 5 illustrates an electrical schematic of the switch assembly with overload switch of FIGS.  4 A-C.  
         [0027]    FIGS.  6 A-C illustrate various views of an embodiment of a connector assembly according to the present invention for use with the switch assembly of FIGS.  4 A-C.  
         [0028]    FIGS.  7 A-B illustrate various views of an embodiment of a female flag terminal for use in the connector assembly of FIGS.  6 A-C.  
         [0029]    FIGS.  8 A-C illustrate various views of an embodiment of a wedging tool in accordance with the present invention.  
         [0030]    [0030]FIG. 9 illustrates insertion of female flag terminals into the connector assembly using the wedging tool in accordance with the present invention.  
         [0031]    FIGS.  10 A-B illustrate connection of the connector assembly to the switch assembly in accordance with the present invention. 
     
    
       [0032]    While the invention is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.  
       DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0033]    In the interest of clarity, not all features of actual implementations are described in the disclosure that follows. It will of course be appreciated that in the development of any such actual implementations, as in any such project, numerous engineering and design decisions must be made to achieve the developers&#39; specific goals (e.g., compliance with mechanical-related and business-related constraints), which will vary from one implementation to another. Moreover, attention will necessarily be paid to proper engineering and design practices for the environment in question. It will be appreciated that such development efforts might be complex and time-consuming, but would nevertheless be a routine undertaking for those of skill in the art having the benefit of the present disclosure.  
         [0034]    Referring to FIG. 3, an embodiment of a switch assembly  100  according to the present invention is illustrated. In FIG. 3, the switch assembly  100  is illustrated in a perspective view without an overload switch, which may be a separately produced and self-contained component. The switch assembly  100  has first and second sides  110  and  112 , first and second ends  114  and  116 , and a bottom  118 . The bottom  118  of the switch assembly  100  mounts to a lower end frame (not shown) of a disposer as described below.  
         [0035]    The switch assembly includes a body  102 , a first plate  140 , a second plate  160 , and a contact switch  150 . The body  102  is preferably composed of a non-conductive material, which is preferably polyester. The body  102  defines a housing  120  for an overload switch (not shown) adjacent the first end  114 . The housing  120  includes first retainers  124 , second retainers  126 , and biasing tabs  128 .  
         [0036]    The first retainers  124  are disposed on the corners of the housing  120 . Having a triangular cross-section, the first retainers  124  include angled leading edges  125   a  and define shoulders  125   b . In addition, the first retainers  124  define ledges  121  with the housing  120 . The shoulders  125   b  are disposed outside of the housing  120  and face toward the top of the assembly  100 . During installation, the angled leading edges  125   a  are pressed into slots (not shown) defined in the lower end frame. Once installed, the shoulders  125   b  engage one side of the lower end frame, and the ledges  121  engage the opposite side of the lower end frame. Thus, the first retainers  124  retain the assembly  100  on the lower end frame of the disposer to resist inadvertent displacement from the lower end frame.  
         [0037]    The second retainers  126  are disposed on the sides of the housing  120 . The second retainers  126  include arms  127  angled slightly into the housing  120 . On the arms  127 , the second retainers  126  include angled leading edges  128   a  and define shoulders  128   b . The shoulders  128   b  are disposed inside the housing  120  and face toward the top of the assembly  100 . The shoulders  128   b  of the second retainers  126  are disposed at approximately the same level as the shoulders  125   b  of the first retainers  124 .  
         [0038]    As best described below, the second retainers  126  temporarily hold the overload switch (not shown) in the housing  120  when installing the assembly  100  with overload switch on the lower end frame. Furthermore, during installation, the angled leading edges  128   a  of the second retainers  126  are pressed into slots (not shown) defined in the lower end frame, and the shoulders  128   b  engage one side of the lower end frame. Thus, the second retainers  126  also retain the assembly  100  on the lower end frame to resist inadvertent displacement of the assembly  100  therefrom. The tabs  128  are disposed on the top of the housing  120  and contact or press firmly against the overload switch.  
         [0039]    The first plate  140 , the second plate  160 , and the contact switch  150  are attached on the second end  116  of the body  102 . The first plate  140  is attached to the topside of the second end  116  with a fastener  142 . The fastener  142  is preferably be a one-piece eyelet composed of brass. The first plate  140  is composed of conductive material, which is preferably strip brass, and has an approximate thickness of 0.032-inch. The first plate  140  includes a terminal  182  -for attachment to a lead from the motor as described below and includes a terminal  184  for attachment to a lead from the power source as described below.  
         [0040]    The second plate  160  is also attached to the end  116  of the body  102  and is disposed substantially parallel to the first plate  140 . The second plate  160  is attached to the bottom-side of the second end  116  with a fastener or eyelet, which is best shown as fastener  162  in FIG. 4C below. The second plate  160  includes an aperture (not visible) allowing the eyelet  142  of the first plate  140  to be accessed when assembling the switch  100 . Like the first plate  140 , the second plate  160  is preferably composed of strip brass and preferably has an approximate thickness of 0.032-inch. The second plate  160  includes a terminal  183  for attachment to a lead from the motor as described below.  
         [0041]    As explained previously, the contact switch  150  moves in conjunction with a mechanical or centrifugal actuator and acts to activate or deactivate the start windings of the motor in the disposer. The contact switch  150  includes a first conductive blade  151  and a second conductive blade  156 , which provide power to the start windings when in contact. The first blade  151  is attached or staked to the first conductive plate  140 . The second blade  156  is preferably formed as an integrated conductive piece with the second plate  160 .  
         [0042]    The first blade  151  includes a contact or bulbous dimple  153  on its distal end for contacting the centrifugal actuator of the disposer. The first blade  151  also includes a contact extension  155 , which is preferably composed of copper with a top layer of silver oxide. The contact extension  155  makes electrical contact with a similar contact extension  158  of the second blade  156  of the contact switch  150  as described below. The first blade  151  may further include one or more bends and/or changes in width for biasing its contact with the centrifugal actuator.  
         [0043]    In the present embodiment, the first plate  140  and first blade  151  are preferably stamped pieces that are staked together, which is a desirable configuration because the first blade  151  requires a material that bends while the terminals  182  and  184  of the first plate  140  require a more rigid material. In particular, one end of the first blade  151  is staked to the first plate  140  and is disposed against the body  102 . The first blade  151  is preferably composed of strip phosphor bronze. However, the first plate  140  and first blade  151  may be an integral component composed of a conductive material offering both a sufficient degree of bending for a blade portion and a sufficient degree of rigidity for terminal portions.  
         [0044]    For the present embodiment having staked pieces, the first plate  140  includes an aperture for the eyelet  142  and includes material staking areas or dimples  144  and  146  stamped in its surface. The first blade  151  also includes an aperture for the eyelet  142  and includes material staking areas that are not visible in FIG. 3 because they appear underneath the first plate  140 . When the first blade  151  and first plate  140  are staked together, the material staking areas of the first blade  151  align with the material staking areas  144  and  146  protruding from the bottom surface of the first plate  140 . The material staking areas on the first plate  140  and the first blade  151  preferably, but not necessarily, have an asymmetrical arrangement with respect to the axis of symmetry for the plate  140  and the blade  151 . In this way, the first plate  140  and first blade  151  may be properly staked together with the first blade  151  pointing and bending in the appropriate direction in relation to the terminals  182  and  184  on the first plate  140 .  
         [0045]    The second blade  156  of the contact switch  150  is preferably formed as part of the second plate  160 . The second blade  156  includes the second contact extension  158 , which is preferably composed of copper with a top layer of silver oxide. The second contact extension  158  establishes electrical connection with the first contact extension  155  of the first blade  151  when the first blade  151  is bent by the centrifugal actuator. The second blade  156  may include one or more bends and/or changes in width.  
         [0046]    Referring to FIGS.  4 A-C, the switch assembly  100  with the overload switch  170  is illustrated and is shown in electrical schematic form in FIG. 5. The first blade  151  of the contact switch  150  is electrically connected to the terminals  182  and  184 . The first blade  151  extends from the second side  112  of the assembly  100 . The second blade  156  is electrically connected to the third terminal  183 . The second blade  156  also extends from the second side  112  and extends adjacent the first blade  151  of the contact switch  150 . The second blade  156  extends for a shorter length than the first blade  151 .  
         [0047]    As in the prior art, the contact switch  150  is normally open, but is held closed at initial start-up of the disposer by contact with the movable plate of the centrifugal actuator, as discussed in FIG. 1. The contact switch  150  opens as the first blade  151  bends upward when the movable plate is lifted by the centrifugal actuator. Contact between the first and second blades  151  and  156  breaks, and the start winding of the motor is electrically disconnected. As best shown in FIG. 5, opening of the contact switch  150  ends the electrical connection of the start winding  44 S to the power source V and leaves only the run winding  44 R connected to the power source V. As previously noted, this may typically occur when the motor reaches approximately 1500 to 1600 r.p.m. for 60 Hz. motors or 1300 to 1400 r.p.m. for 50 Hz. motors within about 0.3 seconds.  
         [0048]    As is known in the art, a minimum load is required for holding the first and second blades  151  and  156  together. Furthermore, the contact switch  150  must accommodate any over travel of the centrifugal actuator, because the first blade  151  contacts the movable plate of the actuator. Therefore, the motion of the first blade  151  preferably accounts for possible differences in tolerance that are incurred during assembly of the disposer. Accommodating these differences ensures that the minimum load on the contact switch  150  is maintained when the centrifugal actuator is not activated.  
         [0049]    Any wear on the blade tip  153  can decrease the load on the switch  150 . The contour of the tip  153 , preferably rounded, and the material of the blade  151 , preferably strip phosphor bronze, can be suitably chosen to reduce any characteristic wear. Moreover, the material of the movable plate contacting the tip  153  can be composed of thermoset or thermoplastic to reduce any characteristic wear.  
         [0050]    The housing  120  of the assembly  100  houses the overload switch  170  as noted earlier. The overload switch  170  may be and typically is a separately produced and self-contained component. Preferably, the overload switch  170  is manufactured by Thermodisc Incorporated, a subsidiary of Emerson Electric Co., having a type 30M frame style. The overload switch  170  includes a reset button  172 , a terminal  181 , and a connection point  185 . The overload switch  170  is positioned within the housing  120  by insertion from the bottom  118  of the assembly  100 . The housing  120  defines at least one open side  122  for the terminals  181  and  185  of the overload switch  170 . Once installed in the housing  120 , the terminal  181  and connection point  185  extends from the first side  110  of the assembly  100 . As best shown in an electrical schematic of FIG. 5, the first terminal  181  of the assembly  100 , which is associated with the overload switch  170 , connects to the start windings  44 S and run windings  44 R of the motor. The fifth terminal or connection point  185  associated with the overload switch  170  connects to the power source V. Operating power usually consists either of 120 VAC at 60 Hz or 240 VAC at 50/60 Hz.  
         [0051]    Returning to FIGS.  4 A-C and highlighting one inventive feature of the disclosed switch assembly, it should be noted that the switch assembly  100  positively retains or holds the overload switch  170  in the housing  120  during installation. As best shown in FIG. 4B, the second retainers  126  are angled slightly into the housing  120 . The overload switch  170  inserts into the bottom of the housing  120 , causing the arms of the retainers  126  to flex open to accommodate the width of the switch. Once fully inserted, the retainers  126  flex back as the switch  170  surpasses the shoulders  128   b  of the second retainers  126 . The shoulders  128   b  then temporarily hold the overload switch  170  in the housing so that the assembly  100  and overload switch  170  can be easily installed together on the lower end frame.  
         [0052]    The assembly  100  attaches to the lower end frame in one direction. As the assembly  100  is moved adjacent the lower end frame, the first and second retainers  124  and  126  are pressed into slots defined in the lower end frame, and the reset button  172  of the switch  170  is disposed through a hole (not shown) defined in the lower end frame. The second retainers  126  flex away from the overload switch  170  as they are inserted into the slots. The shoulders  127   b  of the second retainers  126  then engage one side of the lower end frame, as do the shoulders  125   b  of the first retainers  124 . Being triangular, the first and second retainers  124  and  126  both facilitate attachment of the assembly  100  to the lower end frame for both manual and automated procedures. In addition, the fact that the first retainers  124  are angled opposite to the second retainers  126  further helps to align the assembly  100  adjacent the slots defined in the lower end frame. With the retainers  124  and  126  installed, the ledges  121  engage the opposite side of the lower end frame. The tabs  128  disposed on the top of the housing  120  contact or press firmly against the top of the overload switch  170 . Thus, the bottom of the overload switch  170  is positively held by the housing  120  against the opposite surface of the lower end frame.  
         [0053]    As noted earlier in the prior art, an operator was required to keep the overload switch  170  stabilized within the prior art assembly while attaching it to the lower end frame. Moreover, any automated attempts to assemble the overload switch  170  using the prior art assembly and attach them to the lower end frame would typically required holding the overload switch  170  and prior art assembly together. However, according to one embodiment of the disclosed invention, the operator may now “snap” the overload switch  170  into place in the switch assembly  100  by sliding the overload switch  170  past the deformable retainers  126 . The overload switch  170  is positively held in the housing  120  before and during attachment to the lower end frame, which greatly simplifies automated assembly.  
         [0054]    The embodiment of the switch assembly  100  has a number of additional advantages over the prior art. The arrangement of the terminals  181 - 183  allows the leads L 1 -L 3  of the motor to be connected to the switch assembly  100  and switch  170  from one direction. This is because, unlike the prior art, the terminals  181 ,  182 , and  183  lie on the same side  110  of the assembly  100 , as best shown in FIG. 4A. By contrast, the switch assemblies in the prior art described above with reference to FIGS. 2A and 2B have terminals extending in different directions to receive the leads. For example, on the switch  60   a  depicted in FIG. 2A, the terminals  81 - 83  extend in three different directions and receive separate terminal connectors  91 - 93  in three mating operations.  
         [0055]    Having the three motor leads L 1 -L 3  connect to the terminals  181 - 183  on the same side  110  of the assembly  100  allows for more accurate attachment of the leads when assembling the switch  100 . Additionally, having the three leads L 1 -L 3  connect to terminals  181 - 183  on the same side  110  may be better suited to the space limitations that exist at the bottom of the disposer. Moreover, having the three leads L 1 -L 3  connect to terminals  181 - 183  on the same side  110  allows the leads to be pre-assembled and housed in a common connector assembly  200  illustrated in FIGS.  6 A-C.  
         [0056]    In FIGS.  6 A-C, the common connector assembly  200  is illustrated in a side view with partial cross section, a back view, and an end cross-sectional view, respectively. The connector assembly  200  is a one piece connector for three leads, corresponding to leads L 1 -L 3 . The connector assembly  200  includes a body  202 , which is preferably molded from nylon. The body  202  has three housings  210 ,  220 , and  230 . Each housing  210 ,  220 , and  230  defines a passage  212 ,  222 , and  232  and a cavity  216 ,  226 , and  236 . Preferably, the passage  212 ,  222 , and  232  defines one or more slanted surfaces or guides  213 ,  223 , and  233  to facilitate insertion of terminal connectors into the housings  210 ,  220 , and  230 .  
         [0057]    A reverse stopping surface or locking ramp  214 ,  224 , and  234  is defined between the passage  212 ,  222 , and  232  and the cavity  216 ,  226 , and  236 . The reverse stopping surface  214 ,  224 , and  234  may extend, for example, approximately 0.027-inch into the passage  212 ,  222 , and  232 . The reverse stopping surface  214 ,  224 , and  234  engages a back edge of a terminal connector (not shown) when inserted into the cavity  216 ,  226 , and  236 , as best shown in FIGS.  10 A-B below. Each housing  210 ,  220 , and  230  also defines a wire slot  218 ,  228 , and  238  for a lead wire (not shown).  
         [0058]    The housings  210 ,  220 , and  230  receive terminal connectors attached to leads from the motor. In a preferred embodiment, a flag terminal as illustrated in FIGS.  7 A-B is connected to a lead from the motor and disposed in the housings  210 ,  220 , or  230 . In FIGS.  7 A-B, an embodiment of a flag terminal  260  is illustrated in a top view and a side view. The flag terminal  260  can be composed of brass, tin-plated brass, nickel-plated steel, or the like and can be formed from stock having a thickness of approximately 0.016-inch.  
         [0059]    The flag terminal  260  includes a terminal portion  262  for connection to a terminal of the switch assembly (not shown) and includes an attachment portion  264  for attachment to a lead wire (not shown). The attachment portion  264  includes first crimp bands  266  and second crimp bands  268 . The first crimp bands  266  hold the insulation of the lead. The second crimp bands  268  hold a wire of the lead. The lead wire used with the flag terminal  260  may be sized, for example, from  18  gauge to  14  gauge. The lead wire is attached perpendicularly to the terminal portion  262 , as best shown in FIG. 10A.  
         [0060]    The terminal portion  262  includes flag curls to allow the terminal portion  262  to mate with the male terminals  181 - 183  of the switch assembly as described below. The terminal portion  262  includes leading edge  263  and a back edge  265 . Preferably, the leading edges  263  are chamfered. The back edge  265  is intended to engage the reverse stopping surfaces  214 ,  224 , and  234  of the connector assembly  200  as described below.  
         [0061]    During manufacture and assembly of the connector assembly  200 , the flag terminal  260  is crimped to the lead wire and is then inserted into the connector assembly. In a preferred embodiment of the present invention, the flag terminal  260  is inserted into the connector assembly  200  of FIGS.  6 A-C using a special insertion or wedging tool. The wedging tool is shown in relevant detail in FIGS.  8 A-C and is shown in use in FIG. 9.  
         [0062]    Referring to FIGS.  8 A-C, an embodiment of a wedging tool used to insert the flag terminals into the connector assembly  200  is illustrated in a side view, a top view, and an end view, respectively. The wedging tool  280  includes an insertion or wedging bit  282 . In one embodiment, the wedging tool  280  is intended for manual use and can include a handle portion (not shown) attached to the wedging bit  282 . As will be readily apparent to those skilled in the art, however, automated procedures and techniques can accomplish the insertion of the flag terminals into the connector assembly.  
         [0063]    The insertion or wedging bit  282  may be composed of steel and may have a hardness of approximately 50 to 54 Rockwell. The insertion or wedging bit  282  includes a first portion or body  284  having a second portion or tip  286  extending therefrom. The first portion or body  284  is approximately 0.300-inch wide and approximately 0.042-inch thick. The top surface of the first portion or body  284  has rounded longitudinal edges. As described below, the rounding of the edges may prevent damage to the connector assembly  200  when the bit  282  is used to insert a flag terminal  260  therein. The bottom surface of the body  284  defines a stop  285  where the thickness of the body is approximately 0.115-inch.  
         [0064]    Extending from the body  284 , the first portion or tip  286  is substantially flat and narrow. A shoulder  287  is defined between the body  284  and the tip  286 . The tip  286  has the same thickness as the narrower portion of the body  284  and is approximately 0.042-inch thick. The tip  286  is approximately 0.100-inches wide, which corresponds to the distance between the flag curls on the sides of the terminal portion  262  of the flag terminal  260 . The tip  286  is approximately 0.240-inches long, which corresponds to the length of the terminal portion  262  of the flag terminal  260 . The distal end  288  of the tip  286  is rounded and has a top edge that is angled at approximately 25-degrees. The distance from the stop  285  on the body  284  to the distal end  288  of the tip  286  is approximately 0.500-inches.  
         [0065]    The insertion or wedging bit  282  is used to install flag terminals into the housings of the connector assembly. Referring to FIG. 9, the insertion or wedging tool  280  is shown with a flag terminal  260  on the insertion bit  282 . The tool  280  is shown ready for inserting the flag terminal  260  into the housing  210  of the connector assembly  200 . The connector assembly  200  is shown in cross section to reveal internal details, such as another flag terminal  260  already installed in housing  220 .  
         [0066]    After the crimp bands  266  and  268  of the attachment portion  264  have been crimped to the wire lead, the flag terminal  260  is disposed on the insertion or wedging bit  282  as shown. In particular, the tip  286  is inserted into the terminal portion  262  of the flag terminal  260  from the back edge  265 . The shoulder  287  engages the back edge  265 , which stops the depth of the insertion of the tip  286  into the terminal portion  262 . The stop  285  of the body  284  may also engage the edge of the attachment portion  264 .  
         [0067]    The terminal portion  262  is inserted into the passageway  212  of the housing  210 . In manual assembly, an operator holds a handle portion (not shown) of the tool  280  to insert the flag terminal  260 . The passageway  212  initially receives the terminal portion  262  and later houses the attachment portion  264 . The slanted surfaces or guides  213  facilitate insertion of the flag terminal  260 . In addition, the chamfered leading edges  263  of the terminal  260  reduce or prevent scraping material of the housing  210  when the terminal  260  is inserted into the connector assembly  200 .  
         [0068]    The terminal portion  262  is inserted until the back edge  265  passes the reverse stopping surface  214 . The terminal portion  262  is then positively installed and retained in the cavity  216 . During insertion, the bit  282  does not interfere with the connector assembly  200 . The operator then pulls the tip  286  out of the terminal portion  262 , which is held in the cavity  216  by the engagement of the back edge  265  and the reverse stopping surface  214 .  
         [0069]    Referring to FIGS. 10A and 10B, flag terminals  260  are shown installed in the connector assembly  200 . In FIG. 10A, a top cross-section of the connector assembly  200  reveals flag terminals  260  installed in housings  210  and  220 . In FIG. 10B, a side cross-section of the connector assembly  200  reveals flag terminals  260  installed in housings  210 ,  220  and  230 .  
         [0070]    When installed, the internal walls of the cavity  216 ,  226 , and  236  and the reverse stopping surfaces  214 ,  224 , and  234  retain the flag terminals  260 . Forward motion is prevented by interference between the passages  218 ,  228 , and  238  and the attachment portions  264  of the flag terminals  260 . Interference between the stopping surfaces  214 ,  224 , and  234  with the rear edges  265  of the terminal portions  262  prevents removal of the flag terminals  260 .  
         [0071]    With the flag terminals  260  and leads L 1 -L 3  installed, the connector assembly  200  couples to the terminals  181 - 183  on one side  110  of the switch assembly  100 . In FIG. 10A, connection between the switch assembly  100  and the connector assembly  200  is shown from the top. In FIG. 10B, connection between the switch assembly  100  and the connector assembly  200  is shown from the side.  
         [0072]    The first housing  210  houses the flag terminal  260  connected to lead L 1  associated with both the run and start windings of the motor and is designed to connect with the first terminal  181  of the overload switch  170 . The second housing  220  houses the flag terminal  260  connected to lead L 2  from the run windings of the motor and is designed to connect with the second terminal  182  of the assembly  100 . The third housing  230  houses the flag terminal  260  connected to lead L 3  from the start windings of the motor and is designed to connect with the third terminal  183  of the assembly  100 .  
         [0073]    Instead of performing three mating operations as seen in the prior art, an operator uses the single connector assembly  200  to simultaneously connect the three motor lead wires L 1 -L 3  to the appropriate terminals  181 - 183  of the switch assembly  100 . The single connector assembly  200  allows this portion of the manufacturing process to become automated. Furthermore, the single connector assembly  200  reduces or eliminates the possibility of connecting a lead to the wrong terminal of the switch assembly  100  by a manufacturing operator.  
         [0074]    As best shown in FIG. 10A, the first housing  210  is positioned further back from the second housings  220 , as the first terminal  181  associated with the overload switch  170  extends further from the first side  110  of the switch assembly  100  than the second terminal  182 . Having the first housing  210  further back from the second housing  220  allows the lead wire L 1  to extend unhindered from the housing  210 . Moreover, the position of the first housing  210  differentiates the lead wire L 1  associated with the overload switch  170  when assembling the lead wires L 1 -L 3  to the connector assembly  200 .  
         [0075]    As best shown in FIG. 10B, the second and third housings  220  and  230  are aligned one above the other, as the second and third terminals  182  and  183  are positioned parallel in the assembly  100 . Moreover, the second and third housings  220  and  230  are flush with one another, as the second and third terminals  182  and  183  extend for substantially equivalent lengths from the first side  110  of the assembly  100 . The arrangement of the terminals  181 - 183  on the switch assembly  100  allows the connector assembly  200  to align in only one orientation with respect to the terminals  181 - 183 , thus facilitating the connection and obviating the possibility of connecting the wrong lead to the switch assembly  100 .  
         [0076]    Due to inventive aspects of the switch assembly  100  and connector assembly  200  of the disclosed invention, assembling a waste disposer having a motor with three leads L 1 -L 3  is greatly simplified. During the assembly of the disposer, the three leads L 1 -L 3  of the motor are housed in common. To house the leads L 1 -L 3  in common, terminal connectors  260  are attached to each lead L 1 -L 3  and are installed and retained in the common connector assembly  200 . Before affixing the switch assembly  100  to the disposer, the overload switch  170  is positively retained in the switch assembly  100 . The overload switch  170  is snapped into place in the switch assembly  100  by sliding the overload switch  170  past deformable retainers  126 .  
         [0077]    The switch assembly  100  is then affixed to the disposer. To affix the switch assembly  100 , deformable retainers  124  on the switch assembly  100  are snapped into slots defined in a lower end frame of the disposer. Finally, the three leads L 1 -L 3  of the motor are simultaneously connected to one side of the switch assembly  100 . Terminal connectors  260  attached to the leads L 1 -L 3  and housed in the common connector assembly  200  are simultaneously mated to three terminals  181 - 183  extending from the one side of the switch assembly  100 . The three leads L 1 -L 3  are permitted to connect to the switch assembly  100  in only one orientation, because the three leads L 1 -L 3  are housed with an asymmetrical arrangement in the common connector assembly  200 .  
         [0078]    Thus, the design of the connector assembly  200  allows it to be properly pre-assembled with the leads L 1 -L 3  and flag terminals  260 . The switch assembly  100  and the connector assembly  200  provide for easier connection of the leads L 1 -L 3  to the motor terminals  181 - 183  either manually or through automation. Finally, the use of the single connector assembly  200  connecting in one direction to one side of the switch assembly  100  is more ergonomic for an operator performing the assembly. Thus, the switch assembly  100  and connector assembly  200  greatly simplify the manufacture of the disposer and reduces the chances of improper connection of the leads from the motor as compared to the prior art discussed above.  
         [0079]    While the present invention has been described with respect to particular embodiments, one should not understand these embodiments to limit the scope of the various aspects of the invention, which instead is defined by the below claim language and its equivalents.