Patent 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.

Full Description:
RELATED APPLICATIONS  
       [0001]    This application is a divisional of prior, co-pending U.S. patent application Ser. No. 10/152,138, filed May 21, 2002, which is a divisional of prior, U.S. patent application Ser. No. 09/452,479, filed Dec. 1, 1999, which is now U.S. Pat. No. 6,445,097. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The invention relates to power tools and, more particularly, to a method for assembling and an electrical connector assembly for a power tool.  
         BACKGROUND OF THE INVENTION  
         [0003]    A typical power tool includes a motor housing and an electric motor supportable by the motor housing and electrically connectable with a power source. The electric motor may include a field assembly, including one or more field windings, a rotatable armature supporting a commutator, a carbon brush for electrically engaging the commutator, and a switch for electrically connecting the components of the electric motor to the power source. In some power tools, the components of the electric motor are directly electrically wired to one another to provide a complete electrical circuit for the motor.  
           [0004]    In some other power tools, the components of the electric motor include respective terminals and the motor also includes an electrical connection system electrically connecting the motor components. In such power tools, the electrical connection system includes separate contact strips which are separately mounted on the housing. Once mounted, the forward ends of the contact strips are engaged with the field terminals, and the rearward ends of the contact strips engage the brush terminals or the wiring harness for connection to the switch to provide a complete electrical circuit for the motor.  
         SUMMARY OF THE INVENTION  
         [0005]    An independent problem with power tools having above-described directly-wired components is that direct wiring of the motor components during assembly of such power tools is time-consuming and labor-intensive, greatly increasing the cost and the complexity of the method and the machinery for assembling the power tools.  
           [0006]    An independent problem with the power tool with the above-described electrical connection system including contact strips is that, while the contact strips improve the efficiency of assembly of the power tool, each of the separate contact strips must be accurately positioned and fixed to the housing so that the components of the motor can be electrically connected. If a contact strip is improperly positioned or improperly fixed to the housing, corrective action is required so that the motor components can be electrically connected to one another, reducing the efficiency of the assembly process.  
           [0007]    An independent problem with the power tool with the above-described electrical connection system is that the motor housing must be designed to fixably support and retain the contact strips in the required position. If the motor housing is improperly formed, the motor housing will not support the contact strips in the required location (for proper connection to the motor components) and, therefore, will not be useable.  
           [0008]    An independent problem with the above-described power tools is that, because the direct wires or the contact strips do not provide additional structural rigidity to the motor housing, the motor housing, which is typically formed of a moldable material, requires a greater amount of material and a more durable material, increasing the cost of the power tool.  
           [0009]    An independent problem with some of the above-described power tools is that the power tool cannot be configured to have different operating conditions, such as with or without a braking capability, without changing the wiring or the electrical connection system of the power tool.  
           [0010]    In some aspects, the invention provides a one-piece trace or spider terminal member assembly which provides points of connection for the motor components, such as the field assembly, the brushes and the switch. To assemble the motor, the one-piece terminal member assembly is positioned in the motor housing. To mount the terminal member assembly, the terminal member assembly is co-molded as a unit with the housing or, alternatively, may snap-fit into connectors formed on the housing. The terminal member assembly and the housing are then 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 assembly, the brushes and the switch are connected to the electrically separated contact elements to provide a suitable complete electrical circuit for the motor. A non-conducting plug may fill the openings created by punching or stamping. The plug also confirms that the openings were punched or stamped. Further, the plug provides a seal to prevent debris from entering the opening and effecting the electrical circuit of the motor.  
           [0011]    In some aspects, the invention provides 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 in the motor housing, electrically separating the plurality of electrically separable contact elements of the terminal member assembly from one another to provide a corresponding 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.  
           [0012]    The housing may be formed of a molded material and the act of mounting the terminal member assembly may include molding the terminal member assembly as a unit with the motor housing. Also, the act of separating may include 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.  
           [0013]    In addition, the act of creating an opening may include 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. The act of punching may provide a corresponding hole in the motor housing substantially aligned with the opening between adjacent ones of the plurality of electrically separated contact elements.  
           [0014]    The method may further comprise the act of positioning a non-conducting element in the opening between adjacent ones of the plurality of electrically separated contact elements and through the corresponding hole in the motor housing. Also, the method may further comprise the act of providing a separate motor housing cover having the 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.  
           [0015]    The motor may include a field having a plurality of field terminals, and each of the plurality of electrically separated contact elements may have at least a first contact. The act of supporting the motor may include supporting the field in the motor housing, and the act of electrically connecting the plurality of electrically separated contact elements to the motor may include 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. The act of supporting the field may occur substantially simultaneously with the 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.  
           [0016]    Also, the motor may include a switch having a switch terminal, and at least one of the plurality of electrically separated contact elements may have a first contact and a second contact. The act of supporting the motor may include supporting the switch on the motor housing, and the act of electrically connecting the plurality of electrically separated contact elements to the motor may include electrically connecting the switch terminal to the second contact of the at least one of the plurality of electrically separated contact elements. The act of supporting the switch may occur substantially simultaneously with the act of electrically connecting the switch terminal to the second contact of the at least one of the plurality of electrically separated contact elements.  
           [0017]    The motor may further include a braking circuit and switch assembly having a braking circuit electrically connected to a switch and a plurality of assembly terminals, and at least another one of the plurality of electrically separated contact elements may have a first contact, a second contact and a third contact. The act of supporting the motor may include supporting the braking circuit and switch assembly on the motor housing, and the act of electrically connecting the plurality of electrically separated contact elements to the motor may include 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.  
           [0018]    In addition, the motor may include a brush having a brush terminal, and at least one of the plurality of electrically separated contact elements may have a first contact and a second contact. The act of supporting the motor may include supporting the brush on the motor housing, and the act of electrically connecting the plurality of electrically separated contact elements to the motor may include electrically connecting the brush terminal to the second contact of the at least one of the plurality of electrically separated contact elements. The act of supporting the brush may occur substantially simultaneously with the act of electrically connecting the brush terminal to the second contact of the at least one of the plurality of electrically separated contact elements.  
           [0019]    In some aspects, the invention provides a power tool comprising a motor housing, an electric motor supportable by the motor housing and electrically connectable with a power source, and an electrical circuit assembly. The electrical circuit assembly is provided by a method comprising the acts of providing a terminal member assembly including a plurality of separable contact elements, mounting the terminal member assembly to the motor housing, separating at least two of the plurality of separable contact elements of the terminal member assembly to provide a corresponding plurality of electrically separated contact elements, and electrically connecting the plurality of electrically separated contact elements to the motor to provide a complete electrical circuit for the motor.  
           [0020]    In some aspects, the invention provides an electrical connector assembly for a power tool, the electrical connector assembly provided by a method comprising the acts of providing a terminal member assembly including a plurality of electrically separable contact elements, mounting the terminal member assembly to the motor housing, electrically 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 and the second electrically separated contact element to the motor to provide a complete electrical circuit for the motor.  
           [0021]    In some aspects, the invention provides an assembly for use in manufacturing a power tool, the assembly comprising, a motor housing for supporting the motor of the power tool, and an electrical connector assembly. The electrical connector assembly is provided by a method comprising the acts of providing a terminal member assembly including a plurality of separable contact elements, mounting the terminal member assembly to the motor housing, and separating the terminal member assembly to provide at least a first electrically separated contact element and a second electrically separated contact element, the first electrically separated contact element and the second electrically separated contact element being electrically connectable to the motor to provide a complete electrical circuit for the motor.  
           [0022]    In some aspects, the invention provides a method for assembling a power tool 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, the act of forming including molding the terminal member with the moldable material of the motor housing, supporting the motor in the housing, and electrically connecting the terminal member and the motor to provide a complete electrical circuit for the motor.  
           [0023]    In some aspects, the invention provides a method for assembling a power tool comprising the acts of providing a first electrical component and a second 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, the act of forming including molding the terminal member with the moldable material of the housing, separating 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.  
           [0024]    An independent advantage of the present invention is that, with the method for assembling and the electrical connector assembly of the present invention, assembly of a power tool is less time consuming and less labor-intensive. The motor components are more easily electrically connected to one another with the terminal member assembly, reducing the cost and the complexity of the method and machinery required to assemble a power tool.  
           [0025]    An independent advantage of the present invention is that, because, in some constructions, the plurality separable contact elements is mounted to the housing as a unitary terminal member assembly, the plurality of electrically separated contact elements is more accurately positioned and supported in the housing, also reducing the cost and complexity of the method and the machinery required to assemble a power tool.  
           [0026]    An independent advantage of the present invention is that, when the terminal member assembly is molded with the housing, the housing does not have to be specially designed to fixably support and retain the terminal member assembly in the required position.  
           [0027]    An independent advantage of the present invention is that, when the terminal member assembly is molded with the housing, the terminal member assembly and the plurality of electrically separated contact elements provide additional rigidity and strength to the housing. As a result, less material or less durable material may be used to form the housing while maintaining the strength of the housing.  
           [0028]    An independent advantage of the present invention is that, in some constructions, the terminal member assembly can accommodate different motor components so that the power tool can be configured to provide different operating conditions. For example, in some constructions, the power tool with such a terminal member assembly can alternately include an on/off switch assembly or a braking circuit and on/off switch assembly without requiring a change to the terminal member assembly.  
           [0029]    Other independent features and independent advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings. 
       
    
    
     DESCRIPTION OF THE DRAWINGS  
       [0030]    [0030]FIG. 1 is a perspective view of a terminal member assembly embodying the invention.  
         [0031]    [0031]FIG. 2 is a perspective exploded view of a portion of a power tool for use with the terminal member assembly shown in FIG. 1.  
         [0032]    [0032]FIG. 3A is a perspective view of another portion of the power tool shown in FIG. 2 for use with the terminal member assembly shown in FIG. 1.  
         [0033]    [0033]FIG. 3B is a schematic diagram of the electrical circuit for the power tool having the construction illustrated in FIGS. 2 and 3A.  
         [0034]    [0034]FIG. 4 is a rear view of the terminal member assembly shown in FIG. 1.  
         [0035]    [0035]FIG. 5 is a rear view of the motor housing and the cover shown in FIG. 2 with the terminal member assembly shown mounted to the motor housing.  
         [0036]    [0036]FIG. 6 is a cross-sectional view taken generally along line  6 - 6  in FIG. 5.  
         [0037]    [0037]FIG. 7A is a perspective view of an alternate construction for the portion of the power tool shown in FIG. 3A.  
         [0038]    [0038]FIG. 7B is a schematic diagram of the electrical circuit for the power tool having the alternate construction illustrated in FIGS. 2 and 7A. 
     
    
       [0039]    Before at least one embodiment of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of the construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.  
       DETAILED DESCRIPTION  
       [0040]    A terminal member assembly  10  embodying the invention and for use in a power tool  14  is illustrated in the Figures. In the illustrated construction (see FIGS. 2 and 3A), the power tool  14  is a circular saw (partially shown). It should be understood that, in other constructions (not shown), the power tool may be any type of electric power tool, such as a grinder, a drill or another type of saw.  
         [0041]    The power tool  14  includes (see FIGS. 2, 3A and  5 ) a motor housing  18  and an operator&#39;s handle  20 , which may be formed with or separately from the housing  18  (as shown in FIG. 3A). The housing  18  is formed of a non-conductive, moldable material and has an open forward end and a generally closed rearward end. A bearing member  22  is formed in the closed end of the housing  18 . As best shown in FIG. 5, a pair of circumferentially-spaced apart openings  23  are formed adjacent the bearing member  22 , and a pair of axially-extending slots  24  are defined adjacent each opening  23 . The purpose for the bearing member  22 , the openings  23  and the slots  24  is explained below in more detail.  
         [0042]    The power tool  14  also includes (see FIGS. 2, 3A and  3 B) an electric motor  26  which is connectable to a power source (not shown) by an electrical circuit and operable to drive a tool element, such as a saw blade (not shown), to work on a workpiece (not shown). For purposes of illustration, components of the motor  26  which are electrically connectable to one another are identified by the same italicized letter (a, b, c or d).  
         [0043]    In the illustrated construction (see FIGS. 2 and 3B), the motor  26  includes a field assembly  30  having one or more field windings  32  and  33 . The field assembly  30  includes a plurality of field terminals  34   a - d  for electrically connecting the field windings  32  and  33  in the electrical circuit for the motor  26 .  
         [0044]    In the illustrated construction, the motor  26  also includes a pair of carbon brush assemblies  38   b  and  38   c . Each brush assembly  38  includes a brush housing  40  having a pair of projections  41  formed thereon and slidably housing a carbon brush  42 . A female brush terminal  46  and a male brush terminal  48  are electrically connected to each brush  42  and selectively electrically connect each brush assembly  38  in the electrical circuit for the motor  26 .  
         [0045]    Each brush  42  is electrically engageable, through the corresponding opening  23  in the housing  18 , with a commutator  49  (schematically illustrated in FIG. 3B) supported on a rotatable armature (not shown). The armature is rotatably supported by the housing  18 , with one end of the armature being supported by the bearing member  22  and the other end being connected to or forming a drive shaft (not shown) for supporting the tool element.  
         [0046]    In one illustrated construction, the motor  26  also includes (see FIGS. 3A and 3B) an on/off switch assembly  50  operable to electrically connect the motor  26  to the power source. The switch assembly  50  includes a two-pole on/off switch  54  connected by switch leads  56   a  and  56   d  to switch terminals  58   a  and  58   d . The switch terminals  58   a  and  58   d  are electrically connectable to the electrical circuit for the motor  26 . A trigger member  62  is supported on the handle  20  and is engageable by an operator to operate the on/off switch  54 .  
         [0047]    As shown in FIGS. 1 and 4, the terminal member assembly  10  provides a one-piece trace or spider terminal for connecting the components of the motor  26  in a complete electrical circuit. The terminal member assembly  10  is formed of a conductive material, preferably by stamping and folding.  
         [0048]    The terminal member assembly  10  includes a plurality of separable contact elements  78 . The number of separable contact elements  78  corresponds to the number and type of components of the motor  26  which are to be connected in the complete electrical circuit for the motor  26 . In the illustrated construction, the terminal member assembly  10  includes four separable contact elements  78   a - d.    
         [0049]    During assembly of the power tool  14 , as discussed below in more detail, the separable contact elements  78   a - d  are separated (see FIGS. 1 and 4) to form a corresponding number of electrically separated contact elements  82  (as shown in FIG. 5 and as schematically illustrated in FIG. 3B). In the illustrated construction (see FIGS. 3B and 5), the terminal member assembly  10  is separated into four electrically separated contact elements  82   a - d  to connect the field assembly  30 , the brush assemblies  38   a  and  38   b , and the switch assembly  50  in the complete electrical circuit for the motor  26 . In the illustrated construction, each of the electrically separated contact elements  82   a - d  has a first contact  84  and a second contact  88 . Also, in the illustrated construction, electrically separated contact elements  82   b  and  82   c  have a third contact  92   b  and  92   c , respectively.  
         [0050]    As shown in FIG. 5, the terminal member assembly  10  is mounted to the housing  18 . In the preferred embodiment, the terminal member assembly  10  is molded as a unit with the moldable material of the housing  18  when the housing  18  is formed.  
         [0051]    In other constructions (not shown), the housing  18  may include connector assemblies (not shown) for fixably mounting the separable contact elements  78   a - d  to the housing  18 . In such constructions, each connector assembly securely fixes the terminal member assembly  10  to the housing  18  before, during and after separation of the separable contact elements  78   a - d  to provide the electrically separated contact elements  82   a - d.    
         [0052]    It should be understood that, while in the illustrated construction, the electrically separated contact elements  82   a - d  are mounted to the housing  18  as a unit, in some aspects of the invention, the electrically separated contact elements  82   a - d  may be molded into the housing  18  separately, rather than as a unit.  
         [0053]    Once the terminal member assembly  10  is mounted to the housing  18 , the separable contact elements  78   a - d  are separated to provide the electrically separated contact element  82   a - d . In the illustrated construction (see FIG. 5), points of electrical separation or openings  94 ,  96 ,  98  and  100  are created between adjacent ones of the separable contact elements  78   a - d  to provide the electrically separated contact elements  82   a - d . Preferably, the openings  94 - 100  are formed by punching the terminal member assembly  10  and the housing  18 , and, during punching, corresponding holes  102 ,  104 ,  106  and  108  are formed in the housing  18  and are substantially aligned with the openings  94 ,  96 ,  98  and  100 , respectively.  
         [0054]    In other constructions (not shown), the terminal member assembly  10  may be formed of electrically separated contact elements (not shown but similar to electrically separated contact elements  82   a - d ) which are physically connected to one another while their electrical separation is maintained. In such constructions, a non-conducting material physically connects each electrically separated contact element to maintain the terminal member assembly  10  as a unit before, during and after mounting of the terminal member assembly  10  to the housing  18 . As a result, in such constructions, punching of the terminal member assembly  10  and the housing  18  is not required to provide the electrically separated contact elements.  
         [0055]    In the illustrated construction (see FIG. 5), the electrical connector assembly also includes a plurality of non-conducting elements  112 ,  114 ,  116  and  118  to be positioned between adjacent ones of the electrically separated contact elements  82   a - d . Preferably, the non-conducting elements  112 ,  114 ,  116  and  118  are positioned in the openings  94 ,  96 ,  98  and  100 , respectively, through the holes  102 ,  104 ,  106  and  108 , respectively. The non-conducting elements  112 - 118  fill the openings  94 - 100 , confirm that the openings  94 - 100  were created or punched, and provide a seal to prevent debris, such as pieces of material from the workpiece or other contaminants, from entering the openings  94 - 100  and effecting the electrical circuit of the motor  26 .  
         [0056]    In the illustrated construction, the power tool  14  also includes (see FIGS. 2, 5 and  6 ) a support member, such as a separate motor housing cover  122 , on which the non-conducting elements  112 - 118  are supported. In the illustrated construction, the non-conducting elements  112 - 118  are formed with the cover  122 . When the cover  122  is positioned over the housing  18 , the non-conducting elements  112 - 118  are positioned through the holes  102 - 108 , respectively, and into the openings  94 - 100 , respectively.  
         [0057]    In other constructions (not shown), the support member supporting the non-conducting elements  112 - 118  may not be a cover (such as the cover  122 ) but may be a support member supportable on the closed rearward end of the housing  18  to support the non-conducting elements  112 - 118  in their respective positions described above.  
         [0058]    To assemble the power tool, the terminal member assembly  10  is mounted in the housing  18  and, preferably, is molded with the material of the housing  18  (as shown in FIG. 5) during molding of the housing  18 . The separable contact elements  78   a - d  are then electrically separated from one another to provide the corresponding number of electrically separated contact elements  82   a - d . To electrically separate the separable contact elements  78   a - d , the openings  94 ,  96 ,  98  and  100  are created between adjacent ones of the separable contact elements  78   a - d , preferably by punching the terminal member assembly  10  and the housing  18 .  
         [0059]    Once the separable contact elements  78   a - d  are separated to provide the electrically separated contact elements  82   a - d , the components of the motor  26  are connected to the electrically separated contact elements  82   a - d  to provide a complete electrical circuit for the motor  26 , as schematically illustrated in FIG. 3B. The field assembly  30  (see FIG. 2) is inserted into the open forward end of the housing  18  and supported in the housing  18 . As the field assembly  30  is inserted, the field terminals  34   a - d  engage the first contacts  84   a - d , respectively, of the electrically separated contact elements  82   a - d , respectively, as schematically illustrated in FIG. 3B.  
         [0060]    The brush assemblies  38   b  and  38   c  (see FIG. 2) are supported on the housing  18  with the projections  41  engaging the slots  24  to fix each brush assembly  38  to the housing  18 . As the brush assemblies  38   b  and  38   c  are supported on the housing  18 , the female brush terminals  46   b  and  46   c  engage the second contacts  88   b  and  88   c , respectively, of the electrically separated contact elements  82   b  and  82   c , respectively, as schematically illustrated in FIG. 3B. Each brush  42   b  and  42   c  can extend through the corresponding opening  23  to electrically engage the commutator  49  once the commutator  49  is supported in the housing  18 .  
         [0061]    In one illustrated construction (partially shown in FIG. 3A), the switch assembly  50  is supported on the housing  18  in the handle  20 . The switch terminals  58   a  and  58   d  are electrically connected to the second contacts  88   a  and  88   d , respectively, of the electrically separated contact elements  82   a  and  82   d , respectively, as shown in FIG. 3A and as schematically illustrated in FIG. 3B.  
         [0062]    Once the components of the motor  26  are electrically connected to the electrically separated contact elements  82   a - d , as described above, a complete electrical circuit for the motor  26  is provided (as schematically illustrated in FIG. 3B).  
         [0063]    As shown in FIGS. 2 and 5, the cover  122  is positioned over the housing  18 . As the cover  122  is positioned (see FIG. 5), the non-conducting elements  112 - 118  are positioned through the holes  102 - 108 , respectively, and into the openings  94 - 100 , respectively. The remaining components (not shown) of the power tool  14  are then assembled to provide a fully-assembled power tool  14 .  
         [0064]    An alternate illustrated construction for the motor  26 ′ of a power tool  14 ′ is shown in FIG. 7A and schematically illustrated in  7 B. Common elements are identified by the same reference numbers “′”.  
         [0065]    In this alternate illustrated construction, the motor  26 ′ includes a braking circuit and on/off switch assembly  126  which may be substituted for the switch assembly  50 , described above, during assembly of the power tool  14 ′. The assembly  126  includes a two-pole on/off switch  54 ′ connected to leads  130 ,  132  and  134 . A trigger (not shown but similar to the trigger  62 ) is operatively connected to the switch  54 ′.  
         [0066]    The assembly  126  also includes a braking circuit  138  (schematically illustrated in FIGS. 7A and 7B). The braking circuit  138  is a regenerative dynamic braking circuit and is similar to that illustrated in U.S. Pat. No. 5,294,874, which is herein incorporated by reference. The leads  130 ,  132  and  134  electrically connect the switch  54 ′ to the braking circuit  138 . A power supply lead  140  and a brush lead  144  having a female terminal  146  are also electrically connected to the braking circuit  138 . Assembly terminals  150   a - d  are formed on the assembly  126  and are for connecting the assembly  126  to the electrical circuit of the motor  26 ′.  
         [0067]    To assemble the power tool  14 ′ having the alternate illustrated construction (partially shown in FIG. 7A and schematically illustrated in FIG. 7B), the assembly  126  is supported on the housing (not shown but similar to the housing  18 ). As schematically illustrated in FIG. 7B, the assembly terminals  150   a  and  150   d  are connected to the second contacts  88   a ′ and  88   d ′, respectively, of the electrically separated contact elements  82   a ′ and  82   d ′, respectively, and the assembly terminals  150   b  and  150   c  are electrically connected to the third contacts  92   b ′ and  92   c ′, respectively, of the electrically separated contact elements  82   b ′ and  82   c ′, respectively.  
         [0068]    The terminal  146  is electrically connected to the male terminal  48   b ′ of the brush assembly  38   b ′. In this alternate construction, the second contact (not shown but similar to the second contact  88   b ) of the electrically separated contact element  82   b ′ is prevented from electrically connecting to the female terminal (not shown but similar to the terminal  46   b ) of the brush assembly  38   b ′. In some constructions, this second contact may simply be broken off from the electrically separated contact element  82   b ′ during assembly of the power tool  14 ′. In other constructions (not shown), the terminal member assembly  10 ′ may be formed so that the electrically separated contact element  82   b ′ does not include a second contact.  
         [0069]    In this alternate illustrated construction, the field assembly  30 ′ includes (see FIG. 7B) field windings  32 ′ and  33 ′ and brake windings  154  and  156 . Field terminals  34   a ′-d′ electrically connect the field windings  32 ′ and  33 ′ and the brake windings  154  and  156  to the electrical circuit for the motor  26 ′ in a manner similar to that described above for the field assembly  30 . The brush assembly  38   c ′ is supported and electrically connected as described above, with the terminal  48   c ′ being electrically connected to the second contact  88   c ′ of the electrically separated contact element  82   c′.    
         [0070]    Once the components of the motor  26 ′ are electrically connected to the electrically separated contact elements  82   a ′-d′, as described above, a complete electrical circuit for the motor  26 ′ is provided (as schematically illustrated in FIG. 7B).  
         [0071]    It should be understood that, while in the illustrated constructions, the motor  26  includes a field assembly  30 , a pair of brush assemblies  38   b  and  38   c  and a switch assembly  50  (or a braking circuit and on/off switch assembly  126 ), in other constructions (not shown), the motor  26  may include other or different components to be electrically connected by the electrically separated contact elements  82   a - d  of the terminal member assembly  10 . It should also be understood that, in some aspects of the invention, the terminal member assembly  10  may be mounted to the housing  18  and separated to provide the electrically separated contact elements  82   a - d  for electrically connecting a first electrical component and a second electrical component of a power tool, other than the components of the motor  26 , described above.  
         [0072]    It should be understood that, while in the illustrated construction, the terminal member assembly  10  is separated to provide four electrically separated contact elements  82   a - d , in other constructions (not shown), the terminal member assembly may be separated to provide less than four or more than four electrically separated contact elements, as required to electrically connect the components of a power tool.  
         [0073]    With the present invention, assembly of the power tool  14  is less time consuming and less labor-intensive, reducing the cost and the complexity of assembly of the power tool  14 . Also, with the present invention, the electrically separated contact elements  82   a - d  are more accurately positioned and supported in the housing  18 . Further, with the present invention, when the terminal member assembly  10  is molded with the housing  18 , the electrically separated contact elements  82   a - d  provide additional rigidity and strength to the housing  18 .  
         [0074]    One or more of the above-discussed and other independent features of the invention are set forth in the following claims.

Technology Classification (CPC): 2