Electrical connectors – Contact comprising cutter – Insulation cutter
Patent
1997-07-24
1999-06-29
Abrams, Neil
Electrical connectors
Contact comprising cutter
Insulation cutter
439862, 310 71, H01R 424
Patent
active
059159880
DESCRIPTION:
BRIEF SUMMARY
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to electrical motors, their method of assembly, and contacts incorporated therein.
2. Summary of the Prior Art
As the number of electrical appliances increases, the need to manufacture and assemble small electrical motors in an efficient manner greatly increases. The motors are typically incorporated into appliances such as vacuum cleaners, kitchen appliances, and any other power accessory used in home or business. One electrical contact that is particularly useful for automated assembly is the Applicant's Mag-Mate Interconnection System. Contacts of this type enable insulation displacement-style contact techniques to be applied to magnet wire terminations, thereby eliminating the need for pre-stripping the magnet wire.
With particular respect to electrical motors, after winding the coils, the magnet wire is placed across a plastic cavity and retained therein by a slight frictional fit. The magnet wire is supported by part of the housing such that as the contact is inserted into the plastic cavity, the magnet wire is guided into the terminal slots of the contact. As the contact is seated, the film insulation upon the wire is striped and further insertion results in the bare wire coming in contact with contact surfaces within the slot. As the contact is being pressed within the cavity, locking barbs upon the contact bite into the plastic cavity assuring terminal retention.
In order to interconnect with a mating lead, various means for lead connection have been provided, such as poke-in latches for directly receiving the wire, tabs for receptacle terminals, posts for wrapping wire thereabout, wire barrels or solder tabs. Contacts of this type have preformed admirably and offer many advantages. However, as the industry becomes more and more sophisticated, it becomes necessary to provide electrical contacts that further enhance the assembly processes capability to be automated.
What is needed is an electrical contact incorporating the advantages outlined above, wherein the interconnection with the wire lead does not require a separate step. It would be advantageous if this interconnection could be formed in some sort of wiping manner. It would further be desirable to take advantage of this interconnection offered by the contact to provide an improved assembly technique that would enable further application of robotic assembly techniques to electrical motors. In particular, it would be desirable to enable the electrical brushes to be assembled with the motor unit in a first preassembled position where the motor shaft carrying the motor windings and the commutator thereupon may be inserted into the coil cavity by robotic techniques, afterwhich the brush assemblies could be displaced into their final position, such that the electrical connection between the lead and the magnet wire is established.
SUMMARY OF THE INVENTION
An aspect of the invention is accomplished by providing a contact for engaging a magnet wire in an insulation displacement manner comprising a magnet wire insulation displacement contact section for engaging the magnet wire, a conductor engaging portion for engaging an electrical conductor to be interconnected with the magnet wire, and a body portion therebetween characterized in that the conductor engaging portion extends from the body portion as a spring member having contact surfaces thereupon for forming a wiping interconnection with the conductor.
A second aspect of this invention is accomplished by providing a method of assembly of an electrical motor as described above wherein brush assemblies comprising a spring loaded brush seated within a brush carrier unit is inserted into the motor housing in a first pre-loaded position located such that the motor shaft with the windings and commutator thereupon by be inserted into the coil cavity afterwhich the brush assembly may be displaced to a second operating position where the brush will come into contact with the commutator and the spring member of the contact en
REFERENCES:
patent: 3979615 (1976-09-01), Neff
patent: 4036545 (1977-07-01), Mysiak et al.
patent: 4366404 (1982-12-01), Ziegler
patent: 4557544 (1985-12-01), Esser
Bitsch Helmut Adam
Ploesser Hartmuth Georg Friedrich
Abrams Neil
Duverne J. F.
Nina Driscoll A.
The Whitaker Corporation
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