US4934041A — Method of assembling brushless electric motors

Claim 1

Independent Claim 116 words

A method of assembling a motor comprising the steps of: providing a stator including a first snap engagement means integrally formed on a stator support means; molding a printed circuit board having an integral second snap engagement means; assembling a sensor with said printed circuit board; assembling said printed circuit board with said stator by means of said first and second snap engagement means to form a stator-printed circuit board assembly such that the snap engagement locates said sensor is a predetermined, preferred position with respect to said stator, assembly said stator-printed circuit board assembly with a cooperative locating means formed on an inner surface of a housing; and affixing a rotor to said locating means.

Claim 2

Independent Claim 116 words

A method of assembling a motor comprising the steps of: providing a stator including a first snap engagement means integrally formed on a stator support means; molding a printed circuit board having an integral second snap engagement means; assembling a sensor with said printed circuit board; assembling said printed circuit board with said stator by means of said first and second snap engagement means to form a stator-printed circuit board assembly such that the snap engagement locates said sensor is a predetermined, preferred position with respect to said stator, assembly said stator-printed circuit board assembly with a cooperative locating means formed on an inner surface of a housing; and affixing a rotor to said locating means.

Claim 3

Dependent Claim 46 words

The method of claim 1 wherein said stator includes a third snap engagement means and said locating means includes a fourth snap engagement means, said method further comprising the steps of configuring said stator third snap engagement means with said locating means fourth snap engagement means.

Claim 4

Dependent Claim 28 words

The method of claim 2 further comprising the steps of providing said fourth snap engagement means in said locating means adjacent to an inner surface of said housing.

Claim 5

Dependent Claim 35 words

The method of claim 1 further comprising the steps of providing said first and second snap engagement means to be snap engagable only when said stator and said locating means are in one relative position.

Claim 6

Dependent Claim 33 words

The method of claim 1 further comprising the steps of providing said first and second snap engagement means such that, when assembled, relative movement between said stator and said locating means is precluded.

Claim 7

Dependent Claim 41 words

The method of claim 1 further comprising the steps of providing said first snap engagement means with a tab projecting from said stator and providing said second snap engagement means with a recess in a receiving surface in said locating means.

Claim 8

Dependent Claim 41 words

The method of claim 1 further comprising the steps of providing said recess to extend about said locating means outer surface only to the extent needed to engage said tab, thereby preventing relative movement between said stator and said locating means.

Claim 9

Dependent Claim 43 words

The method of claim 1 further comprising the steps of providing said first snap engagement means with a tab projecting from said support means and said second snap engagement means with a tab extending from an outer surface of said printed circuit board.

Claim 10

Dependent Claim 45 words

The method of claim 1 further comprising the steps of providing a means for keying said stator to said printed circuit board to allow said stator-printed circuit board to be assembled only when said stator and said printed circuit board are in one relative position.

Claim 11

Dependent Claim 27 words

The method of claim 9 further comprising the steps of providing said keying means to further prevent relative rotation between said stator and said printed circuit board.

Claim 12

Dependent Claim 25 words

The method of claim 1 further comprising the steps of providing a plurality of electrical components, including a sensor, to comprise an electrical commutation means.

Claim 13

Dependent Claim 19 words

The method of claim 11 further comprising the steps of providing said electrical components to include an integrated circuit.

Claim 14

Dependent Claim 35 words

The method of claim 1 further comprising the steps of providing an integral means for attaching said printed circuit board to at least one other printed circuit board to form a printed circuit board array.

Claim 15

Independent Claim 145 words

A method of assembling a motor comprising the steps of: affixing a printed circuit board having electrical components including a sensor to a surface of a housing; providing a stator having a stator support means with a first snap engagement means formed therein, said stator support means further receiving an electromagnet having a bottom surface; providing a locating means at a central position in said housing to extend from an interior surface thereof and terminating in an upper end portion, said locating means having a second snap engagement means formed adjacent to said housing surface and disposed away from said upper end portion; assembling said stator with said locations means by means of said first and second snap engagement means such that the snap engagement locates said electromagnet bottom surface of a predetermined, preferred distance from said sensor; and affixing a rotor to said housing.

Claim 16

Independent Claim 145 words

A method of assembling a motor comprising the steps of: affixing a printed circuit board having electrical components including a sensor to a surface of a housing; providing a stator having a stator support means with a first snap engagement means formed therein, said stator support means further receiving an electromagnet having a bottom surface; providing a locating means at a central position in said housing to extend from an interior surface thereof and terminating in an upper end portion, said locating means having a second snap engagement means formed adjacent to said housing surface and disposed away from said upper end portion; assembling said stator with said locations means by means of said first and second snap engagement means such that the snap engagement locates said electromagnet bottom surface of a predetermined, preferred distance from said sensor; and affixing a rotor to said housing.

Claim 17

Dependent Claim 29 words

The method of claim 14 wherein said first and second snap engagement means are snap engagable only when said stator and said locating means are in one relative position.

Claim 18

Dependent Claim 24 words

The method of claim 15 wherein said first and second snap engagement means further prevents relative movement between said stator and said locating means.

Claim 19

Dependent Claim 36 words

The method of claim 15 wherein said first snap engagement means comprises a tab projecting from said stator and wherein said second snap engagement means comprises a recess in a receiving surface in said locating means.

Claim 20

Dependent Claim 35 words

The method of claim 16 wherein said recess extends about said locating means outer surface only to the extent needed to engage said tab, thereby preventing relative movement between said stator and said locating means.

Claim 21

Independent Claim 165 words

A method of assembling brushless electric motors comprising: molding a planar array of printed circuit boards, said printed circuit boards each having an integral means for attaching adjacent printed circuit boards in said array to one another; assembling each of said printed circuit boards with a plurality of electrical components including a triggering sensor, the printed circuit boards also including a commutation circuit; molding a corresponding plurality of stator support means; assembling said stator support means with electrical connectors; forming at least one electromagnet on said stator support means, thereby forming a stator; assembling each one of said stators with a corresponding one of said printed circuit boards, thereby forming stator - printed circuit board assemblies; electrically connecting said printed circuit boards to said corresponding stator electromagnets; separating said stator - printed circuit board assemblies from one another; assembling each of said stator-printed circuit board assemblies with a corresponding locating means centrally positioned within a motor housing; and affixing a rotor to said locating means.

Claim 22

Independent Claim 165 words

A method of assembling brushless electric motors comprising: molding a planar array of printed circuit boards, said printed circuit boards each having an integral means for attaching adjacent printed circuit boards in said array to one another; assembling each of said printed circuit boards with a plurality of electrical components including a triggering sensor, the printed circuit boards also including a commutation circuit; molding a corresponding plurality of stator support means; assembling said stator support means with electrical connectors; forming at least one electromagnet on said stator support means, thereby forming a stator; assembling each one of said stators with a corresponding one of said printed circuit boards, thereby forming stator - printed circuit board assemblies; electrically connecting said printed circuit boards to said corresponding stator electromagnets; separating said stator - printed circuit board assemblies from one another; assembling each of said stator-printed circuit board assemblies with a corresponding locating means centrally positioned within a motor housing; and affixing a rotor to said locating means.

Claim 23

Dependent Claim 18 words

The method of claim 19 further comprising the steps of providing electrical components that include an integrated circuit.

Claim 24

Dependent Claim 18 words

The method of claim 20 further comprising the steps of providing said integrated circuit with said triggering sensor.

Claim 25

Dependent Claim 21 words

The method of claim 19 further comprising the steps of soldering said stator electrical connectors to said respective printed circuit board.

Claim 26

Dependent Claim 31 words

The method of claim 22 wherein said soldering step includes the step of automatically soldering each of said printed circuit boards in said soldering array to said corresponding stator support means.

Claim 27

Dependent Claim 37 words

The method of claim 19 further comprising the steps of providing said printed circuit board and said stator support means with corresponding snap engagement means formed in said printed circuit boards and said stator support means, respectively.

Claim 28

Dependent Claim 23 words

The method of claim 19 comprising the steps of providing said printed circuit boards with an integrally formed pedestal for receiving said sensor.

Claim 29

Dependent Claim 29 words

The method of claim 19 further comprising the steps of providing said stator support means and said printed circuit boards further comprise cooperative key means for providing self-fixturing therebetween.

Claim 30

Independent Claim 144 words

A method of assembling a motor from an array of molded printed circuit boards each printed circuit board having a plurality of electrical components that comprise an electrical commutation circuit and each having an integral projection with a first engagement means adjacent a free end portion thereof, said method comprising the steps of: affixing a stator at a second engagement means to a printed circuit board first engagement means forming a stator - printed circuit board assembly; electrically connecting for each of said stator - printed circuit board assemblies said stator to said printed circuit board; separating said stator - printed circuit board assemblies from said array; affixing each of said stator - printed circuit board assemblies at a third engagement means thereof to a corresponding fourth engagement means of a locating means within a housing; and affixing a rotor to said locating means.

Claim 31

Independent Claim 144 words

A method of assembling a motor from an array of molded printed circuit boards each printed circuit board having a plurality of electrical components that comprise an electrical commutation circuit and each having an integral projection with a first engagement means adjacent a free end portion thereof, said method comprising the steps of: affixing a stator at a second engagement means to a printed circuit board first engagement means forming a stator - printed circuit board assembly; electrically connecting for each of said stator - printed circuit board assemblies said stator to said printed circuit board; separating said stator - printed circuit board assemblies from said array; affixing each of said stator - printed circuit board assemblies at a third engagement means thereof to a corresponding fourth engagement means of a locating means within a housing; and affixing a rotor to said locating means.

Claim 32

Dependent Claim 31 words

The method of claim 27 wherein said electrically connecting step further comprises, for each assembly, the steps of soldering each stator to said corresponding printed circuit board at contacting electrical terminals.

Claim 33

Dependent Claim 18 words

The method of claim 28 wherein said soldering step further comprises the steps of automatically soldering said terminals.

Claim 34

Dependent Claim 38 words

The method of claim 27 further comprising the steps of providing said stators and said printed circuit boards with a cooperative key means so that said stator will receive said printed circuit boards only in one relative position.

Claim 35

Dependent Claim 38 words

The method of claim 27 further comprising the steps of providing said stators and said housing locating means with a cooperative key means so that said stators will receive said housing locating means in only one relative position.

Claim 36

Dependent Claim 31 words

The method of claim 27 further comprising the steps of: forming an electromagnet on each of said stators; and affixing a plurality of electrical connectors with said electromagnets on said stator.

Claim 37

Dependent Claim 31 words

The method of claim 27 further comprising the steps of inserting electrical terminals into stator receptacles, said terminals for providing electrical contacting surfaces between said stators and said printed circuit boards.

Claim 38

Independent Claim 172 words

A method of assembling brushless electrical motors from an array of molded printed circuit boards each printed circuit board having a plurality of electrical components that comprise an electrical commutation circuit, including a sensor, and each printed circuit board having a first attachment means and an integral projection with a precisely located surface at the free end portion thereof with said sensor mounted on said surface, said method comprising the steps of: affixing a stator, at a second attachment means thereof, to corresponding ones of said printed circuit board first attachment means to form assemblies such that said sensor is positioned at a selected angular distance between and displacement from poles of an electromagnet formed on said stator; electrically connecting said stators to said printed circuit boards; separating said assemblies from said array; affixing each of said assemblies at a third attachment means thereof to a corresponding fourth attachment means of a locating means extending from an inner surface of corresponding housing; and affixing a rotor to each of said locating means.

Claim 39

Independent Claim 172 words

A method of assembling brushless electrical motors from an array of molded printed circuit boards each printed circuit board having a plurality of electrical components that comprise an electrical commutation circuit, including a sensor, and each printed circuit board having a first attachment means and an integral projection with a precisely located surface at the free end portion thereof with said sensor mounted on said surface, said method comprising the steps of: affixing a stator, at a second attachment means thereof, to corresponding ones of said printed circuit board first attachment means to form assemblies such that said sensor is positioned at a selected angular distance between and displacement from poles of an electromagnet formed on said stator; electrically connecting said stators to said printed circuit boards; separating said assemblies from said array; affixing each of said assemblies at a third attachment means thereof to a corresponding fourth attachment means of a locating means extending from an inner surface of corresponding housing; and affixing a rotor to each of said locating means.

Claim 40

Dependent Claim 30 words

The method of claim 34 further comprising the steps of inserting electrical terminals into stator receptacles, said terminals for providing electrical contact between said stators and said printed circuit boards.

Claim 41

Dependent Claim 31 words

The method of claim 34 wherein said electrically connecting step further comprises, for each assembly, the steps of soldering each stator to said corresponding printed circuit board at said contacting terminals.

Claim 42

Dependent Claim 19 words

The method of claim 34 wherein said soldering step further comprises the steps of automatically soldering said contacting terminals.

Claim 43

Dependent Claim 38 words

The method of claim 34 further comprising the steps of providing said stators and said printed circuit boards with a cooperative key means so that said stators will receive said printed circuit board only in one relative position.

Claim 44

Dependent Claim 38 words

The method of claim 34 further comprising the steps of providing said stators and said housing locating means with a cooperative key means so that said stators will receive said housing locating means in only one relative position.

Claim 45

Dependent Claim 30 words

The method of claim 34 further comprising the steps of forming an electromagnet on each of said stators; and affixing a plurality of connectors with said electromagnets on said stator.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1993-06-18	1993-12-18	1994-06-19	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1997-06-18	1997-12-18	1998-06-19	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2001-06-18	2001-12-18	2002-06-19	$7700.00	Window Closed / Lapsed

Method of assembling brushless electric motors

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