WO2015175503A1 - Modular assembly - Google Patents

Abstract

A modular assembly is disclosed that includes a first housing and a second housing that are configure to be mated together. The first and second housing are configured to define an interior volume. The first and second housing support terminals that are configured to engage a power source. Components are positioned in the interior volume and in an embodiment the first housing, the terminals and the components are configure to allow for Z-axis insertion of components into the first housing.

Description

Modular Assembly RELATED APPLICATIONS [0001] This application claims priority to United States Provisional Application No. 61/991,699, filed May 12, 2014, which is incorporated herein by reference in its entirety.. TECHNICAL FIELD [0002] This disclosure relates to the field of modular assemblies, more specifically to modular assemblies with at least two halves that are battery powered. DESCRIPTION OF RELATED ART [0003] Modular assemblies are known. Examples include power tools (such as but not limited to battery powered drills) and numerous other types of equipment that are capable of receiving or using high current. In the case of power tools, typically the battery is removable and can be charged separately but in operation a substantial amount of current (more than 2 amps and often more than 5 amps) can be used when the power tool is in operation. Other types of equipment can include an integrated battery that is not intended to be removed for recharging (instead a connector is provided that is coupled to the battery). In such a configuration it is desirable to provide current at a relatively high rate so that the battery can be quickly charged. Thus, both types of components benefit for being able to accept high current. Existing such modular assemblies, while effective, tend to be constructed in a manner that is extremely manual in nature. Wires are soldered to terminals and to motors or power storage units (such as batteries or capacitors) and because of the high current, tend to be relatively larger diameters (sometimes 14 gauge or larger). The existing assemblies are difficult to assemble and because of the design, do not lend, cannot be made in an automated fashion. [0004] In the past, the low cost of labor in many countries meant that the manual requirements were not problematic. However, in many countries with strong manufacturing bases the cost of labor has risen dramatically. Therefore it has become more challenging to manufacture designs with large amounts of labor. In addition, the use of manual labor for repetitive tasks, while sometimes required, is less desirable as operators can easily make mistakes due to boredom if they are doing the same operation over and over. And even if pokey ok designs are implements, the costs of shipping and duties and taxes makes it less desirable to manufacture a product in a lower labor cost region and ship the product to another region that has a higher labor cost. Therefore, certain individuals would appreciate a modular design that would allow for improvements in automated assembly. SUMMARY [0005] A modular assemblies includes a first housing and a second housing that are configured to join together to form a housing with an internal volume. Each housing can support one or more terminals. The terminals can include a first contact on one end and a second contact on anther end and a body extending therebetween. The body can be integrated into the housing so that it is substantially contained therein and the contacts are exposed sand configured to engage other terminals. The housing is designed so that the terminals can be assembled to PCB assemblies in a manner that is substantially loaded in a z-axis. Thus, the entire assembly can be manufactured in an automated manner. BRIEF DESCRIPTION OF THE DRAWINGS [0006] The present invention is illustrated by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements and in which: [0007] Fig. 1 illustrates a perspective view of an embodiment of a modular assembly. [0008] Fig. 2 illustrates another perspective view of the embodiment depicted in Fig. 1. [0009] Fig. 3 illustrates a partially exploded perspective view of the embodiment depicted in Fig. 1. [0010] Fig. 4 illustrates another perspective view of the embodiment depicted in Fig. 3. [0011] Fig. 5 illustrates a perspective view of an embodiment of a first side of a modular assembly. [0012] Fig. 6 illustrates another perspective view of the embodiment depicted in Fig. 5. [0013] Fig. 7 illustrates a simplified perspective view of the embodiment depicted in Fig. 6. [0014] Fig. 8 illustrates a perspective view of an embodiment of a second side of a modular assembly. [0015] Fig. 9 illustrates a partially exploded simplified perspective view of the embodiment depicted in Fig. 8. [0016] Fig. 10 illustrates another perspective view of the embodiment depicted in Fig. 9. [0017] Fig. 11 illustrates a perspective view of an embodiment of a component that can be used in the embodiment depicted in Fig. 10. DETAILED DESCRIPTION [0018] The detailed description that follows describes exemplary embodiments and is not intended to be limited to the expressly disclosed combination(s). Therefore, unless otherwise noted, features disclosed herein may be combined together to form additional combinations that were not otherwise shown for purposes of brevity. [0019] A modular assembly 10 is disclosed and illustrates a power tool shaped in the form of a battery operated drill. As can be appreciated, however, any number of other shapes and configurations are possible. Thus, without limitation, the modular assembly could be a battery powered tool such as circular saw or a reciprocating saw. In addition, the modular assembly could be a vacuum cleaner, hair dryer or any other device that is battery powered. In devices, such as vacuum cleaners where the battery is more desirably integrated into the assembly and is hidden without the housing, terminals can be provided to deliver high levels of current to the battery. [0020] The modular assembly 10 includes a housing assembly 20 that includes a first housing 21 a and a second housing 21b that are configured to be coupled together. The housing assembly 20 supports a control switch 50 (which in the depicted embodiment is shaped in the form of a trigger) that is configured to control operation of the modular assembly 20. Additional switches can be added as desired if additional functionality and/or controls is/are desired. [0021] The housing assembly 20 supports terminals 26, 27, 28 that are configured to engage contacts on a separable battery pack (not shown) as is common in battery operated power tools. Each of the terminals 26, 27, 28 includes a contact 29 to engage the battery pack and the contacts can have an appropriate plating to ensure good electrical connection between the module assembly 10 and the separable battery pack. One or more of the terminals 26, 27, 28 can have a contact 30 that is configured to engage a pad on a circuit board assembly 40 and is positioned in a power source pocket 25. [0022] It should be noted that the terminals (including their corresponding body) are visible in the depicted illustrations. This is for purposes of ease of depiction. In operation, however, it is likely that a portion of the body of each terminal will be at enclosed within the first or second housings 21a, 21b. Thus, the terminals (including but not limited to terminals 26, 27, 28) can be inserted molded directly into one of the housings 21a, 21 b. [0023] The housing assembly 20 provides an internal volume 22 that can be used to support and contain various components. The depicted embodiments depict the internal volume 25 supporting a circuit board assembly 40, a control switch 50 and a motor assembly 70. Naturally other components can be added as desired. The motor assembly 70 is an embodiment of an energy consumption device and energy consumption devices often are configured to convert electrical energy into some other form of energy, such as mechanical or thermal or a combination thereof. The energy consumption device can also convert electrical energy into other forms, such as but without limitation, light or sound. [0024] As can be appreciated from Fig. 4, the housing can be formed so that it extends along an X-axis and a Y-axis and has walls that define the internal volume and form a recess/cavity that is directed in the Z axis. In an embodiment each of the depicted components that are positioned in the internal volume can include contacts that configured to engage contacts of the terminals (either provided on or molded within the housing) in a manner that allows insertion of the components in the Z-axis. Thus, the first housing 21a (for example) can be formed and can support one or more terminals with contacts that are exposed and intended to engage other contacts. The first housing 21a can be laid on its side (with the opening facing away from the supporting surface) and components (such as circuit board assembly 40, the control switch 50 and the motor assembly 70) can be automatically installed through the use of known assembly equipment, such as but without limitation, pick and place equipment. The second housing can be formed with one or more terminals (or terminal equivalents, as will be discussed below) insert molded into the housing. The the second housing 21b can be installed to the first housing 21a along the Z-axis so as to form the housing assembly 20 and the first and second housings 21a, 21b can be secured together with known fastening techniques such as screws, adhesives, heat staking and the like. If it is desirable to be able to repair the modular assembly 10 then it is preferable to secure the two housings 21a, 21b with a fastener mechanism that can be undone. Thus a convention screw is a beneficial configuration. [0025] It should be noted that in certain configurations it may be desirable to form the housing with a two shot process so that the exterior of the modular assembly 10 has a suitable decorative appearance. The second shot could be a different material that provides a change in appearance, material properties or provides an additional layer to the housing (which can enable more complex insert-molded structures). [0026] As depicted, the terminals (such as terminals 26, 27, 28, 31, 35 and 38) are intended to carry significant amounts of current (preferably more than 2 amps and more preferably more than 5 amps) thus they need to be sized so as to appropriate care the current load without overheating. Fig. 7 illustrates features of the terminals that each include contacts (such as contacts 32, 34, 39) that are configured to engage contacts on components that are intended to be installed within the enclosure 22. In addition, one or more circuit elements 18 (such as capacitors or resistors) can be attached to the terminals. The circuit elements 18 could be electrically attached to the terminals with solder or be attached with an interference fit. [0027] As depicted, the circuit board assembly 40 includes a circuit board 42 and supports circuitry 44 and the circuit board assembly 40 includes pads that can engage contacts 30 provided by the terminals 27, 28, 31, 38. Naturally, the circuit board assembly 40 could also include support one or more terminals that could be configured to engage the terminals supported by the housings. Thus, convention terminals could also be used to provide improved electrical connection between terminals supported by the housing and terminals supported by the circuit board assembly 40. Such terminals, for example, could provide contacts used for compression connections. Terminals could also be configured to operate as IDT contacts if there was a desire to allow for an electrical connection to a conductor protected by an insulation layer. [0028] The first housing 21a can support the switch 50, which includes a translating member 52 and a control module 54 that configured to cause the motor assembly 70 to operate in the desired manner. The control module supports contacts 56 that are configured to engage the corresponding contacts provided by the terminals integrated into the respective housings. The control module 54 can further include terminals that are configured to engage contacts provided on a signal module 60. While the terminals are depicted as being capable of supporting higher current levels, often there is a benefit to being able to provide signals between components, where the signals can provided with low levels of current. The depicted signal module 60 includes a base 60a with a first arm 63 that supports traces 69 that are used to power a LED 80 (and need only low levels of current - less than 1 amp, and likely less than 0.5 amps). The base 60a includes contacts 61 that are configured to be electrically connected to the circuit board assembly 40. The base 60a includes a first member 65 that supports contacts 66 and includes and includes contacts 65 that are configured to engage the control module 54. A foot 67 extends from the base 60a and includes another trace 68 that can be used as a radiating element (e.g., an antenna). [0029] It should be noted that the traces 69 can be positioned closely together as the traces can be accurately formed with conventional LDS type construction or by inking/depositing traces directly onto the base. In either case, the traces can be formed of the desired thickness via known plating techniques (e.g., electroless plating or electroplating). It should be noted that the signal module 60 is formed in a three-dimensional manner (the depicted embodiment extends in the X, Y and Z axis. This provides substantial flexibility. It should also be noted that the signal module 60 can be insert molded into the housing along with any appropriate terminals, if desired. [0030] It should be noted that a terminal may be positioned in one half and configured to engage terminals/contacts on the other half. Thus, substantial flexibility in the three- dimensional structure is possible. [0031] In addition to providing the ability to have three dimensional structures through the use of insert molding techniques, the depicted embodiment may further include traces formed directly on the housing. For example, Fig. 10 illustrates an antenna 90 that is plated directly onto an interior surface 22a of the second housing 21b. Additional circuits can be provided as desired (and in cases where the circuitry is simpler, it may be desirable to replace a separate circuit board with a pattern of circuits (and resulting electrical components) mounted directly on the interior surface 22a. Thus, the depicted embodiment has substantial flexibility that can vary the design depending on the circuitry that is being sued to control the modular assembly 10. [0032] The disclosure provided herein describes features in terms of preferred and exemplary embodiments thereof. Numerous other embodiments, modifications and variations within the scope and spirit of the disclosure will occur to persons of ordinary skill in the art from a review of this disclosure.

Claims

CLAIMS We Claim:

1. A modular assembly, comprising:

a first housing;

a second housing, the second housing configured to be mated to the first housing and collectively defining an internal volume;

a plurality of components positioned in the first housing;

an energy consumption device supported by at least one of the first and second housing; and

a plurality of terminals configured to help electrically connect the energy

consumption device to the components, the first housing and the plurality of terminals are configured to allow the plurality of components to be inserted into the first housing along a Z-axis.

2. The modular assembly of claim 1, wherein at least two of the plurality of terminals are configured to provide current from a power source.

3. The modular assembly of claim 2, wherein the at least two terminals are insert molded into the first housing.

4. The modular assembly of claim 2, wherein the energy consumption device is a motor.

5. The modular assembly of claim 4, wherein one of the plurality of components is a control switch.

6. The modular assembly of claim 5, wherein the power source is a battery.

7. The modular assembly of claim 6, wherein the first and second housing define an interior volume and the motor is positioned at least partially in the interior volume.

8. The modular assembly of claim 1, further comprising a 3-dimensional signal module.

9. The modular assembly of claim 8, wherein traces are provided on a surface of the signal module.