Power tool and electrical device

Abstract

An electric power tool and an electrical device, the electric power tool including a motor, a power source to supply power to the motor, and a printed circuit board ("PCB") electrically connected to the motor and the power source. The printed circuit board includes a switch and a bus bar disposed on a surface of the PCB. The bus bar electrically connects the power source to the switch for delivering current from the power source to the switch.

Description

[0001] Related applications This application claims the benefit of U.S. Provisional Patent Application No. 63 / 648,371, filed May 16, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0002] The embodiments described in this utility model relate to printed circuit boards for power tools. Background Technology

[0003] Power tools typically include a motor with a rotor and a stator. The stator includes a plurality of stator terminals (e.g., three stator terminals) electrically connected to a plurality of switches (e.g., field-effect transistors [“FETs”], metal-oxide-semiconductor FETs [“MOSFETs”], wide-bandgap semiconductor FETs, etc.). The switches are mounted on a printed circuit board (“PCB”) to supply power to the motor. The switches are electrically connected to a power source via metal traces on the PCB. The switches receive power from the power source via the metal traces to supply power to the motor. However, in this case, the metal traces on the PCB may have a thin width between the power source and the switches. Thin metal traces can supply a limited amount of power from the power source to the switches. Increasing the width and overall size of the metal traces would increase the size of the PCB, which may be undesirable and, in some cases, impractical. Utility Model Content

[0004] The power tool described in this invention includes a motor, a power supply for energizing the motor, and a printed circuit board (“PCB”) electrically connected to the motor and the power supply. The printed circuit board includes a switch and a bus disposed on the surface of the printed circuit board. The bus electrically connects the power supply to the switch for delivering current from the power supply to the switch.

[0005] In some respects, a printed circuit board includes a plurality of high-side switches and a plurality of low-side switches, and a switch is one of the plurality of high-side switches.

[0006] In some respects, a printed circuit board includes a plurality of high-side switches and a plurality of low-side switches, and a switch is one of the plurality of low-side switches.

[0007] In some respects, a bus is a positive bus that connects a power source to a plurality of high-side switches.

[0008] In some respects, the printed circuit board includes a negative bus that electrically connects power to a plurality of low-side switches.

[0009] In some cases, power is supplied to the motor from the power source by controlling a switch.

[0010] In some respects, the busbar is made of one of the following: copper, brass, and aluminum.

[0011] In some respects, the surface is a first surface, the switch is a first switch disposed on the first surface having a first top surface, and the bus is a first bus disposed on the first top surface of the first switch, the first bus electrically connecting the power supply to the first switch.

[0012] In some aspects, the printed circuit board includes a second surface opposite to the first surface, a second switch disposed on the second surface (the second switch having a second top surface), and a second bus disposed on the second top surface of the second switch, the second bus electrically connecting power to the second switch.

[0013] The electrical device of this invention includes a power tool battery pack that supplies power to a power input section and a printed circuit board (“PCB”) including a power input section and a power output section. The printed circuit board includes a switch and a bus disposed on the surface of the printed circuit board. The bus supplies power from the power input section to the power output section via the switch.

[0014] In some respects, the electrical device is selected from the group consisting of portable power supplies, lighting devices, and power tools.

[0015] In some respects, the busbar connects the power input section to the switch.

[0016] In some respects, the busbar connects the switch to the power output.

[0017] In some respects, the electrical device includes a motor electrically connected to a power output unit, and the electrical device supplies power to the motor via a control switch.

[0018] In some respects, the power input section is a connector interface and the connector interface is electrically connected to the power tool battery pack and configured to receive power from the power tool battery pack.

[0019] The power tool of this invention includes a motor, a power supply for supplying power to the motor, and a printed circuit board (“PCB”) electrically connected to the motor and the power supply. The printed circuit board includes a motor drive circuit having a plurality of high-side switches, a plurality of low-side switches, and a first bus disposed on the surface of the printed circuit board, the first bus electrically connecting the positive terminal of the power supply to each of the plurality of high-side switches.

[0020] In some aspects, the motor drive circuit includes a second bus disposed on the surface of a printed circuit board, the second bus electrically connecting the negative terminal of the power supply to each of a plurality of low-side switches.

[0021] In some aspects, the motor drive circuit includes a plurality of third buses arranged on the surface of a printed circuit board, the plurality of third buses electrically connecting a plurality of high-side switches to the motor.

[0022] In some respects, multiple third buses connect multiple low-side switches to the motor.

[0023] In some respects, power is supplied to the motor from the power source by controlling a plurality of high-side switches and a plurality of low-side switches.

[0024] Before explaining any implementation in detail, it should be understood that the application of the implementation is not limited to the details of the configuration and arrangement of the components described in the following description or shown in the drawings. The implementation can be practiced or implemented in various ways. Furthermore, it should be understood that the wording and terminology used in this invention are for illustrative purposes and should not be considered restrictive. The use of "comprising," "including," or "having," and variations thereof, is intended to cover the items listed thereafter and their equivalents, as well as additional items. Unless otherwise stated or limited, the terms "mounted," "connected," "supported," and "coupled," and variations thereof, are used broadly and cover direct and indirect mounting, connection, support, and coupling.

[0025] Furthermore, it should be understood that implementations may include hardware, software, and electronic components or modules, and for the purposes of discussion, these components or modules may be illustrated and described as if most components were implemented solely in hardware form. However, those skilled in the art will recognize from this detailed description that, in at least one implementation, the electronic aspects may be implemented by software (e.g., stored on a non-transitory computer-readable medium) executable by one or more processing units (such as microprocessors and / or application-specific integrated circuits (“ASICs”)). Therefore, it should be noted that these implementations may be implemented using a plurality of hardware and software-based devices and a plurality of different structural components. For example, “server,” “computing device,” “controller,” “processor,” etc., described in the specification may include one or more processing units, one or more computer-readable medium modules, one or more input / output interfaces, and various connectors (e.g., system buses) for connection components.

[0026] Related terms used in conjunction with quantities or conditions, such as “about,” “approximately,” “generally,” etc., will be understood by a person skilled in the art to include the value and have a meaning defined by the context (e.g., the term includes at least the degree of error associated with measurement accuracy, the tolerance associated with a particular value [e.g., manufacturing, assembly, use, etc.]). Such terms should also be considered to disclose a range defined by the absolute values ​​of two endpoints. For example, the expression “about 2 to about 4” also discloses a range of “2 to 4.” Related terms may refer to percentages added to or subtracted from the indicated value (e.g., 1%, 5%, 10% or more).

[0027] It should be understood that although some figures show hardware and software located within a particular device, these depictions are for illustrative purposes only. Functions described in this invention as being performed by a single component can be performed by a plurality of components in a distributed manner. Similarly, functions performed by a plurality of components can be combined and performed by a single component. In some embodiments, the components shown can be combined or divided into separate software, firmware, and / or hardware. For example, logic and processing can be distributed among a plurality of electronic processors, rather than being located within a single electronic processor and performed by a single electronic processor. Regardless of how the hardware and software components are combined or divided, the hardware and software components can reside on the same computing device or can be distributed among different computing devices connected via one or more networks or other suitable communication links. Similarly, components described as performing specific functions can also perform additional functions not described in this invention. For example, a device or structure “configured” in a certain way is at least configured in that way, but can also be configured in a way not explicitly listed.

[0028] Other aspects of the implementation will become apparent upon careful reading of the detailed description and accompanying drawings. Attached Figure Description

[0029] Figure 1 An electric tool according to an embodiment of the present invention is shown.

[0030] Figure 2 A control system for power tools according to an embodiment of the present invention is shown.

[0031] Figure 3 A motor used in power tools according to an embodiment of the present invention is shown.

[0032] Figure 4 A printed circuit board (“PCB”) for use in power tools and comprising a plurality of buses according to an embodiment of the present invention is shown.

[0033] Figure 5Another embodiment of a printed circuit board (“PCB”) used in power tools and comprising a plurality of buses, according to the embodiments described herein, is shown.

[0034] Figure 6 Another embodiment of a printed circuit board (“PCB”) used in power tools and comprising a plurality of buses according to the embodiments described herein is shown.

[0035] Figure 7 A motor drive circuit for an electric tool according to an embodiment of the present invention is shown.

[0036] Figure 8 Other embodiments of a printed circuit board (“PCB”) used in power tools and comprising a plurality of buses according to the present invention are shown.

[0037] Figure 9 Another embodiment of a printed circuit board (“PCB”) used in a power tool and comprising a plurality of buses, according to an embodiment of the present invention, is shown.

[0038] Figure 10 The embodiments according to the present invention are shown. Figure 9 An isometric view of the PCB. Detailed Implementation

[0039] The embodiments described herein relate to electrical devices such as power tools, which include buses and switches arranged on a printed circuit board (“PCB”). The power tool includes a motor. The motor includes a rotor and a stator. The stator includes a plurality of stator terminals (e.g., three stator terminals). The PCB is electrically connected to the stator. The PCB includes a plurality of switches and a plurality of buses. In some embodiments, the PCB includes at least six switches arranged in a switch bridge. The switches are, for example, field-effect transistors (“FETs”), such as metal-oxide-semiconductor FETs (“MOSFETs”). In some embodiments, the PCB includes a plurality of buses. A first terminal of each of the plurality of buses is electrically connected to one or more of the switches. A second terminal of each of the plurality of buses is electrically connected to a power source (e.g., a battery pack) for supplying power from the power source to each of the plurality of switches. In some embodiments, each of the plurality of buses is arranged between the power source and a corresponding one or more of the plurality of switches for delivering current from the power source to the switch.

[0040] Figure 1Power tool 100 is shown. Power tool 100 can be, for example, an impact wrench, drill bit, ratchet, saw, hammer drill, impact drive, rotary hammer, grinder, blower, trimmer, etc. Power tool 100 includes a housing or motor housing 105 that houses a motor within power tool 100 (see [link]). Figure 3 The power tool 100 is configured to receive a power source 110 that supplies DC power to various components of the power tool 100, including the motor. The power source 110 may be a rechargeable power tool battery pack that uses, for example, individual lithium-ion battery cells. In some embodiments, the power source 110 is an AC power source (e.g., 120V / 60Hz), and the power tool 100 receives power from a wire coupled to a standard wall outlet. In these embodiments, the received AC power may be converted to DC power using a rectifier.

[0041] Figure 2 A control system for a power tool 100 is shown. The control system includes a controller 200. The controller 200 is electrically and / or communicatively connected to various modules or components of the power tool 100. For example, the controller 200 is electrically connected to a motor 205, a battery interface 210, a trigger switch 215 (connected to trigger 220), one or more sensors or sensing circuits 225, one or more indicators 230, a user input module 235, a power input module 240, and a FET switch module 245 (e.g., including a plurality of FETs). The controller 200 includes a combination of hardware and software operable to control the operation of the power tool 100, monitor the operation of the power tool 100, activate one or more indicators 230 (e.g., LEDs), etc.

[0042] The controller 200 includes a plurality of electrical and electronic components that provide power, operation control, and protection to components and modules within the controller 200 and / or the power tool 100. For example, the controller 200 particularly includes a processing unit 250 (e.g., a microprocessor, microcontroller, electronic processor, electronic controller, or other suitable programmable device), a memory 255, an input unit 260, and an output unit 265. The processing unit 250 particularly includes a control unit 270, an ALU 275, and a plurality of registers 280 (in... Figure 2 The system is shown as a set of registers and is implemented using a known computer architecture (e.g., a modified Harvard architecture, von Neumann architecture, etc.). Processing unit 250, memory 255, input unit 260, and output unit 265, as well as various modules or circuits connected to controller 200, are connected via one or more control and / or data buses (e.g., common bus 285). For illustrative purposes, in... Figure 2 The control and / or data bus is roughly shown in the diagram.

[0043] Memory 255 is a non-transitory computer-readable medium, including, for example, a program storage area and a data storage area. The program storage area and data storage area may include combinations of different types of memory, such as ROM, RAM (e.g., DRAM, SDRAM, etc.), EEPROM, flash memory, hard disk, SD card, or other suitable magnetic, optical, physical, or electronic memory devices. Processing unit 250 is connected to memory 255 and executes software instructions that can be stored in RAM of memory 255 (e.g., during execution), ROM of memory 255 (e.g., on a substantially permanent basis), or another non-transitory computer-readable medium such as another memory or disk. Software included in an implementation of power tool 100 may be stored in memory 255 of controller 200. Software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. Controller 200 is configured to retrieve from memory 255 and execute instructions related to the control processes and methods described herein. In other configurations, controller 200 includes additional, fewer, or different components.

[0044] Battery pack interface 210 includes a combination of mechanical components (e.g., guide rails, recesses, latches, etc.) and electrical components (e.g., one or more terminals) configured and operable to interface power tool 100 with the battery pack (e.g., mechanical, electrical, and communication connections). For example, power supplied to power tool 100 by battery pack 110 is provided to power input module 240 via battery pack interface 210. Power input module 240 includes a combination of active and passive components to regulate or control the power received from battery pack 110 before power is supplied to controller 200. Battery pack interface 210 also supplies power to FET switching module 245, which is switched by a switching FET to selectively supply power to motor 205. Battery pack interface 210 also includes, for example, a communication line 290 for providing a communication line or link between controller 200 and battery pack 110.

[0045] Indicator 230 includes, for example, one or more light-emitting diodes (“LEDs”). Indicator 230 may be configured to display the status of power tool 100 or information associated with power tool 100. For example, indicator 230 may be configured to indicate measured electrical characteristics of power tool 100, device status, etc. User input module 235 is operatively coupled to controller 200 to, for example, select forward or reverse operating mode, torque and / or speed settings of power tool 100 (e.g., using a torque and / or speed switch), etc. In some embodiments, user input module 235 includes a combination of digital and analog input or output devices required to achieve a desired level of control of power tool 100, such as one or more knobs, one or more dials, one or more switches, one or more buttons, etc.

[0046] Sensor 225 includes one or more current sensors, one or more speed sensors, one or more Hall effect sensors, one or more temperature sensors, etc. Controller 200 calculates or includes in memory 255 predetermined operating thresholds and limits for the operation of power tool 100. For example, when controller 200 detects or predicts a potential thermal failure (e.g., in the FET, motor 205, etc.), it can limit or interrupt power to motor 205 until the likelihood of a thermal failure decreases.

[0047] Figure 3 An embodiment of motor 300 is shown, which may be located within the motor housing 105 of power tool 100. In the illustrated embodiment, motor 300 is a three-phase brushless direct current (BLDC) motor. In other embodiments, motor 300 may include a brushless DC motor, a DC motor, an AC motor, etc., with different numbers of phases, controlled by controller 200 using a switching arrangement (e.g., one or more FETs). Motor 300 includes a rotor 302 and a stator 304. Stator 304 is the fixed portion of motor 300 and includes a plurality of attached stator terminals 310. Stator terminals 310 may be connected to a plurality of switches (such as field-effect transistors (FETs) or metal-oxide-semiconductor field-effect transistors (MOSFETs)) on a PCB in power tool 100 for controlling the power supplied to motor 300.

[0048] Although this invention has been described with respect to power tool 100, the controller 200 and printed circuit board (“PCB”) described herein can be implemented in alternative embodiments other than power tool 100. For example, the controller 200 and PCB described herein are implemented in a portable power supply. The portable power supply is configured to receive power 110 and distribute power to an external device using a FET switching module 245. In other embodiments, the controller 200 and PCB described herein are implemented in a lighting device (e.g., a portable lamp). The lighting device is configured to receive power 110 and includes a FET switching module 245 configured as a light-emitting diode (“LED”) driver. The lighting device controls the LED driver to control the light emitted by the lighting device via power received from power supply 110. In other embodiments, the controller 200 and PCB described herein are implemented in any suitable battery-powered site equipment.

[0049] Figure 4 A printed circuit board (“PCB”) 400 used in a power tool 100 is shown. In some embodiments, the PCB 400 includes components... Figure 2 The control system shown includes a controller 200, a FET switching module 245, and related components. The PCB 400 includes a surface (e.g., a first surface) 405. Figure 4 As shown in the embodiments, electrical and electronic components of PCB 400 are mounted to or arranged on surface 405 of PCB 400. Surface 405 may be a conductive layer providing electrical connections between PCB 400 and its components. It should be understood that PCB 400 also includes a second surface positioned opposite to surface 405. In some cases, some or all of the electrical and electronic components of PCB 400 are mounted to or arranged on the second surface. PCB 400 also includes metal traces electrically connecting the components of PCB 400.

[0050] PCB 400 is electrically connected to power supply 110 and motor 300. For example, PCB 400 receives operating power from power supply 110 and selectively controls the operating power supplied to motor 300. PCB 400 also includes a plurality of switches 410 (e.g., FETs of FET switch module 245) and a plurality of buses 415. Each of the plurality of switches 410 is mounted on surface 405 of PCB 400. Each of the plurality of switches 410 can be provided as a separate package, for example, as a separate integrated circuit on PCB 400. The terminals of each of the individual plurality of switches 410 are mounted to PCB 400, for example, using soldering. Similarly, each of the plurality of buses 415 is mounted on surface 405 of PCB 400. Therefore, the plurality of buses 415 are separate from any conductive traces or stampings on PCB 400. In some cases, each of the plurality of buses 415 is arranged on surface 405 relative to one or more corresponding switches of the plurality of switches 410. By positioning each of the plurality of buses 415 on PCB 400 between the power supply 110 and one or more corresponding switches of the plurality of switches 410, a more robust electrical connection between the power supply 110 and the plurality of switches 410 is achieved.

[0051] See Figure 2 The battery pack interface 210 may include a terminal block to form an electrical and communication connection with the battery pack 110. The terminal block includes, for example, a positive terminal, a negative terminal, and one or more communication terminals. See also... Figure 4In some embodiments, the terminal block can be directly mounted to PCB 400. In some embodiments, a connector interface including pins and corresponding pin sockets is used to connect the terminal block to PCB 400. In other embodiments, wires can be routed from the terminal block and soldered to PCB 400 to connect the terminal block to PCB 400. When the terminal block is connected to the PCB, the positive and negative terminals are electrically connected to a plurality of switches 410 using a plurality of buses 415. One or more communication terminals can be connected via conductive traces on PCB 400 to a microcontroller unit (MCU) or other similar unit implementing controller 200 and / or processing unit 250 to form communication line 290. In some embodiments, PCB 400 is connected to motor 205 using motor bus 420. Similar to the plurality of buses 415, motor bus 420 is separate from any conductive traces or stampings on PCB 400. In some cases, each motor bus 420 is arranged on surface 405 relative to one or more corresponding switches among a plurality of switches 410. A more robust electrical connection between the motor and the plurality of switches 410 is achieved by positioning each motor bus 420 on the PCB 400 between the motor 200 and one or more corresponding switches among the plurality of switches 410. In some embodiments, the motor bus 420 is embedded within the PCB 400 and routed to the motor coil. In other embodiments, the PCB 400 is connected to the motor 205 using wires soldered to the PCB 400 and connected to the motor coil.

[0052] In some embodiments, the first terminal of each of the plurality of buses 415 is physically and electrically connected to one or more corresponding switches among the plurality of switches 410. In other words, the first terminal of the bus is electrically connected to one or more switches. For example, the first terminal of each of the plurality of buses 415 is soldered to the source terminal of one or more corresponding switches among the plurality of switches 410. In other embodiments, the first terminal of each of the plurality of buses 415 is soldered to the drain terminal of one or more corresponding switches among the plurality of switches 410. The second terminal of each of the plurality of buses 415 is physically and electrically connected to the power supply 110. Therefore, each of the plurality of buses 415 can be arranged between the power supply 110 and one or more corresponding switches among the plurality of switches 410 and electrically connects the power supply 110 to the corresponding one or more corresponding switches among the plurality of switches 410. In other words, the buses in the plurality of buses 415 are arranged between the power source 110 and one or more of the switches 410 for delivering power (e.g., via current) from the power source 110 to the switches in the plurality of switches 410.

[0053] In some implementations, controller 200 selectively controls each of the plurality of switches 410 to supply power from power supply 110 to motor 300. Each of the plurality of buses 415 is configured to increase the amount of current that can be safely and efficiently delivered to motor 300 via the plurality of switches 410. For example, each of the plurality of buses 415 receives current from power supply 110 and distributes the current to one or more corresponding switches among the plurality of switches 410. Based on the material composition and cross-sectional area of ​​each of the plurality of buses 415, each of the plurality of buses 415 can receive and distribute a greater amount of current from power supply 110 than conventional metal traces on a PCB. By increasing the cross-sectional area of ​​each of the plurality of buses 415, each of the plurality of buses 415 distributes a greater amount of heat through conduction than conventional metal traces or stampings on a PCB. In other words, the larger the cross-sectional area of ​​each of the plurality of busbars 415, the more heat can be transferred through the surrounding environment via conduction to increase the rate of heat transfer.

[0054] In some embodiments, the material composition of each of the plurality of buses 415 is selected from the group consisting of copper, brass, and aluminum. In other words, each of the plurality of buses 415 is made of one of the group consisting of copper, brass, and aluminum. In other embodiments, each of the plurality of buses 415 may be made of any other suitable conductive material. It should be understood that different material compositions have different resistivities, which affect the amount of current flowing through each of the plurality of buses 415. For example, brass generally has a higher resistivity than aluminum and copper. In addition, aluminum generally has a higher resistivity than copper. Therefore, in buses with equal cross-sectional areas, a bus made of copper allows a larger amount of current to flow through the bus than aluminum or brass. Furthermore, the plurality of buses 415 allows a larger amount of current to flow through each bus than conventional metal traces or stamped parts of a PCB without overheating. In some embodiments, a plurality of buses 415 may have an outermost layer made of a material different from the rest of the bus 415. The outermost layer may be selected from the group consisting of tin, nickel, chromium, and gold, and is configured to protect the bus 415 from oxidation and wear. The outermost layer of the bus 415 may be applied by an electroplating process.

[0055] Furthermore, each of the plurality of buses 415 has a cross-sectional area. In some embodiments, the cross-sectional area of ​​each of the plurality of buses 415 is equal to the thickness of the bus multiplied by the width of the bus. In some embodiments, each of the plurality of buses 415 has a different cross-sectional area. In other embodiments, each of the plurality of buses 415 has the same cross-sectional area. In some embodiments, the cross-sectional area of ​​each of the plurality of buses 415 determines the amount of current supplied from the power source 110 to one or more corresponding switches in the plurality of switches 410. In some embodiments, the cross-sectional area of ​​each of the plurality of buses 415 is in the range of 0.00155 square inches (sq in) to 0.5 square inches (e.g., 1 square millimeter (mm) to 322.58 square millimeters). In other embodiments, the cross-sectional area of ​​the buses in the plurality of buses 415 is greater than 0.5 square inches.

[0056] As the cross-sectional area of ​​the buses in the plurality of buses 415 increases, a larger amount of current is delivered to one or more corresponding switches in the plurality of switches 410 because resistance decreases with increasing surface area. In contrast, the metal traces of the PCB 400 have a smaller cross-sectional area than each bus in the plurality of buses 415. Thus, each bus in the plurality of buses 415 delivers a larger amount of current from the power supply 110 to one or more corresponding switches in the plurality of switches 410 than the metal traces of the PCB 400 alone. As the controller 200 selectively controls the plurality of switches 410 to supply power to the motor 300, a larger amount of current is supplied to the motor 300 through the plurality of switches 410.

[0057] In some embodiments, each of the plurality of buses 415 includes a positive bus and a negative bus. In such embodiments, the positive bus is arranged between the positive terminal of the power supply 110 and one or more corresponding switches of the plurality of switches 410. The negative bus is arranged between the negative terminal of the power supply 110 and one or more corresponding switches of the plurality of switches 410. In some embodiments, the plurality of switches 410 are arranged toward the center of the PCB 400, and the plurality of buses 415 are disposed on the outer side of the PCB 400 relative to the plurality of switches 410.

[0058] In traditional PCBs, metal traces and stamping techniques make PCB manufacturing and assembly easier and faster. Buses are typically bulky and add steps to the assembly process of mounting them onto the PCB. Furthermore, buses carry current outside the PCB's insulation layer, which can negatively impact other electrical components on the PCB. However, by carefully planning the PCB design and including buses relative to corresponding switches, the current-carrying capacity of the PCB circuitry can be increased without significantly increasing the size of the electrical components.

[0059] Figure 5 Another printed circuit board (“PCB”) 500 is shown, which has similar components to PCB 400. Figure 5 The embodiments shown have similar reference numerals ranging from 500 to 599, and the differences are explained below. PCB 500 is electrically connected to power supply 110, motor 300, and includes controller 200. Additionally, PCB 500 defines a first surface 505 and a second surface 507 opposite to the first surface 505. PCB 500 includes a plurality of switches 510 and a plurality of buses 515 positioned on the first surface 505.

[0060] like Figure 5As shown, 12 switches 510 (6 high-side switches and 6 low-side switches) are arranged across the first surface 505 of the PCB 500. In other embodiments, the PCB 500 may include 6 switches 510, 12 switches 510, 18 switches 510, etc. In another embodiment, the switches 510 may be arranged only on the second surface 507, or on both the second surface 507 and the first surface 505. The switches 510 are provided as a separate package (i.e., an integrated circuit) and include a plurality of pins. The plurality of pins connect the switches 510 to the power supply 110, the controller 200, the motor 300, or other components of the PCB 500. One or more of the plurality of pins contact the first surface 505, and a plurality of traces are surface-mounted and soldered to the first surface 505 to form electrical and mechanical connections. The plurality of traces connect one or more of the plurality of pins to the controller 200 or other components of the PCB 500. One or more of the plurality of pins may extend toward and contact bus 515 positioned above switch 510. In other embodiments, bus 515 may be located on the same plane as switch 510. One or more of the plurality of pins may be surface-mount soldered to bus 515 to form an electrical connection. In some embodiments, one or more of the plurality of pins may be soldered to PCB 500, and a separate electrical connection from PCB 500 to bus 515 may be provided, for example, via metal traces. The formed electrical connection connects switch 510 to power supply 110 or motor 300. In other embodiments, first and second pins may be through-hole soldered to PCB 500 or bus 515, and switch 510 may include additional mechanical fasteners to form a mechanical connection to PCB 500 in addition to soldering.

[0061] like Figure 5 As shown, each bus 515 can be positioned to directly contact the first surface 505 and the second surface 507, or offset from the first surface 505 and the second surface 507 and contact the top surface of one or more switches 510. Also as... Figure 5As shown, the plurality of buses 515 include buses 515 of different shapes and sizes, and each bus 515 may not extend beyond the boundary of PCB 500. Buses 515 facilitate electrical connections between one switch of switch 510 and one or more switches of power supply 110, motor 300, or other switches 510. In the illustrated embodiment, the plurality of buses 515 includes five first buses 515A coupling two switches 510, one second bus 515B coupling four switches 510 to power supply 110, and two third buses 515C not connected to any switch 510. In other embodiments, the number of buses 515 may be greater than or less than eight, and the number of connections formed by each bus 515 may increase or decrease. In some embodiments, buses 515 may be coupled to a heat sink or may include a plurality of fins to dissipate heat from the bus 515.

[0062] Figure 6 Another printed circuit board (“PCB”) 600 is shown, which has components similar to those of PCBs 400 and 500. Figure 6 The embodiments shown have similar reference numerals in the range of 600 to 699, and the differences are explained below. PCB 600 is electrically connected to power supply 110 and motor 300 via connector interface 112, and includes controller 200. Additionally, PCB 600 defines a first surface 605 and a second surface (not shown) opposite to the first surface 605. PCB 600 includes a plurality of switches 610 and a plurality of buses 615 positioned on the first surface 605.

[0063] like Figure 6 As shown, 12 switches 610 (6 high-side switches and 6 low-side switches) are arranged across the first surface 605 of the PCB 600. In other embodiments, the PCB 600 may include 6 switches 610, 12 switches 610, 18 switches 610, etc. In another embodiment, the switches 610 may be arranged only on the second surface, or on both the second surface and the first surface 605. Similar to switch 510, switch 610 is provided as a separate package (i.e., integrated circuit) and includes a plurality of pins that electrically connect switch 610 to power supply 110, controller 200, motor 300, or other components of the PCB 600. The electrical connections of switch 610 may be similar to those described above. Figure 5 It forms as described.

[0064] like Figure 6As shown, each bus 615 is positioned on the first surface 605 and may be in direct contact with the first surface 605 or offset from the first surface 605 and in contact with the top surface of one or more switches 610. In other embodiments, the bus 615 may be positioned only on the second surface, or on both the second surface and the first surface 605. In yet another embodiment, the bus 615 may be in the same plane as the switch 610. Similar to bus 515, a plurality of buses 615 may have different shapes and sizes, and each bus 615 may not extend beyond the boundary of the PCB 600. Figure 6 As shown, the plurality of buses 615 includes a first bus 615A connected to six switches 610 and a power supply 110, three second buses 615B connected to two switches 610, a third bus 615C connected to the first bus 615A, and two fourth buses 615D connected to the three second buses 615B. The third bus 615C is connected to the first bus 615A to increase its cross-sectional area and allow the first bus 615A to receive a larger current. In other embodiments, the number of buses 615 may be greater than or less than seven in total, and the number of connections formed by each bus 615 may be increased or decreased.

[0065] Figure 7An exemplary embodiment of a motor drive circuit 700 including a plurality of switches 410 and a plurality of buses is shown. The motor drive circuit 700 is also compatible with PCBs 500, 600 and the corresponding switches 510, 610 and the corresponding buses 515, 615. The motor drive circuit 700 is configured as an embodiment of a three-phase brushless motor 205, but can be adapted to other types of motors having different numbers of phases as described above. The motor drive circuit 700 includes three high-side switches 410A, 410B, 410C connected between the positive terminal 705 and the motor 205. In other embodiments, the motor drive circuit 700 may include three sets of high-side switches, each set including one or more high-side switches arranged in series. The number of high-side switches in each set may be equal to the total number of high-side switches divided by the number of phases of the motor. The motor drive circuit 500 includes three low-side switches 410D, 410E, 410F connected between the negative terminal 710 and the motor 205. In other embodiments, the motor drive circuit 700 may include three sets of low-side switches, each set comprising one or more low-side switches arranged in series. The number of low-side switches in each set may be equal to the total number of low-side switches divided by the number of phases of the motor. A positive bus 415A is used to electrically connect the positive terminal 705 to each of the three high-side switches 410A, 410B, and 410C. A negative bus 415B is used to electrically connect the negative terminal 710 to each of the three low-side switches 410D, 410E, and 410F. A plurality of motor buses 415C are used to connect the high-side switches 410A, 410B, and 410C and the low-side switches 410D, 410E, and 410F to the motor 205.

[0066] Figure 8 Other embodiments of the printed circuit board (“PCB”) 805 are shown. Figure 8 The embodiments shown include the same components as PCBs 400, 500, and 600. Figure 8 The embodiments shown have similar reference numerals in the range of 800 to 899, and the differences are noted below. Figure 8 The illustrated embodiments are each electrically connected to a power supply 110, a motor 300, and include a controller 200. Additionally, PCB 805 defines a first surface 810. In some embodiments, PCB 805 defines a second surface opposite the first surface 810. Figure 8 In each of the additional embodiments shown, PCB 805 includes a plurality of switches 815 and a plurality of buses 820 positioned on a first surface 810. In some embodiments, the plurality of switches 815 may be arranged only on a second surface, or arranged on both the second surface and the first surface 810.

[0067] like Figure 8As shown, embodiment 800 includes a PCB 805 having a first surface 810. A plurality of switches 815 are arranged on the first surface 810. In embodiment 800, the plurality of buses 820 is a single bus 820. The single bus 820 is positioned on the top surface of each of the plurality of switches 810. In other words, the single bus 820 is positioned to cover the top surface of each of the plurality of switches 810. Figure 8 Embodiment 825 is also shown. Embodiment 825 includes a PCB 805 having a first surface 810, and a plurality of switches 815 arranged on the first surface 810. In embodiment 825, the plurality of buses 820 is a single bus 820. The single bus 820 is positioned on the top surface of each of the plurality of switches 810. In embodiment 825, the single bus 820 is connected to the first surface 810 via a bus connection portion 822. In some embodiments, the bus connection portion 822 is an extension of the single bus 820 connecting the single bus 820 to the first surface 810. For example, the bus connection portion 822 extends from the single bus 820 and is soldered to the first surface 810.

[0068] like Figure 8 As shown, embodiment 830 includes a plurality of switches 815 arranged on a first surface 810 of PCB 805. Embodiment 830 includes a plurality of buses 820 arranged on the respective top surfaces of the plurality of switches 815. In other words, each of the plurality of buses 820 is arranged on the top surface of the corresponding switch among the plurality of switches 815. Figure 8 Embodiment 835 is also shown. Embodiment 835 includes a PCB 805 having a first surface 810, and a plurality of switches 815 arranged on the first surface 810. In embodiment 835, the plurality of buses 820 is a single bus 820. The single bus 820 is positioned on the top surface of one or more of the plurality of switches 810. As shown in embodiment 835, the single bus 820 is connected to the first surface 810 via a bus connection portion 822.

[0069] Figure 8Embodiment 840 is also shown. Embodiment 840 includes a plurality of switches 815 arranged on a first surface 810 of a PCB 805. Embodiment 840 includes a plurality of buses 820 arranged on the respective top surfaces of the plurality of switches 815. In other words, each of the plurality of buses 820 is arranged on the top surface of a corresponding switch among the plurality of switches 815. Additionally, Embodiment 840 includes buses that are directly connected to the plurality of buses 820 on the first surface 810. In other words, Embodiment 840 includes some buses that are directly connected to the plurality of buses 820 on the first surface 810 but are not arranged on the top surface of the corresponding switches among the plurality of switches 815. Figure 8 Embodiment 845 is also shown. Embodiment 845 includes a PCB 805 having a first surface 810, and a plurality of switches 815 arranged on the first surface 810. In embodiment 845, the plurality of buses 820 is a single bus 820. The single bus 820 is positioned on the top surface of each of the plurality of switches 810. In embodiment 845, the single bus 820 is connected to the first surface 810 via a plurality of bus connection portions 822.

[0070] like Figure 8 As shown, embodiment 850 includes a plurality of switches 815 arranged on a first surface 810 of PCB 805. Embodiment 850 includes a plurality of buses 820 directly connected to the first surface 810, and none of the plurality of buses 820 is arranged on the top surface of any of the plurality of switches 815. Figure 8 Embodiment 855 is also shown. Embodiment 855 includes a plurality of switches 815 arranged on a first surface 810 of PCB 805. Embodiment 855 includes a plurality of buses 820 arranged on the respective top surfaces of the plurality of switches 815. In other words, each of the plurality of buses 820 is arranged on the top surface of a corresponding switch among the plurality of switches 815. In Embodiment 855, each of the plurality of buses 820 is connected to the first surface 810 via a corresponding bus connection portion 822 of the plurality of bus connection portions 822.

[0071] Figure 9 An embodiment 900 of a printed circuit board (“PCB”) 905 is shown, which has components similar to those of PCBs 400, 500, 600 and 805. Figure 9The embodiments shown have similar reference numerals in the range of 900 to 999, and the differences are explained below. PCB 905 is electrically connected to power supply 110, motor 300, and includes controller 200. Additionally, PCB 905 defines a first surface 910 and a second surface 915 opposite to the first surface 910. PCB 905 includes (e.g., via soldering) a plurality of electrical components 920 mounted on the first surface 910 and the second surface 915.

[0072] PCB 905 includes a plurality of buses 925 (e.g., one or more buses 925) arranged as an overhead channel providing clearance between the first surface 910 and the plurality of buses 925 at a distance above the first surface 910. The plurality of buses 925 are connected to the first surface 910 at bus connection portions 930. In some embodiments, the bus connection portions 930 are extensions of the plurality of buses 925 soldered to the first surface 910. In some embodiments, the plurality of buses 925 are not connected to the first surface 910 at an uncoupled side 935, such that the plurality of buses 925 are connected to the first surface 910 only at the bus connection portions 930.

[0073] PCB 905 also includes a plurality of switches 940. The plurality of switches 940 are mounted to a plurality of buses 925 away from the first surface 910. For example, the plurality of switches 940 are mounted on the first surface of the plurality of buses 925 opposite to the second surface, wherein the second surface faces PCB 905. By mounting the plurality of switches 940 on the plurality of buses 925 (e.g., mounting the plurality of switches 940 to a plurality of buses 925 arranged as an overhead channel), the main power path from power supply 110 to the plurality of switches 940 is removed from the first surface 910. As shown in embodiment 900, the main power path moves through the plurality of buses 925 to the plurality of switches 940. In some embodiments, moving the main power path from PCB 905 reduces the temperature of PCB 905. In some embodiments, the material composition of each of the plurality of buses 925 is copper.

[0074] Figure 10 It shows Figure 9 Isometric view 1000 of PCB 905. (e.g.) Figure 10As shown, PCB 905 includes a first surface 910. It should be understood that, although not visible in isometric view 1000, PCB 905 includes a second surface 915 opposite to the first surface 910. PCB 905 includes a plurality of electrical components 920 mounted on the first surface 910. PCB 905 also includes a plurality of buses 925 arranged at a distance above the first surface 910 and connected to an overhead channel of the first surface 910 at bus connection portions 930. As shown in isometric view 1000, in some embodiments, the bus connection portions 930 are a plurality of bus connection portions 930. PCB 905 includes a plurality of switches 940 mounted on the plurality of buses 925 arranged as an overhead channel.

[0075] Therefore, the embodiments described herein particularly provide power tools including printed circuit boards with buses. Various features and advantages are set forth in the appended claims.

Claims

1. A power tool, characterized in that, include: motor; A power source configured to supply power to the motor; and A printed circuit board ("PCB") electrically connected to the motor and the power supply, the PCB including a switch and a bus disposed on the surface of the PCB, the bus electrically connecting the power supply to the switch.

2. The power tool as described in claim 1, characterized in that, The printed circuit board includes a plurality of high-side switches and a plurality of low-side switches, wherein the switch is one of the plurality of high-side switches.

3. The power tool as described in claim 1, characterized in that, The printed circuit board includes a plurality of high-side switches and a plurality of low-side switches, wherein the switch is one of the plurality of low-side switches.

4. The power tool as described in claim 2, characterized in that, The bus is the positive bus that connects the power supply to the plurality of high-side switches.

5. The power tool as described in claim 3, characterized in that, The printed circuit board includes a negative bus that electrically connects the power supply to the plurality of low-side switches.

6. The power tool as claimed in claim 1, characterized in that, Power is supplied to the motor from the power source by controlling the switch.

7. The power tool as claimed in claim 1, characterized in that, The busbar is made of one of the following materials: copper, brass, and aluminum.

8. The power tool as claimed in claim 1, characterized in that, The surface is a first surface, the switch is a first switch disposed on the first surface, the first switch has a first top surface, and the bus is a first bus disposed on the first top surface of the first switch, the first bus electrically connecting the power supply to the first switch.

9. The power tool as claimed in claim 8, characterized in that, The printed circuit board further includes: A second surface, which is opposite to the first surface; A second switch, the second switch being disposed on the second surface, the second switch having a second top surface; and A second bus is disposed on the second top surface of the second switch, and the second bus electrically connects the power supply to the second switch.

10. An electrical device, characterized in that, include: A power tool battery pack, the power tool battery pack being configured to supply power to a power input unit; and A printed circuit board ("PCB") includes a power input section and a power output section, the PCB includes a switch and a bus disposed on the surface of the PCB, the bus supplying power from the power input section to the power output section through the switch.

11. The electrical device as claimed in claim 10, characterized in that, The electrical device is selected from the group consisting of portable power supplies, lighting devices, and power tools.

12. The electrical device as claimed in claim 10, characterized in that, The busbar electrically connects the power input section to the switch.

13. The electrical device as claimed in claim 10, characterized in that, The busbar electrically connects the switch to the power output unit.

14. The electrical device as claimed in claim 10, characterized in that, The electrical device includes a motor electrically connected to the power output unit, and the electrical device supplies power to the motor by controlling the switch.

15. The electrical device as claimed in claim 10, characterized in that, The power input section is a connector interface that is electrically connected to the power tool battery pack and configured to receive power from the power tool battery pack.

16. A power tool, characterized in that, include: motor; A power source that supplies power to the motor; and A printed circuit board ("PCB") electrically connected to the motor and the power supply, the PCB including a motor drive circuit having a plurality of high-side switches, a plurality of low-side switches and a first bus disposed on the surface of the PCB, the first bus electrically connecting the positive terminal of the power supply to each of the plurality of high-side switches.

17. The power tool as claimed in claim 16, characterized in that, The motor drive circuit includes a second bus disposed on the surface of the printed circuit board, the second bus electrically connecting the negative terminal of the power supply to each of the plurality of low-side switches.

18. The power tool as claimed in claim 17, characterized in that, The motor drive circuit includes a plurality of third buses arranged on the surface of the printed circuit board, the plurality of third buses electrically connecting the plurality of high-side switches to the motor.

19. The power tool as claimed in claim 18, characterized in that, The plurality of third buses electrically connect the plurality of low-side switches to the motor.

20. The power tool as claimed in claim 16, characterized in that, Power is supplied to the motor from the power source by controlling the plurality of high-side switches and the plurality of low-side switches.

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