Vehicle starter with integrated thermal protection

A starter assembly for an internal combustion engine, the starter assembly adapted to work with a voltage source and the internal combustion engine to start the engine, the starter assembly comprising:

• an electric motor which drives a starter gear, the starter gear being selectively shiftable between an engaged position and a disengaged position wherein in the starter gear is operably coupled with the internal combustion engine in the engaged position and is decoupled from the internal combustion engine in the disengaged position wherein the electric motor is mounted within a main housing, the main housing being grounded;
• a solenoid coupled with the starter gear wherein energizing the solenoid shifts the starter gear into the engaged position and wherein the starter gear is biased to the disengaged position when the solenoid is de-energized;
• and wherein energizing the solenoid closes a motor switch, the motor switch being disposed in a first electrical line adapted to couple the electric motor with the voltage source whereby closing the motor switch energizes the electric motor and opening the motor switch de-energizes the electric motor;
• a solenoid switch disposed in a second electrical line in communication with the solenoid wherein closing the solenoid switch energizes the solenoid and opening the solenoid switch de-energizes the solenoid wherein the solenoid switch is disposed in a switch housing, the switch housing being mounted on and electrically isolated from the main housing;
• control circuitry including a microprocessor operably coupled with the solenoid switch, the control circuitry being in communication with a motor voltage sensing line whereby the control circuitry is responsive to voltage changes in the electrical motor, the control circuitry also being in communication with an electrical line in communication with the voltage source whereby the control circuitry is responsive to the voltage of the voltage source, the control circuitry being programmed to open the solenoid switch upon the satisfaction of predetermined conditions to thereby prevent damage to the electrical motor;
• wherein the control circuitry is mounted within a control unit housing, the control unit housing being attached to the switch housing;
• a vibrational dampening and electrically isolating mounting assembly for securing the control unit housing and the switch housing to the main housing wherein the mounting assembly electrically isolates the main housing from the control unit housing and from the switch housing;
• and
• a thermally responsive switch positioned to absorb heat generated by operation of the electric motor and wherein the thermally responsive switch opens when experiencing elevated temperatures, the thermally responsive switch being disposed in a third electrical line operably coupled with the solenoid switch wherein energizing the third electrical line closes the solenoid switch and de-energizing the third electrical line opens the solenoid switch, and wherein the third electrical line is grounded by attachment to the starter assembly, the thermally responsive switch being disposed in the third electrical line between the solenoid switch and the ground wherein opening of the thermally responsive switch prevents energizing of the third electrical line and results in the opening of the solenoid switch by opening the third electrical line and thereby preventing the grounding of the solenoid switch and the control circuitry.