Electrically isolated module

An AC powered power tool having an electronic control module disposed within a tool housing of the power tool, the tool housing acting as a heat sink for the electronic control module, the power tool comprising:

• a line voltage passing through the tool housing and connecting to the electronic control module which nests within the tool housing, the electronic control module comprising:
• a power device, the power device connecting to the line voltage and providing a first layer of electrical insulation between the line voltage and a power tab of the power device;
• and
• a thermal pad, wherein the thermal pad is disposed between the power tab and a control module cover, the thermal pad providing a second layer of electrical insulation between the power tab and the cover and providing a predetermined minimum amount of electrical insulation between the line voltage and the tool housing to prevent electrical shock to a user contacting an external surface of the tool housing wherein the tool housing and the control module cover also act as heat sinks to dissipate heat developed by the power device.

An electrically isolated, double insulated electronic control module for use in a power tool, the electronic control module comprising:

• a module housing, the module housing having four walls, a bottom portion connected to the four walls at one end of the four walls, the four walls having an end opposite the bottom portion thereby defining an opening;
• a cover that covers the opening of the module housing;
• a power device having a first side and a second side, the power device second side facing the cover, the power device first side situated on a first side of a bridge portion, the bridge portion comprising a first wall and a second wall to form a receptacle to receive the power device therewithin, a first post and a second post, the first post and the second post each linking to the cover by a first fastener and a second fastener, respectively;
• a thermal pad having a first side and a second side, the first side situated against the cover and the second side situated against the second side of the power device, the first fastener and the second fastener holding the bridge portion, the power device, and the thermal pad against the module housing cover;
• and
• a circuit board having a first side and a second side, the first side of the circuit board situated against a second side of the bridge portion, and the second side of the circuit board situated against a layer of potting compound which rests upon the bottom portion of the module housing.

An electrically isolated, triple insulated electronic control module for use in a power tool, the electronic control module comprising:

• a module housing, the module housing having four walls, a bottom portion connected to the four walls at one end of the four walls, the four walls having an end opposite the bottom portion thereby defining an opening;
• a cover that covers the opening of the module housing;
• a power device having a first side and a second side, the power device second side facing the cover, the power device first side situated on a first side of a bridge portion, the bridge portion comprising a first wall and a second wall to form a receptacle to receive the power device therewithin, a first post and a second post, the first post and the second post each linking to the cover by a first fastener and a second fastener, respectively;
• an insulator having a first side and a second side, the insulator first side facing the cover and the insulator second side situated against the second side of the power device;
• a thermal pad having a first side and a second side, the thermal pad first side situated against the cover and the thermal pad second side situated against the first side of the insulator, the first fastener and the second fastener holding the bridge portion, the power device, the insulator, and the thermal pad against the module housing cover;
• and
• a circuit board having a first side and a second side, the first side of the circuit board situated against a second side of the bridge portion, and the second side of the circuit board situated against a layer of potting compound which rests upon the bottom portion of the module housing.

An electrically isolated, double insulated electronic control module for use in a power tool housing, the electronic control module comprising:

• a module housing, the module housing having four walls, a bottom portion connected to the four walls at one end of the four walls, the four walls having an end opposite the bottom portion thereby defining an opening;
• a cover that covers the opening of the module housing;
• a power device having a first side and a second side, the power device second side facing the cover, the power device first side situated on a first side of a bridge portion, the bridge portion comprising a first wall and a second wall to form a receptacle to receive the power device therewithin, a first post and a second post, the first post and the second post each linking to the cover by a first fastener and a second fastener, respectively;
• a thermal pad having a first side and a second side, the first side situated against the cover and the second side situated against a power tool housing, the first fastener and the second fastener holding the bridge portion and the power device against the module housing cover;
• and
• a circuit board having a first side and a second side, the first side of the circuit board situated against a second side of the bridge portion, and the second side of the circuit board situated against a layer of potting compound which rests upon the bottom portion of the module housing.