Electrically isolated module

An electrically powered tool, said power tool comprising

• an electronic control module disposed within a housing of the power tool, the electronic module comprising:
• a first layer of electrical insulation between a line voltage and the power tool housing, the line voltage for providing power to the power tool;
• and
• a second layer of electrical insulation between the line voltage and the power tool housing, the second layer disposed between the first layer and the power tool housing;
• the first and second layers combining to provide a predetermined minimum amount of electrical insulation between the line voltage and the power tool housing.

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

• a housing;
• a cover that covers an opening of the 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 forming a receptacle to receive the power device therewithin, a first post and a second post linked 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 a housing of the power tool and the thermal pad second side situated against the cover, the first fastener and the second fastener holding the bridge portion, the power device and the insulator 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 housing;
• a cover that covers an opening of the 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 forming a receptacle to receive the power device therewithin, a first post and a second post linked 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, the electronic control-module comprising:

• a module housing;
• a cover that covers an 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 forming a receptacle to receive the power device therewithin, a first post and a second post linked 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 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.

A method of operating a power tool comprising:

• supplying a line voltage to a module at least partially disposed within a housing of the power tool;
• using a power controlling component disposed within the module to provide a first level of electrical isolation between the line voltage and the tool housing;
• and
• using a layer of electrically insulative material between a cover of the module and the power generating component to provide an independent, second level of electrical isolation between the line voltage and the tool housing.

A method of operating a power tool comprising:

• supplying a line voltage to a module at least partially disposed within a housing of the power tool;
• using a power controlling component disposed within the module to provide a first level of electrical isolation between the line voltage and the tool housing;
• and
• using a layer of electrically insulative material between a cover of the module and the power tool housing to provide an independent, second level of electrical isolation between the line voltage and the tool housing.

A method for isolating a line voltage from a power tool housing, wherein the line voltage is used to power a motor within the power tool, the method comprising:

• providing a layer of electrical insulation between the line voltage and an external tab of a power device included in a module connectable to the line voltage and the power tool housing, thereby providing a first layer of electrical insulation between the line voltage and the power tool housing;
• disposing a thermal pad between the power tool housing and the external tab of the power device, thereby providing a second layer of electrical insulation between the line voltage and the power tool housing;
• and
• connecting the module to an internal surface of the power tool such that the power tool housing functions as a heat sink for the module.

An electronic module adapted to provide electrical insulation between a power source a housing of a power tool, the module comprising:

• a means for providing a layer of electrical insulation between the power source and a component of a power device included in the module and responsive to the power source, thereby providing a first layer of electrical insulation between the power source and the power tool housing;
• a means for providing a second layer of electrical insulation between the power source and the power tool housing;
• and
• a means for connecting the module to an internal surface of the power tool housing, thereby utilizing the power tool housing as a heat sink for the module.

An electrically powered tool comprising:

• a housing;
• a motor supported within the housing for providing torque to the power tool;
• and
• an electronic control module responsive to a line voltage and disposed within a housing of the power tool such that the tool housing acts as a heat sink for the electronic control module, wherein the electronic control module comprises:
• a power device disposed in the electronic control module, the power device being responsive to the line voltage and providing a first layer of electrical insulation between the line voltage and tool housing;
• and
• a thermal pad, wherein the thermal pad is disposed between the portion of the power device and the tool housing, the thermal pad providing a second layer of electrical insulation between the line voltage and the tool housing, such that the first and second layers combine to provide a predetermined minimum amount of electrical insulation between the line voltage and the tool housing.

A module for an electrically powered tool, said module comprising:

• a power device responsive to a voltage source and disposed within the module;
• a first layer of electrical insulation disposed between the voltage source and a housing of the power tool;
• and
• a thermal device thermally connecting the power device to the housing of the power tool and providing a second layer of insulation between the voltage source and the housing of the power tool.

A module mounted to a housing of an electrically powered tool, said module comprising:

• a power device responsive to a voltage source, the power device having at least one internal electrically isolative property that provides a first layer of electrical isolation between the voltage source and the tool housing;
• and
• a second layer of electrical isolation between the voltage source and the tool housing, the second layer comprising at least one of an electrically insulative thermal pad and an electrically insulative dielectric layer,
• wherein the combination of the first and second layers provide at least approximately 3750 volts of electrical insulation between the voltage source and the tool housing.