Electric motor brush apparatus and method

A motor assembly comprising:

• a field comprising:
• a laminated stator;
• at least one terminal block secured to the laminated stator and comprising a connector receptacle;
• field windings;
• and
• at least one wire electrically connected to the field windings and positioned partly in the connector receptacle;
• at least one conductive connector comprising:
• two substantially flat and parallel displacement members, each comprising:
• a top portion;
• and
• a distal portion comprising a cutting portion extending from the distal portion toward the top portion and configured to receive the wire;
• and
• two connector spring members, each comprising:
• a substantially flat lower portion adjacent to, connected to, and substantially perpendicular to at least one displacement member;
• and
• an upper portion extending above the top portions of the displacement members and cantilevered along substantially a connector axis of the connector;
• wherein the cutting portions of the displacement members align along the connector axis, and wherein the displacement members are substantially perpendicular to the connector axis;
• wherein the top portions of the displacement members define a brush receiving plane;
• wherein the distal portions of the displacement members extend below the lower portions of the connector spring members;
• and
• wherein the upper portions of the connector spring members are angled toward each other at cantilevered ends, defining with the brush receiving plane a brush receiving channel along the connector axis, wherein the brush receiving channel narrows in the direction of the connector axis toward the cantilevered ends;
• and
• at least one brush holder apparatus comprising:
• a brush holder housing sized to be received within the brush receiving channel, comprising an open end;
• a brush spring enclosed by the brush holder housing;
• and
• a brush located inside the brush holder housing but urged out of the open end of the brush holder housing by the brush spring along the connector axis when the brush holder housing is inserted inside the brush receiving channel;
• wherein the at least one connector is inserted into the connector receptacle such that the cutting portions of the displacement members receive and make electrical connection with the at least one wire;
• and
• wherein the at least one brush holder apparatus is inserted inside the brush receiving channel of the at least one connector along the connector axis in the direction of narrowing of the brush receiving channel until the at least one brush holder apparatus is held securely by the at least one connector.

A method comprising the steps of:

• a) providing:
• a motor housing comprising:
• at least one brush receptacle extending along a longitudinal axis of the brush receptacle and having a top end and a bottom end that are substantially parallel to the longitudinal axis;
• a locking element extending from the top end toward the bottom end of each brush receptacle;
• and
• a cantilevered housing spring member having a distal end extending substantially along the longitudinal axis and extending from the bottom end toward the top end of each brush receptacle;
• and
• at least one brush holder apparatus comprising:
• a brush holder housing sized to be received within the at least one brush receptacle, comprising:
• an upper surface and a lower surface that are substantially parallel;
• a first receiving aperture in the upper surface configured to receive the locking element when the brush holder housing is inserted inside the at least one brush receptacle;
• and
• an open end that is substantially perpendicular to the upper surface;
• a brush spring enclosed by the brush holder housing;
• and
• a brush located inside the brush holder housing but urged out of the open end of the brush holder housing by the brush spring along the longitudinal axis when the brush holder housing is inserted inside the at least one brush receptacle;
• b) inserting the at least one brush holder apparatus, the open end first, into the at least one brush receptacle along the longitudinal axis, causing the housing spring member to move away from the top end of the brush receptacle;
• c) aligning the locking element with the first receiving aperture;
• and
• d) allowing the housing spring member to urge the brush holder apparatus toward the top end of the brush receptacle and causing the first receiving apparatus to receive the locking element.