Universal terminal bar structure with ground contacting feature integrated into a body structure with versatile RFI suppression for electric motors

Abstract

A method of providing RFI suppression in a DC motor provides a universal terminal bar structure 70 including a positive terminal bar 72 and a negative terminal bar 76 , a first choke 80 electrically connected with the positive terminal bar, a second choke 82 electrically connected with the negative terminal bar, a first ground connection 86 constructed and arranged to electrically connect the positive terminal bar to ground, a first breakable section A between the first ground connection and the positive terminal bar, a second ground connection 88 constructed and arranged to electrically connect the negative terminal bar to ground, and a second breakable section B between the second ground connection and the negative terminal bar. Capacitor structure 90 is attached to the terminal bar structure, and the first breakable section is selectively broken, alone or in combination with the second breakable section to provide versatile RFI suppression.

1 - 10 . (canceled)  
   
   
       11 . A method of providing RFI suppression in a DC motor including: 
 providing a universal terminal bar structure comprising: 
 a positive terminal bar and a negative terminal bar,  
 a first ground connection constructed and arranged to electrically connect the positive terminal bar to ground,  
 a first breakable section between the first ground connection and the positive terminal bar,  
 a second ground connection constructed and arranged to electrically connect the negative terminal bar to ground, and  
 a second breakable section between the second ground connection and the negative terminal bar,  
   attaching capacitor structure to the terminal bar structure, and    selectively breaking the first breakable section alone or in combination with the second breakable section.    
   
   
       12 . The method of  claim 11 , wherein the step of attaching capacitor structure includes electrically connecting a capacitor between the positive terminal bar and the negative terminal bar.  
   
   
       13 . The method of  claim 12 , wherein the step of breaking includes breaking only the first breakable section so as to terminate the connection between ground and the positive terminal bar is terminated.  
   
   
       14 . The method of  claim 11 , wherein the step of attaching capacitor structure includes electrically connecting a capacitor between the first ground connection and the positive terminal bar and electrically connecting another capacitor between the positive terminal bar and the negative terminal bar.  
   
   
       15 . The method of  claim 14 , wherein the step of breaking includes breaking only the first breakable section so as to terminate the connection between ground and the positive terminal bar is terminated.  
   
   
       16 . The method of  claim 11 , wherein the step of attaching capacitor structure includes electrically connecting a capacitor between the first ground connection and the positive terminal bar and electrically connecting another capacitor between the second ground connection and the negative terminal bar.  
   
   
       17 . The method of  claim 16 , wherein the step of breaking includes breaking both the first breakable section and the second breakable section to eliminate direct contact of the terminal bars to ground.  
   
   
       18 . The method of  claim 11 , further including molding a connector body about at least a portion of the terminal bar structure.  
   
   
       19 . The method of  claim 11 , further including attaching a lead wire to the positive terminal bar and attaching another lead wire to the negative terminal bar and thereafter, molding a connector body about at least a portion of the terminal bar structure.  
   
   
       20 . The method of  claim 11 , further including electrically connecting at least one first choke with the positive terminal bar and electrically connecting at least one second choke with the negative terminal bar.  
   
   
       21 . The method of  claim 11 , wherein the motor includes an end cap and a motor case, the method further including compressing the first and second ground connections between the end cap and motor case such that under compression, the ground connections cut into the motor case to create ground contact.  
   
   
       22 . The method of  claim 11 , wherein the step of providing the terminal bar structure includes providing the terminal bar structure as a single piece and then separating the positive terminal bar from the negative terminal bar.