Packaging of a control module for a brushless motor

1. A power tool comprising:

a housing;

an electric brushless DC motor disposed within the housing; and

a control unit disposed within the housing and electrically coupled to the motor, the control unit comprising:

a circuit board having a first surface and a second surface;

a first plurality of discrete conductive tracks disposed at or near an edge of the circuit board on the first surface of the circuit board and spaced apart along an axis;

a first main conductive track mounted on the first surface of the circuit board parallel to the axis forming an elongated gap parallel to the axis between the first main conductive track and the first plurality of discrete conductive tracks on the circuit board;

a first plurality of power switches mounted on the first surface of the circuit board, each of the first plurality of power switches including a first portion mounted on the first main conductive track, a second portion mounted on a respective one of the first plurality of discrete conductive tracks, and a third portion mounted on the elongate gap between the first main conductive track and the first plurality of discrete conductive tracks;

a second plurality of power switches mounted on a second surface of the circuit board substantially opposite the first plurality of power switches and electrically coupled to the first plurality of power switches forming an inverter bridge circuit;

a plurality of power terminals arranged on a side edge of the circuit board and coupled to the output of the inverter bridge, the plurality of power terminals being spaced apart along the axis with each power terminals being electrically contacted a respective one of the first plurality of discrete conductive tracks; and

a heat sink including at least one leg mounted on the first main conductive track on the first surface of the circuit board and a main body extending at least partially over at least the first portion of each of the first plurality of power switches;

a second main conductive track mounted on the second surface of the circuit board coupling first nodes of the second plurality of power switches together;

a second plurality of discrete conductive tracks disposed on the second surface of the circuit board substantially opposite the first plurality of discrete conductive tracks parallel to the axis electrically coupling second nodes of the second plurality of power switches to the plurality of power terminals;

a plurality of through-holes through the circuit board between the first and second pluralities of discrete conductive tracks near the side edge of the circuit board, the plurality of power terminals being secured to the plurality of through-holes, wherein the plurality of through-holes comprise conductive vias electrically connecting respective ones of the first and second pluralities of discrete conductive tracks,

wherein each of the plurality of power terminals is mounted over a respective one of the first plurality of conductive tracks and includes a plurality of legs received through the plurality of through-holes and crimped over a respective one of the second plurality of conductive tracks.

2. The power tool of claim 1 , wherein the first main conductive track electrically couples first nodes of the first plurality of power switches together, and the first plurality of discrete conductive tracks electrically couple second nodes of the first plurality of power switches to the plurality of power terminals.

3. The power tool of claim 1 , wherein the heat sink comprises an elongate leg and two side legs mounted on and electrically coupled to the first main conductive track.

4. The power tool of claim 1 , wherein the first plurality of power switches comprise high-side field-effect transistors (FETs), the second plurality of power switches comprise low-side FETs, the first main conductive track is coupled to drains of the high-side FETs, the second main conductive track is coupled to sources of the low-side FETs, and the plurality of power terminals are coupled to sources of respective high-side FETs, and drains of respective low-side FETs.

5. The power tool of claim 1 , wherein the first main conductive track and the second main conductive track are respectively coupled to positive and negative terminals of a power source.

6. The power tool of claim 1 , wherein heat generated by the second plurality of power switches is substantially dissipated by the plurality of power terminals.

7. The power tool of claim 1 , wherein the tool comprises at least one of a finishing nailer, a framing nailer, or a concrete nailer.

8. The power tool of claim 1 , wherein the control unit further comprises a controller electrically coupled to gates of the first plurality of power switches and gates of the second plurality of power switches.

9. The power tool of claim 1 , wherein the control unit further comprises a potting boat in which the circuit boat is disposed, and potting material substantially covering both surfaces of the circuit board but leaving a surface of the heat sink exposed.

10. The power tool of claim 1 , wherein the control unit further comprises a thermally-conductive and electrically-insulating pad disposed over the heat sink and at least a portion of the power terminals, and a secondary heat sink disposed over the pad to be in thermal communication the heat sink and the power terminals.

11. The power tool of claim 10 , wherein the secondary heat sink has three to six times the total size of the heat sink.

12. The power tool of claim 10 , wherein the secondary heat sink comprises a plurality of upwardly projecting fins.