Black Decker Inc.

Black & Decker Inc.

Colin M Crosby

Ryan F Schroeder

Barak N Gohn

David J Smith

Daniel F Heck

Merritt James Tennison

Stephen P Osborne

Jarrett A Dunston

Justin H Ayers

Madhur M Purohit

John B Fogle

Andrew M Palich

William D Spencer

Michael D Grove

Michael P Sikora

Connor T Mohan

Matthew J Velderman

Richard Thomas Walter

Brent Austin Kuehne

Joseph Patrick Kelleher

James D Schroeder

James R Clarke

Nicholas J Lowe

Craig A Oktavec

Daniel F Nace

Pradeep M Pant

Floyd E Moreland

James H Stiles, Iii

David E Gillespie

Zollie W Privett, Jr

Kyle J Christophersen

Sumiteru Mori

Jiaqi Zhang

Tong Zheng

William M Spencer

Joseph C Biser

Christian B Rogerson

Gao Jian

Wang Guoqing

Zhang Yukun

Chen Jianhua

Richard Dizon

Zhu Wen

Wu Yanmin

Lu Xiaoli

Ahmed S Shaik

Kevin Cox

Lynn Weikel

Xiaolie Niu

Merritt J Tennison

Joseph C Baybrick

Stephen P Osbourne

An electric brushless DC motor is provided including a rotor assembly having a substantially-cylindrical metallic rotor body and at least one rotor magnet mounted on a surface of the rotor body, a stator assembly rotatably disposed relative to the rotor assembly, and a molded structure formed in contact with the rotor body. The molded structure includes a first mold portion in engagement with the rotor body that integrally forms a fan at or adjacent an axial end of the rotor body, and a second mold portion extending integrally from the first mold portion at least partially in engagement with an inner surface of the rotor body. The second mold portion engages two axial ends of the at least one magnet to axially support and retain the at least one magnet relative to the rotor body.

Brushless motor having an overmolded rotor

A power tool includes a housing extending generally along a tool axis with opposing lateral side surfaces separated by a first distance, a motor contained in the housing, and an end cap coupled to a rear end of the housing, the end cap having opposed lateral wings extending radially outward from the side surfaces by a second distance that is greater than the first distance. At least one air intake vent is disposed proximate at least one of the wings to allow intake of air ambient air to cool the motor.

Power tool with enhanced air flow

A brushless direct-current (BLDC) motor for a power tool includes a rotor assembly and a stator assembly including stator windings. A ratio of a motor size (Km) constant of the motor to an electrical envelope of the motor including electrical parts of the motor is greater than approximately 850 (N·m/√W)/m{circumflex over ( )}3. A ratio of a motor size (Km) constant of the motor to a magnetic envelope of the motor including stator core and windings is greater than approximately 980 (N·m/√W)/m{circumflex over ( )}3.

Brushless DC motor having high power density for power tool

A brushless direct-current (BLDC) motor for a power tool includes a rotor assembly; a stator assembly including a stator having stator teeth forming slots therebetween and stator windings wound around the stator teeth; stator terminals extending substantially parallel to the longitudinal axis from the stator assembly and being substantially aligned with centerlines of the slots of the stator assembly; and a circuit board mounted on the stator terminals adjacent the stator assembly. The circuit board includes conductive traces facilitating a one of a delta or a series connection between the stator windings. An end insulator is provided at an axial end of the stator to electrically insulate the stator from the stator windings, the end insulator including support members to support the stator terminals relative to the stator assembly. The circuit board is mounted and fastened to the support members.

Brushless DC motor with circuit board for winding interconnections

An electric brushless DC motor is provided including a rotor assembly having a substantially-cylindrical metallic rotor body and at least one rotor magnet mounted on a surface of the rotor body, a stator assembly rotatably disposed relative to the rotor assembly, and a molded structure formed in contact with the rotor body. The molded structure includes a main body having a first axial end that engages at least one axial end of the at least one rotor magnet to axially retain the at least one rotor magnet on the surface of the rotor body and a second axial end that integrally forms a fan adjacent the rotor body.

A brushless direct-current (BLDC) motor includes a stator assembly and a rotor assembly including a rotor supporting permanent magnets rotatable relative to the stator assembly. The stator assembly includes a stator comprising a stator core and stator teeth radially extending from the stator core and defining slots therebetween. A first set of stator windings is wound on the stator teeth, and a second set of stator windings is also wound on the stator teeth such that, on each stator tooth, the first and second windings are provided in an electrically parallel configuration.

Brushless DC motor with stator teeth having multiple parallel sets of windings

A power tool includes a tool housing and a motor assembly received in the tool housing. The motor assembly has a rear end portion, a front end portion, and a motor output shaft. A transmission housing is coupled to the motor housing with a transmission received in the transmission housing, to which the motor output shaft is drivingly coupled. A partition assembly includes a rear cover covering a rear end portion of the transmission housing that faces the front end portion of the motor and a seal. The rear cover of the transmission housing, the front end portion of the motor, and the seal together define at least a first labyrinth path and a second labyrinth path therebetween configured to inhibit grease or dust migration between the transmission housing and the motor assembly.

Power tool with partition assembly between transmission and motor

A brushless motor includes a stator and a rotor rotatably received within the stator, the rotor including a rotor shaft, a rotor body mounted on the rotor shaft and including axial slots, permanent magnets disposed within the axial slots, and a rotor end cap provided at an end of the rotor body to axially retain the permanent magnets within the slots. The rotor end cap includes an outer planar portion that is in contact with the end of the rotor body, and ribs angularly extending from the outer planar portion towards a center portion forming openings therebetween to allow passage of air between adjacent openings in thermal contact with the end of the rotor body.

Brushless motor for a power tool

A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and in contact with an inner curved surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore.

An electric brushless DC motor is provided including an outer rotor assembly having a metallic rotor body, rotor magnets mounted within an inner surface of the rotor body, and a molded structure formed within the rotor body. The molded structure includes at least one of: a main body formed on inner surface of the rotor body to securely cover and retain the rotor magnets on the inner surface of the rotor body, an axial fan formed at an end of the rotor body opposite the rotor magnets, and/or a sense magnet mount formed at approximately a radial center portion of the axial fan.

Brushless motor assembly for a fastening tool

An electric motor is provided including: a stator, an armature rotatably received within the stator and having an armature shaft on which a commutator is mounted, and a brush assembly. The brush assembly defines a first side facing the stator and a second side. The brush assembly includes a brush card mount having openings, brushes in sliding contact with the commutator, and thermally-conductive brush holders that support the brushes. Each brush holder includes a base piece disposed between the first side of the brush assembly and the stator, and a main piece including a brush-holder portion and two side flat portions. The brush-holder portion is axially received through a brush card mount opening from the first side of the brush assembly and protrude over the second side to house a brush. The two side flat portions are axially sandwiched between the base piece and the brush card mount.

Brush assembly having multi-piece brush holders for an electric motor, brush holder main piece with flat portions between base piece and brush card mount

A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and engaging an inner surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore of the stator assembly.

A brushless DC (BLDC) motor is provided including a stator assembly and a rotor rotatably arranged inside the stator. The stator assembly includes a generally-cylindrical lamination stack including a stator ring and stator teeth extending radially inwardly from the stator ring towards a center bore, where the center bore is arranged to receive the rotor therein. The stator assembly further includes an end insulator disposed at an and of the lamination stack, where the end insulator includes a generally-cylindrical outer ring and teeth portions extending radially inwardly from the outer ring towards a center of the end insulator, and the outer ring and the teeth portion correspond to the stator ring and the stator teeth. Stator windings are wound around the stator teeth and the corresponding teeth portion of the end insulator. Each tooth portion includes an outer face having a sloped portion sloped at an angle in the direction of the outer ring of the end insulator to bias the stator windings towards the outer ring.

Brushless motor system for power tools

Growing community of inventors

Baltimore, MD, United States of America

Colin M Crosby