Black Decker Inc.

Other

Black 7 Decker Inc.

David J Smith

Earl M Ortt

Justin H Ayers

Jarrett A Dunston

Brandon L Verbrugge

Hung T Du

Craig A Oktavec

Colin M Crosby

Michael R Marjomaa

John C Stone

Stephen P Osborne

Brian E Friedman

Eric E Hatfield

Richard Thomas Walter

Michael R Sell

Matthew J Velderman

Ryan F Schroeder

Pradeep M Pant

Floyd E Moreland

Zollie W Privett, Jr

Joseph Patrick Kelleher

Stuart E Garber

James D Schroeder

Scott J Eshleman

David E Gillespie

Merritt James Tennison

Andrew M Palich

Kevin L Pulley

John B Fogle

Sumiteru Mori

Joshua F West

Dustin Jefferies

Marcus E E Rydin

Howard T White

Michael Jeffrey Agnes

Robert G Kusmierski

Madhur M Purohit

Daniel F Nace

Barak N Gohn

James H Stiles, Iii

Kyle J Christophersen

Mark T Cherry

Michael A Zemlock

Redeat Girma Alemu

Abraham Sanchez

Kristopher Cochran

Dennis A Bush

Colin C Crosby

Shailesh P Waikar

Tal Gottesman

William F Gallagher

Michael A Zemlok

Scott Eshlemann

Erik A Ekstrom

Joshua M Lewis

Marcell E Coates

Tobias Heep

Timothy J Seeley

Tim Heimrich

Tong Zheng

Rene Thieme

Dustin Jeffries

Changxing Lu

Fulong Liu

Yeli Gu

Jongsoo Lim

Jiaqi Zhang

Daniel Bernhart

Vincent Wensheng Zou

Dieter Schmidtfrerick

Bryce A Wells

Robert Tumberlinson

John D Cox

Sandip D Patel

Alvaro B Haesbaert

Samantha Cunningham

Mori Sumiteru

Marcus EE Rydin

Justin Ayres

A power tool is provided including a tool housing including a motor housing and a handle portion; a battery receptacle disposed at an end of the handle portion opposite the motor housing, the battery receptacle being configured to receive a battery pack; and a brushless DC motor including a stator and a rotor. The stator includes a stator lamination stack, an end insulator, and input terminals supported by the end insulator. A power circuit board is coupled to the input terminals to supply power to the motor. The motor produces a maximum power output of at least 1600 watts for driving an output shaft at a maximum torque of at least 30 inch-pounds and a maximum speed of at least 8000 rotations-per-minute.

Brushless motor for power tools

A power tool is provided including a housing having a grip portion with a grip circumference of smaller than or equal to approximately 120 mm; and a brushless direct-current (BLDC) motor at least partially disposed within the grip portion of the housing and configured to output a maximum power output of at least 450 watts. The motor includes a stator including a stator core and stator windings; and a rotor rotatably received within the stator and including a rotor shaft extending along a longitudinal axis and a series of permanent magnet rings mounted sequentially along the longitudinal axis and surrounding the rotor shaft, each permanent magnet including a plurality of magnetic poles.

High-power motor for a body-grip power tool

A stator assembly for a BLDC motor includes a stator core, at least one magnet wire wound on poles of the stator core, an end insulator mounted on an end surface of the stator core, a non-conductive mount member mounted on the outer circumferential surface of the stator core, and conductive terminals mounted on the non-conductive mount member. Each conductive terminal includes: a main portion mounted on the non-conductive mount, a tang portion extending from a first longitudinal end adjacent the end insulator and folded over the main portion, and a connection tab extending angularly from a second longitudinal end. A contact portion of the magnet wire is wrapped around the tang portion and fused to make an electric connection to the conductive terminal.

Stator assembly for a brushless motor in a power tool preliminary class

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.

Brushless motor having an overmolded rotor

A brushless direct-current (BLDC) motor is provided. The motor includes a stator including a stator core, stator teeth, and windings; a rotor shaft disposed within the stator and extending along a longitudinal axis; and a rotor. The rotor includes a rotor core having a cylindrical body, a permanent magnet ring mounted on an outer surface of the cylindrical body with no intermediate adhesive therebetween, and metal sleeve securely fitted outside the permanent magnet ring. The metal sleeve includes a flange extending radially inwardly that covers an axial end of the permanent magnet ring and is bonded to the rotor core to secure the permanent magnet ring to the rotor core.

Motor rotor with sleeve for retention of magnet ring

A power tool includes a housing and a brushless motor with a rotor and a stator assembly. The motor defines a motor envelope bounded by a rear plane at a rearmost point of the stator assembly and rotor, a front plane at a frontmost point of the stator assembly and rotor, and a generally cylindrical boundary surrounding a radially outermost portion of the stator assembly and rotor. A rotor shaft is rotatably driven by the rotor. A transmission includes an input member rotatably driven by the rotor shaft and an output member. A first bearing supporting the rotor shaft is at least partially received within the motor envelope. A second bearing supporting the rotor shaft or a component of the transmission is at least partially received within the motor envelope. A support plate supporting a component of the transmission may be at least partially received within the motor envelope.

Power tool with compact motor assembly

A power tool is provided including a housing defining a cavity therein, where the housing includes a motor case and a handle portion extending along a longitudinal axis of the housing from the motor case; an electric motor having a drive shaft and mounted within the motor case; a partitioning wall extending radially and separating the motor case portion from the non-motor case portion of the housing; and a bearing pocket with an open end facing the motor case portion formed in the partitioning wall and a main body extending away from the electric motor for receiving a rotor bearing. The handle portion includes two elongate walls extending from the partitioning wall, a circuit board supported by the two elongate walls and including a motor drive circuit, and two covers secured to the two elongate walls to cover the circuit board.

Handheld power tool with brushless electric motor

A brushless direct-current motor is provided includes an inner stator and an outer rotor. The rotor includes a rotor core disposed around the stator, an inner annular member mounted on a rotor shaft, and a plurality of radial blades extending angularly from the rotor core to the inner annular member forming a fan. A first end cap is provided including a radial back plate proximate the fan and a center opening in the radial back plate through which the rotor shaft extends. A second end cap is provided including a main body disposed adjacent the stator opposite the fan. The radial back plate of the first end cap includes at least one sloped surface forming at least one air gap such that the airflow generated by the fan is centrifugally guided within the first end cap by the sloped surface and caused to exit through the air gap.

Outer rotor brushless motor having an axial fan

A power tool is provided including a tool housing including a motor housing and a handle portion extending longitudinally from the motor housing; a battery receptacle disposed at an end of the handle portion opposite the motor housing, the battery receptacle being configured to receive a battery pack; and a brushless DC (BLDC) motor including an electronically-commutated stator assembly and a rotor assembly configured to rotate with respect to the stator assembly, the stator assembly comprising a stator lamination stack sized to be received within the motor housing having a circumference of approximately 140 to approximately 190 mm. The motor produces a maximum power output of at least 1600 watts for driving an output shaft at a maximum torque of at least 30 inch-pounds and a maximum speed of at least 8000 rotations-per-minute.

Brushless motor system for power tools

A motor assembly includes a stator having a stator core, stator windings, and a routing insulator configured to electrically insulate the stator core from the stator windings; a rotor rotatably received within the stator; and a bearing bridge received at least partially within the routing insulator and including a main body forming a center pocket arranged to support a bearing of the rotor shaft. A circuit board is provided including a circuit board, and an overmold structure forming an annular body on a surface of the circuit board arranged to mate with the main body of the bearing bridge to substantially seal the center pocket from ingress of debris particles.

Circuit board assembly for compact brushless motor

A brushless direct-current (BLDC) motor is provided. The motor includes a stator including a stator core, stator teeth, and windings; a rotor shaft disposed within the stator and extending along a longitudinal axis; and a rotor. The rotor includes a rotor core including an inner body mounted on the rotor shaft and radial projections projecting outwardly from the inner body, a permanent magnet mounted on an outer end of the radial projections, and a mold structure formed in contact with the radial projections and configured to secure the permanent magnet to the rotor core.

Overmolded rotor structure

A stator assembly for a brushless DC motor includes a stator core including stator poles and an outer surface, at least one magnet wire wound on the poles forming stator windings, and a bus bar including a non-conductive mount arranged on the outer surface and conductive terminals. Each conductive terminal includes: a main portion mounted on the non-conductive mount substantially parallel to the longitudinal axis of the motor, a tang portion folded over the main portion from a first longitudinal end of the main portion, and a connection tab at a second longitudinal end of the main portion. At least a contact portion of the at least one magnet wire is wrapped around the tang portion and fused to make an electric connection to the conductive terminal, and the connection tab makes electric contact with a wire supplying electric power to the motor.

Stator assembly for a brushless motor in a power tool

A motor is provided including: a stator including a stator core, stator windings, and an end insulator; a rotor rotatably received within the stator; and stator terminals supported by the routing insulator and extending away from the stator. Each stator terminal includes a main body having a curved portion, a tang portion folded over the main body and receiving a portion of a magnet wire therein to make an electrical connection with at least one of the stator windings, and a terminal pin projecting axially away from the stator core. The stator core has a maximum diameter of less than or equal to approximately 34 mm defining an outer envelope of the stator, and the stator terminals are fully contained within the outer envelope.

Compact brushless motor including in-line terminals

A motor is provided including a motor housing having an open end; a stator disposed within the motor housing and including a stator core, stator windings, and an end insulator that electrically insulate the stator core from the stator windings and includes an annular body; a rotor rotatably received within the stator and including a rotor shaft extending along a longitudinal axis and permanent magnets; and a bearing bridge including a center pocket arranged to support a bearing of the rotor shaft. The bearing bridge is received at least partially within the end insulator. The annular body of the end insulator includes at least one peripheral opening located within the motor housing, and the bearing bridge is radially piloted relative to the motor housing via a retaining member received through the at least one peripheral opening.

Brushless motor including a nested bearing bridge

A power tool is provided including a tool housing, a brushless DC (BLDC) motor assembly disposed within the tool housing, and a power module including a printed circuit board (PCB) and power switches mounted on the PCB and electrically coupled to the motor assembly. The PCB includes a width that is greater than a diameter of the motor assembly. A mounting bracket is secured to an end of the motor assembly and includes a mating portion arranged to mate with the end of the motor assembly, mount posts extending radially-outwardly from the mating portion, and axial walls extending between outer ends of the mount posts and at least partially housing the power module to support the PCB in a substantially parallel orientation relative to the rear end of the motor assembly.

Control and power module for driving a brushless motor in a power tool

Growing community of inventors

Columbia, MD, United States of America

David J Smith