Black & Decker Corporation

Other

Earl M Ortt

Hung T Du

Brandon L Verbrugge

David J Smith

Michael Jeffrey Agnes

Eric E Hatfield

John C Stone

Robert J Marcinkowski

Richard Thomas Walter

Stephen P Osborne

Brian E Friedman

Jarrett A Dunston

Justin H Ayers

Michael R Sell

Joshua F West

David E Gillespie

Robert G Kusmierski

Ren H Wang

Michael A Zemlok

Howard T White

Garrett Patrick McCormick

Michael A Zemlock

Jiaqi Zhang

Mark D Williams

Frank A Mannarino

Kevin M Hogan

Allyn Boyce

Shane Ashley Moll

Madhur M Purohit

Spencer G Maid

Robert B Williams

Bradley Jon Mealy

Robert Tumberlinson

Richard H Walter

James C Benton

Shailesh P Waikar

Erik A Ekstrom

Sankarshan N Murthy

John R Cochran

Michael C Doyle

Michael P Kunz

Marcell E Coates

Joseph G Stauffer

Eric J Samuelsen

Allison A Smith

Eric L Bernstein

Garrett P Mccormick

Therese M Rakosky

Kyle J Wheaton

Antonios M Nicolaidis

David E Abbott

Morris R Davies

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

A Brushless Direct-Current (BLDC) motor is provided for a power tool, including a stator comprising a set of coils, a rotor configured to rotate with respect to the stator, power supply lines, terminals secured to the stator outer surface of the stator, and a Hall circuit board. The terminals extend axially on the outer surface of the stator and are radially aligned with one of the stator coils. The terminal block is axially aligned with the same stator coil.

Brushless motor for a power tool

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 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 and conductive terminals. Each conductive terminal includes: a main portion and a tang portion extending from a first 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. The tang portion has a smaller lateral width than the main portion and is folded over the main portion to capture the contact portion of the at least one magnet wire. A power wire supply electric power to the motor is coupled to the conductive terminal proximate the second longitudinal end of the main portion.

A Brushless Direct-Current (BLDC) motor is provided for a power tool, including a stator comprising a coil, a rotor configured to rotate with respect to the stator, terminals secured to the stator, and a sensor circuit mount attached to the stator. The sensor circuit mount defines a plane having a first side and a second side, the sensor circuit mount including Hall sensors mounted on the first side of the plane of the sensor circuit mount facing the stator. Power-supply lines are secured to the terminals to supply electric current to the coil, the power-supply lines being routed from the terminals without traversing the second side of the plane of the sensor circuit mount. The sensor circuit mount is attached to the stator by at least one fastener that extends through an opening of the sensor circuit mount and a receptacle of the stator.

A stator assembly for a brushless DC motor includes a stator core defining poles and having an outer surface, at least one magnet wire wound on the poles forming phases, 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 is arranged to makes electric contact with a wire supplying electric power to the motor.

An electric motor is provided including: a stator assembly having a lamination stack defining poles and magnet wires wound on the poles, and a rotor rotatably arranged inside the stator assembly. A mount having a curved profile and made of non-conductive material is provided. Conductive terminals are mounted on and secured to a first surface of the mount, the conductive terminals being separated and insulated from each other via portions of the mount. A second surface of the mount opposite the first surface is mounted over to an outer surface of the lamination stack in contact therewith to align the plurality of conductive terminals longitudinally along the outer surface of the lamination stack.

A Brushless Direct-Current (BLDC) motor is provided for a power tool, including a stator, and a rotor pivotably arranged inside the stator. The rotor includes a rotor shaft, a rotor lamination stack mounted on the rotor shaft to rotate therewith, and at least one magnet. A bearing is mounted on the rotor shaft to support the rotor shaft. A mount is disposed adjacent the stator along a plane perpendicular to a longitudinal axis of the rotor shaft, the mount having a bearing support member intersecting the longitudinal axis of the rotor shaft and arranged to support the bearing therein. The mount further support hall sensors axially with respect to the rotor, the hall sensors arranged around a circumference of the bearing support to magnetically sense the at least one magnet.

A power tool includes a motor having a stator assembly and a rotor pivotably arranged inside the stator. The stator assembly includes a lamination stack defining a plurality of poles; a plurality of field windings each arranged at at least two opposite poles of said plurality of poles and connected together around the stator assembly; and a plurality of conductive terminals longitudinally arranged along an outer surface of the lamination stack and electrically coupled to the plurality of field windings and a power source.

A power tool includes a brushless DC motor having a stator and a rotor pivotably arranged inside the stator, the stator including a first winding, a second winding, and a third winding. Each winding is arranged at at least two opposite poles connected together. The stator windings may be connected in a delta configuration by electrically coupling adjacent terminals of the first and second windings, second and third windings, and third and first windings at three connection points. A baffle may be provided in parallel and adjacent to the stator, the baffle including at least one conductive routing or stamping to facilitate electrically coupling the first, second, and third windings in at least one of a delta or a wye configuration.

A method of manufacturing an armature for an electric motor, includes: placing a commutator and a lamination stack on an armature shaft, winding magnet wire in slots in the lamination stacks to form coils, attaching ends of the magnet wire to the commutator, and molding plastic around the magnet wire and around the shaft of the armature at ends of the lamination stack. A spinning inertia of the armature is adjusted by adjusting at least one of a mass of the plastic molded and a distribution of the plastic molded. Alternatively and/or additionally, at least one of a resonant frequency and critical speed of the armature is adjusted by adjusting at least one of a geometry of the plastic molded, the physical properties of the plastic and the mechanical properties of the plastic.

Method of manufacturing a power tool with molded armature

A power tool includes a brushless DC motor having a stator assembly and a rotor assembly at least a portion of which is arranged pivotably inside the stator assembly. The rotor assembly includes a rotor lamination stack housing a permanent magnets and a rotor fixedly housed inside a center portion of the lamination stack to pivot therewith. A fan may be fixedly attached to the rotor and arranged adjacent the stator assembly. The fan includes a back plate and blades longitudinally projecting from a periphery of the back plate towards the stator assembly, where a middle portion of the back plate is contoured away from an end cap of the motor to accommodate a projecting portion of the end cap. The permanent magnets may extend beyond the longitudinal length of the rotor lamination stack towards a magnet sensor to facilitate sensing of the permanent magnet via the magnet sensor.

Rotor assembly for brushless motor for a power tool

A power tool includes a brushless DC motor housed inside an upper body of the tool housing and a control unit housed inside a handle of the housing, the control unit including a micro-controller mounted on a control circuit board, a power unit electronically coupled to the micro-controller and mounted on a power circuit board arranged substantially parallel the control circuit board inside the handle, and a heat sink in thermal contact with the power unit. An input unit may be mounted directly on the control circuit board. An upper portion of the heat sink extending towards the upper body of the housing may include a tab protruding underneath a fan assembly of the motor to transfer heat from the power unit to the airflow created by the fan.

Control unit for a power tool

A method for forming an armature for an electric motor includes: securing a lamination stack having slots therein on an armature shaft, securing a commutator on one end of the armature shaft, winding magnet wires in the slots in the lamination stack and securing ends of the magnet wires to the commutator, the magnet wires having armature lead wires that extend from the slots to the commutator; and molding plastic over the magnet wires to encase at least the armature lead wires in plastic. Alternatively and/or additionally, plastic is molded over the magnet wires to retain them in the slots and to support the armature lead wires and prevent them from vibrating when the armature rotates during operation.

Method of forming a power tool

Growing community of inventors

Bel Air, MD, United States of America

Earl M Ortt