Black Decker Inc.

Jiaqi Zhang

David J Smith

Earl M Ortt

Brandon L Verbrugge

Hung T Du

Ren H Wang

Frank A Mannarino

Michael A Zemlock

Kevin M Hogan

Spencer G Maid

Richard Thomas Walter

James D Schroeder

Stephen P Osborne

Shane Ashley Moll

Michael Jeffrey Agnes

Justin H Ayers

Colin M Crosby

Garrett Patrick McCormick

Allyn Boyce

James C Benton

Eric J Samuelsen

Garrett P Mccormick

Richard H Walter

Eric L Bernstein

Allison A Smith

Antonios M Nicolaidis

Kyle J Wheaton

Therese M Rakosky

John C Cox

Ren Hong Wang

Rotor

A power tool has a motor having a stator made by separately forming pole pieces and field coils. The field coils are placed over necks of the pole path pieces. An armature has an outside diameter of at least 0.625 the outside diameter of the stator is placed in the stator. The housing has a girth of 200 mm or less with the motor wound to provide a maximum watts out to housing girth ratio of at least 5 maximum watts outs to 1 mm of housing girth. The field coils may be formed so that they extend beyond pole tips of the pole pieces.

Power tool with motor having a multi-piece stator

A power tool has a motor having a stator made by separately forming pole pieces, return path pieces and field coils. The field coils are placed over necks of the pole path pieces and the return path pieces are affixed to the pole pieces. An armature having an outside diameter of at least 0.625 the outside diameter of the stator is placed in the stator. The field coils may be formed so that they extend beyond pole tips of the pole pieces.

Power tools with motor having a multi-piece stator

A stator of an electric motor is formed by inserting pre-formed magnets on a cylinder having anchors and plastic is molded around the magnets and anchors to secure the magnets to a surface of the cylinder, forming a cylinder/magnet assembly. A pilot feature is formed in at least one endwall of the plastic molding when it is molded. An end plate is located with respect to the cylinder/magnet assembly by mating a corresponding pilot feature of the end plate with the pilot feature in the endwall of the plastic molding. In another aspect of the invention, magnets are inserted into magnet receiving pockets of a cylinder and plastic molded therearound with the magnet pockets holding the magnets in place during molding of the plastic. In another aspect of the invention, the north and south poles of a cylinder and magnet assembly have unequal distribution angles. In another aspect of the invention, the north and south poles of a cylinder and magnet assembly have unequal numbers of magnets. In another aspect of the invention, the anchors are also formed as flux spreaders. In another aspect of the invention, the stator is used in a power tool.

Field assembly for a motor and method of making same

A cylindrical magnet ring assembly having a cylinder magnet flux ring () formed with a plurality of inwardly projecting anchors (); a plurality of permanent magnets (), wherein the magnet can be formed with step portions () in the inner radial surface; a molded plastic member () being molded around the magnets and anchors to secure the magnets to a surface of the cylinder flux ring. There are several variations of the embodiments of the invention. Few embodiments are the following: in one aspect of the invention, magnets are inserted into magnet molded around an assembly ring () and the molded plastic secures the assembly ring to the flux ring; in another aspect, there are two assembly rings, a first assembly ring (is inserted into the one side of the cylinder flux ring then the second assembly ring is inserted into the other side of the cylinder flux ring and mated to the first assembly ring, after that the molded plastic secures the two assembly rings. The foregoing cylindrical magnet ring assembly is used in a stator of a motor which is used in a power tool.

Growing community of inventors

Cockeysville, MD, United States of America

Jiaqi Zhang