Black Decker Inc.

The Black & Decker Company

Michael R Sell

Richard Thomas Walter

Hung T Du

Joshua F West

Earl M Ortt

Brandon L Verbrugge

John C Stone

David J Smith

Howard T White

David C Campbell

Lynn E Lentino

Gale Anthony Heslop

Michael Lester O'Banion

Frederick R Bean

Richard C Nickels, Jr

Martin P Gierke

R Roby Bailey

Alfred Schiazza, Iii

Dale C Grieb

Kevin W Covell

Richard L Hurn

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 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

An electric motor for a power tool includes a stator and an armature disposed in the stator. The armature includes a lamination stack having slots therein; an armature shaft extending coaxially through the lamination stack; a plurality of magnet wires wound in the slots of the lamination stack; a commutator disposed on the armature shaft to which ends of the magnet wires are electrically coupled; and thermally conductive plastic at least partially encasing the magnet wires, the thermally conductive plastic having a base polymer that is a blend of at least two polymers.

An electric motor has a stator in which an armature is disposed. The armature has a shaft. One of the stator or the armature includes a lamination stack having slots in which magnet wires are wound, the magnet wires having a coating of heat activated adhesive. There is further provided plastic molded around the magnet wires with heat of the plastic activating the heat activated adhesive on the magnet wires during molding of the plastic to bond the magnet wires together.

A method for forming an armature for an electric motor includes securing a lamination stack having slots therein on an armature shaft. A commutator is secured on one end of the armature shaft. Magnet wires are wound in the slots in the lamination stack and ends of the magnet wires are secured to the commutator. Plastic is molded around the lamination stack, commutator and magnet wires. Excess plastic is machined off. The magnet wires can have a layer of heat activated adhesive that is activated when the plastic is molded. Slots in the lamination stack can include slot liners formed of thermally conductive plastic. A fan can be formed when the thermally conductive plastic is molded to encapsulate the magnet wires.

Method for forming an armature for an electric motor

An electric motor has an armature and a stators. The armature has a lamination stack having slots therein. An internal shaft extends coaxially through the lamination stack. A plurality of magnet wires are wound in the slots of the lamination stack. A commutator is disposed on the armature shaft to which ends of the magnet wires are electrically coupled. The internal is shaft coupled to an external pinion and bearing journal by an insulated coupling. The magnet wires are at least partially encased in thermally conductive plastic. The magnet wires can have a layer of heat activated adhesive that is activated when the plastic is molded. Slots in the lamination stack can include slot liners formed of thermally conductive plastic. A fan can be formed when the thermally conductive plastic is molded to encapsulate the magnet wires. A power tool has the electric motor.

Dynamoelectric machine having encapsulated coil structure with one or more of phase change additives, insert molded features and insulated pinion

Magnet wires wound in slots in a lamination stack of a dynamoelectric machine are encapsulated, in whole or in part, with plastic. The plastic may be thermally conductive and have features molded therein that enhance heat transfer. The plastic may stiffen the armature and increase its critical speed. Characteristics of the plastic, its geometry and its distribution may be varied to adjust spinning inertia and resonant frequency of the armature. The magnet wires may be compressed into the slots, by application of iso-static pressure or by the pressure of the plastic being molded around them. Larger magnet wire can then be used which increases the power of the electric motor using the armature having the larger magnet wire. A two or three plate mold may be used to mold the plastic around the armature. Balancing features can be molded in place. The plastic can have a base polymer that is a blend of two or more polymers and various thermally conductive fillings.

Method for making an encapsulated coil structure

Magnet wires wound in slots in a lamination stack of a dynamoelectric machine are encapsulated, in whole or in part, with thermally conductive plastic. Pre-formed features having a thermal conductivity higher than the thermally conductive plastic are insert molded when the plastic is molded. The pre-formed features may include a finned end cap and a fan. Alternatively, end domes of the plastic over end coils of the wound magnet wires have a metallic layer on them, such as by being metallized. The end domes can be formed with features which are also metallized. The thermally conductive plastic can have a phase change additive in it. The magnet wires can have a layer of heat activated adhesive that is activated when the plastic is molded. Slots in the lamination stack can include slot liners formed of thermally conductive plastic. A fan can be formed when the thermally conductive plastic is molded to encapsulate the magnet wires.

A viewing window for covering an aperture in a hand-held circular saw includes an optically transmissive member adapted to be coupled with the guard. The member is movable between a closed position, wherein the member substantially covers the aperture, and the open position, wherein the member at least partially uncovers the aperture, to allow the cleaning of the member. A structure is provided for biasing the member to the closed position.

Viewing window for circular saw guard

A switch assembly has a reversible switch with an activation member, electronics, and a plurality of contacts to couple the electronics with a power source. A connector assembly is coupled with the switch assembly contacts. The connector assembly includes a first one-piece connector having a circuit portion coupled with a plurality of contacts. Also, the first connector includes a terminal portion continuous with the circuit portion and connected directly with a positive terminal of the power source. A second one-piece connector has a circuit portion coupled with a second plurality of contacts. The second connector also includes a terminal portion continuous with the circuit portion and directly coupled with a negative terminal of a power source.

Power tool with switch and electrical connector assemblies

The cylindrical plug of a low-voltage, high current capacity connector assembly has an axially positioned sleeve wiping contact and a transversely positioned U-shaped channel member to provide two pairs of planar wiping contact surfaces parallel to the plug axis and substantially perpendicular to the plug housing surface. The socket component, which will accept standard low-voltage, low current car appliance plugs, includes an internally mounted, closed face pin contact and a barrel contact having depending ears positioned to engage the protruding sides of the plug U-shaped channel member. The socket also has an internal boss and housing lip to prevent electrical activation of a standard automotive cigarette lighter plug, and the plug component of the connector assembly has the sleeve contact recessed to prevent contact following insertion into a conventional cigarette lighter socket. The mobile power tool and appliance operating system includes a portable lead-acid battery pack having a high current capacity socket compatible with existing low current plugs used with appliances intended to operate from automotive cigarette lighter sockets. Matable high current capacity plugs are attached to power tools and appliances through retractable cords. The battery pack is receivable in a 120 VAC powered charging base having a self-contained charging circuit including a transformer and a voltage regulator.

Low-voltage, high current capacity connector assembly and mobile power

A mobile power tool and appliance operating system includes a portable lead-acid battery pack having a high current capacity socket compatible with existing low current plugs used with appliances intended to operate from automotive cigarette lighter sockets. Matable high current capacity plugs are attached to power tools and appliances through retractable cords. The battery pack is receivable in a 120 VAC powered charging base having a self-contained charging circuit including a transformer and a voltage regulator. The high current socket housing prevents inadvertent operation with an automotive cigarette lighter plug, and the high current plug housing prevents electrical contact in a automotive cigarette lighter socket, for safety reasons. In another embodiment, the battery pack is provided with two sockets for delivering different power outputs at each respective socket. Recharging of the battery pack can also be accomplished via connection made to one of the sockets.

Growing community of inventors

Bel Air, MD, United States of America

Michael R Sell