Black Decker Inc.

Other

The University of Warwick

The Black and Decker Manufacturing Company

The Black & Decker Company

Atlas Dynamic Devices, LLC

Richard Thomas Walter

Hung T Du

Christopher Ryan Yahnker

Michael R Sell

Dale Kenneth Wheeler

Joshua F West

Earl M Ortt

Brandon L Verbrugge

Robert G Moores, Jr

Daniele C Brotto

John C Stone

Daniel Puzio

Daniel Joseph White

John E Buck

David J Smith

James B Watson

Adan Ayala

Paul S White

Robert Bradus

Thomas Jay Bodine

Edward Allen Harrison

Howard T White

Pradeep M Bhagwat

Samuel G Woods

Michael Jeffrey Agnes

Michael Lester O'Banion

Michael Kenneth Forster

Garrett Patrick McCormick

Frederick R Bean

Bhanuprasad V Gorti

Charles Pollock

Richard C Nickels, Jr

Martin P Gierke

Aris C Cleanthous

Ren H Wang

David A Saar

Helen Geraldine Phyllis Pollock

R Roby Bailey

Donald E Elson

Dale C Grieb

Alfred Schiazza, Iii

Salvatore R Abbratozzato

Stephen P Osborne

Shailesh P Waikar

Colin M Crosby

Alan A Gilmore

Jiaqi Zhang

Allyn Boyce

Peter Edward Morris

Sam Woods

J Michael Weaver

Ahmed S Shaik

Kevin Cox

Bhauprasad V Gorti

Michael J Weaver

James Michael Weaver

Donald Edwin Elson

John L Bowman, Jr

George W Lipa

Garrett Patrick Mccormick

A power tool is provided including a housing and an electric motor disposed within the housing, where the electric motor includes a stator and an armature rotatably received within the stator, and the armature includes an armature shaft on which a commutator is mounted. The power tool includes a brush assembly disposed around the commutator. The brush assembly includes at least two brushes in contact with the commutator and a circuit board mounted on the brush assembly and in electrical contact with the brushes. The circuit board includes at least one electromagnetic interference (EMI) suppression component electrically mounted thereon, the EMI suppression component being electrically coupled to the brushes.

Electromagnetic interference (EMI) suppression in a power tool

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.

An electric motor has a stator in which an armature is disposed. The armature has a lamination stack having slots in which magnet wires are wound. An armature shaft extends coaxially through the lamination stack and a commutator is disposed on the armature shaft to which ends of the magnet wires are electrically coupled. The magnet wires are at least partially encased in thermally conductive plastic. When the thermally conductive plastic is molded, a balancing feature is formed of the thermally conductive plastic. In aspects, the balancing feature can include a layer of the plastic from which plastic can be removed during balancing; one or more balancing rings adjacent axial sides of the lamination stack from which plastic can be removed to balance the armature; or one or more balancing rings having one or more pockets therein in which one or more weights are disposed to balance the armature.

Method for forming a power tool

An improved power tool system includes a power tool and an external power supply connected via a cable to provide utility and safety in a hazardous operation such as loading ammunition into a weapon in an environment of flammable materials and extreme environmental exposure. The power tool includes a sparkless motor, a sparkless controller and sparkless switches, in a sealed enclosure with improved heat transfer means. The power tool has improved torque controlling means to mitigate reaction torque to the operator and equipment when starting or stopping highly inertial loads. A sealed enclosure is provided to prevent liquids from entering the motor and controller cavity and includes a thermally conductive path to conduct heat from the motor and controller through the enclosure to cooling fins and a coolant path formed between the fins and an entrapment wall.

Power transmission tool and system

A method of forming a power tool includes forming and balancing an armature by 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, and molding plastic to at least partially encase the magnet wires in plastic and forming a balancing feature. Plastic is removed from the balancing feature during dynamic balancing of the armature. The armature is then disposed in a stator to form an electric motor and the electric motor is disposed in a power tool.

A method of manufacturing a power tool includes forming an armature by placing an electrically insulative sleeve on an armature shaft, securing a lamination stack having slots therein on the armature shaft with the insulative sleeve disposed therebetween, securing a commutator on one end of the armature shaft with the insulative sleeve disposed therebetween, winding magnet wires in the slots in the lamination stack and securing ends of the magnet wires to the commutator, and molding thermally conductive plastic to at least partially encase the magnet wires in plastic. The armature is then disposed in a stator to form an electric motor and the electric motor is disposed in a power tool. In an aspect, electrically insulative plastic is molded in the slots of the lamination stack to form slot liners and around the ends of the lamination stack to form end spiders. In an aspect, the method includes disposing an electrically insulative seal around the insulative sleeve and abutting the commutator to seal any gap between an end of the insulative sleeve and the commutator.

Method of manufacturing an electric motor of a power tool and of manufacturing the power tool

A system of cordless power tools includes a cordless power tool adapted to removably receive a rechargeable battery pack. The battery pack and the power tool can have complementary grooves and rails or L-shaped surfaces that aid in aligning the positive and negative blade terminals of the battery pack to the positive and negative tool terminals, respectively, of the power tool.

Cordless power tool system having cordless power tool and battery pack that employ cooperating rails and grooves for connection of battery pack to cordless power tool

A tool system with a battery pack and a device that is configured to be selectively coupled to the battery pack. The battery pack has first, second and third pack terminals. The device has a battery mount with a body that defines a well and first and second device terminals. The body defines a well into which the battery pack is removably received. The first and second device terminals extend outwardly from a proximal portion of the battery mount and engage the first and second pack terminals when the battery pack is fully inserted into the well. At least one of the first and second pack terminals and the first and second device terminals is a male terminal that is received into a corresponding one of the first and second pack terminals and the first and second device terminals. A longitudinal axis of each of the first, second and third pack terminals is arranged parallel to a longitudinal axis of the battery pack.

Tool system having rechargeable battery pack

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

Cordless power tool system having slidably-engaging power source connection

Growing community of inventors

Baldwin, MD, United States of America

Richard Thomas Walter