Black Decker Inc.

Stephen P Osborne

Brian E Friedman

Eric E Hatfield

Jarrett A Dunston

David J Smith

Earl M Ortt

Justin H Ayers

David E Gillespie

Daniel Puzio

Robert S Gehret

Stuart E Garber

Daniel L Krout

Robert G Kusmierski

Colin M Crosby

Joao Norona

Daniel F Heck

Eva J Dixon

Joerg Zellerhoff

Amanda Miller

Corey G Robertson

Ryan F Schroeder

Jeffrey D Delcamp

Michael Kenneth Forster

Barak N Gohn

John Charles Vanko

Joseph Patrick Kelleher

Paul S White

John D Cox

Tal Gottesman

William D Spencer

Brian C Sterling

Jeffery D Delcamp

Jeff Delcamp

Richard Thomas Walter

James D Schroeder

Scott J Eshleman

Robert Alan Usselman

Aris C Cleanthous

Michael C Doyle

Jason K Leh

Redeat Girma Alemu

Jiaqi Zhang

Anatoliy Nosov

Kevin Cox

Dharmendra Rathod

Ahmed S Shaik

William M Spencer

Justin Ayres

Joerg Zellerhof

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 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 solar power system and method of operation includes a solar array, a plurality of loads electrically coupled in parallel to the solar array, and a control circuit electrically coupled to the solar array and in communication with the loads. The control circuit is configured to cause the solar array to operate at a maximum power point (MPP), prioritize power requirements of the loads, and variably allocate power from the solar array among the loads according to the prioritized power requirements of the loads.

Solar power system

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.

An electric motor is provided including: a stator, an armature rotatably received within the stator and having an armature shaft on which a commutator is mounted, and a brush assembly. The brush assembly defines a first side facing the stator and a second side. The brush assembly includes a brush card mount having openings, brushes in sliding contact with the commutator, and thermally-conductive brush holders that support the brushes. Each brush holder includes a base piece disposed between the first side of the brush assembly and the stator, and a main piece including a brush-holder portion and two side flat portions. The brush-holder portion is axially received through a brush card mount opening from the first side of the brush assembly and protrude over the second side to house a brush. The two side flat portions are axially sandwiched between the base piece and the brush card mount.

Brush assembly having multi-piece brush holders for an electric motor, brush holder main piece with flat portions between base piece and brush card mount

A power tool includes a tool body including a motor having an output member that drives an accessory. A chuck is coupled for rotation with the output member relative to the tool body and configured to retain the accessory. The chuck has a chuck body that defines at least one light pipe formed therethrough. A light source disposed on a light ring coupled to the tool body and includes at least one light. Each at least one light source aligns with each of the at least one light pipe intermittently during rotation of the chuck.

Lighted power tool

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.

An electric motor is provided including: a stator, an armature rotatably received within the stator and having an armature shaft on which a commutator is mounted, and a brush assembly. The brush assembly defines a first surface facing the stator and a second surface opposite the first surface. The brush assembly includes a brush card mount having openings, brushes in sliding contact with the commutator to supply electric current to the commutator, and thermally-conductive brush holders that house the brushes. Each of the brush holders includes a base portion disposed substantially along a same plane as a surface of the brush card mount to form the first surface of the brush assembly, and a main portion protruding from the base portion through a respective opening of the brush card mount to house a respective brush at least partially over the second surface of the brush assembly.

Brush assembly with brush card mount with brush holders having base and main portion pieces

An electric motor is provided including a stator, an armature rotatably received within the stator and having an armature shaft on which a commutator is mounted, and a brush assembly. The brush assembly includes a planar portion disposed around the commutator and accommodating a plurality of brushes, a bridge portion disposed at an end of the commutator and extending from the planer portion via two or more legs, and metal routing(s) disposed on or within the bridge portion to electrically couple the brushes.

Brush assembly with bridge and leg portions with metal routing

An electric motor is provided including a stator and an armature rotatably received within the stator, the armature having an armature shaft on which a commutator is mounted. The motor also includes a brush assembly having a brush card mount disposed around the commutator, a brush holder mounted on a surface of the brush card mount, and a brush disposed within the brush holder in sliding contact with the commutator to supply electric current to the commutator. A torsion spring is secured to the brush card mount adjacent the brush holder, the spring having a leg arranged to engage the back surface of the brush. A spring stop post is disposed proximate an outer periphery of the brush card mount to limit an outward movement of the leg of the spring away from the back surface of the brush.

Spring post for brush card for a power tool

A power tool includes a housing coupled to an electrical power source, a motor contained in the housing, and a motor control circuit that controls output speed of the motor. A light nut is coupled to the housing to illuminate a work surface. A light unit control circuit controls illumination of the light, unit. A switch unit is coupled to the housing and selectively operable to control the operation of the motor control circuit and the light unit control circuit. The light unit control circuit includes a timer configured to cause the light unit to illuminate a first brightness level when the switch unit is actuated, and to remain illuminated at the first brightness level for a predetermined time period after the trigger is actuated. The predetermined time period restarts if the switch unit is not deactivated before the end of the predetermined time period.

Power tool with light unit

An electric motor includes a stator, a shaft rotatable with respect to the stator, and a lamination stack mounted on the shaft and having radially extending teeth forming slots therebetween. An end insulator is provided at an end of the lamination stack having forming slots therebetween. Motor coils are wound in the lamination stack slots and the end insulator slots. A fan having blades attached to a fan ring and mounted to an end of the lamination stack. The fan ring includes longitudinally-extending tongues arranged to be mounted at the end of the lamination stack and the end insulator includes longitudinally-extending notches corresponding to the tongues of the fan ring to allow the tongues to be in direct contact with the end of the lamination stack.

Power tool having improved motor fan assembly

An electric motor is provided including a stator assembly having a stator body and magnets attached to an inner surface of the stator body via an adhesive, and an armature rotatably received within the stator assembly and having an armature shaft on which a commutator is mounted. A brush assembly is provided including a brush card mount disposed around the commutator and a mating housing longitudinally extending from the brush card mount. The mating housing includes a cylindrical wall and a mating surface formed substantially perpendicularly to an inner surface of the cylindrical wall and arranged to mate with an end surface of the stator body. The mating surface of the mating housing includes posts longitudinally extending along the inner surface of the cylindrical wall and recessed surfaces formed therebetween, the posts being mounted on the end surface of the stator body.

Brush assembly mount

Growing community of inventors

Pikesville, MD, United States of America

Stephen P Osborne