US 11,865,690 B2
Control and power module for driving a brushless motor in a power tool
Andrew M. Palich, Ellicott City, MD (US); Michael R. Marjomaa, Mount Wolfe, PA (US); Kevin L. Pulley, White Marsh, MD (US); David J. Smith, Columbia, MD (US); Dennis A. Bush, Dillsburg, PA (US); Mark T. Cherry, White Marsh, MD (US); Scott Eshlemann, Timonium, MD (US); and Tal Gottesman, Parkville, MD (US)
Assigned to Black & Decker Inc., New Britain, CT (US)
Filed by Black & Decker Inc., New Britain, CT (US)
Filed on Aug. 10, 2022, as Appl. No. 17/885,342.
Application 17/885,342 is a continuation of application No. 16/794,509, filed on Feb. 19, 2020, granted, now 11,426,855.
Application 16/794,509 is a continuation of application No. 15/335,568, filed on Oct. 27, 2016, granted, now 10,603,777, issued on Mar. 31, 2020.
Claims priority of provisional application 62/358,732, filed on Jul. 6, 2016.
Claims priority of provisional application 62/248,798, filed on Oct. 30, 2015.
Prior Publication US 2022/0379454 A1, Dec. 1, 2022
This patent is subject to a terminal disclaimer.
Int. Cl. B25F 5/00 (2006.01); B23D 45/04 (2006.01); B25F 5/02 (2006.01); H01M 10/12 (2006.01); H02K 11/215 (2016.01); H02K 11/33 (2016.01); H02K 7/14 (2006.01); H01M 10/42 (2006.01)
CPC B25F 5/008 (2013.01) [B23D 45/044 (2013.01); B25F 5/02 (2013.01); H01M 10/42 (2013.01); H02K 7/145 (2013.01); H02K 11/215 (2016.01); H02K 11/33 (2016.01); H01M 2010/4271 (2013.01); H01M 2220/30 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A power tool comprising:
a tool housing;
a brushless DC (BLDC) motor assembly including a motor housing disposed within the tool housing and having a substantially-cylindrical main body with a rear end at least partially closing the main body, the motor assembly further including a stator and a rotor rotatable relative to the stator both disposed within the motor housing;
a power module including a printed circuit board (PCB) and a plurality of power switches mounted on the PCB and electrically coupled to the motor assembly, wherein the PCB includes a width that is greater than a diameter of the motor assembly; and
a mounting bracket secured to an end of the motor assembly and including a mating portion arranged to mate with the end of the motor assembly, a plurality of mount posts extending radially-outwardly from the mating portion, and a plurality of axial walls extending between outer ends of the plurality of mount posts and at least partially housing the power module to support the PCB in a substantially parallel orientation relative to the rear end of the motor assembly,
wherein the mating portion comprises a substantially cylindrical portion arranged to mate around a circumferential portion of the motor housing at or near the rear end of the motor housing.