US 11,894,744 B2
Stator assembly for a brushless motor in a power tool
David J. Smith, Columbia, MD (US); Justin H. Ayers, Jarrettsville, MD (US); David E. Gillespie, Baltimore, MD (US); Eric E. Hatfield, Anthem, AZ (US); Earl M. Ortt, Towson, MD (US); Stephen P. Osborne, Glen Arm, MD (US); Brian Friedman, Baltimore, MD (US); and Jarrett A. Dunston, Anderson, SC (US)
Assigned to BLACK & DECKER INC., New Britain, CT (US)
Filed by Black & Decker Inc., New Britain, CT (US)
Filed on Feb. 7, 2022, as Appl. No. 17/666,376.
Application 17/666,376 is a continuation of application No. 17/484,595, filed on Sep. 24, 2021.
Application 17/484,595 is a continuation of application No. 16/689,269, filed on Nov. 20, 2019, granted, now 11,133,720, issued on Sep. 28, 2021.
Application 16/689,269 is a continuation of application No. 15/783,435, filed on Oct. 13, 2017, granted, now 10,523,080, issued on Dec. 31, 2019.
Application 15/783,435 is a continuation of application No. 13/919,352, filed on Jun. 17, 2013, granted, now 9,819,241, issued on Nov. 14, 2017.
Application 13/919,352 is a continuation in part of application No. 13/704,033, granted, now 10,056,806, issued on Aug. 21, 2018, previously published as PCT/US2011/040306, filed on Jun. 14, 2011.
Claims priority of provisional application 61/660,335, filed on Jun. 15, 2012.
Claims priority of provisional application 61/354,537, filed on Jun. 14, 2010.
Claims priority of provisional application 61/354,543, filed on Jun. 14, 2010.
Prior Publication US 2022/0158517 A1, May 19, 2022
This patent is subject to a terminal disclaimer.
Int. Cl. H02K 3/52 (2006.01); H02K 7/14 (2006.01)
CPC H02K 3/521 (2013.01) [H02K 3/522 (2013.01); H02K 7/145 (2013.01); H02K 2203/06 (2013.01)] 10 Claims
OG exemplary drawing
 
1. A power tool comprising:
a housing including a motor housing and a handle portion;
a motor control unit disposed within the handle portion;
a transmission assembly mounted forward of the motor housing; and
a motor housed inside the motor housing, the motor having a stator assembly and a rotor rotatably arranged inside the stator, the stator assembly comprising:
a stator core defining a plurality of poles and having an outer surface that is substantially cylindrical formed around a longitudinal axis of the motor;
at least one magnet wire wound on the plurality of poles forming a plurality of stator windings; and
a bus bar comprising: a non-conductive mount arranged on the outer surface of the stator core, and a plurality of conductive terminals arranged to receive electric power from a power source and supply electric power to a plurality of phases,
wherein each of the conductive terminals includes: a main portion at least partially mounted on the non-conductive mount, a tang portion extending angularly from a first longitudinal end of the main portion, and a connection tab extending angularly from a second longitudinal end of the main portion, wherein the first longitudinal end of the main portion is rearward of the second longitudinal end relative to the transmission assembly, 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 power wire supplying electric power to the motor, wherein the power wire is received from the motor control unit through the handle portion and connects to the connection tab without traversing rearwardly past the second longitudinal end of the main portion.