US 11,670,977 B2
Outer rotor brushless motor stator mount
John B. Fogle, White Hall, MD (US); Dustin Jeffries, Baltimore, MD (US); Michael R. Marjomaa, Mount Wolfe, PA (US); Kevin L. Pulley, White Marsh, MD (US); Vincent W. Zou, Lutherville-Timonium, MD (US); Jarrett A. Dunston, Bel Air, MD (US); David J. Smith, Columbia, MD (US); Rene Thieme, Riesa (DE); Tim Heimrich, Bad Camberg (DE); Tobias Heep, Hadamar-Steinbach (DE); Daniel Bernhart, Bad Camberg (DE); and Dieter Schmidtfrerick, Idstein (DE)
Assigned to Black & Decker Inc., New Britain, CT (US)
Filed by Black & Decker Inc., New Britain, CT (US)
Filed on Apr. 23, 2020, as Appl. No. 16/856,762.
Claims priority of provisional application 62/837,935, filed on Apr. 24, 2019.
Claims priority of provisional application 62/881,105, filed on Jul. 31, 2019.
Prior Publication US 2020/0343780 A1, Oct. 29, 2020
Int. Cl. H02K 5/16 (2006.01); H02K 5/15 (2006.01); H02K 1/2786 (2022.01); H02K 11/33 (2016.01); B25F 5/02 (2006.01); H02K 7/14 (2006.01); H02K 29/08 (2006.01); H02K 1/28 (2006.01); H02K 3/52 (2006.01); H02K 9/06 (2006.01); H02K 15/03 (2006.01); H02K 21/22 (2006.01)
CPC H02K 1/2786 (2013.01) [B25F 5/02 (2013.01); H02K 1/28 (2013.01); H02K 3/522 (2013.01); H02K 5/15 (2013.01); H02K 5/16 (2013.01); H02K 5/161 (2013.01); H02K 7/14 (2013.01); H02K 7/145 (2013.01); H02K 9/06 (2013.01); H02K 11/33 (2016.01); H02K 15/03 (2013.01); H02K 21/22 (2013.01); H02K 29/08 (2013.01)] 15 Claims
OG exemplary drawing
 
1. A brushless direct-current (BLDC) motor comprising:
a rotor shaft extending along a center axis;
a stator having a stator core, a plurality of teeth extending radially outwardly from the stator core, a plurality of windings wound around the stator teeth, a stator collar mounted on the stator core, and a plurality of terminals mounted on the stator collar in a direction parallel to the longitudinal axis and electrically coupled to the plurality of windings;
a rotor having a rotor core disposed around the stator, a plurality of permanent magnets secured to the rotor core, and an inner annular member mounted on the rotor shaft;
a first end cap including a radial back plate disposed on a first side of the stator and having a front center opening through which the rotor shaft is supported via a front bearing; and
a second end cap having an inner annular body, an outer annular body, and a main body extending on a second side of the stator from the inner annular body to the outer annular body, the inner annular body extending axially inwardly and forming a rear center opening, wherein the inner annular body includes a first portion that extends at least partially into an opening of the stator core and supports the rotor shaft via a rear bearing radially intersecting at least a portion of the stator, and a second portion rearward of the first portion that receives a rear end of the rotor shaft therein and houses a sensor board therein, the sensor board accommodating at least one positional sensor facing the end of the rotor shaft,
wherein the second end cap further comprises a plurality of openings formed in the main body around the inner annular body for passage of the plurality of terminals so distal ends of the plurality of terminals project outside the second end cap, wherein a radial plane passing through the sensor board intersects the plurality of terminals.