US 11,691,260 B2
Brushless motor system for power tools
Joseph P. Kelleher, Parkville, MD (US); William F. Gallagher, Stewartstown, PA (US); Sean R. Templeton, Finksburg, MD (US); Mark R. Poetzl, Rising Sun, MD (US); Seth M. Robinson, Henryville, PA (US); Marcell E. Coates, Baltimore, MD (US); Madhur M. Purohit, Towson, MD (US); Timothy J. Seeley, Bel Air, MD (US); and Joshua M. Lewis, Baltimore, MD (US)
Assigned to Black & Decker Inc., New Britain, CT (US)
Filed by Black & Decker Inc., New Britain, CT (US)
Filed on Oct. 6, 2021, as Appl. No. 17/495,494.
Application 17/495,494 is a continuation of application No. 16/580,424, filed on Sep. 24, 2019, granted, now 11,241,781.
Application 16/580,424 is a continuation of application No. 15/292,568, filed on Oct. 13, 2016, granted, now 10,500,708, issued on Dec. 10, 2019.
Claims priority of provisional application 62/241,385, filed on Oct. 14, 2015.
Prior Publication US 2022/0134530 A1, May 5, 2022
Int. Cl. B25F 5/00 (2006.01); B25F 5/02 (2006.01); H02K 3/487 (2006.01); H02K 3/52 (2006.01); H02K 5/20 (2006.01); H02K 9/22 (2006.01); H02K 11/33 (2016.01); B24B 23/02 (2006.01); H02K 7/116 (2006.01); H02K 7/14 (2006.01); H02K 9/06 (2006.01); H02K 11/215 (2016.01); H02K 7/08 (2006.01); H02K 9/04 (2006.01); H02K 1/14 (2006.01); H02K 1/2706 (2022.01); H02K 3/18 (2006.01); H02K 21/16 (2006.01); H02K 3/34 (2006.01); H02K 5/10 (2006.01); H02K 3/38 (2006.01)
CPC B25F 5/008 (2013.01) [B24B 23/028 (2013.01); B25F 5/02 (2013.01); H02K 1/146 (2013.01); H02K 1/2706 (2013.01); H02K 3/18 (2013.01); H02K 3/34 (2013.01); H02K 3/487 (2013.01); H02K 3/522 (2013.01); H02K 5/10 (2013.01); H02K 5/207 (2021.01); H02K 7/08 (2013.01); H02K 7/116 (2013.01); H02K 7/145 (2013.01); H02K 9/04 (2013.01); H02K 9/06 (2013.01); H02K 9/227 (2021.01); H02K 11/215 (2016.01); H02K 11/33 (2016.01); H02K 21/16 (2013.01); H02K 3/38 (2013.01); H02K 2203/09 (2013.01); H02K 2203/12 (2013.01); H02K 2213/03 (2013.01)] 22 Claims
OG exemplary drawing
 
1. A power tool comprising:
a gear case having a spindle;
a motor case connected to a rear end of the gear case along a longitudinal axis;
a handle portion extending from a rear end of the motor case along the longitudinal axis;
a motor housed inside the motor case, the motor having a stator, a rotor rotationally arranged relative to the stator, and a fan in rotational connection with the rotor;
at least one air intake arranged at least one of the motor case or the handle portion near the rear end of the motor case; and
a power module including a plurality of power switches for driving the motor and a heat sink, the power module being housed in at least one of the motor case or the handle portion near the rear end of the motor case such that rotation of the fan causes air flow to enter through the air intake and flow near the heat sink and through the motor, wherein the power module comprises a power circuit board orientated along a radial plane that perpendicularly intersects the longitudinal axis, and wherein the plurality of power switches is mounted on the power circuit board.