US 11,951,603 B2
Brushless motor system for power tools
Joseph P. Kelleher, Parkville, MD (US); William F. Gallagher, Stewartstown, PA (US); Craig A. Oktavec, Forest Hill, MD (US); David J. Smith, Columbia, 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 May 9, 2023, as Appl. No. 18/314,352.
Application 18/314,352 is a continuation of application No. 17/495,494, filed on Oct. 6, 2021, granted, now 11,691,260.
Application 17/495,494 is a continuation of application No. 16/580,424, filed on Sep. 24, 2019, granted, now 11,241,781, issued on Feb. 8, 2022.
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 2023/0278187 A1, Sep. 7, 2023
Int. Cl. B25F 5/00 (2006.01); B24B 23/02 (2006.01); B25F 5/02 (2006.01); H02K 1/14 (2006.01); H02K 1/2706 (2022.01); H02K 3/18 (2006.01); H02K 3/34 (2006.01); H02K 3/487 (2006.01); H02K 3/52 (2006.01); H02K 5/10 (2006.01); H02K 5/20 (2006.01); H02K 7/08 (2006.01); H02K 7/116 (2006.01); H02K 7/14 (2006.01); H02K 9/04 (2006.01); H02K 9/06 (2006.01); H02K 9/22 (2006.01); H02K 11/215 (2016.01); H02K 11/33 (2016.01); H02K 21/16 (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)] 18 Claims
OG exemplary drawing
 
1. A power tool comprising:
a tool housing including a motor housing and a handle portion;
a battery receptacle disposed at an end of the handle portion opposite the motor housing, the battery receptacle being configured to removably receive a battery pack;
a brushless DC (BLDC) motor including an electronically-commutated stator assembly and a rotor assembly configured to rotate relative to the stator assembly, the stator assembly comprising a stator lamination stack sized to be received within the motor housing having a circumference of approximately 140 to approximately 190 mm;
a power switching circuit including a plurality of solid-state power switches disposed on a current path from the battery pack to the motor;
an electronic controller configured to switch a switching operation of the plurality of solid-state power switches to regulate supply of electric power from the battery pack to the motor; and
a gear case mounted on the tool housing forward of the motor, the gear case supporting an output shaft rotatably driven by the motor;
wherein the handle portion is attached to a rear end of the motor housing and elongated along a longitudinal axis of the motor housing, and
wherein the motor produces a maximum power output of at least 1600 watts for driving the output shaft when powered by the battery pack.