US 12,068,663 B2
Brushless motor having an overmolded rotor
John B. Fogle, White Hall, MD (US); Colin M. Crosby, Baltimore, MD (US); David J. Smith, Columbia, MD (US); Merritt J. Tennison, Seattle, WA (US); and Madhur M. Purohit, Towson, MD (US)
Assigned to Black & Decker Inc., New Britain, CT (US)
Filed by Black & Decker Inc., New Britain, CT (US)
Filed on Jul. 29, 2021, as Appl. No. 17/388,812.
Application 17/388,812 is a continuation of application No. 16/169,435, filed on Oct. 24, 2018, granted, now 11,081,933.
Application 16/169,435 is a continuation of application No. 14/973,090, filed on Dec. 17, 2015, granted, now 10,193,417, issued on Jan. 29, 2019.
Claims priority of provisional application 62/093,785, filed on Dec. 18, 2014.
Claims priority of provisional application 62/093,803, filed on Dec. 18, 2014.
Prior Publication US 2021/0359575 A1, Nov. 18, 2021
This patent is subject to a terminal disclaimer.
Int. Cl. H02K 7/14 (2006.01); B25F 5/00 (2006.01); H02K 1/27 (2022.01); H02K 1/2791 (2022.01); H02K 1/28 (2006.01); H02K 5/16 (2006.01); H02K 7/02 (2006.01); H02K 7/08 (2006.01); H02K 9/06 (2006.01); H02K 11/215 (2016.01); H02K 11/33 (2016.01); H02K 29/08 (2006.01); H02K 1/18 (2006.01)
CPC H02K 7/145 (2013.01) [B25F 5/00 (2013.01); H02K 1/27 (2013.01); H02K 1/2791 (2022.01); H02K 1/28 (2013.01); H02K 5/161 (2013.01); H02K 7/02 (2013.01); H02K 7/086 (2013.01); H02K 9/06 (2013.01); H02K 11/215 (2016.01); H02K 11/33 (2016.01); H02K 29/08 (2013.01); H02K 1/187 (2013.01); H02K 2203/03 (2013.01)] 19 Claims
OG exemplary drawing
 
1. An electric brushless DC (BLDC) motor comprising:
a rotor assembly having a substantially-cylindrical metallic rotor body and at least one rotor magnet;
a stator assembly rotatably disposed relative to the rotor assembly; and
a molded structure including a first mold portion located outside the rotor body that integrally forms a fan at or adjacent an axial end of the rotor body such that an outer diameter of the fan does not exceed an outer diameter of the electric motor, and a second mold portion extending integrally from the first mold portion within the rotor body, wherein the second mold portion engages two axial ends of the at least one magnet to securely support and retain the at least one magnet relative to the rotor body.