US 12,088,160 B2
Brushless DC motor with circuit board for winding interconnections
Barak N. Gohn, Shrewsbury, PA (US); Colin M. Crosby, Baltimore, MD (US); Nicholas J. Lowe, Lutherville-Timonium, MD (US); James R. Clarke, York, PA (US); Daniel F. Heck, Toms River, NJ (US); Michael P. Sikora, Baltimore, MD (US); Christian B. Rogerson, Towson, MD (US); Ryan F. Schroeder, Hampstead, MD (US); Connor T. Mohan, Fallston, MD (US); and Michael D. Grove, Windsor, PA (US)
Assigned to Black & Decker Inc., New Britain, CT (US)
Filed by Black & Decker Inc., New Britain, CT (US)
Filed on Dec. 14, 2021, as Appl. No. 17/550,341.
Claims priority of provisional application 63/129,797, filed on Dec. 23, 2020.
Prior Publication US 2022/0200388 A1, Jun. 23, 2022
Int. Cl. H02K 1/27 (2022.01); H02K 1/16 (2006.01); H02K 1/276 (2022.01); H02K 1/28 (2006.01); H02K 3/28 (2006.01); H02K 3/46 (2006.01); H02K 3/52 (2006.01); H02K 5/16 (2006.01); H02K 7/14 (2006.01); H02K 9/06 (2006.01); H02K 11/33 (2016.01); H02K 21/12 (2006.01); H02K 21/16 (2006.01); B25F 5/00 (2006.01); H02K 11/215 (2016.01)
CPC H02K 21/12 (2013.01) [H02K 1/16 (2013.01); H02K 1/165 (2013.01); H02K 1/27 (2013.01); H02K 1/276 (2013.01); H02K 1/28 (2013.01); H02K 3/28 (2013.01); H02K 3/46 (2013.01); H02K 3/522 (2013.01); H02K 5/16 (2013.01); H02K 7/145 (2013.01); H02K 9/06 (2013.01); H02K 11/33 (2016.01); H02K 21/16 (2013.01); B25F 5/001 (2013.01); H02K 11/215 (2016.01); H02K 2203/03 (2013.01); H02K 2213/03 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A brushless direct-current (BLDC) motor comprising:
a rotor assembly including rotor shaft extending along a longitudinal axis and a rotor supporting a plurality of magnets mounted on the rotor shaft;
a stator assembly including a stator comprising a stator core and a plurality of stator teeth radially extending from the stator core and defining a plurality of slots therebetween, and a plurality of stator windings wound on the plurality of stator teeth;
a plurality of stator terminals extending substantially parallel to the longitudinal axis from the stator assembly; and
a circuit board mounted on the plurality of stator terminals adjacent the stator assembly, the circuit board including a plurality of conductive traces extending between the plurality of stator terminals to facilitate at least one of a parallel or a series connection between at least two stator windings of the plurality of stator windings corresponding to the same phase of the motor,
an end insulator provided at an axial end of the stator to electrically insulate the stator from the plurality of stator windings, the end insulator including a plurality of support members to support the plurality of stator terminals relative to the stator assembly, wherein each support member of the end insulator includes two posts for each of the plurality of stator terminals projecting on circumferential sides of the stator terminal to support the stator terminal relative to the end insulator, wherein the circuit board is mounted on the plurality of support members and fastened to at least one of the two posts of each support member.