CN219740129U - Power tool - Google Patents

Abstract

The power tool described herein includes a housing, a brushless Direct Current (DC) motor, a non-conductive terminal mount, and a plurality of terminals. The housing has a motor housing portion, a handle portion, and a battery pack interface. A brushless DC motor is located within the motor housing portion and has a rotor and a stator. A non-conductive terminal mount is located on the outer peripheral surface of the stator and includes an angled surface. The angled surface is not substantially parallel to the longitudinal axis of the motor. A plurality of terminals are mounted on the angled surfaces of the terminal mount. Each of the terminals is angled in a first direction such that the terminals are not substantially parallel to a longitudinal axis of the motor.

Description

Power tool

Cross Reference to Related Applications

The present application claims priority from U.S. provisional patent application No. 63/035,273, filed on 5 th 6 th 2020, U.S. provisional patent application No. 63/036,035, filed on 8 th 2020, and U.S. provisional patent application No. 63/050,166, filed on 10 7 th 2020, all of which are incorporated herein by reference in their entirety.

Technical Field

The present disclosure relates to a brushless motor for a power tool.

Background

Power tools typically include a motor connected to a power source to power the tool. One such motor is a brushed direct current ("DC") motor. In a brushed DC motor, the motor brushes turn on and off electrical connection to the motor due to the rotation of the rotor. Conventionally, brush DC motors are used in power tools because of their relative ease of manufacture and low cost.

Disclosure of Invention

Brush DC motors have several drawbacks when used in power tools. One disadvantage of brushed DC motors is that the brushes eventually wear, thereby shortening the life of the power tool. In addition, because the brushes make and break electrical connection, sparks and electrical noise may be generated within the power tool. Brushless DC motors are another type of motor used in power tools. Brushless DC motors use electronically controlled switches rather than brushes to selectively power the coils of the motor to drive the rotor.

Embodiments of the present disclosure relate to brushless DC motors for power tools and power tools incorporating such brushless DC motors. The power tool described herein includes: a housing; a controller located within the housing; and a brushless motor located within the housing and controlled by the controller. The brushless motor includes a stator assembly and a rotor assembly. The stator assembly includes a stator core having stator laminations with annular portions and inwardly extending stator teeth. The rotor assembly includes a rotor core having rotor laminations and defining a central aperture that receives the output shaft.

The power tool described herein includes a housing, a brushless Direct Current (DC) motor, a non-conductive terminal mount, and a plurality of terminals. The housing has a motor housing portion, a handle portion, and a battery pack interface. The battery pack interface is configured to removably receive and support a battery pack. A brushless DC motor is located within the motor housing portion and has a rotor and a stator. The rotor is coupled to a motor shaft arranged to produce an output outside the housing. A non-conductive terminal mount is located on the outer peripheral surface of the stator and includes an angled surface. The angled surface is not substantially parallel to the longitudinal axis of the motor. A plurality of terminals are mounted on the angled surfaces of the terminal mount. Each of the terminals is angled in a first direction such that the terminals are not substantially parallel to a longitudinal axis of the motor. The first end of each of the terminals includes a tang ring configured to be electrically and physically connected to the stator coil. A second end of each of the terminals, opposite the first end, is electrically connected to a power source configured to provide power to the stator coil. The first end of each of the terminals is closer to the longitudinal axis than the corresponding second end of each of the terminals.

The power tool described herein includes a housing, a brushless DC motor, and a plurality of terminals. The housing has a motor housing portion, a handle portion, and a battery pack interface. The battery pack interface is configured to removably receive and support a battery pack. A brushless DC motor is located within the motor housing portion and has a rotor and a stator. The rotor is coupled to a motor shaft arranged to produce an output outside the housing. The stator includes a lamination stack and a stator molding that supports the lamination stack to form a molded stator body. The stator molding includes a first axial end portion and a second axial end portion opposite the first axial end portion. The plurality of terminals are located on an outer peripheral surface of the stator. Each of the terminals includes a first portion substantially parallel to the longitudinal axis and a second portion extending from the first portion and bent in a radial direction of the motor toward the longitudinal axis of the motor and over a first axial end portion of the stator molding.

The power tool described herein includes a housing and a brushless DC motor. The housing has a motor housing portion, a handle portion, and a battery pack interface. The battery pack interface is configured to removably receive and support a battery pack. A brushless Direct Current (DC) motor is located within the motor housing portion and has a rotor and a stator. The rotor is coupled to a motor shaft arranged to produce an output outside the housing. The rotor includes a plurality of magnets located within the rotor stack, each of the magnets having a length along a longitudinal axis of the brushless DC motor. The length of the magnet along the longitudinal axis defines a rotor envelope along the longitudinal axis. The rotor includes bearing pockets located within the rotor stack at an axial end of the rotor stack and radially within a diameter of the magnet. A recessed bearing (recessed bearing) is located within the bearing pocket. A recessed bearing is located within the rotor envelope and is configured to support the motor shaft.

Before any embodiments are explained in detail, it is to be understood that the embodiments are not limited in their application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The embodiments may be practiced or carried out in a variety of different ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," or "having" and variations thereof is meant to encompass the items listed below and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms "mounted," "connected," "supported," and "coupled" and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.

In addition, it should be understood that embodiments may include hardware, software, and electronic components or modules that, for purposes of discussion, may be shown and described as if most of the components were implemented solely in hardware. However, one of ordinary skill in the art will recognize, based on a reading of this detailed description, that in at least one embodiment, the electronic-based aspects may be implemented in software (e.g., stored on a non-transitory computer-readable medium) executable by one or more processing units, such as a microprocessor and/or an application specific integrated circuit ("ASIC"). Thus, it should be noted that embodiments may be implemented using a number of hardware and software based devices as well as a number of different structural components. For example, the terms "server," "computing device," "controller," "processor," and the like as described in the specification may include one or more processing units, one or more computer readable medium modules, one or more input/output interfaces, and a plurality of different connections (e.g., a system bus) connecting the components.

Relative terms such as "about," "substantially," and the like, as used in connection with a quantity or condition, will be understood by those of ordinary skill in the art to include the stated value and have the meaning dictated by the context (e.g., the term includes at least the degree of error associated with measurement accuracy, tolerances associated with particular values [ e.g., manufacturing, assembly, use, etc. ], and the like). Such terms should also be considered to disclose ranges defined by the absolute values of the two endpoints. For example, the expression "about 2 to about 4" also discloses the range "2 to 4". Relative terms may refer to percentages (e.g., 1%, 5%, 10%, or more) of the indicated value being added or subtracted.

It should be understood that while some of the figures show hardware and software located within a particular device, these depictions are for illustrative purposes only. The functions described herein as being performed by one component may be performed by multiple components in a distributed fashion. Also, functions performed by multiple components may be combined and performed by a single component. In some embodiments, the illustrated components may be combined or divided into separate software, firmware, and/or hardware. For example, the logic and processes may be distributed among multiple electronic processors rather than being located in and executed by a single electronic processor. Regardless of how the hardware and software components are combined or partitioned, the hardware and software components may reside on the same computing device or may be distributed among different computing devices connected by one or more networks or other suitable communication links. Similarly, components described as performing a particular function may also perform additional functions not described herein. For example, a device or structure that is "configured" in some way is configured at least in that way, but may also be configured in ways that are not explicitly listed.

Other aspects of the embodiments will become apparent by consideration of the detailed description and accompanying drawings.

Drawings

Fig. 1 shows a power tool comprising a brushless DC motor.

Fig. 2 shows a block diagram of the brushless power tool as illustrated in fig. 1.

Fig. 3A, 3B, 3C, and 3D illustrate a motor stator according to embodiments described herein.

Fig. 4A, 4B, 4C, and 4D illustrate a motor stator according to embodiments described herein.

Fig. 5A, 5B, and 5C illustrate a motor stator according to embodiments described herein.

Fig. 6A and 6B illustrate a motor stator according to embodiments described herein.

Fig. 7A, 7B, and 7C illustrate a motor stator according to embodiments described herein.

Fig. 8A, 8B, and 8C illustrate a motor stator according to embodiments described herein.

Fig. 9A, 9B, and 9C illustrate a motor stator according to embodiments described herein.

Fig. 10A, 10B, and 10C illustrate a motor stator according to embodiments described herein.

Fig. 11A and 11B illustrate a motor stator according to embodiments described herein.

Fig. 12A and 12B illustrate a motor stator according to embodiments described herein.

Fig. 13A and 13B illustrate a motor stator according to embodiments described herein.

Fig. 14A and 14B illustrate a motor stator according to embodiments described herein.

Fig. 15 illustrates a motor stator according to embodiments described herein.

Fig. 16 illustrates an enlarged view of a terminal assembly of the motor stator of fig. 15 in accordance with an alternative embodiment.

Fig. 17 illustrates an enlarged view of another terminal assembly of the motor stator of fig. 15 in accordance with another alternative embodiment.

Fig. 18 is a perspective view of a stator assembly according to an exemplary embodiment.

Fig. 19 is a perspective view of a molded stator body of the stator assembly of fig. 18.

Fig. 20 is a perspective view of a stator winding wound onto the molded stator body of fig. 19.

Fig. 21 is a top view of the stator winding of fig. 20.

Fig. 22 is a perspective view of a phase line coupled to the stator winding of fig. 20.

Fig. 23 is an exploded view of the stator assembly of fig. 18.

Fig. 24 is a flow chart depicting a method of manufacturing a stator assembly for an electric motor, in accordance with one embodiment.

Fig. 25 is a perspective view of a stator assembly according to another exemplary embodiment.

Fig. 26 is a perspective view of a stator winding of the stator assembly of fig. 25.

Fig. 27 is a perspective view of a phase line coupled to the stator winding of fig. 26.

Fig. 28 is a perspective view of a stator assembly according to another exemplary embodiment.

Fig. 29A, 29B and 29C are perspective views of stator assemblies according to still other exemplary embodiments.

Fig. 30A and 30B illustrate a motor stator according to embodiments described herein.

Fig. 31A and 31B illustrate a motor according to embodiments described herein.

Fig. 32A and 32B illustrate a motor according to embodiments described herein.

Fig. 33A and 33B illustrate a motor according to embodiments described herein.

Fig. 34A and 34B illustrate a motor according to embodiments described herein.

Fig. 35A and 35B illustrate a motor according to embodiments described herein.

Fig. 36 illustrates a motor stator according to embodiments described herein.

Fig. 37 illustrates a motor stator according to embodiments described herein.

Fig. 38 illustrates a motor stator according to embodiments described herein.

Fig. 39 illustrates a motor stator according to embodiments described herein.

Fig. 40A, 40B, 40C, and 40D illustrate a motor stator according to embodiments described herein.

Fig. 41 illustrates a motor terminal according to embodiments described herein.

Detailed Description

Fig. 1 illustrates a power tool 100 including a brushless Direct Current (DC) motor. In a brushless motor power tool, such as power tool 100, the switching element is selectively enabled and disabled by a control signal from a controller to selectively apply power from a power source (e.g., a battery pack) to drive the brushless motor. The power tool 100 is illustrated as a brushless hammer drill having a housing 102 with a handle portion 104 and a motor housing portion 106. The power tool 100 further includes an output unit 107, a torque setting dial 108, a forward/reverse selector 110, a trigger 112, a battery pack interface 114, and a light 116. Although fig. 1 illustrates a hammer drill, in some embodiments, the motor described herein is incorporated into other types of power tools, including drills/wrenches, impact wrenches, circular saws, reciprocating saws, wire cutters, blade blowers, vacuum cleaners, and the like.

Fig. 2 shows a simplified block diagram 120 of a brushless power tool 100 that includes a power source 122, a Field Effect Transistor (FET) 124, a motor 126, a hall effect sensor 128, a motor controller 130, user inputs 132, and other components 133 (battery power meter, work Light (LED), current/voltage sensor, etc.). The power supply 122 provides DC power to the various components of the power tool 100 and may be rechargeable and use a power tool battery pack such as lithium ion battery technology. In some cases, the power source 122 may receive AC power (e.g., 120V/60 Hz) from a tool plug coupled to a standard wall outlet and then filter, condition, and rectify the received power to output DC power. Each hall effect sensor 128 outputs motor feedback information, such as an indication (e.g., a pulse) as the magnet of the rotor rotates across the surface of the hall sensor. Based on motor feedback information from the hall sensor 128, the motor controller 130 can determine the position, speed, and acceleration of the rotor. The motor controller 130 also receives user control from a user input 132, such as by depressing a trigger 112 or switching the forward/reverse selector 110. In response to the motor feedback information and user control, the motor controller 130 transmits control signals to control the FET 124 to drive the motor 126. By selectively enabling and disabling FET 124, power from power source 122 is selectively applied to the stator coils of motor 126 to cause rotation of the rotor. Although not shown, the motor controller 130 and other components of the power tool 100 are electrically coupled to the power source 122 such that the power source 122 provides power thereto.

Various embodiments of the motor 126 are shown and described with reference to fig. 3A-39. Any terminal design may be used with any motor or stator disclosed herein. For example, terminals disclosed as being located on a single terminal mount may alternatively be individually located around the outer circumference of the stator (e.g., spaced apart by about 120 °), and terminals disclosed as being located around the outer circumference of the stator (e.g., spaced apart by about 120 °) may alternatively be located on a single terminal mount.

Fig. 3A, 3B, 3C and 3D illustrate a motor 300 that includes a terminal assembly 305 having a plurality of angled terminals 310. The terminals 310 are angled relative to the longitudinal axis 315 of the motor 300 such that the terminals 310 are not substantially parallel to the longitudinal axis 315 of the motor 300. In some embodiments, the terminals 310 are angled at an angle of 15 ° relative to the longitudinal axis 315 of the motor 300. In other embodiments, the terminals 310 are angled at an angle between 5 ° and 90 ° such that the terminals 310 are again substantially non-parallel to the longitudinal axis 315 of the motor 300. The terminals may be mounted on a terminal mount 316 (see fig. 3C), which may be made of resin, rubber, or another non-conductive material. The terminal mount 316 may include an angled surface on which the terminals 310 are mounted such that the terminals 310 are arranged at an angle of 15 ° or an angle between 5 ° and 90 °. The angled surface may be angled relative to the longitudinal axis 315 of the motor 300 such that the angled surface is not substantially parallel to the longitudinal axis 315 of the motor 300. In some embodiments, the terminal 310 is bent back to a minimum desired safety angle. In some embodiments, stator coils (i.e., stator windings, wire leads, stator winding leads) 317A-317C are soldered, resistance welded, or fused to one end of terminal 310. For example, one end of the stator coil 317 is brazed, resistance welded or fused to the compression tang ring 320 on the first end of the terminal 310. In some embodiments, the wires connecting the terminal 310 to the power source 122 via the FET 124 are soldered or otherwise connected to a second end of the terminal 310 opposite the first end of the terminal 310 on which the tang ring 320 is located.

The stator coil 317 is energized to generate a magnetic field. The stator coil 317 is electrically connected to the corresponding phase line via the terminal 310. In other words, the phase lines are electrically connected to the stator coil 317. For example, the stator coil 317 is selectively energized by the power supply 122 via the FET 124. In the illustrated embodiment, the stator coil 317 includes three phases. The three phases of the stator coil 317 may be interconnected in a triangle, Y-shape, or any other suitable configuration.

As shown in fig. 3A-3C, in some embodiments, the motor 300 includes a lamination stack 325, a stator molding 330 molded or held to the lamination stack 325 to form a molded stator body 335 (fig. 3A). The stator molding 330 of the molded stator body 335 includes a first axial end portion 340, a second axial end portion 345, and an extension portion 350 extending axially along the outer/peripheral surface of the lamination stack 325. The extension 350 is curved along the outer circumferential surface of the lamination stack 325. In the illustrated embodiment, the extension portion 350 extends from the first axial end portion 340 at least partially between the first axial end portion 340 and the second axial end portion 345. The stator molding 330 includes a post 355 formed to extend away from the first axial end portion 340. Posts 355 are wire routing features that assist in the process of winding stator coil 317 onto molded stator body 335. Fig. 3D illustrates the positioning of angled terminals 310 as compared to parallel terminals 360 that may be used in an alternative scenario.

Fig. 4A-4D illustrate another embodiment of a motor 400 similar to the motor 300 described above, wherein like features are shown with like reference numerals increased by "100" unless otherwise explained below. Fig. 4A, 4B, 4C, and 4D illustrate a motor 400 that includes a terminal assembly 405 having a plurality of terminals 410 that are angled and skewed. The terminals 410 are angled relative to the longitudinal axis 415 of the motor 400 such that the terminals 410 are not substantially parallel to the longitudinal axis 415 of the motor 400 in multiple dimensions (e.g., tilted and twisted/skewed). The terminals 410 are angled substantially non-parallel to the longitudinal axis 415 (as in fig. 3A-3C) in the radial direction and along the outer surface of the lamination stack 425. In some embodiments, the terminals 410 are angled at an angle of 15 ° along two dimensions relative to the longitudinal axis 415 of the motor 400. In other embodiments, the terminals 410 are angled at an angle between 5 ° and 90 ° such that the terminals 410 are again substantially non-parallel to the longitudinal axis 415 of the motor 400 along two dimensions. In other words, each of the terminals 410 may additionally be angled in a second direction (different from the first direction in which the terminals 310 of fig. 3A-3D are angled) and about an axis parallel to the longitudinal axis 415.

Fig. 5A-5C illustrate another embodiment of a motor 500 similar to the motor 300 described above, wherein like features are shown with like reference numerals increased by "200" unless otherwise explained below. Fig. 5A, 5B, and 5C illustrate a motor 500 that includes a plurality of terminals 510 that do not include tangs (e.g., tangs 320, 420 that would have been folded over the main portions 323, 423 of the terminals 310, 410 as shown in fig. 3A-4D). Alternatively, terminal 510 includes a V-shaped recess 520 at a first end for connecting to a motor winding, and a flat power connection portion 522 for receiving a power line. In some embodiments, the motor windings are wound around the V-shaped notches 520 and then, for example, soldered, welded, or fused to the terminals 510. In some embodiments, the terminal 510 is bent over the insulating member at the end of the motor 500 (i.e., the first axial end portion 540 of the stator molding 530) in the radial direction of the motor 500, e.g., in a manner similar to that shown in fig. 7A and 7C.

Fig. 6A and 6B illustrate another embodiment of a motor 600 similar to the motor 300 described above, wherein like features are shown with like reference numerals increased by "300" unless otherwise explained below. Fig. 6A and 6B illustrate a motor 600 that includes a plurality of terminals 610 that do not include tangs (e.g., tangs 320, 420 that would otherwise fold over the main portions 323, 423 of the terminals 310, 410 as shown in fig. 3A-4D). Alternatively, the terminal 610 includes two slots 620 at a first end for connecting the motor windings. In some embodiments, the motor windings are pressed into slots 620 and then, for example, soldered, welded, or fused. The terminals 610 each include two slots 620 for receiving, for example, four passes of the motor windings. As shown in fig. 6A, the terminals 610 may be angled and/or tilted/skewed in a similar manner as described in other embodiments disclosed herein.

Fig. 7A, 7B and 7C illustrate another embodiment of a motor 700 similar to the motor 300 described above, wherein like features are shown with like reference numerals increased by "400" unless otherwise explained below. Fig. 7A, 7B and 7C illustrate a motor 700 that includes a plurality of terminals 710 that do not include tangs 320, 420 that would otherwise fold over the main portions 323, 423 of the terminals 310, 410 as shown in fig. 3A-4D. Alternatively, the terminal 710 includes a tang 720 folded over a second portion 724 that extends at an angle of about 45 ° relative to the longitudinal axis 715 of the motor 700. The terminal 710 in fig. 7A to 7C includes three parts. The main or first portion 723 is parallel to the longitudinal axis 715 of the motor 700. The second portion 724, which extends at an angle of about 135 ° relative to the first portion 723, is bent in the radial direction of the motor 700. In other words, the second portion 724 extends at an angle of about 45 ° relative to the flat portion of the first axial end portion 740 of the motor 700. The third portion 720 is a tang. The motor winding wire may be wound around the tang 720 and the tang 720 may be folded over the second portion 724 of the terminal 710.

Fig. 8A, 8B and 8C illustrate another embodiment of a motor 800 similar to the motor 300 described above, wherein like features are shown with like reference numerals increased by "500" unless otherwise explained below. Fig. 8A, 8B and 8C illustrate a motor 800 that includes a plurality of terminals 810 that do not include tangs 320, 420 that would otherwise fold over the main portions 323, 423 of the terminals 310, 410 as shown in fig. 3A-4D. Alternatively, the terminal includes a tang 820 folded over a second portion 824 that is perpendicular to the longitudinal axis 815 of the motor 800. The terminal 810 in fig. 8A to 8C includes three parts. The first portion 823 is parallel to the longitudinal axis 815 of the motor 800. The second portion 824, which is perpendicular to the first portion 823 and parallel to the flat portion of the first axial end portion 840 of the motor 800, is bent in the radial direction of the motor 800. The third portion 820 is a tang 820. The motor winding wire may be wound around the tang 820 and the tang 820 may be folded over the second portion 824 of the terminal 810.

Fig. 9A, 9B and 9C illustrate another embodiment of a motor 900 similar to the motor 300 described above, wherein like features are shown with like reference numerals increased by "600" unless otherwise explained below. Fig. 9A, 9B and 9C illustrate a motor 900 that includes a plurality of terminals 910 that do not include tangs 320, 420 that would otherwise fold over the main portions 323, 423 of the terminals 310, 410 as shown in fig. 3A-4D. Alternatively, the terminal 910 includes a tang 920 folded over the second portion 924 (i.e., tangential to the longitudinal axis 915 of the motor 900). The terminal 910 in fig. 9A to 9C includes three parts. The first portion 923 is parallel to the longitudinal axis 915 of the motor 900. A second portion 924 perpendicular to the first portion 923 and tangential to the longitudinal axis 915 of the motor 900 is bent tangentially relative to the outer diameter of the motor 900 (i.e., tangential to the circumference of the first axial end portion 940 of the motor 900). The third portion 920 is a tang 920. The motor winding wire may be wound around the tang 920 and the tang 920 may be folded over the second portion 924 of the terminal 910. As shown in fig. 9C, the terminal 910 further includes a power line connection portion 926. The power line connection portion 926 may be parallel to the first portion 923, but may be located in a different plane. The power lines electrically connected to the FETs 124 may be soldered or otherwise connected to the power line connection portion 926 to provide power to the motor coils via the terminals 910. As shown in fig. 9A, in some embodiments, the terminal 910 may be mounted on the terminal mount 916 such that a portion of the terminal 910 (e.g., the power line connection portion 926) protrudes through a hole in the terminal mount 916.

As shown in fig. 9A and 9B, the terminals 910 are separately mounted on terminal mounts 916 which are spaced about 120 ° apart around the circumferential/outer peripheral surface of the motor 900. However, as explained above, in other embodiments, the terminals 910 are located on a single terminal mount 916 as shown in other previous embodiments. Similarly, terminals shown on a single terminal mount in other embodiments may be positioned separately around the circumference of the motor in a similar manner as shown in fig. 9A and 9B.

Fig. 10A, 10B and 10C illustrate another embodiment of a motor 1000 similar to the motor 300 described above, wherein like features are shown with like reference numerals increased by "700" unless otherwise explained below. Fig. 10A, 10B, and 10C illustrate a motor 1000 that includes a plurality of terminals 1010. Each terminal includes tangs 1020 oriented tangentially relative to the outer diameter of the motor 1000 and the stator. The tangs 1020 fold over a main portion 1023 of the terminal 1010 that is parallel to the longitudinal axis 1015 of the motor 1000. Motor winding wire may be wound around tangs 1020, and tangs 1020 may be folded tangentially over terminals 1010 relative to the outer diameter of motor 1000 and the stator. The motor 1000 is similar to the motor 900 of fig. 9A and 9B in that both motors 900 and 1000 have terminals 910, 1010 distributed separately around the circumferential/outer peripheral surfaces of the motors 900, 1000. As shown in fig. 10A, in some embodiments, the terminals 1010 may be mounted on the terminal mount 1016 such that a portion of the terminals 1010 (e.g., the power line connection portion 1026) protrudes through a hole in the terminal mount 1016.

Fig. 11A and 11B illustrate another embodiment of a motor 1100 similar to the motor 300 described above, wherein like features are shown with like reference numerals increased by "800" unless otherwise explained below. Fig. 11A and 11B illustrate a motor 1100 that includes a plurality of terminals 1110 that do not include tangs 1020 (e.g., tangs 1020 that would otherwise fold over a main portion 1023 of terminal 1010 as shown in fig. 10A-10C). Alternatively, the terminal 1110 includes a radial V-shaped notch 1120. The terminal 1110 in fig. 11A and 11B includes three parts. The first portion 1123 is parallel to the longitudinal axis 1115 of the motor 1100. The second portion 1124 perpendicular to the first portion 1123 is bent in the radial direction of the motor 1100. The third portion 1120 includes a V-shaped notch 1120 oriented radially with respect to the motor 1100. The V-shaped notch 1120 extends generally perpendicularly from the second portion 1124 and extends generally parallel to the longitudinal axis 1115 of the motor 1100. The V-shaped notch 1120 includes two slots 1128 for receiving, for example, four passes of the motor winding 1117, as shown in fig. 11B. In some embodiments, the motor windings 1117 are pressed or fused into the V-shaped notches 1120 in a radial direction. In some embodiments, the V-notch portion 1120 is folded over the second portion 1124 of the terminal 1110. The illustrated motor 1100 includes terminals 1110 that are arranged 120 apart from each other and mounted on individual and separate non-conductive mounts 1116, similar to the embodiment shown in fig. 9A-10C. As shown in fig. 11A, in some embodiments, the terminal 1110 may be mounted on the terminal mount 1116 such that a portion of the terminal 1110 (e.g., the power line connection portion 1126) protrudes through an aperture in the terminal mount 1116.

Fig. 12A and 12B illustrate another embodiment of a motor 1200 similar to the motor 300 described above, wherein like features are shown with like reference numerals increased by "900" unless otherwise explained below. Fig. 12A and 12B illustrate a motor 1200 that includes a plurality of terminals 1210 that do not include tangs 1020 (e.g., tangs 1020 that would otherwise fold over a main portion 1023 of terminal 1010 as shown in fig. 10A-10C). Alternatively, the terminal 1210 includes an axial V-shaped recess 1220 at a first end of the main portion 1223 of the terminal 1210 for connecting to a motor winding, and a flat power connection portion 1226 for receiving a power line. The axial V-shaped notch 1220 extends from the main portion 1223 and parallel to the longitudinal axis 1215 of the motor 1200 in the same plane as the main portion 1223. In some embodiments, the motor windings are wound around the V-shaped notches 1220 and then, for example, soldered or welded. The V-shaped notch 1220 includes two slots 1228 for receiving, for example, four passes of the motor windings (in a similar manner as shown in fig. 11B). In some embodiments, the terminal 1210 is bent in the radial direction of the motor 1200 on the insulating member/first axial end portion 1240 at the end of the motor stator. In some embodiments, the motor windings are pressed or fused into the V-shaped notch 1220. The illustrated motor 1200 includes terminals that are arranged 120 ° apart from each other and mounted on individual and separate nonconductive mounts 1216, similar to the embodiment shown in fig. 9A-11B. As shown in fig. 12A, in some embodiments, the terminals 1210 may be mounted on the terminal mount 1216 such that a portion of the terminals 1210 (e.g., the power line connection portion 1226) protrudes through an aperture in the terminal mount 1216.

Fig. 13A and 13B illustrate another embodiment of a motor 1300 similar to the motor 300 described above, wherein like features are shown with like reference numerals increased by "1000" unless otherwise explained below. Fig. 13A and 13B illustrate a motor 1300 that includes a plurality of terminals 1310 that do not include tangs 1020 (e.g., tangs 1020 that would otherwise fold over a main portion 1023 of terminal 1010 as shown in fig. 10A-10C). Alternatively, the terminal 1310 includes two slots 1328 at a first end of the main portion 1323 of the terminal 1310 for connecting the motor windings. In some embodiments, the motor windings are pressed into slots 1328 and then, for example, soldered or welded. The terminal 1310 includes two slots 1328 for receiving, for example, four passes of the motor winding. The illustrated motor 1300 includes terminals that are arranged 120 ° apart from each other and mounted on individual and separate non-conductive mounts 1316, similar to the embodiment shown in fig. 9A-12B. As shown in fig. 13A and 13B, in some embodiments, the terminal 1310 may be mounted on the terminal mount 1316 such that a portion of the terminal 1310 (e.g., the power line connection portion 1326) protrudes through a hole in the terminal mount 1316.

Fig. 14A and 14B illustrate another embodiment of a motor 1400 similar to the motor 300 described above, wherein like features are shown with like reference numerals increased by "1100" unless otherwise explained below. Fig. 14A and 14B illustrate a motor 1400 that includes a plurality of terminals 1410 that do not include tangs 320, 420 that would otherwise fold over the main portions 323, 423 of the terminals 310, 410 as shown in fig. 3A-4D. Alternatively, the terminal 1410 includes a tang 1420 that is folded over a second portion 1424 that is generally perpendicular to the longitudinal axis 1415 of the motor 1400. The terminal 1410 in fig. 14A to 14B includes three portions. The first portion 1423 is generally parallel to the longitudinal axis 1415 of the motor 1400. A second portion 1424, which is generally perpendicular to the first portion 1423, is bent in a radial direction relative to the longitudinal axis 1415 of the motor 1400. The third portion 1420 is a tang 1420. The motor winding wire may be wound around the tang 1420, and the tang 1420 may be folded over the second portion 1424 of the terminal 1410. The illustrated motor 1400 includes terminals 1410, similar to the embodiment shown in fig. 9A-13B, that are arranged 120 ° apart from each other and mounted on individual and separate non-conductive mounts 1416. As shown in fig. 14A, in some embodiments, the terminal 1410 may be mounted on the terminal mount 1416 such that a portion of the terminal 1410 (e.g., the power line connection portion 1426) protrudes through a hole in the terminal mount 1416.

Fig. 15 illustrates another embodiment of a motor 1500 similar to the motor 300 described above, wherein like features are shown with like reference numerals increased by "1200" unless otherwise explained below. Fig. 15 illustrates a motor 1500 that includes a terminal assembly 1505 that includes a plurality of terminals 1510 that do not include tangs 320, 420 as shown in fig. 3A-4D. Alternatively, the terminal 1510 includes a terminal post 1520 extending from a first end of the terminal 1510 generally parallel to the longitudinal axis 1515 of the motor 1500 and in the same plane as the main portion 1523 of the terminal 1510. Terminal 1510 in fig. 15 includes two parts. The main portion 1523 is substantially parallel to the longitudinal axis 1515 of the motor 1500. The second portion 1520 is a terminal post 1520. The motor winding wire may be wound around the terminal post 1520 and ultrasonically welded to the terminal post 1520, for example, using an ultrasonic generator (sonotrode). The power line may be soldered or otherwise connected to the second end of the main portion 1523 of the terminal 1510.

Fig. 16 illustrates an enlarged view of a terminal assembly 1505 of the motor 1500 of fig. 15 in accordance with an alternative embodiment. Like features of the alternative embodiment of fig. 16 are labeled with like reference numerals as in fig. 15. In fig. 16, terminal post 1520 is fitted with a pressed-on and fused terminal cap 1620 to connect the motor winding wire to terminal post 1520. For example, the motor winding wire is fused to the top end of the terminal cap 1620, which is the end farther from the main portion 1523 of the terminal 1510.

Fig. 17 illustrates an enlarged view of a terminal assembly 1505 of the motor 1500 of fig. 15 in accordance with another alternative embodiment. Like features of the alternative embodiment of fig. 17 are labeled with like reference numerals as in fig. 15. In fig. 17, terminal post 1520 is fitted with a pressed-on and fused terminal block cap 1720 to connect the motor winding wire to terminal post 1520. For example, the motor winding wire is fused to the top end of conductive portion 1721 of terminal block cap 1720, which is the end farther from main portion 1523 of terminal 1510. Insulating/nonconductive phenolic portions 1722 of terminal block cap 1720 may be located between conductive portions 1721 and outside conductive portions 1721, as shown in fig. 17. In some embodiments, terminal posts 1520 may protrude through holes in terminal block cap 1720, as shown in fig. 17.

Fig. 18-23 illustrate another embodiment of a stator assembly 1810 for a motor similar to motors 300-1500 described above. As previously described, the electric motor may be used with a variety of different tools, such as power tools (e.g., rotary hammers, pipe thread machines, cutting tools, etc.), outdoor tools (e.g., trimmers, bench saws, blowers, etc.), and other electrical devices (e.g., electric devices, etc.).

Referring to fig. 18, a stator assembly 1810 includes a lamination stack 1814, a stator molding 1818 molded to the lamination stack 1814 to form a molded stator body 1822 (see fig. 19). The stator assembly 1810 further includes stator windings 1826A, 1826B, 1826C that are energized to generate a magnetic field. The stator windings 1826A-1826C include wire loops 1830A, 1830B, 1830C (i.e., wire leads, stator winding leads) that are electrically connected to corresponding phase wires 1834A, 1834B, 1834C (i.e., power lines that provide power to the stator windings 1826A-1826C via the FETs 124). In other words, the phase lines 1834A-1834C are directly electrically connected to the stator windings 1826A-1826C. For example, stator windings 1826A-1826C are selectively energized by motor controller 130 (see fig. 2). In the illustrated embodiment, the stator windings 1826A-1826C are three-phase. The three phases of stator windings 1826A-1826C may be interconnected in a delta, Y, or any other suitable configuration. Thus, stator assembly 1810 eliminates the need for a separate terminal block/assembly for phase connection of stator windings 1826A through 1826C. This achieves a lower overall cost, a lower material inventory and a simpler injection mold.

Referring to fig. 18 and 19, the stator molding 1818 of the molded stator body 1822 includes a first axial end portion 1838, a second axial end portion 1842, and a connecting portion 1846 extending axially along the outer circumferential surface of the lamination stack 1814. The connection portion 1846 is bent along an outer circumferential surface of the lamination stack 1814. In the illustrated embodiment, the connection portion 1846 extends at least partially between the first axial end portion 1838 and the second axial end portion 1842. The stator molding 1818 includes a post 1850 formed to extend away from the first axial end portion 1838. The posts 1850 are wire routing features that assist in the process of winding the stator windings 1826A-1826C onto the molded stator body 1822.

With continued reference to fig. 19, the stator molding 1818 includes a spacer 1854 formed on the connection portion 1846. The spacer 1854 creates a separation between the loops 1830A-1830C and the phase lines 1834A-1834C and helps guide and position the loops 1830A-1830C. In some embodiments, the spacers 1854 create a separation distance between adjacent stator windings that is twice the size of the stator winding connections. In other embodiments, the spacers 1854 create a separation distance between adjacent stator winding connections that is four times the size of the stator winding connections. The stator molding 1818 also includes a wire trap 1858 to hold the phase wires 1834A-1834C in place and act as strain relief. The cartridge 1858 also includes snap-fit fingers 1862 on opposite ends thereof that are configured to interface with separate clips 1866 (fig. 23).

Referring to fig. 20 to 21, stator windings 1826A to 1826C are wound onto a molded stator body 1822 using a precision winding machine. During the winding process, wire loops 1830A-1830C are formed as part of stator windings 1826A-1826C. In some embodiments, the stator winding leads are routed to features (e.g., posts) on the winder fixture to create wire loops 1830A-1830C. In the illustrated embodiment of fig. 20, wire loops 1830A-1830C include respective eyelets 1832A-1832C formed with magnet wires configured to receive phase wires 1834A-1834C. The diameters of the eyelets 1832A-1832C may vary depending on, for example, the diameters of the phase lines 1834A-1834C. At this point in the manufacturing process, the wire loops 1830A-1830C extend radially outward from the stator molding 1818. Wire stripping may remove the magnetic wire coating at wire loops 1830A-1830C to prepare the coil leads for a later brazing step. In an alternative embodiment, an alternative wire varnish removal step is utilized. Specifically, if wire magnetic wire stripping cannot remove only material on the wire loops 1830A-1830C, then after winding, a separate operation is completed to fuse or resistance weld the wire loops 1830A-1830C into the shape shown in fig. 20. The fusing operation will burn off the enamel and bond the wires together at each phase connection point into a connected unit.

Referring to fig. 22, wire loops 1830A through 1830C are then connected to phase wires 1834A through 1834C. Wire loops 1830A-1830C are bent into the position shown in fig. 22 and phase wires 1834A-1834C are inserted into corresponding eyelets 1832A-1832C. The phase wires 1834A-1834C and wire loops 1830A-1830C are then soldered together to establish an appropriate electrical connection.

Referring to fig. 23, phase wires 1834A-1834C are secured to stator molding 1818 by clips 1866. Specifically, clip 1866 is attached to cartridge 1858 via fingers 1862 to form a snap-fit connection. The attached clip 1866 and the clip seat 1858 cooperate to hold the phase wires 1834A-1834C in place and provide strain relief for the soldered connection between the wire loops 1830A-1830C and the phase wires 1834A-1834C. In some embodiments, clip 1866 includes guides for phase wires 1834A-1834C that guide the routing and positioning of the phase wires within the tool housing. In other embodiments, clip 1866 is larger such that it is configured to support both phase wires 1834A-1834C and wire loops 1830A-1830C in one single piece. For example, clip 1866 may also be sized to partially enclose eyelets 1832A-1832C.

Referring to fig. 24, a method 2400 of manufacturing a stator assembly 1810 for an electric motor is shown according to one embodiment. In general, the illustrated method 2400 includes: step 2404 of producing a molded stator body 1822 by molding the stator lamination stack 1814; step 2408 of winding stator windings 1826A through 1826C onto molded stator body 1822 and forming wire loops 1830A through 1830C; step 2412 of preparing wire loops 1830A-1830C for electrical connection to phase wires 1834A-1834C. Step 2412 may include bending, fusing, and stripping wire loops 1830A-1830C. The method 2400 further includes: step 2416 of connecting phase lines 1834A-1834C to wire loops 1830A-1830C (i.e., establishing an electrical connection between phase lines 1834A-1834C and wire loops 1830A-1830C); and a step 2420 of securing phase wires 1834A-1834C to stator assembly 1810 using, for example, clamp 1866.

Referring to fig. 25-27, another embodiment of a stator assembly 2510 is shown that is similar to the stator assembly 1810 described above, wherein like features are shown with like reference numerals increased by "700" unless otherwise explained below. The wire loops 2530A, 2530B, 2530C of the stator assembly 2510 do not include eyelets 32A-32C and the phase wires 2534A, 2534B, 2534C are directly soldered or fused to the wire loops 2530A-2530C. Such an arrangement may reduce the overall size of the stator assembly 2510.

Referring to fig. 26, wire loops 2530A-2530C are routed to features (e.g., posts) (not shown) formed on stator molding 2518 to form initial wire loops 2530A-2530C (with or without eyelets). This feature may be formed of plastic and molded as part of the stator molding 2518 and then removed from the stator molding 2518 after the winding of the stator windings 2526A-2526C is completed. Multiple turns of coil leads may be required to form a robust connection point, and this may also depend on the size of magnet wire used. In some embodiments, the 1.3 mm diameter wire has a single turn, and in other embodiments, the 0.5 mm diameter wire has two or three turns to create wire loops 2530A-2530C.

Referring to fig. 27, phase wires 2534A-2534C are directly soldered to wire loops 2530A-2530C. Fusion or resistance welding processes may also be used before or after the wire loops 2530A-2530C are bent into place. The stator assembly 2510 can include a clamp 2566 that is large enough to secure the phase wires 2534A-2534C and the wire loops 2530A-2530C. In other embodiments, a second clamp may be provided to support the phase and wire loop connection.

Referring to fig. 28, another embodiment of a stator assembly 2810 is shown that is similar to the stator assembly 1810 described above, wherein like features are shown with like reference numerals increased by "1000" unless otherwise explained below. The stator assembly 2810 of fig. 28 is similar to the stator assembly 2510 shown in fig. 25-27, except that the wire loops 2830A, 2830B, 2830C and the phase wires 2834A, 2834B, 2834C are secured to and electrically connected to each other using terminals 2839A, 2839B, 2839C (e.g., splice terminals such as 2D crimp AMPLIVAR ™ splice terminals). Fig. 28 schematically illustrates terminals 2839A to 2839C. In some embodiments, terminals 2839A through 2839C are splice terminals configured to have open sides to receive wire loops 2830A, 2830B, 2830C and phase wires 2834A, 2834B, 2834C. The sides of terminals 2839A through 2839C are then crimped together, for example, using a crimping tool, to secure and electrically connect wire loops 2830A, 2830B, 2830C and phase wires 2834A, 2834B, 2834C. In some embodiments, terminals 2839A-2839C include serrated inner surfaces with burrs (i.e., a number of shallow teeth), for example, to better secure wire loops 2830A, 2830B, 2830C and phase wires 2834A, 2834B, 2834C and/or pierce insulation included on phase wires 2834A, 2834B, 2834C.

In some embodiments, the clip 2866 is a snap-fit clip that includes guides for securing the phase lines 2834A, 2834B, 2834C and providing strain relief for the phase lines 2834A, 2834B, 2834C. In some embodiments, clip 2866 is larger than clip 2866 shown in fig. 28, and may support and/or house both phase wires 2834A, 2834B, 2834C and wire loops 2830A, 2830B, 2830C on the outer peripheral surface of stator assembly 2810. In other embodiments, a second clip may be provided to support the wire loops 2830A, 2830B, 2830C. In some embodiments, the larger clip described above or the second clip described above (i.e., the clip supporting and/or accommodating the phase and wire loop connection) may act as a potting boat to be filled with epoxy for intrusion protection and vibration isolation as well as support.

Referring to fig. 29A-29B, another embodiment of a stator assembly 2910 is shown that is similar to the stator assembly 2810 described above, wherein like features are shown with like reference numerals increased by "100" unless otherwise explained below. The stator assembly 2910 of fig. 29 is similar to the stator assembly 2810 shown in fig. 28, except that the wire loops 2830A, 2830B, 2830C and the phase wires 2834A, 2834B, 2834C are secured to each other and electrically connected using serrated terminals 2939A, 2939B, 2939C on the terminal mount 2916 of the terminal assembly 2905 mounted on the outer peripheral surface of the stator assembly 2910. In some embodiments, the terminals 2939A-2939C include serrated surfaces with burrs (e.g., a number of shallow teeth), e.g., to better secure the wire loops 2930A, 2930B, 2930C and the phase wires 2934A, 2934B, 2934C to each other and/or to pierce insulation included on the phase wires 2934A, 2934B, 2934C. Fig. 29A illustrates the stator assembly 2910 with the clip 2966 removed, and fig. 29B illustrates the stator assembly 2810 with the clip 2966 secured to the stator assembly 2910. In some embodiments, the wire loops 2930A, 2930B, 2930C and the phase wires 2934A, 2934B, 2934C may additionally or alternatively be brazed together, fused together, or the like.

As illustrated in fig. 29A-29B, in some embodiments, the stator assembly 2910 may not include the spacer 2854 on the connection portion 2846 of fig. 28. Additionally, fig. 29A-29B illustrate a clip 2966 that is different from the clip 2866 of fig. 28. The clip 2966 may be a second clip as described above with reference to fig. 28 that supports and/or accommodates phase and wire loop connections rather than the phase wires 2834A, 2834B, 2834C as shown in fig. 28. As shown in fig. 29C, in some embodiments, the clip 266 is secured to the stator assembly 2910 using one or more fasteners 2968 (e.g., screws). In some embodiments, both clips 2866 and 2966 may be used on any of the stator assemblies disclosed herein. Similarly, in some embodiments, the stator assembly may include a larger clip that provides the combined function of each of the clips 2866 and 2966.

Fig. 30A and 30B illustrate another embodiment of a motor 3000 similar to the motor 300 described above, wherein like features are shown with like reference numerals increased by "2700" unless otherwise explained below. Fig. 30A and 30B illustrate a motor 3000 that includes a plurality (e.g., three) of terminals 3010 (e.g., insulation Displacement Crimp (IDC) terminals, such as MAG-MATE ™ IDC terminals). Terminals 3010 may provide electrical connection between stator windings 3026A to 3026C and a Printed Circuit Board (PCB) 3012. The terminals 3010 are positioned at the insulating member/first axial end portion 3040 at one end of the motor 3000 (i.e., not on the outer circumferential surface of the stator lamination stack 3025).

As shown in fig. 30A and 30B, the insulating member/first axial end portion 3040 may include a protrusion 3062 protruding away from the lamination stack 3025 generally parallel to the motor axis 3015. Each protrusion 3062 may include a hole 3063 and/or one or more slots 3064 configured to receive the terminal 3010 and the stator windings 3026A-3026C (see exploded perspective view of fig. 30B). The first portion 3023 of the terminal 3010 may be configured to receive the stator windings 3026A to 3026C and may be configured to be crimped to electrically and physically connect the first portion 3023 of the terminal 3010 to the stator windings 3026A to 3026C. The second portion 3024 of the terminal 3010 may be configured to be inserted into a through hole in the PCB 3012 and may be configured to be soldered to the PCB 3012 to provide an electrical and physical connection between the terminal 3010 and the PCB 3012.

Although PCB 3012 is shown as a full circle in fig. 30A and 30B, in some embodiments, PCB 3012 includes a through hole in its center, e.g., to allow the shaft of the motor to enter or pass through a plane defined by the surface of PCB 3012. In some embodiments, PCB 3012 is not circular and may be of different shapes and may or may not include a through hole in its center. In some embodiments, PCB 3012 includes hall sensor 128, FET 124, and/or motor controller 130 previously described herein with reference to fig. 2. In some embodiments, the FET 124 and/or the motor controller 130 may be located on other PCBs within the power tool 100 (e.g., within the handle 104 and/or in the bottom of the power tool 100 proximate the battery pack interface 114). When the motor 3000 is placed inside the motor housing portion 106 of the power tool 100, the PCB 3012 may be located on the front side of the motor 3000 (i.e., between the motor 3000 and the output unit 107), or the PCB 3012 may be located on the rear side of the motor 3000 such that the motor 3000 is located between the output unit 107 and the PCB 3012.

Fig. 31A and 31B illustrate a motor 3100 that includes a recessed bearing 3105 with a rotor inside diameter press. Rotor shaft 3110 is molded or pressed into rotor stack 3115. The recessed bearing 3105 is pressed onto the shaft 3110 into a pocket 3120 inside the rotor stack 3115. As a result, the recessed bearing 3105 is within the length of the rotor magnet 3125 (i.e., within the length of the rotor envelope 3130), which saves space within the power tool housing and may allow the power tool 100 to be more compact than a power tool having a motor that does not include the recessed bearing 3105. In some embodiments, the pocket 3120 that receives the recessed bearing 3105 fits within the diameter 3135 of the rotor magnet 3125. The hall plate bearing retention cap 3140 protrudes into the bearing pocket 3120 and onto the recessed bearing 3105 using, for example, a sliding fit. For example, the sliding fit may include a protruding portion 3150 (e.g., a protruding ring or a portion of a protruding ring) configured to slidingly fit between an outer surface of the recessed bearing 3105 and an inner surface of the pocket 3120. In some embodiments, the hall plate 3145 secured to or integrated within the retaining cap 3140 is a doughnut-shaped PCB, which may have similar characteristics to the PCB 3012 and its alternative designs as described above with respect to fig. 30A and 30B. Fig. 31B illustrates an exploded side cross-sectional view of the motor 3100 with the retaining cap 3140 removed from the motor 3100 and the stator assembly 3155 of fig. 31A removed.

Fig. 32A and 32B illustrate another embodiment of a motor 3200 similar to motor 3100 described above, wherein like features are shown with like reference numerals increased by "100" unless otherwise explained below. Fig. 32A and 32B illustrate a motor 3200 that includes a recessed bearing 3205 with a rotor inside diameter press (e.g., similar to motor 3100 of fig. 31A and 31B). In contrast to motor 3100, which includes a single rotor lamination 3115, motor 3200 includes two distinct notched laminations 3215A and 3215B (e.g., inner lamination 3215A and outer lamination 3215B) that are molded and pressed together to create a recessed bearing rotor lamination stack 3215. In some embodiments, the hot melt column is soldered down prior to assembly of the motor. In some embodiments, a clearance space (e.g., 0.5 mm) for the hall plate mount is provided inside the rotor pocket 3220. Similar to the motor 3100 of fig. 31A and 31B, the recessed bearing 3205 is within the length of the rotor magnet 3125 or rotor envelope 3130, which saves space within the power tool housing and may allow the power tool 100 to be more compact than a power tool having a motor that does not include the recessed bearing 3205.

Fig. 33A and 33B illustrate another embodiment of a motor 3300 that is similar to motor 3100 described above, wherein like features are shown with like reference numerals increased by "200" unless otherwise explained below. Fig. 33A and 33B illustrate a motor 3200 that includes a recessed bearing 3305 having a rotor outer diameter depression that is opposite to the rotor inner diameter depression of the motor 3100 of fig. 31A and 31B. The rotor shaft 3310 is molded or pressed into the rotor stack 3315, but unlike the rotor shaft 3110 of fig. 31A and 31B, the rotor shaft 3310 does not protrude completely through the rotor stack 3315. A recessed bearing 3305 is molded into the rotor stack 3315 opposite the pinion end. The second shaft 3312 is pressed into the hall plate cap 3340 and is configured to be guided into an injection molded bearing 3305 in the rotor 3315. Similar to the bearings 3105, 3205 of fig. 31A-32B, the recessed bearing 3305 is within the length of the rotor magnet 3325 or rotor envelope 3330, which saves space within the power tool housing and may allow the power tool 100 to be more compact than a power tool having a motor that does not include the recessed bearing 3305.

The hall plate cap 3340 protrudes into or around the outer surface of the rotor stack 3315 using, for example, a slip fit. For example, the sliding fit may include a protruding portion 3350 (e.g., a protruding ring or portion of a protruding ring) configured to be a sliding fit between an outer surface of the rotor stack 3315 and an inner surface of the stator 3355. Fig. 33B illustrates an exploded side cross-sectional view of the motor 3300 with the hall plate cap 3340 removed from the motor 3300 and the stator assembly 3355 of fig. 33A removed.

Fig. 34A and 34B illustrate another embodiment of a motor 3400 similar to the motor 3300 described above, wherein like features are shown with like reference numerals increased by "100" unless otherwise explained below. Fig. 34A and 34B illustrate a motor 3400 that includes a recessed bearing 3405 with a rotor outer diameter press (similar to motor 3300 of fig. 33A and 33B). However, unlike motor 3300, and similar to motor 3200 of fig. 32A and 32B, motor 3400 includes two different notched laminations 3415A and 3415B (e.g., inner lamination 3415A and outer lamination 3415B) that are molded and pressed together to create recessed bearing rotor lamination stack 3415. In some embodiments, the hot melt column is soldered down prior to assembly of the motor. In some embodiments, a clearance space (e.g., 0.5 mm) for the hall plate mount is provided inside the rotor pocket 3420. Similar to the motors 3100, 3200, 3300 of fig. 31A-33B, the recessed bearing 3405 is within the length of the rotor magnet 3425 or rotor envelope 3430, which saves space within the power tool housing and may allow the power tool 100 to be more compact than a power tool having a motor that does not include the recessed bearing 3405.

Fig. 35A and 35B illustrate another embodiment of a motor 3500 that is similar to motor 3100 described above, wherein like features are shown with like reference numerals increased by "400" unless otherwise explained below. Fig. 35A and 35B illustrate a motor 3500 having an extended bearing mount 3540 with rotor bore compressions. Rotor shaft 3510 is molded or pressed into rotor lamination stack 3515. The bearing 3505 is pressed onto the bearing mount 3540 inside the rear pocket 3520 of the mount 3540. Rear bearing 3505 is press fit inside diameter onto shaft 3510 and insert molded into bearing mount 3540. In some embodiments, the bearing mount 3540 includes a hall plate 3545, which may be doughnut-shaped, as described above with respect to the previous embodiments. As shown in fig. 35A, the motor shaft 3510 may pass through the hall plate 3545 and a portion of the bearing mount 3540 to be supported by the bearing 3505. Also similar to the previous embodiment, bearing mount 3540 may include protrusions 3550 configured to slidingly mate between an outer surface of rotor stack 3515 and an inner surface of stator 3555 to secure bearing mount 3540 to motor 3500. The design shown in fig. 35A and 35B saves space within the power tool housing and may allow the power tool 100 to be more compact than a power tool having a motor that does not include bearings 3505 housed in bearing mounts 3540.

Fig. 36-38 illustrate other embodiments of motors similar to the motors 300-1500 described above and shown in fig. 3A-15, wherein like features are indicated with like reference numerals, with tens and units of reference numerals being identical, but hundreds of bits being incremented according to the figures.

Fig. 36 illustrates an embodiment of a motor 3600 having terminals 3610 that are substantially similar to the terminals of the motor 1400 of fig. 14A and 14B, but with a slight variation. The explanation of the components of motor 1400 applies to similarly numbered components of motor 3600.

Fig. 37 illustrates an embodiment of a motor 3700 having terminals 3710 similar to the terminals of the motors 1200 and 1300 of fig. 12A-13B, but with a slight variation. The explanation of the components of motors 1200 and 1300 applies to similarly numbered components of motor 3700.

Fig. 38 illustrates an embodiment of a motor 3800 having terminals 3810 that are substantially similar to the terminals of the motor 1300 of fig. 13A and 13B, but with a slight variation. The explanation of the components of motor 1300 applies to similarly numbered components of motor 3800. Although only one terminal 3810 is shown in the motor 3800 of fig. 38, similar to other embodiments (such as the motor 1300 of fig. 13A and 13B), the motor 3800 may include a total of three terminals 3810. Terminals 3810 may be located on a single terminal mount or may be individually positioned about 120 ° apart, each of which is shown in other embodiments disclosed herein.

Fig. 39 illustrates another embodiment of a motor 3900 that is similar to the motor 3000 described above and shown in fig. 30A-30B, wherein like features are shown with like reference numerals increased by "900" unless otherwise explained below. Motor 3900 may be similar to motor 3000 except that motor 3900 may use different terminals 3910. For example, the terminal 3910 may include tangs 3920 similar to other terminals described in other embodiments. As previously described herein with respect to other embodiments, tangs 3920 may be used to connect terminals to motor windings. The explanation of the components of motor 3000 applies in other ways to similarly numbered components of motor 3900. For example, the second portion 3924 of the terminal 3910 may be configured to connect to a PCB similar to the PCB 3012, even though such a PCB is not shown in fig. 39.

Fig. 40A-40D illustrate another embodiment of a motor 4000 similar to the motor 300 described above, wherein like features are shown with like reference numerals increased by "3700" unless otherwise explained below. Fig. 40A, 40B, 40C and 40D illustrate a motor 4000 that includes a terminal assembly 4005 having a plurality of terminals 4010 with a major portion 4023 of the terminals being generally parallel to a longitudinal axis 4015 of the motor 4000. However, in other embodiments, the terminal 4010 may be angled or slanted/skewed, similar to other embodiments described herein. Terminal 4010 includes a plurality of tangs 4020A, 4020B, and 4020C that are different from tangs 320, 420 of terminals 310, 410, such as shown in fig. 3A-4D. For example, tangs 4020A and 4020B (e.g., primary tangs) rotate to be substantially perpendicular to longitudinal axis 4015 of motor 4000. Tangs 4020A and 4020B are each bent from respective sides of main portion 4023 of terminal 4010 on top of main portion 4023 of terminal 4010. The motor winding wire is fused to primary tangs 4020A and 4020B. In some embodiments, the motor winding wire is not wound around the primary tangs 4020A and 4020B, but rather the motor winding wire passes only through/under tangs 4020A and 4020B and is fused to tangs 4020A and 4020B. Additionally, the terminals 4010 each include a secondary tang 4020C (e.g., a tension tang) located below the primary tangs 4020A, 4020B on the main portion 4023 of the terminal 4010. In some embodiments, the secondary tangs 4020C are used to provide tension to the motor winding wire, but the motor winding wire is not fused to the secondary tangs 4020C. In other words, the motor winding wire is wound around the secondary tang 4020C, but is not fused to the secondary tang 4020C.

As shown in fig. 40D, the terminal 4010 can include a mounting protrusion 4013 that protrudes from a surface of the primary portion 4023 opposite the secondary tang 4020C. In some embodiments, mounting protrusions 4013 are configured to fit into corresponding slots of non-conductive terminal mounts 4016 to mount terminals 4010 to terminal mounts 4016. Although not shown in other embodiments, the terminals of other embodiments may include mounting protrusions similar to the mounting protrusions 413 shown in fig. 40D.

Fig. 41 illustrates a terminal 4110 that may be used on the motor 4000 of fig. 40A-40D as an alternative to the terminal 4010 according to some embodiments. As shown in fig. 41, the terminal 4110 includes a plurality of tangs 4120A, 4120B, and 4120C, which are different from the tangs 4020A to 4020C of the terminal 4010 shown in, for example, fig. 40A to 40D. The tang 4120A is folded over the main portion 4123 of the terminal 4110 in a direction perpendicular to the longitudinal axis of the motor from one side of the terminal 4110 (similar to tangs 4020A and 4020B of fig. 40A-40D). However, as shown in fig. 41, there is only a single vertically folded tang 4120A on the terminal 4110. Terminal 4110 also includes a tension tang 4120C that is closer to one side of terminal 4110 than the other side of terminal 4110. The tension tang 4120C can be used similar to the tension tang 4020C previously explained herein. For example, the tension tangs 4120C are used to provide tension to the motor winding wire, but the motor winding wire is not fused to the tension tangs 4120C. More specifically, the motor wire is wrapped around the tension tang 4120 before the tang 4120A is folded over the main portion 4123. After winding of the motor wire is completed, the tang 4120A can be folded over the main portion 4123 (as shown in fig. 41) and fused to the motor wire passing under the tang 4120A. In some embodiments, the tang 4120A is configured to fold closer to the surface of the main portion 4123 on the side of the main portion 4123 where the tension tang 4120C is not provided (e.g., to provide space for motor wire between the main portion 4123 and the tang 4120A on the side of the main portion 4123 where the tension tang 4120C is provided). In some embodiments, the terminal 4110 may also include a wire stop tang 4120B configured to act as a stop to prevent the motor wire from moving side-to-side during the winding and fusing process. In some embodiments, the motor wire is not fused to the wire stop tang 4120B and may be fused only to the fold tang 4120A.

In other embodiments, tangs 4120B and 4120C may have functions that are opposite to those described above. For example, the tang 4120C may alternatively act as a wire stop tang to prevent the motor wire from moving side-to-side during the winding and fusing process. Similarly, tang 4120B may alternatively act as a tension tang around which motor winding wire is wound.

Accordingly, some embodiments provide, among other things, a brushless motor.

Claims (20)

1. A power tool, comprising:

a housing having a motor housing portion, a handle portion, and a battery pack interface, wherein the battery pack interface is configured to removably receive and support a battery pack;

a brushless dc motor located within the motor housing portion and having a rotor and a stator, wherein the rotor is coupled to a motor shaft arranged to produce an output outside the housing, characterized by:

a non-conductive terminal mount located on an outer peripheral surface of the stator and comprising an angled surface, wherein the angled surface is not substantially parallel to a longitudinal axis of the motor; and

a plurality of terminals mounted on the angled surface of the terminal mount, wherein each of the terminals is angled in a first direction such that the terminals are not substantially parallel to the longitudinal axis of the motor;

Wherein the first end of each of the terminals includes a tang ring configured to be electrically and physically connected to the stator coil;

wherein a second end of each of the terminals opposite the first end is electrically connected to a power source configured to provide power to the stator coil; and is also provided with

Wherein the first end of each of the terminals is closer to the longitudinal axis than the corresponding second end of each of the terminals.

2. The power tool of claim 1, wherein each of the terminals is angled in a second direction different from the first direction and about an axis parallel to the longitudinal axis.

3. The power tool of claim 1, wherein the stator comprises a lamination stack and a stator molding supporting the lamination stack to form a molded stator body;

wherein the stator molding includes a first axial end portion, a second axial end portion, and an extension portion extending axially along an outer circumferential surface of the stator; and is also provided with

Wherein the non-conductive terminal mount is located on the extension.

4. The power tool of claim 3, wherein the stator molding includes a post on and extending away from the first axial end portion, the post configured to receive the stator coil to assist in winding the stator coil onto the molded stator body.

5. The power tool of claim 3, wherein the extension portion is curved along an outer peripheral surface of the stator.

6. The power tool of claim 1, wherein the handle portion spatially connects the motor housing portion and the battery interface.

7. A power tool, comprising:

a housing having a motor housing portion, a handle portion, and a battery pack interface, wherein the battery pack interface is configured to removably receive and support a battery pack;

a brushless dc motor located within the motor housing portion and having a rotor and a stator, characterized by:

wherein the rotor is coupled to a motor shaft arranged to produce an output outside the housing,

wherein the stator comprises a stack of laminations and a stator molding supporting the stack of laminations to form a molded stator body,

wherein the stator moulding comprises a first axial end portion and a second axial end portion opposite the first axial end portion; and

a plurality of terminals located on the outer peripheral surface of the stator, each of the terminals including a first portion substantially parallel to the longitudinal axis of the brushless dc motor and a second portion extending from the first portion and oriented in a radial direction of the motor toward the longitudinal axis of the motor and bent over a first axial end portion of the stator molding.

8. The power tool of claim 7, wherein the second portion is substantially perpendicular to the first portion and the longitudinal axis.

9. The power tool of claim 7, wherein the second portion of each terminal includes a tang configured to be electrically and physically connected to the stator coil.

10. The power tool of claim 9, wherein the tang of each terminal is folded over the second portion of its respective terminal such that the tang extends at least one of the group consisting of: extends away from the longitudinal axis in a plane defined by the longitudinal axis and the center of the first portion of the respective terminal, and extends tangentially with respect to the circumference of the first axial end portion of the stator molding.

11. The power tool of claim 7, wherein the second portion of each terminal includes a protruding portion that protrudes substantially perpendicularly from the second portion, wherein the protruding portion includes a slot configured to be electrically and physically connected to the stator coil.

12. The power tool of claim 7, wherein each of the terminals is mounted on a separate non-conductive terminal mount distributed around the outer peripheral surface of the stator.

13. The power tool of claim 7, wherein each of the terminals includes a power connection portion configured to be electrically connected to a power source; and is also provided with

Wherein the power connection portion is substantially parallel to and in a different plane than the first portion of its respective terminal.

14. The power tool of claim 13, wherein the power connection portion of each terminal protrudes through a hole in the terminal mount to which the corresponding terminal is mounted.

15. The power tool of claim 7, wherein the stator molding includes a post on and extending away from the first axial end portion, the post configured to receive a stator coil to assist in winding the stator coil onto the molded stator body.

16. The power tool of claim 7, wherein the handle portion spatially connects the motor housing portion and the battery interface.

17. A power tool, comprising:

a housing having a motor housing portion, a handle portion, and a battery pack interface, wherein the battery pack interface is configured to removably receive and support a battery pack; and

A brushless dc motor located within the motor housing portion and having a rotor and a stator, characterized by:

wherein the rotor is coupled to a motor shaft arranged to produce an output outside the housing,

wherein the rotor comprises a plurality of magnets within a rotor stack, each of the magnets having a length along a longitudinal axis of the brushless DC motor, the lengths of the magnets along the longitudinal axis defining a rotor envelope along the longitudinal axis,

wherein the rotor comprises a bearing pocket which is located within the rotor stack at an axial end of the rotor stack and radially within the diameter of the magnets, and

wherein a recessed bearing is located within the bearing pocket, the recessed bearing being located within the rotor envelope and configured to support the motor shaft.

18. The power tool of claim 17, wherein:

a bearing retention cap configured to extend into the bearing pocket and onto the recessed bearing; and

a printed circuit board secured to the bearing retaining cap and including a hall effect sensor configured to detect when the magnets rotate past the hall effect sensor.

19. The power tool of claim 17, wherein the rotor includes one of an inside diameter press and an outside diameter press.

20. The power tool of claim 17, wherein the rotor comprises one of: a single rotor lamination, two different notched laminations including an inner lamination and an outer lamination.