Abstract: An electric motor has a stator in which an armature is disposed. The armature has a shaft. One of the stator or the armature includes a lamination stack having slots in which magnet wires are wound, the magnet wires having a coating of heat activated adhesive. There is further provided plastic molded around the magnet wires with heat of the plastic activating the heat activated adhesive on the magnet wires during molding of the plastic to bond the magnet wires together.

Abstract: A method of manufacturing an armature for an electric motor, includes: placing a commutator and a lamination stack on an armature shaft, winding magnet wire in slots in the lamination stacks to form coils, attaching ends of the magnet wire to the commutator, and molding plastic around the magnet wire and around the shaft of the armature at ends of the lamination stack. A spinning inertia of the armature is adjusted by adjusting at least one of a mass of the plastic molded and a distribution of the plastic molded. Alternatively and/or additionally, at least one of a resonant frequency and critical speed of the armature is adjusted by adjusting at least one of a geometry of the plastic molded, the physical properties of the plastic and the mechanical properties of the plastic.

Abstract: A power tool has a motor having a stator made by separately forming pole pieces and field coils. The field coils are placed over necks of the pole path pieces. An armature has an outside diameter of at least 0.625 the outside diameter of the stator is placed in the stator. The housing has a girth of 200 mm or less with the motor wound to provide a maximum watts out to housing girth ratio of at least 5 maximum watts outs to 1 mm of housing girth. The field coils may be formed so that they extend beyond pole tips of the pole pieces.

Abstract: A grease gun includes a housing, a motor positioned within the housing, a pump assembly coupled to and driven by the motor, and a chamber supported by the housing in fluid communication with the pump assembly. The chamber is configured to store a liquid. The grease gun also includes an outlet in fluid communication with the chamber and a measurement system operable to measure an amount of liquid being dispensed through the outlet. The measurement system monitors a change in current of the motor over a cycle of the pump assembly, compares the change in current to a predetermined value, and, if the change in current is greater than the predetermined value, increases a pump cycle counter to indicate that liquid was dispensed.

Abstract: A power tool assembly includes a hand-held power tool, a dust collector removably coupled to the power tool, and first and second power tool battery packs each of which is interchangeably coupled with the power tool and the dust collector for separately powering the power tool and the dust collector, respectively.

Abstract: A grease gun includes a housing, a motor positioned within the housing, a pump assembly coupled to and driven by the motor, and a chamber supported by the housing in fluid communication with the pump assembly. The chamber is configured to store a liquid. The grease gun also includes an outlet in fluid communication with the chamber and a measurement system operable to measure an amount of liquid being dispensed through the outlet. The measurement system monitors a change in current of the motor over a cycle of the pump assembly, compares the change in current to a predetermined value, and, if the change in current is greater than the predetermined value, increases a pump cycle counter to indicate that liquid was dispensed.

Abstract: A power tool has a motor having a stator made by separately forming pole pieces and field coils. The field coils are placed over necks of the pole path pieces. An armature has an outside diameter of at least 0.625 the outside diameter of the stator is placed in the stator. The housing has a girth of 200 mm or less with the motor wound to provide a maximum watts out to housing girth ratio of at least 5 maximum watts outs to 1 mm of housing girth. The field coils may be formed so that they extend beyond pole tips of the pole pieces.

Abstract: A power tool has a motor having a stator made by separately forming pole pieces, return path pieces and field coils. The field coils are placed over necks of the pole path pieces and the return path pieces are affixed to the pole pieces. An armature having an outside diameter of at least 0.625 the outside diameter of the stator is placed in the stator. The field coils may be formed so that they extend beyond pole tips of the pole pieces.

Abstract: A powered dispensing tool includes a housing, a motor positioned within the housing, a rack coupled to the motor for powered translation in at least one of a forward direction and a reverse direction, and a transmission selectively coupling the motor and the rack. The transmission includes an input ring rotatable in response to rotation of the motor in a first direction corresponding with powered translation of the rack in the forward direction, a first clutch member engaged with the rack through an intermediate gear, and a second clutch member that receives torque from the input ring and that is movable in response to rotation of the motor in the first direction toward a first position engaging the first clutch member. The second clutch member is also movable in response to rotation of the motor in an opposite, second direction toward a second position disengaged from the first clutch member.

Abstract: A power tool has a motor having a stator made by separately forming pole pieces, return path pieces and field coils. The field coils are placed over necks of the pole path pieces and the return path pieces are affixed to the pole pieces. An armature having an outside diameter of at least 0.625 the outside diameter of the stator is placed in the stator. The field coils may be formed so that they extend beyond pole tips of the pole pieces.

Abstract: A power tool has a motor having a stator made by separately forming pole pieces, return path pieces and field coils. The field coils are placed over necks of the pole path pieces and the return path pieces are affixed to the pole pieces. An armature having an outside diameter of at least 0.625 the outside diameter of the stator is placed in the stator. The field coils may be formed so that they extend beyond pole tips of the pole pieces.

Abstract: A brush assembly may include a support member, a conductive arm having a first end portion and a second end portion, where the first end portion is coupled to the support member, a brush coupled to the second end portion of the conductive arm, and a biasing member configured to apply a force to the conductive arm.

Abstract: An electric motor has a field assembly, such as a stator, for a dynamoelectric machine has field coils that are wound to a net shape. Lead wires are brought out from the ends of each field coil. The field coils are insulated with insulating sleeves or insulating slot liners. The field coils are assembled with stator core pieces, such as pole pieces and return path pieces, into the stator. The stator core pieces are formed prior to being assembled with the field coils. In an aspect of the invention, the pole pieces and return path pieces are separately formed and then assembled together with the field coils, which have also been separately formed.

Abstract: An electric motor has a field assembly, such as a stator, for a dynamoelectric machine has field coils that are wound to a net shape. Lead wires are brought out from the ends of each field coil. The field coils are insulated with insulating sleeves or insulating slot liners. The field coils are assembled with stator core pieces, such as pole pieces and return path pieces, into the stator. The stator core pieces are formed prior to being assembled with the field coils. In an aspect of the invention, the pole pieces and return path pieces are separately formed and then assembled together with the field coils, which have also been separately formed.

Abstract: An electric motor has a field assembly, such as a stator, for a dynamoelectric machine has field coils that are wound to a net shape. Lead wires are brought out from the ends of each field coil. The field coils are insulated with insulating sleeves or insulating slot liners. The field coils are assembled with stator core pieces, such as pole pieces and return path pieces, into the stator. The stator core pieces are formed prior to being assembled with the field coils. In an aspect of the invention, the pole pieces and return path pieces are separately formed and then assembled together with the field coils, which have also been separately formed.

Abstract: A power tool has a motor having a stator made by separately forming pole pieces, return path pieces and field coils. The field coils are placed over necks of the pole path pieces and the return path pieces are affixed to the pole pieces. An armature having an outside diameter of at least 0.625 the outside diameter of the stator is placed in the stator. The field coils may be formed so that they extend beyond pole tips of the pole pieces.

Abstract: A brush assembly may include a support member, a conductive arm having a first end portion and a second end portion, where the first end portion is coupled to the support member, a brush coupled to the second end portion of the conductive arm, and a biasing member configured to apply a force to the conductive arm.

Abstract: A brush assembly may include a support member, a conductive arm having a first end portion and a second end portion, where the first end portion is coupled to the support member, a brush coupled to the second end portion of the conductive arm, and a biasing member configured to apply a force to the conductive arm.

Abstract: An electric motor has a field assembly, such as a stator, has field coils that are wound to a net shape. Lead wires are brought out from the ends of each field coil. The field coils are insulated. The field coils are assembled with stator core pieces, such as pole pieces and return path pieces, into the stator. The stator core pieces are formed prior to being assembled with the field coils. In an aspect of the invention, the pole pieces and return path pieces are separately formed and then assembled together with the field coils, which have also been separately formed. The pole pieces and return path pieces are formed with mating features that are mated to hold the pole pieces and return path pieces together.

Abstract: An electric motor, power tool using the electric motor, and method of making the electric motor includes making a stator that includes pole portions that have axial lengths less than an axial length of a back iron portion. Alternatively, or in addition, the pole portions have axially opposed ends that decrease in width. Alternatively, or in addition, the pole portions have dovetail features that are received in corresponding recesses of the back iron portion.