Abstract: An electric brushless DC motor is provided including a rotor assembly having a substantially-cylindrical metallic rotor body and at least one rotor magnet mounted on a surface of the rotor body, a stator assembly rotatably disposed relative to the rotor assembly, and a molded structure formed in contact with the rotor body. The molded structure includes a first mold portion in engagement with the rotor body that integrally forms a fan at or adjacent an axial end of the rotor body, and a second mold portion extending integrally from the first mold portion at least partially in engagement with an inner surface of the rotor body. The second mold portion engages two axial ends of the at least one magnet to axially support and retain the at least one magnet relative to the rotor body.

Abstract: A brushless direct-current (BLDC) motor for a power tool includes a rotor assembly and a stator assembly including stator windings. A ratio of a motor size (Km) constant of the motor to an electrical envelope of the motor including electrical parts of the motor is greater than approximately 850 (N·m/?W)/m{circumflex over (?)}3. A ratio of a motor size (Km) constant of the motor to a magnetic envelope of the motor including stator core and windings is greater than approximately 980 (N·m/?W)/m{circumflex over (?)}3.

Abstract: A brushless direct-current (BLDC) motor for a power tool includes a rotor assembly; a stator assembly including a stator having stator teeth forming slots therebetween and stator windings wound around the stator teeth; stator terminals extending substantially parallel to the longitudinal axis from the stator assembly and being substantially aligned with centerlines of the slots of the stator assembly; and a circuit board mounted on the stator terminals adjacent the stator assembly. The circuit board includes conductive traces facilitating a one of a delta or a series connection between the stator windings. An end insulator is provided at an axial end of the stator to electrically insulate the stator from the stator windings, the end insulator including support members to support the stator terminals relative to the stator assembly. The circuit board is mounted and fastened to the support members.

Abstract: An electric brushless DC motor is provided including a rotor assembly having a substantially-cylindrical metallic rotor body and at least one rotor magnet mounted on a surface of the rotor body, a stator assembly rotatably disposed relative to the rotor assembly, and a molded structure formed in contact with the rotor body. The molded structure includes a main body having a first axial end that engages at least one axial end of the at least one rotor magnet to axially retain the at least one rotor magnet on the surface of the rotor body and a second axial end that integrally forms a fan adjacent the rotor body.

Abstract: A brushless direct-current (BLDC) motor includes a stator assembly and a rotor assembly including a rotor supporting permanent magnets rotatable relative to the stator assembly. The stator assembly includes a stator comprising a stator core and stator teeth radially extending from the stator core and defining slots therebetween. A first set of stator windings is wound on the stator teeth, and a second set of stator windings is also wound on the stator teeth such that, on each stator tooth, the first and second windings are provided in an electrically parallel configuration.

Abstract: A brushless motor includes a stator and a rotor rotatably received within the stator, the rotor including a rotor shaft, a rotor body mounted on the rotor shaft and including axial slots, permanent magnets disposed within the axial slots, and a rotor end cap provided at an end of the rotor body to axially retain the permanent magnets within the slots. The rotor end cap includes an outer planar portion that is in contact with the end of the rotor body, and ribs angularly extending from the outer planar portion towards a center portion forming openings therebetween to allow passage of air between adjacent openings in thermal contact with the end of the rotor body.

Abstract: A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and in contact with an inner curved surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore.

Abstract: A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and in contact with an inner curved surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore.

Abstract: A brushless motor includes a stator and a rotor rotatably received within the stator, the rotor including a rotor shaft, a rotor body mounted on the rotor shaft and including axial slots, permanent magnets disposed within the axial slots, and a rotor end cap provided at an end of the rotor body to axially retain the permanent magnets within the slots. The rotor end cap includes an outer planar portion that is in contact with the end of the rotor body, and ribs angularly extending from the outer planar portion towards a center portion forming openings therebetween to allow passage of air between adjacent openings in thermal contact with the end of the rotor body.

Abstract: An electric brushless DC motor is provided including a rotor assembly having a substantially-cylindrical metallic rotor body and at least one rotor magnet mounted on a surface of the rotor body, a stator assembly rotatably disposed relative to the rotor assembly, and a molded structure formed in contact with the rotor body. The molded structure includes a main body having a first axial end that engages at least one axial end of the at least one rotor magnet to axially retain the at least one rotor magnet on the surface of the rotor body and a second axial end that integrally forms a fan adjacent the rotor body.

Abstract: An electric brushless DC motor is provided including an outer rotor assembly having a metallic rotor body, rotor magnets mounted within an inner surface of the rotor body, and a molded structure formed within the rotor body. The molded structure includes at least one of: a main body formed on inner surface of the rotor body to securely cover and retain the rotor magnets on the inner surface of the rotor body, an axial fan formed at an end of the rotor body opposite the rotor magnets, and/or a sense magnet mount formed at approximately a radial center portion of the axial fan.

Abstract: A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and in contact with an inner curved surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore.

Abstract: A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and in contact with an inner curved surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore.

Abstract: An electric motor is provided including: a stator, an armature rotatably received within the stator and having an armature shaft on which a commutator is mounted, and a brush assembly. The brush assembly defines a first side facing the stator and a second side. The brush assembly includes a brush card mount having openings, brushes in sliding contact with the commutator, and thermally-conductive brush holders that support the brushes. Each brush holder includes a base piece disposed between the first side of the brush assembly and the stator, and a main piece including a brush-holder portion and two side flat portions. The brush-holder portion is axially received through a brush card mount opening from the first side of the brush assembly and protrude over the second side to house a brush. The two side flat portions are axially sandwiched between the base piece and the brush card mount.

Abstract: A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and in contact with an inner curved surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore.

Abstract: A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and in contact with an inner curved surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore.

Abstract: A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and engaging an inner surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore of the stator assembly.

Abstract: A brushless DC (BLDC) motor is provided including a stator assembly and a rotor rotatably arranged inside the stator. The stator assembly includes a generally-cylindrical lamination stack including a stator ring and stator teeth extending radially inwardly from the stator ring towards a center bore, where the center bore is arranged to receive the rotor therein. The stator assembly further includes an end insulator disposed at an and of the lamination stack, where the end insulator includes a generally-cylindrical outer ring and teeth portions extending radially inwardly from the outer ring towards a center of the end insulator, and the outer ring and the teeth portion correspond to the stator ring and the stator teeth. Stator windings are wound around the stator teeth and the corresponding teeth portion of the end insulator.

Abstract: A power tool is provided including an elongated housing. The housing includes a motor case disposed at a front end thereof and a handle portion extending along a longitudinal axis of the housing from the motor case to a rear end of the housing. The handle portion includes two elongated walls extending from the motor case along the longitudinal axis of the housing to form a planar opening within the handle portion. A partition wall is arranged along an axis substantially perpendicular to the longitudinal axis of the housing, separating the handle portion from the motor case. An electric motor having a drive shaft is mounted within the motor case, and a module casing supporting a planar circuit board is received within the planar opening and supported by the elongated walls within the handle portion of the housing axially along the longitudinal axis of the housing.

Abstract: An electric motor is provided including: a stator, an armature rotatably received within the stator and having an armature shaft on which a commutator is mounted, and a brush assembly. The brush assembly defines a first side facing the stator and a second side. The brush assembly includes a brush card mount having openings, brushes in sliding contact with the commutator, and thermally-conductive brush holders that support the brushes. Each brush holder includes a base piece disposed between the first side of the brush assembly and the stator, and a main piece including a brush-holder portion and two side flat portions. The brush-holder portion is axially received through a brush card mount opening from the first side of the brush assembly and protrude over the second side to house a brush. The two side flat portions are axially sandwiched between the base piece and the brush card mount.