Patents by Inventor Earl M. Ortt

Earl M. Ortt has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 10923989
    Abstract: A Brushless Direct-Current (BLDC) motor is provided for a power tool, including a stator, and a rotor pivotably arranged inside the stator. The rotor includes a rotor shaft, a rotor lamination stack mounted on the rotor shaft to rotate therewith, and at least one magnet. A bearing is mounted on the rotor shaft to support the rotor shaft. A mount is disposed adjacent the stator along a plane perpendicular to a longitudinal axis of the rotor shaft, the mount having a bearing support member intersecting the longitudinal axis of the rotor shaft and arranged to support the bearing therein. The mount further support hall sensors axially with respect to the rotor, the hall sensors arranged around a circumference of the bearing support to magnetically sense the at least one magnet.
    Type: Grant
    Filed: October 10, 2018
    Date of Patent: February 16, 2021
    Assignee: Black & Decker Inc.
    Inventors: Eric E. Hatfield, Earl M. Ortt
  • Publication number: 20200112231
    Abstract: A Brushless Direct-Current (BLDC) motor is provided for a power tool, including a stator comprising a coil, a rotor configured to rotate with respect to the stator, terminals secured to the stator, and a sensor circuit mount attached to the stator. The sensor circuit mount defines a plane having a first side and a second side, the sensor circuit mount including hall sensors mounted on the first side of the plane of the sensor circuit mount facing the stator. Power-supply lines are secured to the terminals to supply electric current to the coil, the power-supply lines being routed from the terminals without traversing the second side of the plane of the sensor circuit mount. The sensor circuit mount is attached to the stator by at least one fastener that extends through an opening of the sensor circuit mount and a receptacle of the stator.
    Type: Application
    Filed: December 4, 2019
    Publication date: April 9, 2020
    Inventors: Eric E. Hatfield, Earl M. Ortt
  • Publication number: 20200091793
    Abstract: A stator assembly for a brushless DC motor includes a stator core defining poles and having an outer surface, at least one magnet wire wound on the poles forming phases, and a bus bar including a non-conductive mount arranged on the outer surface and conductive terminals. Each conductive terminal includes: a main portion mounted on the non-conductive mount substantially parallel to the longitudinal axis of the motor, a tang portion folded over the main portion from a first longitudinal end of the main portion, and a connection tab at a second longitudinal end of the main portion. At least a contact portion of the at least one magnet wire is wrapped around the tang portion and fused to make an electric connection to the conductive terminal, and the connection tab is arranged to makes electric contact with a wire supplying electric power to the motor.
    Type: Application
    Filed: November 20, 2019
    Publication date: March 19, 2020
    Inventors: David J. Smith, Justin H. Ayers, David E. Gillespie, Eric E. Hatfield, Earl M. Ortt, Stephen P. Osborne, Brian E. Friedman, Jarrett A. Dunston
  • Patent number: 10523080
    Abstract: A power tool includes a motor having a stator assembly and a rotor pivotably arranged inside the stator. The stator assembly includes a lamination stack defining a plurality of poles; a plurality of field windings each arranged at at least two opposite poles of said plurality of poles and connected together around the stator assembly; and a plurality of conductive terminals longitudinally arranged along an outer surface of the lamination stack and electrically coupled to the plurality of field windings and a power source.
    Type: Grant
    Filed: October 13, 2017
    Date of Patent: December 31, 2019
    Assignee: Black & Decker Inc.
    Inventors: David J. Smith, Justin H. Ayers, David E. Gillespie, Eric E. Hatfield, Earl M. Ortt, Stephen Osborne, Brian Friedman, Jarrett A. Dunston
  • Publication number: 20190044415
    Abstract: A Brushless Direct-Current (BLDC) motor is provided for a power tool, including a stator, and a rotor pivotably arranged inside the stator. The rotor includes a rotor shaft, a rotor lamination stack mounted on the rotor shaft to rotate therewith, and at least one magnet. A bearing is mounted on the rotor shaft to support the rotor shaft. A mount is disposed adjacent the stator along a plane perpendicular to a longitudinal axis of the rotor shaft, the mount having a bearing support member intersecting the longitudinal axis of the rotor shaft and arranged to support the bearing therein. The mount further support hall sensors axially with respect to the rotor, the hall sensors arranged around a circumference of the bearing support to magnetically sense the at least one magnet.
    Type: Application
    Filed: October 10, 2018
    Publication date: February 7, 2019
    Inventors: Eric E. Hatfield, Earl M. Ortt
  • Publication number: 20180323681
    Abstract: A power tool includes a brushless DC motor having a stator and a rotor pivotably arranged inside the stator, the stator including a first winding, a second winding, and a third winding. Each winding is arranged at at least two opposite poles connected together. The stator windings may be connected in a delta configuration by electrically coupling adjacent terminals of the first and second windings, second and third windings, and third and first windings at three connection points. A baffle may be provided in parallel and adjacent to the stator, the baffle including at least one conductive routing or stamping to facilitate electrically coupling the first, second, and third windings in at least one of a delta or a wye configuration.
    Type: Application
    Filed: July 12, 2018
    Publication date: November 8, 2018
    Inventors: Eric E. Hatfield, Earl M. Ortt
  • Publication number: 20180294688
    Abstract: An electric motor is provided including: a stator assembly having a lamination stack defining poles and magnet wires wound on the poles, and a rotor rotatably arranged inside the stator assembly. A mount having a curved profile and made of non-conductive material is provided. Conductive terminals are mounted on and secured to a first surface of the mount, the conductive terminals being separated and insulated from each other via portions of the mount. A second surface of the mount opposite the first surface is mounted over to an outer surface of the lamination stack in contact therewith to align the plurality of conductive terminals longitudinally along the outer surface of the lamination stack.
    Type: Application
    Filed: June 7, 2018
    Publication date: October 11, 2018
    Inventors: David J. Smith, Justin H. Ayers, David E. Gillespie, Eric E. Hatfield, Earl M. Ortt, Stephen Osborne, Brian Friedman, Jarrett A. Dunston
  • Patent number: 10056806
    Abstract: A power tool includes a brushless DC motor having a stator and a rotor pivotably arranged inside the stator, the stator including a first winding, a second winding, and a third winding. Each winding is arranged at at least two opposite poles connected together. The stator windings may be connected in a delta configuration by electrically coupling adjacent terminals of the first and second windings, second and third windings, and third and first windings at three connection points. A baffle may be provided in parallel and adjacent to the stator, the baffle including at least one conductive routing or stamping to facilitate electrically coupling the first, second, and third windings in at least one of a delta or a wye configuration.
    Type: Grant
    Filed: June 14, 2011
    Date of Patent: August 21, 2018
    Assignee: Black & Decker Inc.
    Inventors: Eric E. Hatfield, Earl M. Ortt
  • Publication number: 20180041088
    Abstract: A power tool includes a motor having a stator assembly and a rotor pivotably arranged inside the stator. The stator assembly includes a lamination stack defining a plurality of poles; a plurality of field windings each arranged at at least two opposite poles of said plurality of poles and connected together around the stator assembly; and a plurality of conductive terminals longitudinally arranged along an outer surface of the lamination stack and electrically coupled to the plurality of field windings and a power source.
    Type: Application
    Filed: October 13, 2017
    Publication date: February 8, 2018
    Inventors: David J. Smith, Justin H. Ayers, David E. Gillespie, Eric E. Hatfield, Earl M. Ortt, Stephen Osborne, Brian Friedman, Jarrett A. Dunston
  • Patent number: 9819241
    Abstract: A power tool includes a motor having a stator assembly and a rotor pivotably arranged inside the stator. The stator assembly includes a lamination stack defining a plurality of poles; a plurality of field windings each arranged at at least two opposite poles of said plurality of poles and connected together around the stator assembly; and a plurality of conductive terminals longitudinally arranged along an outer surface of the lamination stack and electrically coupled to the plurality of field windings and a power source.
    Type: Grant
    Filed: June 17, 2013
    Date of Patent: November 14, 2017
    Assignee: Black & Decker Inc.
    Inventors: David J. Smith, Justin Ayers, David E. Gillespie, Eric E. Hatfield, Earl M. Ortt, Stephen Osborne, Brian Friedman, Jarrett A. Dunston
  • Patent number: 9472989
    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.
    Type: Grant
    Filed: August 26, 2014
    Date of Patent: October 18, 2016
    Assignee: Black & Decker Inc.
    Inventors: Hung T. Du, Brandon L. Verbrugge, Joshua F. West, Michael R. Sell, Richard T. Walter, David J. Smith, Earl M. Ortt, John C. Stone, Howard T. White
  • Patent number: 9450472
    Abstract: A power tool includes a brushless DC motor having a stator assembly and a rotor assembly at least a portion of which is arranged pivotably inside the stator assembly. The rotor assembly includes a rotor lamination stack housing a permanent magnets and a rotor fixedly housed inside a center portion of the lamination stack to pivot therewith. A fan may be fixedly attached to the rotor and arranged adjacent the stator assembly. The fan includes a back plate and blades longitudinally projecting from a periphery of the back plate towards the stator assembly, where a middle portion of the back plate is contoured away from an end cap of the motor to accommodate a projecting portion of the end cap. The permanent magnets may extend beyond the longitudinal length of the rotor lamination stack towards a magnet sensor to facilitate sensing of the permanent magnet via the magnet sensor.
    Type: Grant
    Filed: June 14, 2011
    Date of Patent: September 20, 2016
    Assignee: Black & Decker, Inc.
    Inventors: Eric E. Hatfield, Joseph G. Stauffer, Earl M. Ortt
  • Patent number: 9318932
    Abstract: A power tool includes a brushless DC motor housed inside an upper body of the tool housing and a control unit housed inside a handle of the housing, the control unit including a micro-controller mounted on a control circuit board, a power unit electronically coupled to the micro-controller and mounted on a power circuit board arranged substantially parallel the control circuit board inside the handle, and a heat sink in thermal contact with the power unit. An input unit may be mounted directly on the control circuit board. An upper portion of the heat sink extending towards the upper body of the housing may include a tab protruding underneath a fan assembly of the motor to transfer heat from the power unit to the airflow created by the fan.
    Type: Grant
    Filed: June 14, 2011
    Date of Patent: April 19, 2016
    Assignee: Black & Decker Inc.
    Inventors: Madhur M. Purohit, Earl M. Ortt, Erik Ekstrom, Shailesh P. Waikar, Marcell E. Coates, Eric E. Hatfield
  • Patent number: 8997332
    Abstract: A method for forming an armature for an electric motor includes: securing a lamination stack having slots therein on an armature shaft, securing a commutator on one end of the armature shaft, winding magnet wires in the slots in the lamination stack and securing ends of the magnet wires to the commutator, the magnet wires having armature lead wires that extend from the slots to the commutator; and molding plastic over the magnet wires to encase at least the armature lead wires in plastic. Alternatively and/or additionally, plastic is molded over the magnet wires to retain them in the slots and to support the armature lead wires and prevent them from vibrating when the armature rotates during operation.
    Type: Grant
    Filed: November 1, 2012
    Date of Patent: April 7, 2015
    Assignee: Black & Decker Inc.
    Inventors: Hung T. Du, Brandon L. Verbrugge, Joshua F. West, Michael R. Sell, Richard T. Walter, David J. Smith, Earl M. Ortt, John C. Stone, Howard T. White
  • Patent number: 8937412
    Abstract: An electric motor for a power tool includes a stator and an armature disposed in the stator. The armature includes a lamination stack having slots therein; an armature shaft extending coaxially through the lamination stack; a plurality of magnet wires wound in the slots of the lamination stack; a commutator disposed on the armature shaft to which ends of the magnet wires are electrically coupled; and thermally conductive plastic at least partially encasing the magnet wires, the thermally conductive plastic having a base polymer that is a blend of at least two polymers.
    Type: Grant
    Filed: November 1, 2012
    Date of Patent: January 20, 2015
    Assignee: Black & Decker Inc.
    Inventors: Hung T. Du, Brandon L. Verbrugge, Joshua F. West, Michael R. Sell, Richard T. Walter, David J. Smith, Earl M. Ortt, John C. Stone, Howard T. White
  • Publication number: 20140360008
    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.
    Type: Application
    Filed: August 26, 2014
    Publication date: December 11, 2014
    Inventors: Hung T. Du, Brandon L. Verbrugge, Joshua F. West, Michael R. Sell, Richard T. Walter, David J. Smith, Earl M. Ortt, John C. Stone, Howard T. White
  • Patent number: 8901787
    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.
    Type: Grant
    Filed: November 1, 2012
    Date of Patent: December 2, 2014
    Assignee: Black & Decker Inc.
    Inventors: Hung T. Du, Brandon L. Verbrugge, Joshua F. West, Michael R. Sell, Richard T. Walter, David J. Smith, Earl M. Ortt, John C. Stone, Howard T. White
  • Patent number: 8850690
    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.
    Type: Grant
    Filed: November 1, 2012
    Date of Patent: October 7, 2014
    Assignee: Black & Decker Inc.
    Inventors: Hung T. Du, Brandon L. Verbrugge, Joshua F. West, Michael R. Sell, Richard T. Walter, David J. Smith, Earl M. Ortt, John C. Stone, Howard T. White
  • Patent number: 8823234
    Abstract: An electric motor has a rotor and a stator. The rotor or the stator has arced permanent magnets that have essentially the same inner radius (IR) and outer radius (OR). In an aspect, the stator has a stator housing having a plurality of poles. Each pole includes a plurality of flat magnets affixed to an inner surface of the stator housing. In an aspect, flats on the outside of the stator housing key the stator assembly in a power tool housing. In an aspect, flat magnets are pre-magnetized, pre-assembled with alternating magnetic polarities, inserted into a stator housing, and remagnetized to a final, desired magnetic polarity configuration. In an aspect, pre-magnetized magnets and unmagnetized magnets are pre-assembled with unmagnetized magnets between magnetized magnets, the pre-assembled magnets inserted into a stator housing, and the unmagnetized magnets magnetized to a final, desired magnetic polarity configuration.
    Type: Grant
    Filed: October 12, 2007
    Date of Patent: September 2, 2014
    Assignee: Black & Decker Inc.
    Inventors: Earl M. Ortt, Hung T. Du, Sankarshan Murthy
  • Publication number: 20140132093
    Abstract: A power tool includes a brushless DC motor housed inside an upper body of the tool housing and a control unit housed inside a handle of the housing, the control unit including a micro-controller mounted on a control circuit board, a power unit electronically coupled to the micro-controller and mounted on a power circuit board arranged substantially parallel the control circuit board inside the handle, and a heat sink in thermal contact with the power unit. An input unit may be mounted directly on the control circuit board. An upper portion of the heat sink extending towards the upper body of the housing may include a tab protruding underneath a fan assembly of the motor to transfer heat from the power unit to the airflow created by the fan.
    Type: Application
    Filed: June 14, 2011
    Publication date: May 15, 2014
    Applicant: Black & Decker Inc.
    Inventors: Madhur M. Purohit, Earl M. Ortt, Erik Ekstrom, Shailesh P. Waikar, Marcell E. Coates, Eric E. Hatfield