Abstract: An electric motor having an armature which includes a coating of thermally conductive plastic applied in a conventional injection molding process. The armature also includes a fan which is integrally formed from the thermally conductive plastic applied to the armature. The process of molding thermally conductive plastic around the armature and integrally forming a fan at one end of the armature completely eliminates the need to apply one or more coatings of a trickle resin to the armature. It also eliminates the need to separately form a fan and to secure the separately formed fan by a suitable adhesive to the armature, which together significantly simplify and reduce the manufacturing cost of the armature. The thermally conductive molded plastic coating also better fills the spaces between the magnet wires around the armature, thus promoting even more efficient cooling of the armature during use and better holding of the magnet wires stationary relative to one another.

Abstract: A flux ring for a motor of a power tool has an annular housing which fits inside the motor can of the motor. At least one magnet is on the ring. The at least one magnet includes a portion formed from an isotropic magnetic material and a portion formed from an anisotropic magnetic material. Preferably, the isotropic magnetic material is sandwiched by the anisotropic magnetic material. The magnets being molded onto the flux ring in a two shot process.

Abstract: An electric motor having an armature which includes a coating of thermally conductive plastic applied in a conventional injection molding process. The armature also includes a fan which is integrally formed from the thermally conductive plastic applied to the armature. The process of molding thermally conductive plastic around the armature and integrally forming a fan at one end of the armature completely eliminates the need to apply one or more coatings of a trickle resin to the armature. It also eliminates the need to separately form a fan and to secure the separately formed fan by a suitable adhesive to the armature, which together significantly simplify and reduce the manufacturing cost of the armature. The thermally conductive molded plastic coating also better fills the spaces between the magnet wires wound around the armature, thus promoting even more efficient cooling of the armature during use and better holding of the magnet wires stationary relative to one another.

Abstract: An electric motor having an armature which includes a coating of thermally conductive plastic applied in a conventional injection molding process. The armature also includes a fan which is integrally formed from the thermally conductive plastic applied to the armature. This completely eliminates the need to apply one or more coatings of a trickle resin to the armature. It also eliminates the need to separately form and secure a fan by a suitable adhesive to the armature, which together significantly simplifies the manufacturing and cost of the armature. The plastic coating also better fills the spaces between the magnet wires, thus promoting even more efficient cooling and better holding of the magnet wires stationary relative to one another. The thermally conductive plastic coating may be mixed with other suitable materials to provide a density approximately equal to the magnet wires. This eliminates the need to balance the armature after the injection molding step.

Abstract: A motor for a power tool adapted to be powered by either an AC power source or a DC power source. The motor 12 includes a permanent magnet field 30 having an armature 34 disposed within the field. The armature 34 includes a shaft 36 having a DC commutator 38 disposed at one end of the shaft. The DC commutator is coupled to a first armature winding. An AC commutator 42 is disposed coaxially over a portion of the DC commutator 38 and is coupled to a second armature winding 44. A first pair of brushes 46 are disposed on the DC commutator 38 for coupling power from a DC power source to the first armature winding 40. A second pair of brushes 48 couple rectified AC power to the second armature winding 44. A power module including an AC/DC selector switch 26 enables a user to select whether AC or DC power is to be used to power the tool.

Abstract: A power tool has an electric motor with a stator assembly and an armature rotatable within the stator assembly. A commutator is rotatable with the armature and is connected to the armature via a shaft. The commutator has an outer layer formed from a titanium graphite material. Brushes are associated with the commutator and are held in an end plate. The brushes are formed from a titanium graphite material.