Patents by Inventor Jarrett A. Dunston

Jarrett A. Dunston 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).

  • Publication number: 20200343780
    Abstract: A brushless direct-current motor is provided includes an inner stator and an outer rotor. A rotor shaft extends through a stator core of the inner stator. A first end cap includes a radial back plate disposed on a first side of the stator and a front center opening through which the rotor shaft is supported via a front bearing. A second end cap includes an inner annular body extending axially inwardly and forming a rear center opening, an outer annular body, and a main body extending on a second side of the stator. The inner annular body includes a first portion that extends at least partially into an opening of the stator core and supports the rotor shaft via a rear bearing, and a second portion rearward of the first portion that received a rear end of the rotor shaft therein and houses a sensor board therein.
    Type: Application
    Filed: April 23, 2020
    Publication date: October 29, 2020
    Inventors: John B. Fogle, Dustin Jeffries, Michael R. Marjomma, Kevin L. Pulley, Vincent W. Zou, Jarrett A. Dunston, David J. Smith, Rene Thieme, Tim Heimrich, Tobias Heep, Daniel Bernhart, Dieter Schmidtfrerick
  • Publication number: 20200343789
    Abstract: A brushless direct-current motor is provided includes an inner stator and an outer rotor. The rotor includes a rotor core disposed around the stator, an inner annular member mounted on a rotor shaft, and a plurality of radial blades extending angularly from the rotor core to the inner annular member forming a fan. A first end cap is provided including a radial back plate proximate the fan and a center opening in the radial back plate through which the rotor shaft extends. A second end cap is provided including a main body disposed adjacent the stator opposite the fan. The radial back plate of the first end cap includes at least one sloped surface forming at least one air gap such that the airflow generated by the fan is centrifugally guided within the first end cap by the sloped surface and caused to exit through the air gap.
    Type: Application
    Filed: April 23, 2020
    Publication date: October 29, 2020
    Inventors: John B. Fogle, Dustin Jeffries, Michael R. Marjomma, Kevin L. Pulley, Vincent W. Zou, Jarrett A. Dunston, David J. Smith, Rene Thieme, Tim Heimrich, Tobias Heep, Daniel Bernhart, Dieter Schmidtfrerick
  • Publication number: 20200321826
    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.
    Type: Application
    Filed: June 22, 2020
    Publication date: October 8, 2020
    Inventors: Colin M. Crosby, Merritt J. Tennison, Ryan F. Schroeder, Jarrett A. Dunston, David J. Smith, Barak N. Gohn, Andrew M. Palich, Justin H. Ayers
  • Publication number: 20200321825
    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.
    Type: Application
    Filed: June 22, 2020
    Publication date: October 8, 2020
    Inventors: Colin M. Crosby, Merritt J. Tennison, Ryan F. Schroeder, Jarrett A. Dunston, David J. Smith, Barak N. Gohn, Andrew M. Palich, Justin H. Ayers
  • Patent number: 10727715
    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.
    Type: Grant
    Filed: January 29, 2020
    Date of Patent: July 28, 2020
    Assignee: Black & Decker Inc.
    Inventors: Colin M. Crosby, Merritt J. Tennison, Ryan F. Schroeder, Jarrett A. Dunston, David J. Smith, Barak N. Gohn, Andrew M. Palich, Justin H. Ayers
  • Publication number: 20200169142
    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.
    Type: Application
    Filed: January 29, 2020
    Publication date: May 28, 2020
    Inventors: Colin M. Crosby, Merritt J. Tennison, Ryan F. Schroeder, Jarrett A. Dunston, David J. Smith, Barak N. Gohn, Andrew M. Palich, Justin H. Ayers
  • 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: 10587163
    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.
    Type: Grant
    Filed: April 7, 2017
    Date of Patent: March 10, 2020
    Assignee: Black & Decker Inc.
    Inventors: Colin M. Crosby, Merritt J. Tennison, Ryan F. Schroeder, Jarrett A. Dunston, David J. Smith, Barak N. Gohn, Andrew M. Palich, Justin H. Ayers
  • Publication number: 20200016734
    Abstract: A power tool is provided including a tool housing including a motor housing and a handle portion; a battery receptacle disposed at an end of the handle portion opposite the motor housing, the battery receptacle being configured to receive a battery pack having a maximum voltage of at least 60 V; and a brushless DC (BLDC) motor including an electronically-commutated stator assembly and a rotor assembly magnetically interacting with the rotor assembly to rotate with respect to the stator assembly, the stator assembly comprising a stator lamination stack sized to be received within the motor housing having a circumference of approximately 140 to approximately 190 mm. The motor produces a maximum power output of at least 1600 watts for driving an output shaft at a maximum torque of at least 30 inch-pounds and a maximum speed of at least 8000 rotations-per-minute.
    Type: Application
    Filed: September 24, 2019
    Publication date: January 16, 2020
    Inventors: Joseph P. Kelleher, William F. Gallagher, Craig A. Oktavec, David J. Smith, 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
  • Patent number: 10328566
    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.
    Type: Grant
    Filed: October 13, 2016
    Date of Patent: June 25, 2019
    Assignee: Black & Decker Inc.
    Inventors: Colin M. Crosby, Justin H. Ayers, David J. Smith, David E. Gillespie, Sumiteru Mori, Jarrett A. Dunston, Ryan F. Schroeder
  • Patent number: 10328567
    Abstract: A power tool motor is provided including a stator assembly and a rotor assembly rotatably disposed within the stator assembly. The stator assembly includes: a generally-cylindrical lamination stack having a stator ring and stator teeth extending radially inwardly towards a center bore arranged to receive the rotor assembly therein; an end insulator disposed at an and of the lamination stack and having an outer ring and teeth portions extending radially inwardly from the outer ring towards a center of the end insulator; and stator windings wound around the stator teeth and the teeth portion of the end insulator. A generally cylindrical seal member is disposed to interface with an end of the stator, which includes a mating surface having indents configured to mate with ends of the stator windings or ends of the teeth portion of the end insulator to substantially seal respective gaps therebetween from entry of workpiece particulate.
    Type: Grant
    Filed: October 13, 2016
    Date of Patent: June 25, 2019
    Assignee: Black & Decker Inc.
    Inventors: Craig A. Oktavec, David J. Smith, Jarrett A. Dunston, Andrew M. Palich, Michael R. Marjomaa, Kevin L. Pulley
  • 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: 9991770
    Abstract: An electric motor is provided including a stator and an armature rotatably received within the stator, the armature having an armature shaft on which a commutator is mounted. The motor also includes a brush assembly having a brush card mount disposed around the commutator, a brush holder mounted on a surface of the brush card mount, and a brush disposed within the brush holder in sliding contact with the commutator to supply electric current to the commutator. A torsion spring is secured to the brush card mount adjacent the brush holder, the spring having a leg arranged to engage the back surface of the brush. A spring stop post is disposed proximate an outer periphery of the brush card mount to limit an outward movement of the leg of the spring away from the back surface of the brush.
    Type: Grant
    Filed: November 9, 2015
    Date of Patent: June 5, 2018
    Assignee: Black & Decker Inc.
    Inventors: Daniel F. Heck, Stephen P. Osborne, Jarrett A. Dunston
  • 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
  • Publication number: 20170294819
    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.
    Type: Application
    Filed: April 7, 2017
    Publication date: October 12, 2017
    Applicant: Black & Decker Inc.
    Inventors: Colin M. Crosby, Merritt J. Tennison, Ryan F. Schroeder, Jarrett A. Dunston, David J. Smith, Barak N. Gohn, Andrew M. Palich, Justin H. Ayers
  • Publication number: 20170110946
    Abstract: A power tool motor is provided including a stator assembly and a rotor assembly rotatably disposed within the stator assembly. The stator assembly includes: a generally-cylindrical lamination stack having a stator ring and stator teeth extending radially inwardly towards a center bore arranged to receive the rotor assembly therein; an end insulator disposed at an and of the lamination stack and having an outer ring and teeth portions extending radially inwardly from the outer ring towards a center of the end insulator; and stator windings wound around the stator teeth and the teeth portion of the end insulator. A generally cylindrical seal member is disposed to interface with an end of the stator, which includes a mating surface having indents configured to mate with ends of the stator windings or ends of the teeth portion of the end insulator to substantially seal respective gaps therebetween from entry of workpiece particulate.
    Type: Application
    Filed: October 13, 2016
    Publication date: April 20, 2017
    Inventors: Craig A. OKTAVEC, David J. SMITH, Jarrett A. Dunston, Andrew M. PALICH, Michael R. MARJOMAA, Kevin L. PULLEY
  • Publication number: 20170110945
    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.
    Type: Application
    Filed: October 13, 2016
    Publication date: April 20, 2017
    Inventors: Colin M. CROSBY, Justin H. AYERS, David J. SMITH, David E. Gillespie, Sumiteru MORI, Jarrett A. Dunston, Ryan F. SCHROEDER
  • Publication number: 20160065039
    Abstract: An electric motor is provided including a stator and an armature rotatably received within the stator, the armature having an armature shaft on which a commutator is mounted. The motor also includes a brush assembly having a brush card mount disposed around the commutator, a brush holder mounted on a surface of the brush card mount, and a brush disposed within the brush holder in sliding contact with the commutator to supply electric current to the commutator. A torsion spring is secured to the brush card mount adjacent the brush holder, the spring having a leg arranged to engage the back surface of the brush. A spring stop post is disposed proximate an outer periphery of the brush card mount to limit an outward movement of the leg of the spring away from the back surface of the brush.
    Type: Application
    Filed: November 9, 2015
    Publication date: March 3, 2016
    Applicant: Black & Decker Inc.
    Inventors: Daniel F. Heck, Stephen P. Osborne, Jarrett A. Dunston