Abstract: An electric brushless DC motor is provided including a stator assembly, a rotor assembly having a rotor body and at least one rotor magnet, and a molded structure including a first mold member extending within the rotor body in contact with the at least one rotor magnet, a second mold member extending integrally from the first mold member beyond a first axial end of the rotor body to engage a first axial end surface of the at least one magnet, and a third mold member extending integrally from the first mold member beyond a second axial end of the rotor body to form a fan at or adjacent the second axial end of the rotor body. The fan generates airflow through the stator assembly with a rotation of the rotor body.

Abstract: A power tool is provided including a housing, a brushless direct-current (BLDC) motor, and a gear assembly. The motor includes a stator having an inner stator, a rotor shaft extending along a center axis and including a first bearing and a second bearing; an outer rotor, a first end cap, and a second end cap. The first end cap includes a radial back plate having a center opening in the radial back plate through which the rotor shaft extends and pins projecting around the rotor shaft and parallel to the rotor shaft. The gear assembly is mounted on the first end cap and includes planetary gears supported by the pins in engagement with the rotor shaft.

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: An electric motor is provided including an inner rotor, an outer stator, a first end cap formed on a first side of the stator, a second end cap formed on a second side of the stator and secured to the first end cap to form a compartment around the stator and the rotor, and motor wires electrically coupled to stator windings and extending out of the compartment through a wire lid. A terminal box is mounted to the wire lid to receive the motor wires, and it includes a box base fastened to the second end cap and forming a first sealed coupling to the wire lid, and a cover that makes a second sealing coupling with the box base. The terminal box receives a plurality of power wires external to the electric motor and electrically couples them to the motor wires within the box base.

Abstract: A brushless direct-current (BLDC) motor for a power tool outputs a maximum power output in the range of approximately 450 to 950 watts and a continuous power output in the range of approximately 400 to 730 watts over a discharge cycle of the battery pack when the battery pack has a maximum voltage of approximately 20 volts and a capacity of approximately 5 amp·hours. The motor includes a rotor with an outer diameter that is less than or equal to approximately 16 mm. A ratio of the maximum power output of the motor to a length of the motor is in the range of approximately 8.5 to 17.5 W/mm.

Abstract: An electric motor system includes a motor housing and an electric motor disposed in the motor housing. The electric motor includes a stator and a rotor that rotates relative to the stator, and an output shaft coupled to the rotor and configured to transmit torque from the electric motor to power equipment. The electric motor system includes a shroud is received over at least a portion of the motor housing, an electronics housing containing electronics for controlling operation of the electric motor; and a first fan outside of the motor housing, driven by rotation of the electric motor, and configured to cause airflow through the electronics housing and within the shroud around an exterior of the motor housing.

Abstract: A power tool is provided including a housing having a grip portion with a grip circumference of smaller than or equal to approximately 120 mm; and a brushless direct-current (BLDC) motor at least partially disposed within the grip portion of the housing and configured to output a maximum power output of at least 450 watts. The motor includes a stator including a stator core and stator windings; and a rotor rotatably received within the stator and including a rotor shaft extending along a longitudinal axis and a series of permanent magnet rings mounted sequentially along the longitudinal axis and surrounding the rotor shaft, each permanent magnet including a plurality of magnetic poles.

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 power tool includes a housing including a motor case and a handle; a motor disposed within the motor case and having motor lead wires; a battery receiving portion provided on an end of the handle configured to receive a removable battery pack; a control unit configured to receive electric power form the battery pack and output power wires; and a wire guide and retention unit disposed within the handle. The wire guide and retention unit includes a main body and ring terminals fastened to the main body. The ring terminals couple with the motor lead wires on one end and with the power wires on another end.

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 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.

Abstract: An electric power apparatus includes a main planar body having a circular opening that supports a brushless direct-current (BLDC) motor. The motor includes a stator, a rotor, a motor spindle extending through the circular opening, a first end cap formed on a first side of the stator and mounted on the main planar body; and a second end cap formed on a second side of the stator and secured to the first end cap to form a substantially watertight seal around the stator and the rotor. A ratio of a maximum power output of the motor when powered by at least one battery pack to a height of the motor as measured from an upper surface of the main planar body to a top surface of the motor is greater than or equal to approximately 34 watts/mm.

Abstract: An electric lawn apparatus is provided including a frame having an upper body and two side plates extending downwardly from sides of the upper body defining a cavity therein, an operator seat mounted on the upper body, two drive motors secured to the side plates away from the cavity, and a battery compartment formed within the cavity. The battery compartment receives battery packs therein along a rear-front axis of the electric lawn apparatus in a side-by-side orientation, where each battery pack has a maximum rated voltage of approximately 40V to 80V. A ratio of the cumulative energy output of the battery packs to a lateral distance between the drive motors is greater than or equal to approximately 0.23 kW/cm.

Abstract: An electric motor is provided including a stator, a rotor, a motor spindle coupled to the rotor and extending along a center axis, a first end cap formed on a first side of the stator, a second end cap formed on a second side of the stator and secured to the first end cap to form a first compartment around the stator and the rotor, an electro-magnetic brake module disposed on a side of the second end cap opposite the stator and engaged with the motor spindle, and a motor cover mounted on the second end cap to form a second compartment around the electro-magnetic brake module. The first end cap, the second end cap, and the motor cover form a substantially watertight seal around the stator, the rotor, and the position sensor assembly.

Abstract: An electric motor is provided including a stator, a rotor, a motor spindle coupled to the rotor and extending along a center axis, a first end cap formed on a first side of the stator, a second end cap formed on a second side of the stator and secured to the first end cap to form a first compartment around the stator and the rotor, and a motor component mounted on the second end cap outside the first compartment. A motor cover is mounted on the second end cap to form a second compartment around the motor component. The first end cap, the second end cap, and the motor cover form a substantially watertight seal around the stator, the rotor, and the position sensor assembly.

Abstract: An electric power apparatus includes a main planar body having a circular opening that supports a brushless direct-current (BLDC) motor. The motor includes a stator, a rotor, a motor spindle extending through the circular opening, a first end cap formed on a first side of the stator and mounted on the main planar body; and a second end cap formed on a second side of the stator and secured to the first end cap to form a substantially airtight sealed compartment around the stator and the rotor. The rotor includes a series of openings in a radial wall that generates an airflow circulating through the sealed compartment to transfer heat from the stator to the first end cap and the second end cap.

Abstract: A power tool is provided including a housing including a grip portion; and a brushless direct-current (BLDC) motor at least partially disposed within the grip portion of the housing. The motor includes a stator having a rotor core, a rotor, and front and rear bearing support structures. The stator core includes a non-segmented construction with a maximum diameter of approximately smaller than or equal to 34 mm, and a ratio of a motor size (Km) constant of the motor to a length of the motor is in the range of approximately 0.39 to 0.59 (Nmm/?W)/mm. When powered by a 20 V battery pack, a ratio of a maximum power output of the motor to a volume of the motor is at least approximately 0.0106 W/mm{circumflex over (?)}3.

Abstract: A power tool or a mower is provided including brushless direct-current motor having an inner stator and an outer rotor. A rotor shaft extends through a stator core of the inner stator. The motor includes a first end cap disposed on a first side of the stator and supporting the rotor shaft via a front bearing and a second end cap disposed on a second side of the stator and supporting the rotor shaft via a rear bearing. The front end cap is mounted on a housing of the power tool or a deck of the mower while the rear end cap is located fully outside the housing or the deck.

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.

Abstract: A power tool is provided including a housing, a brushless direct-current (BLDC) motor, and a gear assembly. The motor includes a stator having an inner stator, a rotor shaft extending along a center axis and including a first bearing and a second bearing; an outer rotor, a first end cap, and a second end cap. The first end cap includes a radial back plate having a center opening in the radial back plate through which the rotor shaft extends and pins projecting around the rotor shaft and parallel to the rotor shaft. The gear assembly is mounted on the first end cap and includes planetary gears supported by the pins in engagement with the rotor shaft.