Patents by Inventor John D. Cox

John D. Cox 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: 20240375253
    Abstract: An electric grinding tool includes a motor housing coupleable to an electrical power source, a motor configured to receive power from the electrical power source and including an output shaft extending along a motor axis, a handgrip coupled to and coaxial with the motor housing, a tool holder rotatably driven upon rotation of the motor, the tool holder configured to receive a shaft of a grinding accessory, and a light unit coupled to and at least partially recessed in a front end portion of the electric grinding tool. The light unit includes a plurality of lights mounted to an at least partially ring shaped printed circuit board that is received in a support ring, and a cover ring received over the lights.
    Type: Application
    Filed: July 25, 2024
    Publication date: November 14, 2024
    Inventors: John C. Vanko, Tal Gottesman, Daniel Puzio, Michael K. Forster, John D. Cox, Joseph P. Kelleher, Stuart Garber, Joerg Zellerhoff, Joao Norona, Robert S. Gehret, Scott Eshleman, Stephen P. Osborne, Brian E. Friedman, Robert A. Usselman, Anatoliy Nosov, Michael C. Doyle
  • Publication number: 20240258883
    Abstract: A power tool system includes a power tool having a tool housing. The tool housing includes a battery pack receptacle having a set of tool terminals. A brushless motor includes an output shaft operably coupled to drive a tool element, a stator having an outer diameter of approximately 60 mm to approximately 80 mm, and a stack length of approximately 75% to approximately 125% of the outer diameter of the stator. A controller is operably connected to the set of tool terminals and to the brushless motor to control power delivery to the brushless motor. A battery pack includes a battery pack housing connectable to the battery pack receptacle on the tool housing and a set of battery cells. The set of battery cells includes at least 15 battery cells each having a nominal voltage of approximately 3.6V and an impedance of approximately ?13 m?. A set of battery pack terminals is connectable to the set of tool terminals.
    Type: Application
    Filed: February 12, 2024
    Publication date: August 1, 2024
    Inventors: John D. Cox, Michael Varipatis, Matthew J. Velderman, Christopher W. Shook
  • Patent number: 11936248
    Abstract: A power tool system includes a power tool having a tool housing. The tool housing includes a battery pack receptacle having a set of tool terminals. A brushless motor includes an output shaft operably coupled to drive a tool element, a stator having an outer diameter of approximately 60 mm to approximately 80 mm, and a stack length of approximately 75% to approximately 125% of the outer diameter of the stator. A controller is operably connected to the set of tool terminals and to the brushless motor to control power delivery to the brushless motor. A battery pack includes a battery pack housing connectable to the battery pack receptacle on the tool housing and a set of battery cells. The set of battery cells includes at least 15 battery cells each having a nominal voltage of approximately 3.6V and an impedance of approximately ?13 m?. A set of battery pack terminals is connectable to the set of tool terminals.
    Type: Grant
    Filed: October 20, 2020
    Date of Patent: March 19, 2024
    Assignee: BLACK & DECKER INC.
    Inventors: John D. Cox, Michael Varipatis, Matthew J. Velderman, Christopher W. Shook
  • Patent number: 11855521
    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.
    Type: Grant
    Filed: February 1, 2022
    Date of Patent: December 26, 2023
    Assignee: BLACK & DECKER, INC.
    Inventors: Dustin Jefferies, David J. Smith, Marcus E. E. Rydin, Justin H. Ayers, Sumiteru Mori, John B. Fogle, John D. Cox, Kristopher Cochran, Barak N. Gohn
  • Publication number: 20230405792
    Abstract: A power tool is provided including a power supply interface receiving a removable battery pack, a brushless direct current (BLDC) motor including a rotor and a stator, and a multi-phase inverter bridge circuit. A controller is provided to output drive signals to the inverter bridge circuit to control flow of current from to the motor, where each drive signal is activated within each corresponding phase of the motor within a conduction band. The controller is configured to control a length of the conduction band at a variable value within a first torque range below a torque threshold and at a substantially constant value within a second torque range above the torque threshold. The torque threshold is greater than approximately 1 Newton-meters and the motor produces a maximum power output of at least approximately 1250 watts at the torque of approximately 1 Newton-meters.
    Type: Application
    Filed: September 1, 2023
    Publication date: December 21, 2023
    Applicant: Black & Decker Inc.
    Inventors: John D. Cox, Michael K. Forster, John C. Vanko, Daniel J. White, Bhanuprasad V. Gorti, Matthew J. Velderman, Andrew E. Seman, JR.
  • Patent number: 11794327
    Abstract: A power tool is provided including a power supply interface receiving a medium-voltage-rated removable battery pack having a maximum rated voltage in the range of 40 to 80 volts, and a brushless direct current (BLDC) motor. The motor includes a rotor and a stator having at least three stator windings corresponding to at least three phases of the motor, the rotor being moveable by the stator when the stator windings are appropriately energized within the corresponding phases. A multi-phase inverter bridge circuit is disposed between the power supply interface and the motor, and a controller is configured to output drive signals to the inverter bridge circuit to control flow of current from the battery pack to the motor such that the motor produces a maximum power output of at least approximately 1750 watts at a torque of approximately 1.5 to 2 Newton-meters.
    Type: Grant
    Filed: March 17, 2022
    Date of Patent: October 24, 2023
    Assignee: BLACK & DECKER, INC.
    Inventors: John D. Cox, Michael K. Forster, John C. Vanko, Daniel J. White, Bhanuprasad V. Gorti, Matthew J. Velderman, Andrew E. Seman, Jr.
  • Publication number: 20230108641
    Abstract: A system is provided with a set of removable battery packs and a set of power tools each including a motor, a controller, and a battery receiving portion. For each power tool, the controller is configured to identify a type of battery pack coupled to the battery receiving portion and set a conduction band associated with phases of the motor or an advance angle by which phases of the motor are shifted based on the identified type of the battery pack.
    Type: Application
    Filed: December 13, 2022
    Publication date: April 6, 2023
    Inventors: Christopher W. Shook, John D. Cox, Barak N. Gohn, Jason K. Leh, Wing W. Lin, Jason D. McKillican, Marcell E. Coates
  • Patent number: 11569765
    Abstract: A system is provided with a set of removable battery packs and a set of power tools each including a motor, a controller, and a battery receiving portion. For each power tool, the controller is configured to identify a type of battery pack coupled to the battery receiving portion and limit a maximum amount of electric current drawn from the battery pack by the motor based on the identified type of the battery pack. The greater a ratio of an impedance of the motor to an impedance of the battery pack, the less the controller limits the maximum amount of electric current drawn from the battery pack such that for a given battery pack of the set of removable battery packs, the lower the impedance of the motor, the more current the motor draws from the given battery pack.
    Type: Grant
    Filed: October 9, 2020
    Date of Patent: January 31, 2023
    Assignee: Black & Decker Inc.
    Inventors: Christopher W. Shook, John D. Cox, Barak N. Gohn, Jason K. Leh, Wing W. Lin, Jason D. McKillican, Marcell E. Coates
  • Publication number: 20220354052
    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.
    Type: Application
    Filed: May 2, 2022
    Publication date: November 10, 2022
    Inventors: Dustin Jefferies, Bhanuprasad V. Gorti, John B. Fogle, John D. Cox
  • Publication number: 20220247269
    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 20V 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.
    Type: Application
    Filed: February 1, 2022
    Publication date: August 4, 2022
    Inventors: Dustin Jefferies, David J. Smith, Marcus E. E. Rydin, Justin H. Ayers, Sumiteru Mori, John B. Fogle, John D. Cox, Kristopher Cochran, Barak N. Gohn
  • Patent number: 11394338
    Abstract: In a loaded condition, the controller increases at least one of the conduction band or the advance angle from a baseline value up to a maximum value within a first torque range below a torque threshold to as to maintain the output speed of the motor at a linear speed-torque profile. After the at least one of the conduction band or the advance angle reaches the maximum value, the controller maintains the at least one of the conduction band or the advance angle at the maximum value within a second torque range greater than or equal to the torque threshold so as to maintain the output speed of the motor at a naturally-curved speed-torque profile.
    Type: Grant
    Filed: September 16, 2020
    Date of Patent: July 19, 2022
    Assignee: Black & Decker Inc.
    Inventor: John D. Cox
  • Publication number: 20220209706
    Abstract: A power tool is provided including a power supply interface receiving a medium-voltage-rated removable battery pack having a maximum rated voltage in the range of 40 to 80 volts, and a brushless direct current (BLDC) motor. The motor includes a rotor and a stator having at least three stator windings corresponding to at least three phases of the motor, the rotor being moveable by the stator when the stator windings are appropriately energized within the corresponding phases. A multi-phase inverter bridge circuit is disposed between the power supply interface and the motor, and a controller is configured to output drive signals to the inverter bridge circuit to control flow of current from the battery pack to the motor such that the motor produces a maximum power output of at least approximately 1750 watts at a torque of approximately 1.5 to 2 Newton-meters.
    Type: Application
    Filed: March 17, 2022
    Publication date: June 30, 2022
    Inventors: John D. Cox, Michael K. Forster, John C. Vanko, Daniel J. White, Bhanuprasad V. Gorti, Matthew J. Velderman, Andrew E. Seman, JR.
  • Patent number: 11329597
    Abstract: Conduction band control schemes are presented for reducing noise and/or lower harmonics in power tools. A controller in the tool is interfaced with a plurality of motor switches and, for each phase, operates to output a pulse-width modulated (PWM) signal to one or more of the motor switches to control power supplied to the electric motor. The controller is also configured to monitor a parameter indicative of the load on the motor. In response to detecting a load greater than a threshold, the controller controls power output of the motor by setting conduction band of the motor switches and the advance angle to baseline values predetermined values. In response to detecting a load less than the threshold, the controller reduces at least one of the conduction band and the advance angle to a value less than the baseline values.
    Type: Grant
    Filed: April 27, 2018
    Date of Patent: May 10, 2022
    Assignee: Black & Decker Inc.
    Inventors: John C. Vanko, Michael K. Forster, Tal Gottesman, John D. Cox
  • Patent number: 11173584
    Abstract: A power tool is provided including a brushless DC (BLDC) motor, a rectifier that receives an alternative current from a power supply and outputs a rectified signal supplied to a DC power bus, and an inverter circuit having motor switches connected electrically between the DC power bus and the motor. A control module controls a switching operation of the power switches to regulate supply power from the power supply to the motor. The control module controls the switching operation so as to, within a half cycle of the AC power supply voltage waveform, increase current draw from the power supply from a first threshold at or after a first zero-crossing of the half cycle up to a second threshold, and reduce current draw from the power supply from the second threshold up to a third threshold at or prior to a second zero-crossing of the half cycle.
    Type: Grant
    Filed: June 27, 2019
    Date of Patent: November 16, 2021
    Assignee: Black & Decker Inc.
    Inventors: Alexander Manasseh, Scott J. Eshleman, Robert A. Usselman, John D. Cox
  • Publication number: 20210299842
    Abstract: An actuator assembly for a power tool includes an actuator with a permanent magnet. The actuator is moveable between a first position for a first mode of operation, and a second position for a second mode of operation. A first positioning member is adjacent the first position composed of a ferromagnetic material to attract the permanent magnet. A second positioning member is adjacent the second position and composed of a ferromagnetic material to attract the permanent magnet. An electromagnet may be energized to move the actuator between the first position and the second position. When the electromagnet is not energized and the actuator is in the first position, the actuator is retained in the first position. When the electromagnet is not energized and the actuator is in the second position, the actuator is retained in the second position. When the electromagnet is energized, the actuator moves between the first and second positions.
    Type: Application
    Filed: June 11, 2021
    Publication date: September 30, 2021
    Inventors: Daniel Puzio, Robert S. Gehret, John D. Cox, Robert J. Opsitos, JR., Robert G. Kusmierski, Craig A. Schell, Michael Haupt, Joseph Kelleher
  • Patent number: 11083429
    Abstract: A scanning system having a plurality of X-ray sources together with a single X-ray detector that uses sequentially emitted overlapping fan-shaped or cone-shaped beams to image a target such as the leg of a horse. The X-ray detector is rotated closer to the target and the X-ray emitter sources are rotated at a greater distance from the target. The positioning systems of the X-ray detector and the X-ray sources may be operated independently of one another, with each of the X-ray detector and the X-ray sources being also rotated about separate axes passing therethrough (while they are both being rotated around the target) as a way to keep the X-ray sources and the X-ray detector parallel to one another while working in very tight spaces.
    Type: Grant
    Filed: August 24, 2020
    Date of Patent: August 10, 2021
    Assignee: Principle Imaging Corporation
    Inventors: John D. Cox, Gary R. Cantu, Iain Hueton
  • Patent number: 11070162
    Abstract: A power tool is provided with a multi-phase brushless motor including a rotor and a stator having stator windings corresponding to at least three phases of the motor. A power switch circuit is provided including high-side and low-side power switches. A power supply interface receives alternating-current (AC) power from an AC power supply or battery direct-current (DC) power from one or more battery packs. A rectifier converts the AC power to a rectified DC voltage on a bus line. A capacitor is disposed across the bus line such that, within each half cycle of the AC power voltage waveform, the power switch circuit draws current from the AC power supply within a first time period and from the capacitor within a second time period, the capacitor having a capacitance value such that the first time period is greater than the second time period.
    Type: Grant
    Filed: July 16, 2019
    Date of Patent: July 20, 2021
    Assignee: Black & Decker Inc.
    Inventors: John D. Cox, Michael K. Forster, John C. Vanko, Daniel J. White, Bhanuprasad V. Gorti, Matthew J. Velderman, Andrew E. Seman, Jr.
  • Patent number: 11059159
    Abstract: An actuator assembly for a power tool includes an actuator with a permanent magnet. The actuator is moveable between a first position for a first mode of operation, and a second position for a second mode of operation. A first positioning member is adjacent the first position composed of a ferromagnetic material to attract the permanent magnet. A second positioning member is adjacent the second position and composed of a ferromagnetic material to attract the permanent magnet. An electromagnet may be energized to move the actuator between the first position and the second position. When the electromagnet is not energized and the actuator is in the first position, the actuator is retained in the first position. When the electromagnet is not energized and the actuator is in the second position, the actuator is retained in the second position. When the electromagnet is energized, the actuator moves between the first and second positions.
    Type: Grant
    Filed: May 1, 2017
    Date of Patent: July 13, 2021
    Assignee: BLACK & DECKER INC.
    Inventors: Daniel Puzio, Robert S. Gehret, John D. Cox, Robert J. Opsitos, Jr., Robert G. Kusmierski, Craig A. Schell, Michael Haupt, Joseph Kelleher
  • Patent number: 11063548
    Abstract: A power tool is provided including a power supply interface receiving a medium-voltage-rated removable battery pack having a maximum rated voltage in the range of 40 to 80 volts, and a brushless direct current (BLDC) motor. The motor includes a rotor and a stator having at least three stator windings corresponding to at least three phases of the motor, the rotor being moveable by the stator when the stator windings are appropriately energized within the corresponding phases, each phase being characterized by a corresponding voltage waveform energizing the corresponding stator winding. A multi-phase inverter bridge circuit is disposed between the power supply interface and the motor, and a controller is configured to output drive signals to the inverter bridge circuit to control flow of current from the battery pack to the motor such that the motor produces a maximum power output of at least 2500 watts.
    Type: Grant
    Filed: September 23, 2019
    Date of Patent: July 13, 2021
    Assignee: Black & Decker Inc.
    Inventors: John D. Cox, Michael K. Forster, John C. Vanko, Daniel J. White, Bhanuprasad V. Gorti, Matthew J. Velderman, Andrew E. Seman, Jr.
  • Publication number: 20210119514
    Abstract: A power tool system includes a power tool having a tool housing. The tool housing includes a battery pack receptacle having a set of tool terminals. A brushless motor includes an output shaft operably coupled to drive a tool element, a stator having an outer diameter of approximately 60 mm to approximately 80 mm, and a stack length of approximately 75% to approximately 125% of the outer diameter of the stator. A controller is operably connected to the set of tool terminals and to the brushless motor to control power delivery to the brushless motor. A battery pack includes a battery pack housing connectable to the battery pack receptacle on the tool housing and a set of battery cells. The set of battery cells includes at least 15 battery cells each having a nominal voltage of approximately 3.6V and an impedance of approximately ?13 m?. A set of battery pack terminals is connectable to the set of tool terminals.
    Type: Application
    Filed: October 20, 2020
    Publication date: April 22, 2021
    Inventors: John D. Cox, Michael Varipatis, Matthew J. Velderman, Christopher W. Shook