Patents by Inventor Keith Boulanger
Keith Boulanger 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).
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Publication number: 20240136872Abstract: A power tool including a housing and a motor assembly positioned within the housing. The motor assembly includes a stator with winding slots that receive stator windings and a rotor. The rotor includes a rotor body with a first slot positioned a first distance from a center of the rotor body, a second slot positioned a second distance from the center of the rotor body, and a third slot positioned a third distance from the center of the rotor body. The first slot, the second slot, and the third slot are curved about a common center. The rotor further includes a first magnet positioned within the first slot, a second magnet positioned within the second slot, and a third magnet positioned within the third slot.Type: ApplicationFiled: October 23, 2023Publication date: April 25, 2024Inventor: Keith Boulanger
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Publication number: 20240097542Abstract: A method of manufacturing a brushless electric motor including providing a stator that includes a core defining a plurality of stator teeth, positioning a rotor within the stator, coupling a stator end cap to an end of the core, winding a plurality of coils on the plurality of stator teeth, and overmolding a plurality of coil contact plates within the stator end cap. The coil contact plates short-circuit diagonally opposite coils on the stator.Type: ApplicationFiled: November 28, 2023Publication date: March 21, 2024Inventors: Andrew T. Beyerl, Keith Boulanger, Matthew R. Bailey, Carl B. Westerby
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Publication number: 20240063679Abstract: Power tools described herein include a housing, a brushless direct current (DC) motor, a non-conductive terminal mount, and a plurality of terminals. The housing has a motor housing portion, a handle portion, and a battery pack interface. The brushless DC motor is located within the motor housing portion and has a rotor and a stator. The non-conductive terminal mount is located on an outer peripheral surface of the stator and includes an angled surface. The angled surface is not substantially parallel to a longitudinal axis of the motor. The plurality of terminals is mounted on the angled surface of the terminal mount. Each of the terminals is angled in a first direction such that the terminals are not substantially parallel to the longitudinal axis of the motor.Type: ApplicationFiled: November 1, 2023Publication date: February 22, 2024Inventors: Matthew R. Bailey, Keith M. Klosterman, Keith Boulanger, Jeffrey C. Hessenberger, Andrew T. Beyerl, Jorge L. Ibarra
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Patent number: 11881750Abstract: A motor assembly for use with a power tool includes a motor housing, a brushless electric motor disposed at least partially in the motor housing, and a PCB assembly coupled to the motor housing. The PCB assembly includes a heat sink, a power PCB coupled to a first side of the heat sink, and a position sensor PCB coupled to a second side of the heat sink opposite the first side and in facing relationship with the motor.Type: GrantFiled: August 24, 2021Date of Patent: January 23, 2024Assignee: MILWAUKEE ELECTRIC TOOL CORPORATIONInventors: Andrew T. Beyerl, Keith Boulanger, Matthew R. Bailey, Carl B. Westerby
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Patent number: 11811287Abstract: Power tools described herein include a housing, a brushless direct current (DC) motor, a non-conductive terminal mount, and a plurality of terminals. The housing has a motor housing portion, a handle portion, and a battery pack interface. The brushless DC motor is located within the motor housing portion and has a rotor and a stator. The non-conductive terminal mount is located on an outer peripheral surface of the stator and includes an angled surface. The angled surface is not substantially parallel to a longitudinal axis of the motor. The plurality of terminals is mounted on the angled surface of the terminal mount. Each of the terminals is angled in a first direction such that the terminals are not substantially parallel to the longitudinal axis of the motor.Type: GrantFiled: June 4, 2021Date of Patent: November 7, 2023Assignee: Milwaukee Electric Tool CorporationInventors: Matthew R. Bailey, Keith M. Klosterman, Keith Boulanger, Jeffrey C. Hessenberger, Andrew T. Beyerl, Gerald A. Zucca
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Patent number: 11799334Abstract: A power tool including a housing and a motor assembly positioned within the housing. The motor assembly includes a stator with winding slots that receive stator windings and a rotor. The rotor includes a rotor body with a first slot positioned a first distance from a center of the rotor body, a second slot positioned a second distance from the center of the rotor body, and a third slot positioned a third distance from the center of the rotor body. The first slot, the second slot, and the third slot are curved about a common center. The rotor further includes a first magnet positioned within the first slot, a second magnet positioned within the second slot, and a third magnet positioned within the third slot.Type: GrantFiled: October 21, 2020Date of Patent: October 24, 2023Assignee: Milwaukee Electric Tool CorporationInventor: Keith Boulanger
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Publication number: 20230318105Abstract: A battery pack includes an outer housing and a plurality of pouch cells arranged within the outer housing. Each of the plurality of pouch cells has a first cell end, a second cell end, and a cell side surface provided between the first cell end and the second cell end. The cell side surface includes a first face, a second face, and a third face. Each of the plurality of pouch cells has a thickness in a first direction extending between the first cell end and the second cell end and has a two-dimensional projection in a plane that is orthogonal to the first direction.Type: ApplicationFiled: March 31, 2023Publication date: October 5, 2023Inventors: Keith Boulanger, Ryan B. Jipp, Kyle C. Fassbender, Matthew R. Polakowski, Nicholas A. Sanchez, Richard M. Sebzda
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Publication number: 20230291247Abstract: The disclosure provides, in one aspect, an electric motor comprising a stator and a rotor assembly including a rotor body and a pinion gear integrally formed as a single piece with the rotor body.Type: ApplicationFiled: March 10, 2023Publication date: September 14, 2023Inventors: Keith BOULANGER, Anthony E. BREITBACH, Keith M. KLOSTERMAN, Jorge L. IBARRA
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Publication number: 20230283221Abstract: An electrical combination, a tool system, an electric motor, a battery pack, and operating and manufacturing methods. The tool may include a tool housing, a motor supported by the tool housing, the motor having a nominal outer diameter of up to about 80 millimeters (mm), the motor being operable to output at least about 2760 watts (W), and a tool terminal electrically connected to the motor; a battery pack including a pack housing defining a volume of the battery pack, the volume being up to about 5.2×106 cubic millimeters (mm3), battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 80 volts (V), and a pack terminal electrically connectable to the tool terminal to transfer current between the battery pack and the tool; and a controller operable to control the transfer of current.Type: ApplicationFiled: May 15, 2023Publication date: September 7, 2023Inventors: Samuel Sheeks, Jeffrey M. Brozek, Keith Boulanger, Andrew T. Beyerl, Timothy R. Obermann, Alex Huber, Samantha L. Billetdeaux, Lance D. Lamont, Matthew J. Mergener
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Publication number: 20230155430Abstract: A stator includes insulation including a back insulation portion covering a back stator portion, a first tooth portion covering a first tooth, a second tooth portion covering a second tooth. A first flange portion has a first face that is in facing relationship with the back insulation portion. A second flange portion has a second face that is in facing relationship with the back insulation portion. The first face and the second face together substantially defining a boundary plane, such that a cross-sectional slot area is defined between the back insulation portion, the first tooth portion, the second tooth portion, and the boundary plane. A plurality of conductive wires are arranged in the cross-sectional slot area, the wires defining a cross-sectional winding area within the cross-sectional slot area. A ratio of the cross-sectional winding area to the cross-sectional slot area is greater than or equal to 0.45.Type: ApplicationFiled: June 2, 2020Publication date: May 18, 2023Inventors: Andrew T. BEYERL, Keith BOULANGER, Ryan B. JIPP, Timothy R. OBERMANN, Matthew R. BAILEY
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Patent number: 11652437Abstract: An electrical combination, a tool system, an electric motor, a battery pack, and operating and manufacturing methods. The tool may include a tool housing, a motor supported by the tool housing, the motor having a nominal outer diameter of up to about 80 millimeters (mm), the motor being operable to output at least about 2760 watts (W), and a tool terminal electrically connected to the motor; a battery pack including a pack housing defining a volume of the battery pack, the volume being up to about 5.2×106 cubic millimeters (mm3), battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 80 volts (V), and a pack terminal electrically connectable to the tool terminal to transfer current between the battery pack and the tool; and a controller operable to control the transfer of current.Type: GrantFiled: July 2, 2018Date of Patent: May 16, 2023Assignee: Milwaukee Electric Tool CorporationInventors: Samuel Sheeks, Jeffrey M. Brozek, Keith Boulanger, Andrew T. Beyerl, Timothy R. Obermann, Alex Huber, Samantha L. Billetdeaux, Lance D. Lamont, Matthew J. Mergener
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Publication number: 20230061923Abstract: A power tool including a housing, a controller within the housing, and a brushless motor within the housing and controlled by the controller. The brushless motor including a stator assembly including a stator core having stator laminations with an annular portion and inwardly extending stator teeth. The stator assembly defines a stator envelope in an axial direction extending between axial ends of stator end caps of the stator assembly. The brushless motor further includes a rotor assembly including a rotor core having rotor laminations and defining a central aperture that extends in the axial direction and that receives a shaft, and a position sensor board assembly including position sensors and configured to provide position information of the rotor core to the controller. The rotor assembly and the position sensor board assembly are provided at least partially within the stator envelope.Type: ApplicationFiled: November 7, 2022Publication date: March 2, 2023Inventors: Andrew T. Beyerl, Keith Boulanger, Alex Huber, William A. Elger, Jeffrey M. Wackwitz
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Publication number: 20230021235Abstract: An electrical combination, a motorized device system, a motor assembly, a battery pack, and operating methods. The combination may include an electrical device including a device housing, a load supported by the device housing, the load being operable to output at least about 1800 watts (W), and a device terminal electrically connected to the load; a battery pack including a pack housing, battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 20 volts, and a pack terminal electrically connectable to the device terminal to transfer current between the battery pack and the electrical device; and a controller operable to control the transfer of current.Type: ApplicationFiled: August 26, 2022Publication date: January 19, 2023Inventors: Samuel Sheeks, Keith Boulanger, Andrew T. Beyerl, Timothy R. Obermann, Carl B. Westerby, Matthew J. Mergener, Cameron R. Schulz, Kyle C. Fassbender, Matthew R. Polakowski
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Patent number: 11496022Abstract: A power tool including a housing, a controller within the housing, and a brushless motor within the housing and controlled by the controller. The brushless motor including a stator assembly including a stator core having stator laminations with an annular portion and inwardly extending stator teeth. The stator assembly defines a stator envelope in an axial direction extending between axial ends of stator end caps of the stator assembly. The brushless motor further includes a rotor assembly including a rotor core having rotor laminations and defining a central aperture that extends in the axial direction and that receives a shaft, and a position sensor board assembly including position sensors and configured to provide position information of the rotor core to the controller. The rotor assembly and the position sensor board assembly are provided at least partially within the stator envelope.Type: GrantFiled: September 14, 2020Date of Patent: November 8, 2022Assignee: Milwaukee Electric Tool CorporationInventors: Andrew T. Beyerl, Keith Boulanger, Alex Huber, William A. Elger, Jeffrey M. Wackwitz
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Patent number: 11476527Abstract: An electrical combination, a motorized device system, a motor assembly, a battery pack, and operating methods. The combination may include an electrical device including a device housing, a load supported by the device housing, the load being operable to output at least about 1800 watts (W), and a device terminal electrically connected to the load; a battery pack including a pack housing, battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 20 volts, and a pack terminal electrically connectable to the device terminal to transfer current between the battery pack and the electrical device; and a controller operable to control the transfer of current.Type: GrantFiled: July 25, 2018Date of Patent: October 18, 2022Assignee: MILWAUKEE ELECTRIC TOOL CORPORATIONInventors: Samuel Sheeks, Keith Boulanger, Andrew T. Beyerl, Timothy R. Obermann, Carl B. Westerby, Matthew J. Mergener, Cameron R. Schulz, Kyle C. Fassbender, Matthew R. Polakowski
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Patent number: 11462794Abstract: An electrical combination, a motorized device system, a motor assembly, a battery pack, and operating methods. The combination may include an electrical device including a device housing, a load supported by the device housing, the load being operable to output at least about 1800 watts (W), and a device terminal electrically connected to the load; a battery pack including a pack housing, battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 20 volts, and a pack terminal electrically connectable to the device terminal to transfer current between the battery pack and the electrical device; and a controller operable to control the transfer of current.Type: GrantFiled: January 24, 2020Date of Patent: October 4, 2022Assignee: MILWAUKEE ELECTRIC TOOL CORPORATIONInventors: Samuel Sheeks, Keith Boulanger, Andrew T. Beyerl, Timothy R. Obermann, Carl B. Westerby, Matthew J. Mergener, Cameron R. Schulz, Kyle C. Fassbender, Matthew R. Polakowski
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Patent number: 11374528Abstract: An electrical combination, a tool system, an electric motor, a battery pack, and operating and manufacturing methods. The tool may include a tool housing, a motor supported by the tool housing, the motor having a nominal outer diameter of up to about 80 millimeters (mm), the motor being operable to output at least about 2760 watts (W), and a tool terminal electrically connected to the motor; a battery pack including a pack housing defining a volume of the battery pack, the volume being up to about 5.2×106 cubic millimeters (mm3), battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 80 volts (V), and a pack terminal electrically connectable to the tool terminal to transfer current between the battery pack and the tool; and a controller operable to control the transfer of current.Type: GrantFiled: December 2, 2019Date of Patent: June 28, 2022Assignee: MILWAUKEE ELECTRIC TOOL CORPORATIONInventors: Samuel Sheeks, Jeffrey M. Brozek, Keith Boulanger, Andrew T. Beyerl, Timothy R. Obermann, Alex Huber, Samantha L. Billetdeaux, Lance D. Lamont, Matthew J. Mergener
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Publication number: 20210384809Abstract: A motor assembly for use with a power tool includes a motor housing, a brushless electric motor disposed at least partially in the motor housing, and a PCB assembly coupled to the motor housing. The PCB assembly includes a heat sink, a power PCB coupled to a first side of the heat sink, and a position sensor PCB coupled to a second side of the heat sink opposite the first side and in facing relationship with the motor.Type: ApplicationFiled: August 24, 2021Publication date: December 9, 2021Inventors: Andrew T. Beyerl, Keith Boulanger, Matthew R. Bailey, Carl B. Westerby
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Publication number: 20210384793Abstract: Power tools described herein include a housing, a brushless direct current (DC) motor, a non-conductive terminal mount, and a plurality of terminals. The housing has a motor housing portion, a handle portion, and a battery pack interface. The brushless DC motor is located within the motor housing portion and has a rotor and a stator. The non-conductive terminal mount is located on an outer peripheral surface of the stator and includes an angled surface. The angled surface is not substantially parallel to a longitudinal axis of the motor. The plurality of terminals is mounted on the angled surface of the terminal mount. Each of the terminals is angled in a first direction such that the terminals are not substantially parallel to the longitudinal axis of the motor.Type: ApplicationFiled: June 4, 2021Publication date: December 9, 2021Inventors: Matthew R. Bailey, Keith M. Klosterman, Keith Boulanger, Jeffrey C. Hessenberger, Andrew T. Beyerl, Gerald A. Zucca
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Patent number: 11114927Abstract: A brushless electric motor includes a stator and a rotor. The stator includes a core defining a plurality of stator teeth, a first end cap proximate a first end of the core, a second end cap proximate a second end of the core, and a plurality of coils disposed on the respective stator teeth. The stator also includes a plurality of coil contact plates overmolded within one of the first end cap or the second end cap that short-circuit diagonally opposite coils on the stator.Type: GrantFiled: November 11, 2020Date of Patent: September 7, 2021Assignee: MILWAUKEE ELECTRIC TOOL CORPORATIONInventors: Andrew T. Beyerl, Keith Boulanger, Matthew R. Bailey, Carl B. Westerby