Patents by Inventor Kevin L. PULLEY

Kevin L. PULLEY 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: 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: 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: 20200180134
    Abstract: A power tool is provided including a brushless DC (BLDC) motor having a stator assembly and a rotor; a substantially-cylindrical motor housing having an open end for receiving the stator assembly, a rear end, a substantially-cylindrical bearing pocket formed in the rear end to receive the rear bearing of the motor therein, and a radially-extending slot formed at or near its rear end; and a positional sensor board radially received within the slot along a central receiving axis. The positional sensor board includes a curved inner edge shaped to be positioned around the bearing pocket and includes positional sensors mounted around the curved inner edge and facing the rotor to sense a rotational position of the rotor. The curved inner edge is disposed on a side corner of the positional sensor board such that the positional sensor board is asymmetrically-shape in a direction of the receiving axis.
    Type: Application
    Filed: February 19, 2020
    Publication date: June 11, 2020
    Inventors: Andrew M. Palich, Michael R. Marjomaa, Kevin L. Pulley, David J. Smith, Dennis A. Bush, Mark T. Cherry
  • Publication number: 20200161927
    Abstract: A brushless motor is provided including a rotor rotating around a center axis and a stator including a stator core and stator teeth radially extending from the stator core forming stator slots therebetween. Each stator tooth includes a radial main body and a tooth tip extending substantially laterally from an end of the radial main body opposite the stator core, and stator windings are wound around the stator teeth. Winding retention wedges are axially received within the slots, each winding retention wedge comprising: a first portion received within gaps formed between tooth tips of adjacent stator teeth, and a second portion received at least partially between adjacent stator windings to apply a force substantially in a range of a radially-inward direction to a lateral direction to the adjacent stator windings.
    Type: Application
    Filed: November 8, 2019
    Publication date: May 21, 2020
    Inventors: Michael R. MARJOMAA, John B. FOGLE, Kevin L. PULLEY, David J. SMITH
  • Patent number: 10603777
    Abstract: A power tool is provided including a tool housing; at least one battery receptacle accommodated on the tool housing, the battery receptacle being adapted to receive a battery pack having a maximum voltage of at least 60 volts; and a brushless DC (BLDC) motor disposed within the tool housing, the motor including a stator assembly and a rotor assembly rotatably disposed within the stator assembly. A motor control and power module is disposed in close proximity to the motor, including a power switch circuit electrically coupled to the motor and a first controller configured to control a switching operation of the power switch circuit for supply of power from the battery pack to the motor. A battery management control module is disposed in close proximity to the battery receptacle, including a second controller distinct from the first controller, the second controller configured to manage an operation of the battery pack.
    Type: Grant
    Filed: October 27, 2016
    Date of Patent: March 31, 2020
    Assignee: Black & Decker Inc.
    Inventors: Andrew M. Palich, Michael R. Marjomaa, Kevin L. Pulley, David J. Smith, Dennis A. Bush, Mark T. Cherry, Scott Eshlemann, Tal Gottesman
  • Publication number: 20190321961
    Abstract: A power tool is provided including a motor housing having a substantially-cylindrical main body having an open end and a rear end. A brushless DC motor is provided including a stator assembly received through the open end of the motor housing and secured within the main body of the motor housing. A motor control and power module disposed proximate the rear end of the motor housing includes a printed circuit board (PCB) on which power switch and a controller are mounted. A mounting bracket is secured to the motor housing at the rear end to support the module such that the PCB is substantially parallel to the rear end. The mounting bracket includes a mating portion projecting axially to come to contact with the motor housing around the rear end to structurally support the mounting bracket with respect to the motor housing.
    Type: Application
    Filed: July 2, 2019
    Publication date: October 24, 2019
    Inventors: Andrew M. Palich, Michael R. Marjomaa, Kevin L. Pulley, David J. Smith, Dennis A. Bush, Mark T. Cherry, Scott Eshlemann, Tal Gottesman
  • 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: 20170120435
    Abstract: A power tool is provided including a tool housing; at least one battery receptacle accommodated on the tool housing, the battery receptacle being adapted to receive a battery pack having a maximum voltage of at least 60 volts; and a brushless DC (BLDC) motor disposed within the tool housing, the motor including a stator assembly and a rotor assembly rotatably disposed within the stator assembly. A motor control and power module is disposed in close proximity to the motor, including a power switch circuit electrically coupled to the motor and a first controller configured to control a switching operation of the power switch circuit for supply of power from the battery pack to the motor. A battery management control module is disposed in close proximity to the battery receptacle, including a second controller distinct from the first controller, the second controller configured to manage an operation of the battery pack.
    Type: Application
    Filed: October 27, 2016
    Publication date: May 4, 2017
    Inventors: Andrew M. Palich, Michael R. Marjomaa, Kevin L. Pulley, David J. Smith, Dennis A. Bush, Mark T. Cherry, Scott Eshlemann, Tal Gottesman
  • 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