Abstract: A motor assembly includes a stator having a stator core, stator windings, and a routing insulator configured to electrically insulate the stator core from the stator windings; a rotor rotatably received within the stator; and a bearing bridge received at least partially within the routing insulator and including a main body forming a center pocket arranged to support a bearing of the rotor shaft. A circuit board is provided including a circuit board, and an overmold structure forming an annular body on a surface of the circuit board arranged to mate with the main body of the bearing bridge to substantially seal the center pocket from ingress of debris particles.

Abstract: A motor is provided including: a stator including a stator core, stator windings, and an end insulator; a rotor rotatably received within the stator; and stator terminals supported by the routing insulator and extending away from the stator. Each stator terminal includes a main body having a curved portion, a tang portion folded over the main body and receiving a portion of a magnet wire therein to make an electrical connection with at least one of the stator windings, and a terminal pin projecting axially away from the stator core. The stator core has a maximum diameter of less than or equal to approximately 34 mm defining an outer envelope of the stator, and the stator terminals are fully contained within the outer envelope.

Abstract: A motor is provided including a motor housing having an open end; a stator disposed within the motor housing and including a stator core, stator windings, and an end insulator that electrically insulate the stator core from the stator windings and includes an annular body; a rotor rotatably received within the stator and including a rotor shaft extending along a longitudinal axis and permanent magnets; and a bearing bridge including a center pocket arranged to support a bearing of the rotor shaft. The bearing bridge is received at least partially within the end insulator. The annular body of the end insulator includes at least one peripheral opening located within the motor housing, and the bearing bridge is radially piloted relative to the motor housing via a retaining member received through the at least one peripheral opening.

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 motor assembly includes a stator having a stator core, stator windings, and a routing insulator configured to electrically insulate the stator core from the stator windings; a rotor rotatably received within the stator; and a bearing bridge received at least partially within the routing insulator and including a main body forming a center pocket arranged to support a bearing of the rotor shaft. A circuit board is provided including a circuit board, and an overmold structure forming an annular body on a surface of the circuit board arranged to mate with the main body of the bearing bridge to substantially seal the center pocket from ingress of debris particles.

Abstract: A motor is provided including: a stator including a stator core, stator windings, and an end insulator; a rotor rotatably received within the stator; and stator terminals supported by the routing insulator and extending away from the stator. Each stator terminal includes a main body having a curved portion, a tang portion folded over the main body and receiving a portion of a magnet wire therein to make an electrical connection with at least one of the stator windings, and a terminal pin projecting axially away from the stator core. The stator core has a maximum diameter of less than or equal to approximately 34 mm defining an outer envelope of the stator, and the stator terminals are fully contained within the outer envelope.

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.

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: A motor is provided including a motor housing having an open end; a stator disposed within the motor housing and including a stator core, stator windings, and an end insulator that electrically insulate the stator core from the stator windings and includes an annular body; a rotor rotatably received within the stator and including a rotor shaft extending along a longitudinal axis and permanent magnets; and a bearing bridge including a center pocket arranged to support a bearing of the rotor shaft. The bearing bridge is received at least partially within the end insulator. The annular body of the end insulator includes at least one peripheral opening located within the motor housing, and the bearing bridge is radially piloted relative to the motor housing via a retaining member received through the at least one peripheral opening.