Abstract: A power module for driving a motor is provided including a power circuit board, power switches operatively connected to the motor disposed on a first side of the circuit board, and positional sensors disposed on a side surface of the power circuit board facing the motor. The power circuit board includes a thermally-conductive core carrier layer, a first electrically-insulating layer disposed on a first surface of the core carrier layer and on which the power switches are mounted, and a second electrically-insulating layer disposed on a second surface of the core carrier layer and on which the positional sensors are mounted. The second electrically-insulating layer is etched to expose the conductive core layer on at least approximately 70% of a surface area of the second side of the circuit board.

Abstract: A power tool is provided including a gear case having a spindle, a motor case connected to a rear end of the gear case along a longitudinal axis; a handle portion extending from a rear end of the motor case along the longitudinal axis; a motor housed inside the motor case; a fan in rotational connection with the motor; at least one air intake arranged at least one of the motor case or the handle portion near the rear end of the motor case; and a power module including power switches for driving the motor and a heat sink. The power module is housed in at least one of the motor case or the handle portion near the rear end of the motor case such that rotation of the fan causes air flow to enter through the air intake and flow near the heat sink and through the motor.

Abstract: A power tool including an electric motor is provided. The tool includes a substantially disc-shaped printed circuit board (PCB), power switches mounted on the PCB; magnetic sensors mounted on the PCB facing the motor; a heat sink in thermal communication with the power switches disposed between the PCB and the electric motor; and a molded casing structurally securing the heat sink relative to the PCB. The molded casing includes a center opening, at least one first opening provided at a first radial distance from the center opening arranged to receive the magnetic sensors therein, and at least one second opening provided at a second radial distance from the center opening arranged to securely receive the heat sink therein.

Abstract: A brushless DC motor includes a stator, a rotor, and motor terminals mounted on the stator. Each motor terminal includes a planar portion extending circumferentially from the end insulator, a wire-receiving member extending from a first end of the planar portion and folded over an outer surface of the planar portion away from the center axis of the stator at an angle of less than 90 degrees, and a tab portion extending from a second end of the planar portion parallel to the center axis of the stator. A circuit board is disposed adjacent the motor including power switches mounted thereon for energizing the stator windings. Slots are formed in the circuit board to align with and securely receive the tab portions of the motor terminals, thus electrically connecting the motor terminals to the power switches.

Abstract: A power tool including an electric motor is provided. The tool includes a substantially disc-shaped printed circuit board (PCB), power switches mounted on the PCB; magnetic sensors mounted on the PCB facing the motor; a heat sink in thermal communication with the power switches disposed between the PCB and the electric motor; and a molded casing structurally securing the heat sink relative to the PCB. The molded casing includes a center opening, at least one first opening provided at a first radial distance from the center opening arranged to receive the magnetic sensors therein, and at least one second opening provided at a second radial distance from the center opening arranged to securely receive the heat sink therein.

Abstract: An electronic module is provided for a power tool having an electric motor. The module includes a module housing having a radial portion and a cylindrical portion extending from the radial portion away from the electric motor and defining an open end, a printed circuit board (PCB) received within the module housing through the open end thereof, power switches mounted on the PCB, and magnetic sensors mounted on the PCB facing the motor substantially equidistantly from a center of the PCB. The module housing includes openings disposed in the radial portion angularly around a center of the module housing to receive the magnetic sensors therein to allow the magnetic sensors to magnetically interface with the electric motor.

Abstract: A power tool is provided, including a housing; an electric brushless DC motor disposed within the housing; and a power module disposed within the housing and electrically coupled to the motor. The power module includes a circuit board, a first set of power switches mounted on a first surface of the circuit board, a second set of power switches mounted on a second surface of the circuit board substantially opposite the first set of power switches and electrically coupled to the first set of power switches forming an inverter bridge circuit, power terminals arranged on a side edge of the circuit board and coupled to the output of the inverter bridge, a first heat sink mounted on the first surface of the circuit board covering the first set of power switches, and a second heat sink covering the first heat sink and at least portions of the power terminals.

Abstract: An electronic module for controlling a motor includes a module housing including a bottom surface, walls, and an open face, a printed circuit board (PCB) arranged along a plane within the module housing; a plurality of power terminals; and a plurality of power switches mounted on the PCB to switchably connect a supply of electric power from a power source to the plurality of power terminals. The plurality of power switches includes first portions projecting outside the module housing through one of the walls along a direction substantially parallel to the plane for coupling to a plurality of wires couplable to the motor, and second portions extending substantially perpendicularly to the plane and electrically contacting the PCB.

Abstract: A power tool includes a housing having a motor housing portion, a transmission housing portion, and a handle portion. The motor housing portion includes a top surface generally opposite a bottom surface. A motor is disposed in the motor housing portion. A transmission is disposed in the transmission housing portion. A power switch is disposed on the handle portion. An electronic mode select switch is disposed on a surface of the motor housing portion. A first gripping region is on a top portion of the motor housing portion, a second gripping region is on the handle portion, and a third gripping region is on a bottom portion of the motor housing portion. The first gripping region includes a first concave recess on a first side of the motor housing portion and a second concave recess on a second side of the motor housing portion.

Abstract: A power tool includes a housing, a motor disposed in the housing, a motor controller disposed in the housing and electrically coupled to the motor, and a transmission disposed in the housing and coupled to the motor. A tool bit holder is rotatably driven by the motor via the transmission and receives a tool bit for rotatably driving threaded fasteners. A power switch and an electronic model select switch are actuatable from outside the housing and are coupled to the motor controller. The power switch controls power delivery to the motor. The electronic mode select switch is configured to select between at least a first mode of operation in which power delivery to the motor is controlled by actuation of the power switch and an electronic lock on mode in which continuous power is delivered to the motor upon a single actuation and release of the power switch.

Abstract: A power tool is provided including a gear case having a spindle, a motor case connected to a rear end of the gear case along a longitudinal axis; a handle portion extending from a rear end of the motor case along the longitudinal axis; a motor housed inside the motor case; a fan in rotational connection with the motor; at least one air intake arranged at least one of the motor case or the handle portion near the rear end of the motor case; and a power module including power switches for driving the motor and a heat sink. The power module is housed in at least one of the motor case or the handle portion near the rear end of the motor case such that rotation of the fan causes air flow to enter through the air intake and flow near the heat sink and through the motor.

Abstract: A brushless DC motor includes a stator, a rotor, and motor terminals mounted on the stator. Each motor terminal includes a planar portion extending circumferentially from the end insulator, a wire-receiving member extending from a first end of the planar portion and folded over an outer surface of the planar portion away from the center axis of the stator at an angle of less than 90 degrees, and a tab portion extending from a second end of the planar portion parallel to the center axis of the stator. A circuit board is disposed adjacent the motor including power switches mounted thereon for energizing the stator windings. Slots are formed in the circuit board to align with and securely receive the tab portions of the motor terminals, thus electrically connecting the motor terminals to the power switches.

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: An electric brushless DC motor is provided including an outer rotor assembly having a metallic rotor body, rotor magnets mounted within an inner surface of the rotor body, and a molded structure formed within the rotor body. The molded structure includes at least one of: a main body formed on inner surface of the rotor body to securely cover and retain the rotor magnets on the inner surface of the rotor body, an axial fan formed at an end of the rotor body opposite the rotor magnets, and/or a sense magnet mount formed at approximately a radial center portion of the axial fan.

Abstract: An electronic module is provided for a power tool having an electric motor. The module includes a module housing having a radial portion and a cylindrical portion extending from the radial portion away from the electric motor and defining an open end, a printed circuit board (PCB) received within the module housing through the open end thereof, power switches mounted on the PCB, and magnetic sensors mounted on the PCB facing the motor substantially equidistantly from a center of the PCB. The module housing includes openings disposed in the radial portion angularly around a center of the module housing to receive the magnetic sensors therein to allow the magnetic sensors to magnetically interface with the electric motor.

Abstract: An electronic module is provided for a power tool having an electric motor. The module includes a printed circuit board (PCB) having a first surface and a second surface; first set of power switches mounted on the first surface of the PCB; second set of power switches mounted on the PCB and electrically coupled to the first power switches forming an inverter bridge circuit for driving the electric motor; a first heat sink surface-mounted on the first surface of the PCB and having a planar main body disposed over the first power switches; a module housing arranged to receive the PCB therein; and a second heat sink secured to the module housing in thermal communication with the first heat sink to transfer heat from the first power switches.

Abstract: An electronic module is provided for a power tool having an electric motor. The electronic module includes a printed circuit board (PCB) being substantially disc-shaped; power switches mounted on the PCB forming an inverter bridge circuit for driving the electric motor; a controller mounted on the PCB and configured to control a switching operation of the power switches; positional sensors mounted on the PCB substantially equidistantly from a center of the PCB within the control portion and in communication with the controller to provide positional signals related to a rotational position of the electric motor to the controller; and a module housing arranged to receive the PCB therein. The module housing includes a planar portion in parallel to the PCB and openings disposed in the planar portion angularly around a center of the module housing to receive the positional sensors therein.

Abstract: A power tool is provided including a tool housing and a brushless DC (BLDC) motor disposed within the tool housing. The motor includes a stator assembly and a rotor assembly having a rotor lamination stack mounted on a rotor shaft to rotate therewith. The power tool also includes a power module for driving the motor, which includes: a printed circuit board, power switches operatively connected to the motor disposed on a first surface of the printed circuit board, positional sensors disposed on a second surface of the printed circuit board around a periphery of a center portion of the printed circuit board, and a heat sink having a substantially planar surface facing the second surface of the printed circuit board and disposed between the motor and the printed circuit board. The heat sink includes a through-hole therein sized to axially expose the positional sensors in the direction of the motor.

Abstract: A power tool is provided, including a housing; an electric brushless DC motor disposed within the housing; and a power module disposed within the housing and electrically coupled to the motor. The power module includes a circuit board, a first set of power switches mounted on a first surface of the circuit board, a second set of power switches mounted on a second surface of the circuit board substantially opposite the first set of power switches and electrically coupled to the first set of power switches forming an inverter bridge circuit, power terminals arranged on a side edge of the circuit board and coupled to the output of the inverter bridge, a first heat sink mounted on the first surface of the circuit board covering the first set of power switches, and a second heat sink covering the first heat sink and at least portions of the power terminals.

Abstract: A power module for driving a motor is provided including a power circuit board, power switches operatively connected to the motor disposed on a first side of the circuit board, and positional sensors disposed on a side surface of the power circuit board facing the motor. The power circuit board includes a thermally-conductive core carrier layer, a first electrically-insulating layer disposed on a first surface of the core carrier layer and on which the power switches are mounted, and a second electrically-insulating layer disposed on a second surface of the core carrier layer and on which the positional sensors are mounted. The second electrically-insulating layer is etched to expose the conductive core layer on at least approximately 70% of a surface area of the second side of the circuit board.