Patents by Inventor Marcell E. Coates

Marcell E. Coates 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).

  • Patent number: 11691260
    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.
    Type: Grant
    Filed: October 6, 2021
    Date of Patent: July 4, 2023
    Assignee: Black & Decker Inc.
    Inventors: Joseph P. Kelleher, William F. Gallagher, Sean R. Templeton, Mark R. Poetzl, Seth M. Robinson, Marcell E. Coates, Madhur M. Purohit, Timothy J. Seeley, Joshua M. Lewis
  • Patent number: 11689082
    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.
    Type: Grant
    Filed: August 10, 2022
    Date of Patent: June 27, 2023
    Assignee: Black & Decker Inc.
    Inventors: Madhur M. Purohit, Joshua M. Lewis, Marcell E. Coates, Michael D. Grove, Victor A. Dorado
  • 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: 11583991
    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.
    Type: Grant
    Filed: October 6, 2021
    Date of Patent: February 21, 2023
    Assignee: Black & Decker Inc.
    Inventors: Marcell E. Coates, Madhur M. Purohit, Timothy J. Seeley, Joshua M. Lewis, David J. Smith, Bryce A. Wells
  • 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: 20220385143
    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.
    Type: Application
    Filed: August 10, 2022
    Publication date: December 1, 2022
    Inventors: Madhur M. PUROHIT, Joshua M. LEWIS, Marcell E. COATES, Michael D. GROVE, Victor A. DORADO
  • Patent number: 11444512
    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.
    Type: Grant
    Filed: November 18, 2020
    Date of Patent: September 13, 2022
    Assignee: Black & Decker Inc.
    Inventors: Madhur M. Purohit, Joshua M. Lewis, Marcell E. Coates, Michael D. Grove, Victor A. Dorado
  • Publication number: 20220134530
    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.
    Type: Application
    Filed: October 6, 2021
    Publication date: May 5, 2022
    Inventors: Joseph P. Kelleher, William F. Gallagher, Sean R. Templeton, Mark R. Poetzl, Seth M. Robinson, Marcell E. coates, Madhur M. Purohit, Timothy J. Seeley, Joshua M. Lewis
  • Publication number: 20220024017
    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.
    Type: Application
    Filed: October 6, 2021
    Publication date: January 27, 2022
    Inventors: Marcell E. COATES, Madhur M. PUROHIT, Timothy J. SEELEY, Joshua M. LEWIS, David J. SMITH, Bryce A. WELLS
  • Patent number: 11047528
    Abstract: A power tool is provided including a housing, a brushless direct-current (BLDC) electric motor disposed inside the housing, power switches disposed between a power supply and the electric motor and including high-side switches and low-side switches, and a control unit configured to control a switching operation of the power switches to operate the electric motor and electronically brake the motor by simultaneously activating the high-side switches or the low-side switches to stop the rotation of the motor upon detection of a condition prompting the braking of the motor. The control unit is configured to detect the condition that prompts the braking of the electric motor, set a braking profile for braking the electric motor based on the detected condition, and execute braking of the electric motor using the braking profile.
    Type: Grant
    Filed: February 10, 2017
    Date of Patent: June 29, 2021
    Assignee: Black & Decker Inc.
    Inventors: John C. Vanko, Marcell E. Coates, Daniel F. Nace, Matthew J. Velderman, Sean M. Kelly, James E. Goble
  • Publication number: 20210111649
    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: Application
    Filed: October 9, 2020
    Publication date: April 15, 2021
    Inventors: Christopher W. Shook, John D. Cox, Barak N. Gohn, Jason K. Leh, Wing W. Lin, Jason D. McKillican, Marcell E. Coates
  • Publication number: 20210091639
    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.
    Type: Application
    Filed: November 18, 2020
    Publication date: March 25, 2021
    Inventors: Madhur M. PUROHIT, Joshua M. LEWIS, Marcell E. COATES, Michael D. GROVE, Victor A. DORADO
  • Patent number: 10873244
    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.
    Type: Grant
    Filed: September 19, 2017
    Date of Patent: December 22, 2020
    Assignee: Black & Decker Inc.
    Inventors: Madhur M. Purohit, Joshua M. Lewis, Marcell E. Coates, Michael D. Grove, Victor A. Dorado
  • Patent number: 10848034
    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.
    Type: Grant
    Filed: September 19, 2017
    Date of Patent: November 24, 2020
    Assignee: Black & Decker Inc.
    Inventors: Madhur M. Purohit, Joshua M. Lewis, Marcell E. Coates, Michael D. Grove, Victor A. Dorado
  • Patent number: 10786894
    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.
    Type: Grant
    Filed: October 13, 2016
    Date of Patent: September 29, 2020
    Assignee: Black & Decker Inc.
    Inventors: Marcell E. Coates, Madhur M. Purohit, Timothy J. Seeley, Joshua M. Lewis, David J. Smith, Bryce A. Wells
  • Patent number: 10500708
    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, a handle portion attached to a rear end of the motor case, and a motor housed inside the motor case. The motor includes a stator, a rotor rotationally arranged inside the stator, and a fan in rotational connection with the rotor. At least one air intake is arranged at least one of the motor case or the handle portion near the rear end of the motor case. A power module including power switches and a heat sink 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.
    Type: Grant
    Filed: October 13, 2016
    Date of Patent: December 10, 2019
    Assignee: Black & Decker Inc.
    Inventors: Joseph P. Kelleher, William F. Gallagher, Sean R. Templeton, Mark R. Poetzl, Seth M. Robinson, Marcell E. Coates, Madhur M. Purohit, Timothy J. Seeley, Joshua M. Lewis
  • Publication number: 20180084646
    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.
    Type: Application
    Filed: September 19, 2017
    Publication date: March 22, 2018
    Inventors: Madhur M. PUROHIT, Joshua M. LEWIS, Marcell E. COATES, Michael D. GROVE, Victor A. DORADO
  • Publication number: 20180083510
    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.
    Type: Application
    Filed: September 19, 2017
    Publication date: March 22, 2018
    Inventors: Madhur M. PUROHIT, Joshua M. LEWIS, Marcell E. COATES, Michael D. GROVE, Victor A. DORADO
  • Publication number: 20180034346
    Abstract: A power tool is provided including a housing, a brushless DC motor housed inside the housing, and a control unit housed inside the housing for controlling an operation of the brushless DC motor. The control unit includes a potting boat having an open portion, a circuit board received within the potting boat through the open portion, power switching elements mounted on the circuit board, a potting compound receiving within the potting boat to substantially surround the circuit board, and a heat sink in thermal communication with the power switching elements. The heat sink has a surface exposed outside the potting compound through the open portion of the potting boat.
    Type: Application
    Filed: October 10, 2017
    Publication date: February 1, 2018
    Applicant: Black & Decker Inc.
    Inventors: Madhur M. Purohit, Shailesh P. Waikar, Marcell E. Coates
  • Patent number: 9812930
    Abstract: A power tool is provided including a housing; a brushless DC motor housed inside an upper body of the housing; a control unit housed inside a handle of the housing, the control unit comprising a micro-controller mounted over a control circuit board; and a variable-speed switch assembly including a main body mounted directly on a surface of the control circuit board, a trigger, a plunger linearly movable with the trigger with respect to the main body, a speed-sensing mechanism housed inside the main body and coupled to the plunger to generate a variable-speed voltage signal based on the position of the plunger, and at least one output pin connecting the speed-sensing mechanism of the variable-speed switch assembly directly to at least one conductive track on the control circuit board to provide the variable-speed voltage signal to the micro-controller via the at least one conductive track.
    Type: Grant
    Filed: April 1, 2016
    Date of Patent: November 7, 2017
    Assignee: Black & Decker Inc.
    Inventors: Madhur M. Purohit, Shailesh P. Waikar, Marcell E. Coates