Patents by Inventor Merritt J. Tennison
Merritt J. Tennison 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: 20220166283Abstract: An electric brushless DC (BLDC) motor includes a motor housing having a substantially cylindrical body including an open end and a peripheral slot formed through a circumferential surface of the cylindrical body extending from the open end; a stator having stator windings; and a rotor including a rotor shaft and rotor magnets. A series of motor terminals are provided substantially adjacent one another and extending substantially parallel to an axial direction of the rotor shaft along on an outer circumferential surface of the stator. The motor terminals are at least partially received within the peripheral slot of the motor housing so as to be accessible outside the motor housing.Type: ApplicationFiled: February 8, 2022Publication date: May 26, 2022Inventors: David J. Smith, David E. Gillespie, Merritt J. Tennison
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Patent number: 11283325Abstract: An electric brushless DC (BLDC) motor includes a stator and a rotor. The rotor includes a rotor shaft, a rotor core, a bearing, and a sense magnet ring. And end cap is radially oriented with respect to the rotor shaft and securely disposed adjacent the stator, the end cap having a first surface facing the stator, a second surface facing away from the stator, a bearing pocket centrally disposed to receive the at least one bearing of the rotor therein to support the rotor, and at least two retention features projecting from the first surface at a distance with respect to one another to form a lateral gap therebetween. A positional sensor board is radially received from a peripheral side of the end cap in contact with the first surface of the end cap and within the lateral gap between the retention features of the end cap.Type: GrantFiled: February 5, 2019Date of Patent: March 22, 2022Assignee: Black & Decker Inc.Inventors: David J. Smith, David E. Gillespie, Merritt J. Tennison
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Patent number: 11251676Abstract: A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and in contact with an inner curved surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore.Type: GrantFiled: June 22, 2020Date of Patent: February 15, 2022Assignee: Black & Decker Inc.Inventors: Colin M. Crosby, Merritt J. Tennison, Ryan F. Schroeder, Jarrett A. Dunston, David J. Smith, Barak N. Gohn, Andrew M. Palich, Justin H. Ayers
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Patent number: 11245306Abstract: A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and in contact with an inner curved surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore.Type: GrantFiled: June 22, 2020Date of Patent: February 8, 2022Assignee: Black & Decker Inc.Inventors: Colin M. Crosby, Merritt J. Tennison, Ryan F. Schroeder, Jarrett A. Dunston, David J. Smith, Barak N. Gohn, Andrew M. Palich, Justin H. Ayers
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Publication number: 20210359575Abstract: 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.Type: ApplicationFiled: July 29, 2021Publication date: November 18, 2021Inventors: John B. Fogle, Colin M. Crosby, David J. Smith, Merritt J. Tennison, Madhur M. Purohit
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Patent number: 11081933Abstract: 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.Type: GrantFiled: October 24, 2018Date of Patent: August 3, 2021Assignee: Black & Decker Inc.Inventors: John B. Fogle, Colin M. Crosby, David J. Smith, Merritt J. Tennison, Madhur M. Purohit
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Publication number: 20200321825Abstract: A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and in contact with an inner curved surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore.Type: ApplicationFiled: June 22, 2020Publication date: October 8, 2020Inventors: Colin M. Crosby, Merritt J. Tennison, Ryan F. Schroeder, Jarrett A. Dunston, David J. Smith, Barak N. Gohn, Andrew M. Palich, Justin H. Ayers
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Publication number: 20200321826Abstract: A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and in contact with an inner curved surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore.Type: ApplicationFiled: June 22, 2020Publication date: October 8, 2020Inventors: Colin M. Crosby, Merritt J. Tennison, Ryan F. Schroeder, Jarrett A. Dunston, David J. Smith, Barak N. Gohn, Andrew M. Palich, Justin H. Ayers
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Patent number: 10727715Abstract: A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and in contact with an inner curved surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore.Type: GrantFiled: January 29, 2020Date of Patent: July 28, 2020Assignee: Black & Decker Inc.Inventors: Colin M. Crosby, Merritt J. Tennison, Ryan F. Schroeder, Jarrett A. Dunston, David J. Smith, Barak N. Gohn, Andrew M. Palich, Justin H. Ayers
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Publication number: 20200169142Abstract: A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and in contact with an inner curved surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore.Type: ApplicationFiled: January 29, 2020Publication date: May 28, 2020Inventors: Colin M. Crosby, Merritt J. Tennison, Ryan F. Schroeder, Jarrett A. Dunston, David J. Smith, Barak N. Gohn, Andrew M. Palich, Justin H. Ayers
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Patent number: 10587163Abstract: A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and engaging an inner surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore of the stator assembly.Type: GrantFiled: April 7, 2017Date of Patent: March 10, 2020Assignee: Black & Decker Inc.Inventors: Colin M. Crosby, Merritt J. Tennison, Ryan F. Schroeder, Jarrett A. Dunston, David J. Smith, Barak N. Gohn, Andrew M. Palich, Justin H. Ayers
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Patent number: 10523081Abstract: A power tool is provided including a housing and an electric brushless DC (BLDG) motor housed inside the housing. The motor includes a stator, a rotor pivotably arranged inside the stator, and a motor end cap arranged at an end of the stator. At least one of the motor end cap or the stator includes flexible posts that engage a surface of the other one of the motor end cap or the stator to absorb tolerances associated with the stator and the end cap.Type: GrantFiled: November 25, 2015Date of Patent: December 31, 2019Assignee: Black & Decker Inc.Inventors: David J. Smith, David E. Gillespie, Merritt J. Tennison
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Publication number: 20190173349Abstract: An electric brushless DC (BLDC) motor includes a stator and a rotor. The rotor includes a rotor shaft, a rotor core, a bearing, and a sense magnet ring. And end cap is radially oriented with respect to the rotor shaft and securely disposed adjacent the stator, the end cap having a first surface facing the stator, a second surface facing away from the stator, a bearing pocket centrally disposed to receive the at least one bearing of the rotor therein to support the rotor, and at least two retention features projecting from the first surface at a distance with respect to one another to form a lateral gap therebetween. A positional sensor board is radially received from a peripheral side of the end cap in contact with the first surface of the end cap and within the lateral gap between the retention features of the end cap.Type: ApplicationFiled: February 5, 2019Publication date: June 6, 2019Inventors: David J. Smith, David E. Gillespie, Merritt J. Tennison
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Patent number: 10236742Abstract: A power tool is provided including a housing; and an electric brushless DC (BLDG) motor housed inside the housing. The motor includes a motor housing having a substantially cylindrical body and a back plate, the cylindrical body of the motor housing defining a slot at or proximate the back plate; a stator housed within the motor housing; a rotor pivotably arranged inside the stator, the rotor including a rotor shaft, a rotor core rotatably mounted on the rotor shaft and housing rotor magnets therein, and a sense magnet ring affixed to the rotor shaft and having magnets aligned with the rotor magnets; and a positional sensor board having positional sensors mounted thereon, the positional sensor board being received through the slot of the motor housing to dispose the positional sensors in close proximity to the sense magnet ring.Type: GrantFiled: November 25, 2015Date of Patent: March 19, 2019Assignee: BLACK & DECKER INC.Inventors: David J. Smith, David E. Gillespie, Merritt J. Tennison
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Publication number: 20190058373Abstract: 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.Type: ApplicationFiled: October 24, 2018Publication date: February 21, 2019Applicant: Black & Decker Inc.Inventors: John B. Fogle, Colin M. Crosby, David J. Smith, Merritt J. Tennison, Madhur M. Purohit
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Patent number: 10193417Abstract: 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 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 a sense magnet mount formed at approximately a radial center portion of the axial fan. Alternatively or additionally, the molded structure includes a radial member projecting inwardly from the main body towards a center of the outer rotor assembly, and a bearing support member having a substantially cylindrical shape in an axial direction of the outer rotor and supported by the at least one radial member.Type: GrantFiled: December 17, 2015Date of Patent: January 29, 2019Assignee: Black & Decker Inc.Inventors: John B. Fogle, Colin M. Crosby, David J. Smith, Merritt J. Tennison, Madhur M. Purohit
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Publication number: 20170294819Abstract: A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and engaging an inner surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore of the stator assembly.Type: ApplicationFiled: April 7, 2017Publication date: October 12, 2017Applicant: Black & Decker Inc.Inventors: Colin M. Crosby, Merritt J. Tennison, Ryan F. Schroeder, Jarrett A. Dunston, David J. Smith, Barak N. Gohn, Andrew M. Palich, Justin H. Ayers
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Publication number: 20160181891Abstract: 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 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 a sense magnet mount formed at approximately a radial center portion of the axial fan. Alternatively or additionally, the molded structure includes a radial member projecting inwardly from the main body towards a center of the outer rotor assembly, and a bearing support member having a substantially cylindrical shape in an axial direction of the outer rotor and supported by the at least one radial member.Type: ApplicationFiled: December 17, 2015Publication date: June 23, 2016Applicant: Black & Decker Inc.Inventors: John B. Fogle, Colin M. Crosby, David J. Smith, Merritt J. Tennison, Madhur M. Purohit
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Publication number: 20160149474Abstract: A power tool is provided including a housing; and an electric brushless DC (BLDG) motor housed inside the housing. The motor includes a motor housing having a substantially cylindrical body and a back plate, the cylindrical body of the motor housing defining a slot at or proximate the back plate; a stator housed within the motor housing; a rotor pivotably arranged inside the stator, the rotor including a rotor shaft, a rotor core rotatably mounted on the rotor shaft and housing rotor magnets therein, and a sense magnet ring affixed to the rotor shaft and having magnets aligned with the rotor magnets; and a positional sensor board having positional sensors mounted thereon, the positional sensor board being received through the slot of the motor housing to dispose the positional sensors in close proximity to the sense magnet ring.Type: ApplicationFiled: November 25, 2015Publication date: May 26, 2016Applicant: Black & Decker Inc.Inventors: David J. Smith, David E. Gillespie, Merritt J. Tennison
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Publication number: 20160149467Abstract: A power tool is provided including a housing; and an electric brushless DC (BLDG) motor housed inside the housing. The motor includes a stator, a rotor pivotably arranged inside the stator, the rotor having a rotor shaft and a rotor lamination stack rotatably mounted on the rotor shaft. The lamination stack includes laminations affixed together and having slots that align axially to receive a plurality of rotor magnets therein; and an end lamination having generally the same profile as the laminations and affixed to an end of the laminations, the end lamination having slots that correspond to the slots of the laminations, the end lamination integrally including radial projections that partially project into the slots of the end lamination, each radial projections engaging an end of a corresponding rotor magnet to axially block the rotor magnet within a corresponding slot of the laminations.Type: ApplicationFiled: November 25, 2015Publication date: May 26, 2016Applicant: Black & Decker Inc.Inventors: David J. Smith, David E. Gillespie, Merritt J. Tennison