Abstract: An electric motor comprising a stator and a rotor assembly at least partially received in the stator. The rotor assembly includes a rotor body, a fan, and a shaft. The rotor body includes a lamination stack which defines a central aperture. The fan is formed separately from the rotor body, and the fan is coupled to the rotor body by a torque coupling. The shaft includes an outer surface. The shaft is pressed into the central aperture of the lamination stack with the outer surface engaged with the central aperture by an interference fit.

Abstract: A battery pack for use with a power tool having an electric connector. The battery pack including a housing containing one or more battery cells, a first terminal in electrical communication with the battery cells, the first terminal including a pair of spaced apart terminal walls forming a gap therebetween and a coil spring at least partially positioned within the gap. Where the coil spring is configured to selectively engage and form an electrical connection with the electric connector of the power tool when the electric connector is at least partially positioned within the gap.

Abstract: A method of forming a molded rotor assembly for an electric motor includes providing a lamination stack, molding an insulative material to the lamination stack to form an integral fan and magnet retention coupled to the lamination stack, the lamination stack and the integral fan and magnet retention together forming a rotor body, and pressing a shaft into a central aperture formed in the rotor body to achieve an interference fit between the shaft and the lamination stack.

Abstract: An electric motor includes a stator and a rotor assembly received in the stator. The rotor assembly includes a rotor body having a lamination stack, and an integral fan and magnet retention formed by molding an insulative material to the lamination stack. The rotor assembly also includes a shaft pressed into the rotor body. The shaft is pressed into the rotor body after the insulative material is molded to the lamination stack to form the integral fan and magnet retention.

Abstract: An electric motor includes a stator and a rotor assembly received in the stator. The rotor assembly includes a shaft, a rotor core, a rotor molding that is molded to the rotor core, and a fan. A coupler is formed on the rotor molding and a corresponding mounting hub is formed on the fan. The shaft is pressed into the rotor core after the rotor molding is molded to the rotor core, and the fan is affixed to the rotor molding by connecting the coupler and the mounting hub after the shaft is pressed into the rotor core.

Abstract: An electric motor includes a stator and a rotor assembly received in the stator. The rotor assembly includes a rotor body having a lamination stack, and an integral fan and magnet retention formed by molding an insulative material to the lamination stack. The rotor assembly also includes a shaft pressed into the rotor body. The shaft is pressed into the rotor body after the insulative material is molded to the lamination stack to form the integral fan and magnet retention.

Abstract: An electric motor includes a stator including an annular stator core and an end cap coupled to an axial end of the stator core. The stator core and the end cap together define a body portion and a plurality of teeth projecting inwardly from the body portion. Each tooth includes a tooth crown portion at a radially distal end and a tooth body portion extending between the body portion and the crown portion. Steps are formed on at least one tooth body portion at the axial end of the stator core.