# US 10,500,708 B2 · Power tool > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,500,708 B2 - Document ID: US10500708B2 - Status: Granted - Kind: B2 - Application number: 15/292,568 - Filed: 2016-10-13 - Published: 2017-04-20 - Granted: 2019-12-10 - Earliest claimed: 2015-10-14 - Assignees: Black & Decker Inc. - Applicants: 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 - Web page: https://patentgrep.com/patent/US10500708B2 ## CPC - B25F 5/008: {Cooling means} - B24B 23/028: {Angle tools} - B25F 5/02: Construction of casings, bodies or handles {(B25F5/006, B25F5/008 take precedence)} - H02K 1/146: {consisting of a generally annular yoke with salient poles} - H02K 1/2706: Inner rotors - H02K 3/18: Windings for salient poles - H02K 3/34: between conductors or between conductor and core, e.g. slot insulation - H02K 3/487: Slot-closing devices - H02K 3/522: {for generally annular cores with salient poles} - H02K 5/10: with arrangements for protection from ingress, e.g. water or fingers - H02K 5/207: {with openings in the casing specially adapted for ambient air} - H02K 7/08: Structural association with bearings - H02K 7/116: with gears - H02K 7/145: {Hand-held machine tool} - H02K 9/04: having means for generating a flow of cooling medium - H02K 9/06: with fans or impellers driven by the machine shaft - H02K 9/227: {Heat sinks} - H02K 11/215: Magnetic effect devices, e.g. Hall-effect or magneto-resistive elements - H02K 11/33: Drive circuits, e.g. power electronics (H02K11/38 takes precedence) - H02K 21/16: having annular armature cores with salient poles (with homopolar co-operation H02K21/20) - H02K 3/38: around winding heads, equalising connectors, or connections thereto - H02K 2203/09: Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations - H02K 2203/12: Machines characterised by the bobbins for supporting the windings - H02K 2213/03: Machines characterised by numerical values, ranges, mathematical expressions or similar information - B25F: COMBINATION OR MULTI-PURPOSE TOOLS NOT OTHERWISE PROVIDED FOR; DETAILS OR COMPONENTS OF PORTABLE POWER-DRIVEN TOOLS NOT PARTICULARLY RELATED TO THE OPERATIONS PERFORMED AND NOT OTHERWISE PROVIDED FOR {(machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass B23P23/00 and subgroups)} - B24B: MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING (grinding of gear teeth B23F, of screw-threads B23G1/36; by electro-erosion B23H; abrasive or related blasting B24C; tools for grinding, buffing or sharpening B24D; polishing compositions C09G1/00; abrasives C09K3/14; electrolytic etching or polishing C25F3/00; grinding arrangements for use on assembled railway tracks E01B31/17); DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS - H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53}) ## 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. ## Claims ### Claim 1 A power tool comprising: 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; a motor housed inside the motor case, the motor having a stator, a rotor rotationally arranged inside the stator, and a fan in rotational connection with the rotor; 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 a plurality of power switches for driving the motor and a heat sink, the power module being 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, wherein the at least one air intake comprises a plurality of axial walls therein defining a plurality of intake conduits arranged to receive and direct air from outside the power tool into the motor case. ### Claim 2 (depends on 1) The power tool of claim 1, further comprising at least one air exhaust vent disposed at or near the rear end of the gear case, the at least one exhaust vent being axially separated from the at least one air intake by the motor case. ### Claim 3 (depends on 1) The power tool of claim 1, further comprising a control module disposed within the handle portion, the control module configured to control a switching operation of the plurality of power switches to drive the motor. ### Claim 4 (depends on 1) The power tool of claim 1, wherein the at least one air intake comprises a pair of generally oblong air intakes disposed around a periphery of the power module. ### Claim 5 (depends on 1) The power tool of claim 1, wherein the intake conduits are further defined by an arcuate baffle having a generally angular orientation, the baffle generating a path of airflow outside the power tool that is considerably different from path of particulate stream associated with a workpiece engaged by the power tool during power tool operation. ### Claim 6 (depends on 5) The power tool of claim 5, wherein the arcuate baffle angularly extends from a rear edge of the air intake, a distal end of the baffle together with a front edge of the air intake defining a plurality of radial inlets separated by the axial walls. ### Claim 7 (depends on 1) The power tool of claim 1, further comprising at least one air filter disposed on the at least one air intake. ### Claim 8 (depends on 7) The power tool of claim 7, wherein the at least one air filter comprises two generally oblong bands, a plurality of ribs extending between the two bands, and filter material. ### Claim 9 (depends on 8) The power tool of claim 8, wherein the at least one filter is generally arcuate along its length and comprises a pair of retaining tabs from its ends for attachment to the at least one air intake. ### Claim 10 (depends on 1) The power tool of claim 1, wherein less than 10% of the airflow generated by the motor fan passes through the handle portion and more that 90% of the airflow generated by the motor fan enters through the at least one air intake. ### Claim 11 (depends on 1) The power tool of claim 1, wherein the power module comprises a substantially disc-shaped power board, the plurality of power switches being mounted on the power board, and wherein the heat sink includes a generally planar body secured to the power board. ### Claim 12 (depends on 11) The power tool of claim 11, wherein the power board and heat sink are disposed in parallel to an end surface of the stator. ### Claim 13 A power tool comprising: a gear case having a spindle; a motor case connected to a rear end of the gear case defining a longitudinal axis; a handle portion attached to a rear end of the motor case and elongated along the longitudinal axis; a battery receptacle disposed at a rear end of the handle portion intercepting the longitudinal axis; a motor housed inside the motor case, the motor having a stator, a rotor rotationally arranged inside the stator, and a fan in rotational connection with the rotor, the motor produces a maximum power output of at least 1600 watts for driving the spindle; and a power module including a circuit board disposed along a plane that is substantially perpendicular to the longitudinal axis and a plurality of power switches for driving the motor mounted on the circuit board, the power module housed in the motor case adjacent the motor, wherein a circumference the motor case around the motor is approximately 1.5 to 2 times greater than a circumference of a gripping area of the handle portion near the end of the handle portion. ### Claim 14 (depends on 13) The power tool of claim 13, wherein the circumference of the motor case around the motor is greater than 200 mm and the circumference of the gripping area of the handle portion is approximately 110 mm to 140 mm. ### Claim 15 (depends on 14) The power tool of claim 14, further comprising a trigger assembly disposed within the handle portion, wherein the circumference of the handle portion is approximately 150 mm to 180 mm where the trigger assembly is located. ### Claim 16 (depends on 15) The power tool of claim 15, wherein the battery receptacle is adapted to receive a battery pack having a maximum nominal voltage of 60V in the battery receptacle. ### Claim 17 (depends on 16) The power tool of claim 16, wherein a center of gravity of the power tool, balanced by the weight of the battery pack countered against the weight of the motor case and the field case, is located within the handle portion approximately in-line with the trigger assembly. ### Claim 18 (depends on 13) The power tool of claim 13, wherein the motor produces a maximum torque of at least 30 inch-pounds (In*Lbs) and a maximum speed of at least 8000 rotations-per-minute (RPM).