# US 11,444,512 B2 · Control and power module for brushless motor > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,444,512 B2 - Document ID: US11444512B2 - Status: Granted - Kind: B2 - Application number: 16/951,303 - Filed: 2020-11-18 - Published: 2021-03-25 - Granted: 2022-09-13 - Earliest claimed: 2016-09-19 - Assignees: Black & Decker Inc. - Applicants: Black & Decker Inc. - Inventors: Madhur M. Purohit; Joshua M. Lewis; Marcell E. Coates; Michael D. Grove; Victor A. Dorado - Web page: https://patentgrep.com/patent/US11444512B2 ## CPC - H02K 11/215: Magnetic effect devices, e.g. Hall-effect or magneto-resistive elements - B25F 5/008: {Cooling means} - B25F 5/02: Construction of casings, bodies or handles {(B25F5/006, B25F5/008 take precedence)} - H02K 5/08: Insulating casings - H02K 5/22: Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes - H02K 5/225: {Terminal boxes or connection arrangements (specially adapted for submersible motors H02K5/132)} - H02K 7/145: {Hand-held machine tool} - H02K 9/22: by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges - H02K 9/227: {Heat sinks} - H02K 11/33: Drive circuits, e.g. power electronics (H02K11/38 takes precedence) - H05K 1/0203: {Cooling of mounted components (H05K1/0272 takes precedence)} - H05K 1/115: {Via connections; Lands around holes or via connections (H05K1/112 takes precedence)} - H05K 1/181: associated with surface mounted components - H05K 3/284: {for encapsulating mounted components (H05K1/185 takes precedence)} - H05K 5/0073: {having specific features for mounting the housing on an external structure} - H05K 5/0247: {Electrical details of casings, e.g. terminals, passages for cables or wiring} - H05K 5/061: {sealed by a gasket held between a removable cover and a body, e.g. O-ring, packing} - H05K 7/1427: {Housings} - H05K 7/2039: {characterised by the heat transfer by conduction from the heat generating element to a dissipating body (arrangements for increasing/decreasing heat-transfer, e.g. fins details, F28F13/00)} - H05K 7/209: {Heat transfer by conduction from internal heat source to heat radiating structure (H05K7/20909 takes precedence)} - H02K 9/223: {Heat bridges} - H02K 29/08: using magnetic effect devices, e.g. Hall-plates, magneto-resistors (H02K29/12 takes precedence) - H02K 2203/03: Machines characterised by the wiring boards, i.e. printed circuit boards or similar structures for connecting the winding terminations - H02K 2211/03: Machines characterised by circuit boards, e.g. pcb - H05K 5/0086: {portable, e.g. battery operated apparatus (casings for switching devices H01H9/02)} - H05K 2201/066: Heatsink mounted on the surface of the printed circuit board [PCB] - H05K 2201/09018: Rigid curved substrate - H05K 2201/09036: Recesses or grooves in insulating substrate - H05K 2201/10053: Switch - H05K 2201/10151: Sensor - H05K 2201/10166: Transistor - H05K 2201/10522: Adjacent components - H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53}) - 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)} - H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS ## 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. ## Claims ### Claim 1 A power tool comprising: a tool housing; an electric motor disposed within the tool housing and having a longitudinal axis; a power module comprising: a module housing having a radial portion disposed adjacent the electric motor and a cylindrical portion extending from the radial portion away from the electric motor and defining an open end opposite the radial portion; a printed circuit board (PCB) received within the module housing through the open end thereof, the PCB being substantially disc-shaped and including a first surface and a second surface; a plurality of power switches mounted on at least one of the first surface and/or the second surface of the PCB; and a plurality of magnetic sensors mounted on the first surface of the PCB facing the motor substantially equidistantly from a center of the PCB; wherein the module housing includes a plurality of openings disposed in the radial portion angularly around a center of the module housing to receive the plurality of magnetic sensors therein to allow the plurality of magnetic sensors to magnetically interface with the electric motor. ### Claim 2 (depends on 1) The power tool of claim 1, wherein the power module further comprises a controller mounted on of the PCB in communication with the plurality of magnetic sensors. ### Claim 3 (depends on 1) The power tool of claim 1, wherein the plurality of power switches comprises a first plurality of switches mounted on the first surface of the PCB and a second plurality of switches mounted on the second surface of the PCB equidistantly from the longitudinal axis. ### Claim 4 (depends on 3) The power tool of claim 3, wherein the respective ones of the first plurality of switches are disposed at an angular distance of approximately 60 degrees apart. ### Claim 5 (depends on 1) The power tool of claim 1, further comprising a plurality of power terminals disposed around a periphery of the PCB and angularly corresponding to the plurality of power switches, the plurality of power terminals being disposed to receive a plurality of motor terminals therein to electrically connect the first plurality of power switches to the electric motor. ### Claim 6 (depends on 5) The power tool of claim 5, wherein the power module includes a plurality of peripheral channels formed in the cylindrical portion through which the plurality of motor terminals extends from the electric motor to the plurality of power terminals. ### Claim 7 (depends on 5) The power tool of claim 5, wherein the plurality of power terminals is mounted on the second surface of the PCB. ### Claim 8 (depends on 1) The power tool of claim 1, wherein the power module further comprises a gasket disposed between the radial portion of the module housing and the first surface of the PCB, the gasket being arranged to seal the outer perimeters of the plurality of openings. ### Claim 9 (depends on 1) The power tool of claim 1, wherein power module further comprises a heat sink in thermal communication with the plurality of power switches, the heat sink being formed as a part of the radial portion of the module housing so as to be exposed on an outer surface of the module housing facing the motor. ### Claim 10 (depends on 9) The power tool of claim 9, wherein the plurality of openings is disposed along a first plane and the heat sink is at least partially disposed along a plane that is closer to the electric motor than the first plane. ### Claim 11 (depends on 9) The power tool of claim 9, wherein the plurality of openings is disposed at a first distance from the longitudinal axis and the heat sink is disposed around the plurality of openings at a second distance from the longitudinal axis that is greater than the first distance. ### Claim 12 (depends on 9) The power tool of claim 9, wherein the heat sink includes a ring-shaped or a C-shaped profile. ### Claim 13 (depends on 6) The power tool of claim 6, further comprising a potting compound that substantially covers both surfaces of the PCB within the module housing. ### Claim 14 An electronic module for a power tool having an electric motor, comprising: a printed circuit board (PCB) being substantially disc-shaped; a plurality of 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 plurality of power switches; a plurality of positional sensors mounted on the PCB substantially equidistantly from a center of the PCB, the plurality of positional sensors 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 including a planar portion in parallel to the PCB, a plurality of openings disposed in the planar portion angularly around a center of the module housing to receive the plurality of positional sensors therein, and a heat sink formed in the planar portion around the plurality of openings in thermal communication with the plurality of power switches. ### Claim 15 (depends on 14) The electronic module of claim 14, further comprising a secondary heat sink mounted on the PCB in thermal communication with at least one of the plurality of power switches. ### Claim 16 (depends on 15) The electronic module of claim 15, wherein the heat sink is in physical contact, directly or via a thermally conductive gap pad, with the secondary heat sink. ### Claim 17 (depends on 14) The electronic module of claim 14, wherein the plurality of openings is disposed along a first plane and the heat sink is at least partially disposed along a plane that is further from the PCB than the first plane. ### Claim 18 (depends on 14) The electronic module of claim 14, wherein the plurality of openings is disposed at a first distance from a longitudinal axis and the heat sink is disposed around the plurality of openings at a second distance from the longitudinal axis that is greater than the first distance. ### Claim 19 (depends on 12) A power tool comprising: a tool housing arranged to house the electric motor; and the electronic module of claim 12 disposed within the tool housing adjacent the electric motor.