Power Tools With Motor Having a Multi-Piece Stator

A hand-held power tool, comprising:

• a housing in which an electric motor of a predetermined frame size is disposed, the motor including:
• a stator having a lamination stack having pole pieces mated to return path pieces and field coils disposed on the pole pieces;
• an armature disposed in the stator, the armature having an outside diameter that is at least 0.625 of an outside diameter of the stator;
• a length of the lamination stack of the stator being at least ten percent shorter than a length of a lamination stack of a stator of a needle wound motor of the same frame size;
• and
• the motor having a maximum power output that is at least the same as a maximum power output of the needle wound motor of the same frame size with the longer lamination stack where both motors have the same maximum no load speed.

A router, comprising:

• a housing in which an electric motor is disposed, the motor coupled to a tool holder;
• the electric motor having a stator and an armature disposed in the stator, the stator having separate pole pieces and return path pieces joined together and field coils disposed around necks of the pole pieces, the armature having an outside diameter that is at least 0.625 an outside diameter of the stator;
• and
• the stator has an outside diameter no greater than 73 mm and a stack length no greater than 50 mm;
• and
• the motor with a maximum no load speed of 28,000 rpm provides at least 2200 maximum watts out.

A reciprocating saw, comprising:

• a housing in which an electric motor is disposed, the electric motor coupled to a driving gear that drives a gear wheel that reciprocates a saw blade;
• the electric motor having a stator and an armature disposed in the stator, the stator having separate pole pieces and return path pieces joined together and field coils disposed around necks of the pole pieces, the armature having an outside diameter that is at least 0.625 an outside diameter of the stator;
• the stator having an outside diameter no greater than 73 mm and a stack length no greater than 40 mm;
• the motor with a maximum no load speed of 24,500 rpm provides at least 1500 maximum watts out.

A hand-held power tool, comprising:

• a housing in which an electric motor of a predetermined frame size is disposed, the motor including:
• a stator having a lamination stack having pole pieces mated to return path pieces and field coils disposed on the pole pieces;
• an armature disposed in the stator, the armature having an outside diameter that is at least 0.625 of an outside diameter of the stator;
• a length of the lamination stack of the stator being the same length as a length of a lamination stack of a stator of a needle wound motor of the same frame size;
• and
• the motor having a maximum power output that is at least ten percent greater than a maximum power output of the needle wound motor of the same frame size with the same length lamination stack where both motors have the same maximum no load speed.