# US 2026/0100656 A1 · Power Control Module With Compact Thermal Management Structure > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2026/0100656 A1 - Document ID: US20260100656A1 - Status: Published application - Kind: A1 - Application number: 19/354,347 - Filed: 2025-10-09 - Published: 2026-04-09 - Earliest claimed: 2024-10-09 - Assignees: Black & Decker Inc. - Applicants: Black & Decker Inc. - Inventors: Matthew A. Siragusa; Brian E. Friedman; Eric W. Wachter - Web page: https://patentgrep.com/patent/US20260100656A1 ## CPC - B25F 5/00: Details or components of portable power-driven tools not particularly related to the operations performed and not otherwise provided for - H02M 7/003: {Constructional details, e.g. physical layout, assembly, wiring or busbar connections} - H05K 1/181: associated with surface mounted components - H05K 7/209: {Heat transfer by conduction from internal heat source to heat radiating structure (H05K7/20909 takes precedence)} - H05K 2201/10166: Transistor - 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)} - H02M: APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF (transformers H01F; dynamo-electric converters H02K47/00; controlling transformers, reactors or choke coils, control or regulation of electric motors, generators or dynamo-electric converters H02P) - H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS ## Abstract A power control module may include a circuit board; a plurality of power switch devices including a plurality of high-side power switches and a plurality of low-side power switches mounted on the circuit board and configured as a multi-phase inverter circuit to provide a plurality of output phase terminals to the electric motor, each power switch device including a first surface mounted on the circuit board and through which at least source and drain terminals of the power switch device are coupled to the circuit board, and a second surface including a metal surface electrically coupled to the drain terminal of the power switch device; and a plurality of power output terminals mounted discretely on the plurality of low-side power switches and electrically contacting the metal surface of the plurality of low-side power switches to be electrically coupled to the plurality of output phase terminals of the inverter circuit. ## Claims ### Claim 1 A control module for supplying electric power from a DC power source to an electric motor, comprising: a circuit board; a plurality of power switch devices including a plurality of high-side power switches and a plurality of low-side power switches mounted on the circuit board and configured as a multi-phase inverter circuit to provide a plurality of output phase terminals to the electric motor, wherein each power switch device includes a first surface mounted on the circuit board and through which at least source and drain terminals of the power switch device are coupled to the circuit board, and a second surface including a metal surface electrically coupled to the drain terminal of the power switch device; and a plurality of power output terminals mounted discretely on the plurality of low-side power switches and electrically contacting the metal surface of the plurality of low-side power switches to be electrically coupled to the plurality of output phase terminals of the inverter circuit, wherein the second surfaces including the metal surfaces of the plurality of power switch devices are oriented along a first plane, wherein lower portions of the plurality of power output terminals that electrically contact the metal surfaces of the plurality of power switch devices are oriented along a second plane parallel to the first plane, and wherein at least one of (i) each power output terminal is located substantially above a corresponding power switch, (ii) each power output terminal is oriented along a plane that is perpendicular to the second plane, or any combination thereof. ### Claim 2 (depends on 1) The control module of claim 1, further comprising: a heatsink having an elongate body extending along an axis mounted on the second surface of the plurality of high-side power switches, wherein the heatsink is electrically coupled to the metal surface of the plurality of high-side power switches. ### Claim 3 (depends on 1) The control module of claim 1, wherein the plurality of power output terminals is not in physical contact with the circuit board. ### Claim 4 (depends on 1) The control module of claim 1, wherein the plurality of power output terminals extends from the metal surfaces of the plurality of power switch devices including the low-side power switches along a plane that is perpendicular to the circuit board. ### Claim 5 (depends on 1) The control module of claim 1, further comprising: a microcontroller mounted on the circuit board, wherein the microcontroller is configured to: monitor a current passing through the at least one shunt component; and control, based on the current passing through the at least one shunt component, a field-oriented communication of the electric motor powered by the control module. ### Claim 6 (depends on 1) The control module of claim 1, wherein the plurality of power output terminals extends from a plurality of first ends mounted discretely on the plurality of low-side power switches and electrically contacting the metal surface of the plurality of low-side power switches to a plurality of second ends including a plurality of power output holes configured to receive a plurality of power output wires, wherein the plurality of second ends including the plurality of power output holes is oriented substantially perpendicular to the circuit board. ### Claim 7 (depends on 6) The control module of claim 6, wherein the plurality of power output terminals includes a plurality of first portions including the plurality of first ends mounted discretely on the plurality of low-side power switches and electrically contacting the metal surface of the plurality of low-side power switches, a plurality of second portions extending perpendicularly from the plurality of first portions, a plurality of third portions extending perpendicularly from the plurality of second portions, and a plurality of fourth portions including the plurality of second ends including the plurality of power output holes extending perpendicularly from the plurality of third portions. ### Claim 8 (depends on 7) The control module of claim 7, further comprising: an insulating frame including: a base portion extending between (i) the plurality of first portions of the plurality of power output terminals and (ii) the and the plurality of third portions of the plurality of power output terminals; at least one upper partition wall extending from the base portion in a direction away from the circuit board between at least one pair of power output terminals of the plurality of power output terminals; at least one sidewall extending from at least one end of the base portion toward the circuit board; and at least one lower partition wall extending from the base portion in a direction toward the circuit board between at least one pair of low-side power switches of the plurality of low-side power switches. ### Claim 9 (depends on 1) The control module of claim 1, further comprising: at least one shunt component mounted on the circuit board and electrically coupled in series with at least one low-side power switch of the plurality of low-side power switches and a node of the DC power source; and a microcontroller mounted on the circuit board, wherein the microcontroller is configured to: monitor a current passing through the at least one shunt component; and control, based on the current passing through the at least one shunt component, a field-oriented communication of the electric motor powered by the control module. ### Claim 10 (depends on 1) An electric power tool comprising: a tool housing; an electric motor disposed in the tool housing; and the control module of claim 1 disposed in the tool housing. ### Claim 11 A control module for supplying electric power from a DC power source to an electric motor, comprising: a circuit board; a plurality of power switch devices including a plurality of high-side power switches and a plurality of low-side power switches mounted on the circuit board and configured as a multi-phase inverter circuit to provide a plurality of output phase terminals to the electric motor, wherein each power switch device includes a first surface mounted on the circuit board and through which at least source and drain terminals of the power switch device are coupled to the circuit board, and a second surface including a metal surface electrically coupled to the drain terminal of the power switch device; and a plurality of power output terminals mounted discretely on the plurality of low-side power switches and electrically contacting the metal surface of the plurality of low-side power switches to be electrically coupled to the plurality of output phase terminals of the inverter circuit, wherein the circuit board is oriented along a first plane, wherein lower portions of the plurality of the plurality of power output terminals that electrically contact the metal surfaces of the plurality of power switch devices are oriented along a second plane, wherein at least one of (i) each power output terminal is located substantially above a corresponding power switch, (ii) each power output terminal is oriented along a plane that is perpendicular to the first plane, or any combination thereof, and wherein the second surfaces including the metal surfaces of the plurality of power switch devices are oriented along a third plane parallel to the first plane and the second plane. ### Claim 12 (depends on 11) The control module of claim 11, further comprising: a heatsink having an elongate body extending along an axis mounted on the second surface of the plurality of high-side power switches, wherein the heatsink is electrically coupled to the metal surface of the plurality of high-side power switches. ### Claim 13 (depends on 11) The control module of claim 11, wherein the plurality of power output terminals is not in physical contact with the circuit board. ### Claim 14 (depends on 11) The control module of claim 11, wherein the plurality of power output terminals extends from the metal surfaces of the plurality of power switch devices including the low-side power switches along a plane that is perpendicular to the circuit board. ### Claim 15 (depends on 11) An electric power tool comprising: a tool housing; an electric motor disposed in the tool housing; and the control module of claim 11 disposed in the tool housing. ### Claim 16 A control module for supplying electric power from a DC power source to an electric motor, comprising: a circuit board; a plurality of power switch devices including a plurality of high-side power switches and a plurality of low-side power switches mounted on the circuit board and configured as a multi-phase inverter circuit to provide a plurality of output phase terminals to the electric motor, wherein each power switch device includes a first surface mounted on the circuit board and through which at least source and drain terminals of the power switch device are coupled to the circuit board, and a second surface including a metal surface electrically coupled to the drain terminal of the power switch device; and a plurality of power output terminals mounted discretely on the plurality of low-side power switches and electrically contacting the metal surface of the plurality of low-side power switches to be electrically coupled to the plurality of output phase terminals of the inverter circuit, wherein the circuit board is oriented along a first plane, wherein lower portions of the plurality of the plurality of power output terminals that electrically contact the metal surfaces of the plurality of power switch devices are oriented along a second plane, wherein at least one of (i) each power output terminal is located substantially above a corresponding power switch, (ii) each power output terminal is oriented along a plane that is perpendicular to the first plane, or any combination thereof, and wherein the second surfaces including the metal surfaces of the plurality of power switch devices are oriented between the first plane and the second plane. ### Claim 17 (depends on 16) The control module of claim 16, further comprising: a heatsink having an elongate body extending along an axis mounted on the second surface of the plurality of high-side power switches, wherein the heatsink is electrically coupled to the metal surface of the plurality of high-side power switches. ### Claim 18 (depends on 16) The control module of claim 16, wherein the plurality of power output terminals is not in physical contact with the circuit board. ### Claim 19 (depends on 16) The control module of claim 16, wherein the plurality of power output terminals extends from the metal surfaces of the plurality of power switch devices including the low-side power switches along a plane that is perpendicular to the circuit board. ### Claim 20 (depends on 16) An electric power tool comprising: a tool housing; an electric motor disposed in the tool housing; and the control module of claim 16 disposed in the tool housing.