Electric motor assembly

• US 7,126,242 B2
• Filed: 04/29/2005
• Issued: 10/24/2006
• Est. Priority Date: 10/31/2002
• Status: Expired due to Fees

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Williams, Robert B., Ortt, Earl M., Marcinkowski, Robert J., Mealy, Bradley J.
• Primary Examiner(s): Lam, Thanh
• Application Number:
  US11/118,918
• Publication Number:
  US 20050184608A1
• Time in Patent Office: 543 Days
• Field of Search: 310/47, 310/50, 310 58- 59, 310/60.R, 310/60.A, 310 61- 62, 310/89, 310/43
• US Class Current: 310/89
• CPC Class Codes: H02K 1/17 Stator cores with permanent magnets
• CPC Class Codes: H02K 15/16 Centering rotors within the stator; Balancing rotors
• CPC Class Codes: H02K 5/00 Casings; Enclosures; Supports
• CPC Class Codes: H02K 5/08 Insulating casings
• CPC Class Codes: H02K 5/148 Slidably supported brushes
• CPC Class Codes: H02K 5/15 Mounting arrangements for bearing-shields or end plates
• CPC Class Codes: H02K 5/1732 radially supporting the rotary shaft at both ends of the rotor H02K5/1737 takes precedence
• CPC Class Codes: H02K 7/116 with gears
• CPC Class Codes: H02K 7/145 Hand-held machine tool
• CPC Class Codes: H02K 9/06 with fans or impellers driven by the machine shaft

Abstract

A field case housing has a substantially cylindrical wall segment, an end segment and a flange all having a substantially constant wall thickness. The flange has reinforcing ribs connected to the wall segment and aperture reinforcing bosses. The end segment, the wall segment and the flange are formed as a single, integral part adapted to reduce warping of the housing during molding. A cylindrical guide member is located in the field case housing and a conical guide member is located in the fan baffle. The cylindrical guide member is adapted to insure a screw passing through the cylindrical guide member is guided to a point within the conical guide member. The fan baffle has a transverse wall with an aperture and guide walls extending adjacent the aperture. The guide walls are adapted to guide an armature past the magnets without contacting and damaging them.

Claims

1. An electric motor assembly comprising:

(a) a field case housing having;

(i) a substantially cylindrical wall segment having a substantially constant wall thickness;

(ii) an end segment including a motor brush seat receiving a base member of a motor brush assembly, and the end segment having a thickness which is substantially the same as the substantially constant wall thickness of the wall segment;

(iii) a flange around an open end of the housing, at least a portion of the flange having a thickness which is substantially the same as the substantially constant wall thickness of the wall segment; and

(b) an end plate adapted to cover the open end of the housing attached to the flange;

wherein the end segment, the wall segment and the flange are formed as a single, integral part and wherein the thicknesses are adapted to reduce warping of the housing as a result of a molding process.

2. An electric motor assembly according to claim 1, wherein the field case housing further comprises an elongate guide member associated with a screw insertion aperture or an additional elongate guide member associated with a screw receiving aperture, the additional elongate guide member having an opening at its distal end with a diameter which is larger than a diameter of the screw insertion aperture, and wherein the electric motor assembly further comprises an additional component having the other of the elongate guide member or the additional elongate guide member, the elongate guide member being adapted to cause a tip of a screw passing through the elongate guide member to be guided to a point within the opening of the additional elongate guide member.

3. An electric motor assembly according to claim 2, wherein the additional component is a fan baffle.

4. An electric motor assembly according to claim 2, wherein the additional component further comprises a transverse wall with an aperture therethrough and at least one guide wall extending from the transverse wall adjacent the aperture, the at least one guide wall being adapted to guide the armature past a motor magnet assembly without contacting and damaging the motor magnet assembly.

5. An electric motor assembly according to claim 4, wherein the additional component is a fan baffle.

6. An electric motor assembly according to claim 1, wherein the flange further comprises a plurality of flange reinforcing ribs connected to the wall segment having a thickness which corresponds to about 75% of the substantially constant wall thickness.

7. An electric motor assembly according to claim 1, wherein the end plate has a bearing retention shoulder adapted to cooperate with a tool component to retain a bearing.

8. An electric motor assembly according to claim 1, wherein the substantially cylindrical wall segment has an internal wall surface with a plurality of arcuate locating ribs adapted to accurately locate another motor component within the housing, the arcuate locating ribs creating a wall thickness of the wall segment which is less than about two times the substantially constant wall thickness.

9. An electric motor assembly according to claim 6, wherein the plurality of flange reinforcing ribs, are substantially radially aligned.

10. An electric motor assembly according to claim 1, wherein the end segment further comprises a plurality of end segment reinforcing ribs having a wall thickness which corresponds to about 75% of the substantially constant wall thickness.

11. An electric motor assembly comprising:

an elongate guide member associated with a screw insertion aperture having a diameter and located in a field case housing or a separate motor component;

an additional elongate guide member associated with a screw receiving aperture in the other of the field case housing or the separate motor component, the elongate guide member having an aperture at a distal end which is larger than a diameter of the screw insertion aperture;

at least one magnet located between the elongate guide member and the additional elongate guide member which exerts a magnetic force on a screw passing from the elongate guide member to the additional elongate guide member;

wherein the elongate guide member is adapted to insure a tip of a screw passing through the elongate guide member is guided to a point within the aperture at the distal end of the additional elongate guide member; and

wherein said screw joins the field case housing and the separate motor component together to thereby retain the magnet in a fixed position therebetween.

12. An electric motor assembly according to claim 11, wherein a diameter of the aperture at the distal end of the additional elongate guide member is at least about 2.5 times the diameter of the screw insertion aperture.

13. An electric motor assembly according to claim 11, wherein the diameter of the aperture at the distal end of the additional elongate guide member is at least about two times the diameter of the screw insertion aperture.

14. An electric motor assembly according to claim 11, wherein the elongate guide member or the additional elongate guide member has a segment which extends outwardly away from an adjacent wall.

15. An electric motor assembly according to claim 11, wherein the at least one magnet is attached to a substantially cylindrical motor can, and wherein an adjacent segment of the motor can cooperates with the elongate guide member, the additional elongate guide member, or both in guiding the screw.

16. An electric motor assembly according to claim 11, wherein the at least one magnet is attached to a substantially cylindrical motor can having a housing alignment member adapted to cooperate with an alignment member on the housing to rotably align the motor can with the housing and a separate motor component alignment member adapted to cooperate with an alignment member of the separate motor component to rotably align the motor can with the separate motor component to thereby align the elongate guide member with the additional elongate guide member.

17. An electric motor assembly according to claim 11, wherein the at least one magnet is attached to a substantially cylindrical motor can and wherein the housing further comprises an internal wall surface with a plurality of arcuate locating ribs adapting to accurately locate the motor can within the housing.

18. An electric motor assembly according to claim 11, wherein the separate motor component further comprises a transverse wall with an aperture therethrough and at least one guide wall extending from the transverse wall adjacent the aperture, the at least one guide wall being adapted to guide the armature past a motor magnet assembly without contacting and damaging the at least one magnet.

19. An electric motor assembly according to claim 11, wherein the field case housing further compriss a substantially cylindrical wall segment having a substantially constant wall thickness and a flange around an open end of the housing having a thickness which is substantially the same as the substantially constant wall thickness of the wall segment, the flange having a plurality of flange reinforcing ribs connected to the wall segment, and the flange having a plurality of apertures with reinforcing bosses around the plurality of apertures, wherein the housing is formed as a single, integral part and wherein the plurality of flange reinforcing ribs and the substantially constant thicknesses are adapted to reduce warping of the housing as a result of a molding process.

20. An electric motor assembly according to claim 19, wherein the plurality of flange reinforcing ribs have a thickness which is about 75% of the substantially constant wall thickness.