阅读说明：本技术 无刷直流马达端盖 (Brushless DC motor end cover ) 是由 伊西德罗·阿拉尼斯 杰森·根茨 迈克尔·拉杰 于 2021-06-18 设计创作，主要内容包括：一种用于无刷马达的端盖,其通过端盖中的翅片消散来自马达的控制器和开关元件的热量。端盖可以直接或热联接到控制器和开关元件以通过翅片消散热量。(An end cap for a brushless motor dissipates heat from the motor's controller and switching elements through fins in the end cap. The end cap may be directly or thermally coupled to the controller and switching element to dissipate heat through the fins.)

1. A tool, comprising:

a motor including a controller and a switching element, the controller controlling the switching element to operate the motor in response to a user input;

an end cap coupled to the motor, the end cap comprising:

an end cap base; and

a fin coupled to the end cap base,

wherein the switching element is thermally coupled to the end cap.

2. The tool of claim 1, wherein the controller is directly coupled to the switch element and the switch element is directly coupled to the end cap.

3. The tool of claim 2, wherein the switch element is directly coupled to the end cap at the fin.

4. The tool of claim 1, wherein the fin extends axially from the end cap.

5. The tool of claim 1, wherein the motor comprises a shaft adapted to output torque generated by the motor.

6. The tool of claim 1, wherein the end cap includes a connecting portion for coupling the end cap to a portion of the tool.

7. The tool of claim 1, wherein the end cap includes an end cap ring located at an axial center of the end cap and defining an end cap opening.

8. The tool of claim 1, wherein the end cap includes a slot, and the slot allows air to flow through the slot.

9. A motor, comprising:

a controller that controls rotation of the motor;

a switching element electrically coupled to the controller, the controller adapted to control the switching element to turn on and off in response to a user input;

an end cap coupled to the motor, the end cap comprising:

an end cap base; and

a fin coupled to the end cap base,

wherein the switching element is thermally coupled to the end cap.

10. The motor of claim 9, wherein the controller is directly coupled to the switching element and the switching element is directly coupled to the end cap.

11. The motor of claim 10, wherein the switching element is directly coupled to the end cap at the fin.

12. The motor of claim 9, wherein the fins extend axially from the end cap.

13. The motor of claim 9, comprising a shaft adapted to output torque generated by the motor.

14. The motor of claim 9, wherein the end cap includes a connection portion for coupling the end cap to a portion of the tool.

15. The motor of claim 9, wherein the end cap includes an end cap ring positioned at an axial center of the end cap and defining an end cap opening.

16. The motor of claim 9, wherein the end cap includes a slot, and the slot allows air to flow through the slot.

Technical Field

The present application relates generally to end caps. More particularly, the present application relates to a brushless dc motor end cap having a heat dissipation structure.

Background

Brushless motors are electromechanical systems commonly used in everyday applications. Some brushless motors operate by having a controller send current signals through coils located on a stationary part called the stator. When an electric current flows through the coil, the coil causes the application of a magnetic force. Brushless motors also include a rotating portion, called the rotor, having magnets that interact with magnetic forces induced by the windings of the stator. The controller sends current through coils on the stator, causing a magnetic field and interaction between the stator magnetic field and magnets on the rotor. By sending current signals through several coil windings in a particular sequence, the stator creates a rotating magnetic field that interacts with the rotor, causing the rotor to rotate and produce torque.

Brushless motors are particularly prevalent in tools such as drills and power tools. The motor is activated by a trigger on the handle of the tool and applies a torque to the working end of the tool. Many of these motors are frame motors, which help prevent the motor from being damaged when the tool is dropped onto the floor. Other motors are frameless, which allows the rotor and stator to move or twist relative to each other when dropped onto the ground. Thus, the frame motor helps prevent damage, but requires end caps to maintain structural stability.

The brushless motor includes a controller including a switching element, such as a Metal Oxide Semiconductor Field Effect Transistor (MOSFET), that turns on and off a current signal sent through a coil of the motor. However, the effectiveness of the controller and its MOSFETs, and brushless motors, is limited by the amount of heat they generate. As a result, these heat generating components require significant cooling to operate effectively, which is typically accomplished in power tools by air flow from the motor fan. Some power tools place the controller and MOSFET in the handle of the tool for reasons of space constraints, cost, simplicity, etc. However, this provides a less compact design and makes cooling the controller more difficult as the airflow generated by the fan is often blocked.

Disclosure of Invention

The present invention broadly comprises an end cap for a brushless motor that acts as a heat sink and dissipates heat from the motor's controller and MOSFETs. The end cap may contain fins for heat dissipation and may be directly or thermally coupled to the controller or MOSFET to dissipate heat through the end cap. In this way, the end cap provides a heat dissipating member having a compact design.

In particular, the invention includes a tool comprising a motor including a controller and a switching element. The controller controls the switching element to operate the motor in response to a user input. The end cap is coupled to the motor and includes an end cap base and a fin coupled to the end cap base. The switching element is thermally coupled to the end cap.

Also disclosed is a motor including a controller that controls rotation of the motor, and a switching element electrically coupled to the controller. The controller is adapted to control the switching elements to be switched on and off in response to a user input. The end cap is coupled to the motor and includes an end cap base and a fin coupled to the end cap base. The switching element is thermally coupled to the end cap.

Drawings

For the purpose of promoting an understanding of the claimed subject matter, there is shown in the drawings embodiments thereof, from an inspection of which, when considered in connection with the following description, the claimed subject matter, its construction and operation, and many of its advantages should be readily understood and appreciated.

Fig. 1 is a side view of a tool according to at least one embodiment of the present invention.

Fig. 2 is a front perspective view of the internal components of a tool according to at least one embodiment of the present invention.

Fig. 3 is a front view of an end cap according to at least one embodiment of the invention.

Fig. 4 is a partial side perspective cross-sectional view of an end cap according to at least one embodiment of the invention taken along lines 4, 4 in fig. 3.

Fig. 5 is a side cross-sectional view of an end cap according to at least one embodiment of the invention taken along lines 5, 5 in fig. 3.

Detailed Description

While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. As used herein, the term "present invention" is not intended to limit the scope of the claimed invention, but rather is used merely for illustrative purposes to discuss exemplary embodiments of the invention.

The present invention broadly comprises an end cap for a brushless motor that dissipates heat from a controller and MOSFETs associated with the motor. The end cap can be directly or thermally coupled to the controller and the MOSFET to dissipate heat through the fins in the end cap.

Fig. 1 illustrates a tool 100 according to at least some embodiments of the invention. As shown, the tool 100 includes a body 105 leading to a handle 110, where the handle 110 has a trigger 112 for selectively allowing power flow from a power source 114 (such as a battery or direct wall socket connection). Thus, the trigger 112 causes the motor 115 to rotate and provide torque to the working end 117, such as a drill bit or screwdriver bit. The end cap 120 may be located at the rear end of the motor 115 for structural and heat dissipation purposes, which will be discussed in more detail below.

The body 105 may be of any size or shape and generally includes at least some of the internal components necessary for the tool 100 to function. For example, the body 105 may house a gear train or electrical components that cause torque to be applied to the working end 117.

The handle 110 may be ergonomically sized and shaped to be held by a user's hand. The trigger 112 may be positioned on an upper portion of the handle 110 where the user's fingers will likely be located during use. The handle 110 may be devoid of a controller or switching element (such as a MOSFET) that controls the motor of the driving tool 100.

The motor 115 may be a dc brushless motor, but the present invention is not limited thereto. Thus, the motor 115 may be any electromagnetic or electromechanical motor without departing from the spirit and scope of the present invention.

As shown in fig. 2-5, the end cap 120 may serve as a structural member to help hold the motor 115 in place during, for example, a tool drop. The end cap 120 may also act as a heat sink by dissipating heat from the end (rear, front, or otherwise) of the end cap 120 to the exterior of the tool 100. For example, the end cap 120 may be directly or thermally coupled to a controller and switching elements (such as MOSFETs) that drive and control the motor 115 to quickly dissipate heat from the most thermally affected components of the motor 115 (such as the controller 130 and switching elements 135, described in further detail below). The end cap 120 may be located at the rear, front, top, bottom, or side of the tool, or any other location on the tool 100.

As shown in fig. 2, the motor 115 may include a drive shaft or shaft 125, the shaft 125 rotating and transmitting torque to a gear train or other member that ultimately transmits torque to the working end 117. The shaft 125 is coupled to the motor 115 and serves as an output of the motor 115 when the motor 115 is activated.

The motor 115 may include a controller 130 coupled to a switching element 135, such as a MOSFET and/or other type of switching element. The controller 130 is adapted to control the switch element 135 to operate the motor 115 in response to a user input, such as activation or depression of the trigger 112. As shown and as understood in the art, the controller 130 causes the switching element 135 to selectively turn on and off various coils within the motor 115 to cause magnetic interaction between the stator and rotor of the motor 115 and thereby drive the motor 115 and cause torque to be output via the shaft 125. The switching elements 135 (such as MOSFETs) may be arranged, for example, in an H-bridge arrangement, or in any other way that is capable of operating the motor 115.

As shown in fig. 3-5, the end cap 120 may include an end cap base and an end cap ring 140 located within a central portion of the end cap 120, one or more fins 145 extending axially from the end cap 120, and one or more grooves 146 between adjacent fins 145. The end cap ring 140 may be located at the axial center of the end cap 120 and define an end cap opening. The end cap ring 140 and end cap opening receive the bearing of the motor 115 and the shaft 125 and allow the shaft 125 to extend through the end cap opening. The slots 146 allow air to flow into the motor 115 for proper ventilation, and the fins 145 help dissipate heat from the motor 115. As shown in fig. 3, the end cap 120 may also include a connecting portion 150 to allow fasteners to couple the end cap to the body 105 or the rest of the tool 100. In some embodiments, fasteners couple the end cap 120 to the stator of the motor 115.

The fins 145 may be conventional fins used with heat dissipation structures to dissipate heat. The fins 145 may also be any other structure that increases the surface area of the end cap 120 and thus allows heat from the controller 130 and the switching element 135 to be dissipated. For example, the fins 145 may be curved or angled structures, or otherwise shaped and sized to dissipate heat from the end cap 120. In one embodiment, as shown, the switching element 135 may be coupled directly to the end cap 120 at the fins 145.

For example, as shown in fig. 5, the end cap 120 is directly coupled to the switching element 135, and the switching element 135 is directly coupled to the controller 130. In this manner, the end cap 120 may dissipate heat more directly and with better efficiency than structures that include other materials between the end cap 120 and the switching element 135. In other embodiments, the end cap 120 is thermally coupled to the switching element and controller 130, meaning that the end cap 120 is coupled to the switching element and controller 130 via a structure intended to conduct heat.

As used herein, the term "couple" and its functional equivalents are not necessarily limited to a direct, mechanical coupling of two or more members. Rather, the term "couple" and its functional equivalents are intended to mean any direct or indirect mechanical, electrical, or chemical connection between two or more objects, features, workpieces, and/or environmental substances. In some examples, "coupled" also means that one object is integral with another object.

The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. The actual scope of the protection sought is intended to be defined by the claims appended hereto when viewed in their proper perspective based on the prior art.