Patent Description:
Many power tools, such as drills and impact drivers, include air intake vents on the rear or side faces of the motor housing for receiving air for cooling the motor, electronics, and/or transmission. Users will sometimes grip the power tool by the motor housing such that portions of their hand will cover the air intake vents, impeding air flow.

<CIT> discloses a power tool having all of the features of the pre-characterizing portion claim <NUM>.

<CIT> discloses a power tool with an air vent which has a filter which is designed to limit the ingress of water droplets or dirt.

<CIT> discloses an electric motor for a power too, with external heat sink.

In an aspect, a power tool includes a housing extending generally along a tool axis with opposing lateral side surfaces separated by a first distance, a motor contained in the housing, and an end cap coupled to a rear end of the housing, the end cap having opposed lateral wings extending radially outward from the side surfaces by a second distance that is greater than the first distance. At least one air intake vent is disposed proximate at least one of the wings to allow intake of air to cool the motor.

Implementations of this aspect may include one or more of the following features. The wing may prevent a user's hand from blocking the air vent when gripping the power tool on the side surfaces. The at least one air intake vent may include at least one air intake vent proximate each wing. The air intake vent may be formed by a gap between the wing of the end cap and the side surface of the housing. The air intake vent may be oriented generally orthogonal to the tool axis. The air intake vent may be oriented at an acute angle to the tool axis. The air intake vent may be oriented in a direction opposite the direction of airflow through the tool housing. The housing may include one or more air exhaust vents. The air intake vents may be disposed axially rearward of the motor and the exhaust vents may be disposed axially forward of the motor. The motor may include a fan for drawing air into the air intake vent and blowing air out of the exhaust vent.

In another aspect, a power tool includes a housing extending along a tool axis with opposing lateral side surfaces separated by a first distance; a motor contained in the housing and including a stator that is stationary relative to the housing, a rotor that rotates relative to the stator, a motor output shaft rotatably driven by the stator, and a fan coupled to the motor output shaft axially forward of the motor; and an end cap coupled to a rear end portion of the housing, the end cap having opposed lateral wings extending radially outward from the side surfaces by a second distance that is greater than the first distance. At least one first intake vent is disposed proximate at least one of the lateral wings and axially rearward of the motor, the air intake vents oriented transverse to the axis. An exhaust vent is defined in the housing axially forward of the motor and proximate the fan. Upon actuation of the motor, air flows into the housing through the at least one first intake vent along a first path, over or through the motor, and out of the exhaust vents. The wings are configured to inhibit blockage of the first intake vents.

Implementations of this aspect may include one or more of the following features. A wing may prevent a user's hand from blocking the air vent when gripping the power tool on the side surfaces. The at least one first air intake vent may include at least one first air intake vent proximate each of the wings. The at least one first air intake vent may be defined by a gap between the wing of the end cap and the side surface of the housing. The first air intake vent may be oriented transverse to the tool axis. The first air intake vent may be oriented orthogonal to the tool axis. The first air intake vent may be oriented at an acute angle to the tool axis in a direction opposite the direction of airflow through the tool housing. A handle with a first end portion may be coupled to the housing and a second end portion may be disposed away from the housing, the second end portion including at least one second intake vent. A control board may be disposed in the handle, where upon actuation of the motor, air flows along a second path over the control board and then mixes with the air from the at least one first intake vent to flow over or through the motor to the at least one exhaust vent. A trigger switch may be coupled to the handle proximate the first end portion with a space defined between the trigger and the handle to form a third intake, where upon actuation of the motor, air flows along a third path over the switch and then mixes with the air from the at least one first air intake vent to flow over or through the motor to the at least one exhaust vent. At least one fourth intake vent may be defined in a rear of the end cap, where upon actuation of the motor, air flows along a fourth path over the control board and then mixes with the air from the at least one first intake vent to flow over or through the motor to the at least one exhaust vent. In an implementation, <NUM>% to <NUM>% of air that enters the housing may flow through the at least one first intake vent and the at least one fourth air vent to cool the motor and <NUM>% to <NUM>% of air that enters the housing may flow through the at least one second intake vent to cool the control board.

In another aspect, a power tool includes a housing extending along a tool axis with opposing lateral side surfaces; an end cap coupled to a rear end portion of the housing; a motor contained in the housing and including a stator that is stationary relative to the housing, a rotor that rotates relative to the stator, a motor output shaft rotatably driven by the stator, and a fan coupled to the motor output shaft axially forward of the motor; a handle having a first end coupled to and extending transverse to the housing to a second end portion; and a control board disposed in the handle. At least one first intake vent is disposed axially rearward of the motor and between the end cap and the housing. At least one second intake vent is disposed proximate the second end portion of the handle. An exhaust vent is defined in the housing axially forward of the motor and proximate the fan. Upon actuation of the motor, air flows into the housing through the at least one first intake vent along a first path, over or through the motor, and to the at least one exhaust vent, and air flows into the housing through the at least one second intake vent along a second path over the control board and then mixes with the air from the at least one first intake vent to flow over or through the motor to the at least one exhaust vent.

Implementations of this aspect may include one or more of the following features. A trigger switch may be coupled to the handle proximate the first end portion with a space defined between the trigger and the handle to form a third intake, where upon actuation of the motor, air flows along a third path over the switch and then mixes with the air from the at least one first air intake vent to flow over or through the motor to the at least one exhaust vent. At least one fourth intake vent may be defined in a rear of the end cap, where upon actuation of the motor, air flows along a fourth path over the control board and then mixes with the air from the at least one first intake vent to flow over or through the motor to the at least one exhaust vent. In an implementation, <NUM>% to <NUM>% of air that enters the housing flows through the at least one first intake vent and the at least one fourth air vent to cool the motor and <NUM>% to <NUM>% of air that enters the housing flows through the at least one second intake vent to cool the control board. The end cap may have opposed lateral wings extending radially outward from the side surfaces by a second distance that is greater than a first distance between the side surfaces. The lateral wings may be configured to redirect airflow from a direction transverse to the axis to a direction along the axis.

In another aspect, a power tool includes a housing extending along a tool axis with opposing lateral side surfaces; an end cap coupled to a rear end portion of the housing; a motor contained in the housing and including a stator that is stationary relative to the housing, a rotor that rotates relative to the stator, a motor output shaft rotatably driven by the stator, and a fan coupled to the motor output shaft axially forward of the motor; a handle having a first end coupled to and extending transverse to the housing to a second end portion; and a control board disposed in the handle. At least one first intake vent is disposed axially rearward of the motor proximate the end cap. At least one second intake vent is disposed proximate the second end portion of the handle. An exhaust vent is defined in the housing axially forward of the motor and proximate the fan. Upon actuation of the motor, approximately <NUM>% to <NUM>% of air that enters the housing flows into the housing through the at least one first intake vent along a first path, over or through the motor, and to the at least one exhaust vent, and approximately <NUM>% to <NUM>% of air that enters the housing flows into the housing through the at least one second intake vent along a second path over the control board and then mixes with the air from the at least one first intake vent to flow over or through the motor to the at least one exhaust vent.

According to a first embodiment, there is provided a power tool comprising:.

According to claim <NUM>, the wing is configured to inhibit a user's hand from blocking the at least one intake vent when gripping the power tool on the side surfaces.

The at least one first intake vent may includes first intake vents proximate each of the wings.

The at least one first intake vent can be defined by a gap between the wing of the end cap and the side surface of the housing.

Each of the at least one first intake vent may be oriented transverse to the tool axis. In addition, each of the at least one first intake vent may be oriented orthogonal to the tool axis. Alternatively, the at least one first intake vent may be oriented at an acute angle to the tool axis in a direction opposite the direction of airflow through the tool housing.

It may further comprise a handle with a first end portion coupled to the housing and a second end portion disposed away from the housing, the second end portion including at least one second intake vent. In addition, it may further comprise a control board disposed in the handle, wherein upon actuation of the motor, air flows through the at least one intake vent, along a second path over the control board and then mixes with the air from the at least one first intake vent to flow over or through the motor to the exhaust vent. It yet may further comprise a trigger switch coupled to the handle proximately the first end portion with a space defined between the trigger and the handle to form a third intake, wherein upon actuation of the motor, air flows through the third intake along a third path over the trigger switch and then mixes with the air from the at least one first intake vent to flow over or through the motor to the exhaust vent. It may further comprise at least one fourth intake vent defined in a rear of the end cap, wherein upon actuation of the motor, air flows along a fourth path through the at least one fourth intake vent, over the control board, and then mixes with the air from the at least one first intake vent to flow over or through the motor to the exhaust vent. <NUM>% to <NUM>% of air that enters the housing may flow through the at least one first intake vent and the at least one fourth intake vent to cool the motor, and <NUM>% to <NUM>% of air that enters the housing may flow through the at least one second intake vent to cool the control board.

According to a second aspect of the present invention, there is provided a power tool comprising:.

It may comprise a trigger switch coupled to the handle proximate the first end portion with a space defined between the trigger and the handle to form a third intake, wherein upon actuation of the motor, air flows along a third path though the third intake, over the trigger switch, and then mixes with the air from the at least one first air intake vent to flow over or through the motor to the exhaust vent.

It may further comprising at least one fourth intake vent defined in a rear of the end cap, wherein upon actuation of the motor, air flows along a fourth path over the control board and then mixes with the air from the at least one first intake vent to flow over or through the motor to the at least one exhaust vent.

<NUM>% to <NUM>% of air that enters the housing may flow through the at least one first intake vent and the at least one fourth air vent to cool the motor and <NUM>% to <NUM>% of air that enters the housing may flow through the at least one second intake vent to cool the control board.

The end cap can have opposed lateral wings extending radially outward from the side surfaces by a second distance that is greater than a first distance between the side surfaces. The lateral wings may be configured to redirect airflow from a direction transverse to the axis to a direction along the axis.

According to a third embodiment , there is provided a power tool comprising:.

Accordingly, there is provided a power tool in accordance with claim <NUM>.

Advantages may include one or more of the following. The wings on end cap may help prevent blockage of air intake vents during use of the power tool. The arrangement of the air intakes and exhaust vents with the fan disposed in front of the motor may facilitate improved cooling of the motor, which tends to grow hotter than the control board, and improved mixing of air that is used to cool the control board and the motor. The arrangement of air intakes and the exhaust vents may also help direct air to cool the motor, the control board, and the electronics in an efficient manner that may correspond to the amount of heat generated by each component. These and other advantages and features will be apparent from the description, the drawings, and the claims.

Referring to <FIG>, in an exemplary embodiment, a power tool <NUM> (e.g., a drill, an impact driver, or a screwdriver) includes a housing <NUM> including a motor housing portion <NUM> and a transmission housing portion <NUM> extending along a tool axis X, an end cap <NUM> coupled to a rear end of the motor housing portion <NUM>, a tool holder <NUM> (such as a chuck or a quick release tool holder) extending axially forward of the housing <NUM>, and a handle <NUM> coupled to the housing <NUM> and extending downward and transverse to the housing <NUM> along a handle axis Y. The handle axis Y may be at a right angle or an obtuse angle (e.g., approximately <NUM>° to <NUM>° relative to the tool axis X. Coupled to a top of the handle <NUM> adjacent the housing <NUM> is a trigger switch <NUM> for actuating the power tool. Coupled to a bottom of the handle <NUM> away from the housing <NUM> is a battery receptacle <NUM> configured to receive a removable and rechargeable battery pack <NUM> for providing power to the power tool <NUM>. In other implementations, the power tool may be powered by alternative power sources such as an AC power cord, compressed air, or a combustion engine.

Disposed inside the motor housing portion <NUM> is a motor <NUM> (e.g., an electric motor such as a brushless DC motor). The motor <NUM> includes a stator <NUM> that is stationary relative to the housing <NUM> and a rotor <NUM> that rotates relative to the housing <NUM> and that drives a motor output shaft <NUM>. Coupled to the front of the rotor <NUM> is a fan <NUM> for cooling the motor as described in greater detail below. The output shaft of the motor drives a transmission <NUM> (e.g., a planetary transmission) that is disposed in the transmission housing portion <NUM> axially forward of the fan <NUM>. The transmission <NUM> rotationally drives an output spindle <NUM>, which in turn rotationally drives the tool holder <NUM>. Disposed in the handle is a control board <NUM> that carries electronic components, such as a controller <NUM> (e.g., a microcontroller), a plurality of electronic switching elements <NUM> (e.g., FETs), and an electronic switch <NUM> coupled to the trigger, which control operation of the motor <NUM> in response to actuation of the trigger switch <NUM>.

The housing <NUM> includes opposed lateral side surfaces <NUM> separated by a first distance D1. The housing also optionally includes lateral bumpers <NUM> that extend radially outward from the lateral side surfaces <NUM>. The bumpers <NUM> help protect the housing <NUM> and its internal components if the tool is dropped. The rear portion of the motor housing portion <NUM> is closed by the end cap <NUM>, which may be coupled to the motor housing portion <NUM> by a plurality of fasteners <NUM> (e.g., screws or bolts). The end cap <NUM> includes a pair of lateral wings <NUM> aligned with the side surfaces and that extend radially outward by a second distance D2 that is greater than the first distance D1.

The power tool <NUM> includes a set of first air intake vents <NUM> at the rear end of the side surfaces <NUM> and a set of second air intake vents <NUM> disposed in the battery receptacle <NUM> or at the bottom of the handle <NUM>. The first air intake vents <NUM> are formed in gaps between the wings <NUM> of the end cap <NUM> and the rear end of the side surfaces <NUM>. However, the first air intake vents could be formed in the end cap adjacent the housing or in the side surfaces of the housing adjacent the end cap. The first intake air vents <NUM> are oriented transverse (e.g., orthogonally) to the tool axis and are located rearward of the motor <NUM>. Air is also able to enter the power tool <NUM> via a third air intake defined as a space <NUM> between the trigger <NUM> and the handle <NUM>. A set of exhaust vents <NUM> are disposed in the side surfaces <NUM> of the housing <NUM> forward of the motor <NUM> and adjacent or in line with the fan <NUM>.

When the fan <NUM> rotates during motor operation, air enters the housing through the first air intake vents <NUM> along arrows A, through the battery receptacle <NUM> through the second air intake vents <NUM> along arrow B, and through the space <NUM> in the trigger <NUM> along arrow C. The air from the first air intake vents <NUM> flows over and/or through the motor <NUM> along arrows F. The air from the second air intake vents <NUM> flows over the control board <NUM> along arrow E and then mixes with the air from first air intake vents <NUM> to flow over and/or through the motor <NUM> along arrows F. The air from the third air intake space <NUM> flows over the trigger and then mixes with the air from first air intake vents <NUM> to flow over and/or through the motor along arrows G and F. All or most of the air that flows over and/or through the motor exits the housing <NUM> through the exhaust vents <NUM> along arrows H.

As shown in <FIG>, the wings <NUM> extend radially outward a second distance D2 from the axis X that is greater than the first distance D1 that the side surfaces <NUM> extend outward from the axis X. This inhibits a user's hand <NUM> from completely covering the first air intake vents <NUM> when the tool is being gripped with the palm <NUM> of the hand <NUM> on the end cap <NUM> and the thumb <NUM> and fingers <NUM> on the side surfaces <NUM>. The wings <NUM> also redirect air entering transverse to the axis to be parallel to the axis to flow over and/or through the motor. In addition, the outward projection of the wings <NUM> together with the bumpers <NUM> help to prevent direct impact onto the side surfaces <NUM> of the motor housing in the event the tool is dropped. This helps prevent damage to the housing and its internal components, including the motor.

Referring to <FIG>, in another embodiment, a power tool <NUM> (e.g., a drill, an impact driver, or a screwdriver) is similar to power tool <NUM> described above with the following differences, where like components have the same reference number starting with "<NUM>" instead of "<NUM>". The power tool <NUM> includes a housing <NUM> including motor housing portion <NUM> and a transmission housing portion <NUM> extending along a tool axis X, an end cap <NUM> coupled to a rear end of the motor housing portion <NUM>, a tool holder <NUM> (such as a chuck or a quick release tool holder) extending axially forward of the housing <NUM>, and a handle <NUM> coupled to the housing <NUM> and extending downward and transverse to the housing <NUM> along a handle axis Y.

Disposed inside the motor housing portion <NUM> is a motor <NUM> (e.g., an electric motor such as a brushless DC motor). The motor <NUM> includes a stator <NUM> that is stationary relative to the housing <NUM> and a rotor <NUM> that rotates relative to the housing <NUM> and that drives a motor output shaft <NUM>. Coupled to the front of the rotor <NUM> is a fan <NUM> for cooling the motor, as described in greater detail below. The output shaft of the motor drives a transmission <NUM> (e.g., a planetary transmission) that is disposed in the transmission housing portion <NUM> axially forward of the fan <NUM>. The transmission <NUM> rotationally drives an output spindle <NUM>, which in turn rotationally drives the tool holder <NUM>. Disposed in the handle is a control board (not shown) similar to control board <NUM> of the power tool <NUM>.

The power tool <NUM> includes a set of first air intake vents <NUM> at the rear end of the side surfaces <NUM>. The power tool <NUM> also includes a set of second air intake vents disposed in the battery receptacle or at the bottom of the handle (not shown but similar to the power tool <NUM>). The first air intake vents <NUM> are formed in gaps between the wings <NUM> of the end cap <NUM> and the rear end of the side surfaces <NUM>. However, the first air intake vents could be formed in the end cap adjacent the housing or in the side surfaces of the housing adjacent the end cap. The first intake air vents <NUM> are oriented transverse (e.g., orthogonally) to the tool axis and are located rearward of the motor <NUM>. Air is also able to end the power tool <NUM> via a third air intake defined as a space <NUM> between the trigger <NUM> and the handle <NUM>. The end cap <NUM> also includes a set of fourth air intake vents <NUM> that extend through the end cap <NUM> to allow air to enter the housing in a direction generally parallel to the axis X. A set of exhaust vents <NUM> are disposed in the side surfaces <NUM> of the housing <NUM> forward of the motor <NUM> and adjacent or in line with the fan <NUM>.

When the fan <NUM> rotates during motor operation, air enters the housing through the first air intake vents <NUM> along arrow A. Air also enters the handle through the battery receptacle through the second air intake vents (similar to arrow B shown in <FIG>). Air also enters the housing through the space <NUM> in the trigger <NUM> along arrow C. Finally, air enters the housing <NUM> axially through the fourth air intake vents <NUM> along arrow D. The air from the first air intake vents <NUM> and the fourth air intake vents <NUM> flows over and/or through the motor <NUM> along arrow F. The air from the second air intake vents flows over the control board and then mixes with the air from first air intake vents <NUM> to flow over and/or through the motor <NUM> (similar to airflows E and F shown in <FIG>). The air from the third air intake space <NUM> flows over the trigger switch and then mixes with the air from first air intake vents <NUM> to flow over and/or through the motor (similar to airflows G and F shown in <FIG>). All or most of the air that flows over and/or through the motor exits the housing <NUM> through the exhaust vents <NUM> along arrows H.

Referring to <FIG>, in another embodiment, a power tool <NUM> (e.g., a drill, an impact driver, or a screwdriver) is similar to power tool <NUM> described above, with the following differences, where like components have the same reference number starting with "<NUM>" instead of "<NUM>". The power tool <NUM> includes a housing <NUM> including motor housing portion <NUM> and a transmission housing portion <NUM> extending along a tool axis X, an end cap <NUM> coupled to a rear end of the motor housing portion <NUM>, a tool holder <NUM> (such as a chuck or a quick release tool holder) extending axially forward of the housing <NUM>, and a handle <NUM> coupled to the housing <NUM> and extending downward and transverse to the housing <NUM> along a handle axis Y.

Disposed inside the motor housing portion <NUM> is a motor <NUM> (e.g., an electric motor such as a brushless DC motor). The motor <NUM> includes a stator <NUM> that is stationary relative to the housing <NUM> and a rotor <NUM> that rotates relative to the housing <NUM> and that drives a motor output shaft <NUM>. Coupled to the front of the rotor <NUM> is a fan <NUM> for cooling as described in greater detail below. The output shaft of the motor drives a transmission <NUM> (e.g., a planetary transmission) that is disposed in the transmission housing portion <NUM> axially forward of the fan <NUM>. The transmission <NUM> rotationally drives an output spindle <NUM>, which in turn rotationally drives the tool holder <NUM>. Disposed in the handle is a control board (not shown) similar to control board <NUM> of the power tool <NUM>.

The housing <NUM> includes opposed lateral side surfaces <NUM> separated by a first distance D1. The housing also optionally includes lateral bumpers <NUM> that extend radially outward from the lateral side surfaces <NUM>. The bumpers <NUM> help protect the housing <NUM> and its internal components if the tool is dropped. The rear portion of the motor housing portion <NUM> is closed by the end cap <NUM>, which may be coupled to the motor housing portion <NUM> by a plurality of fasteners <NUM> (e.g., screws or bolts). The end cap <NUM> includes a pair of lateral wings <NUM> aligned with the side surfaces and that extend radially outward by a second distance D2 that is greater than the first distance D1. The end cap <NUM> also includes a pair of lips <NUM> that extend axially forward from the wings <NUM> at least partially overlapping the side surfaces of the housing.

The power tool <NUM> includes a set of first air intake vents <NUM> at the rear end of the side surfaces <NUM>. The power tool <NUM> also includes a set of second air intake vents disposed in the battery receptacle or at the bottom of the handle (not shown but similar to the power tool <NUM>). The set of first air intake vents <NUM> are formed in gaps between the wings <NUM> of the end cap <NUM> and the rear end of the side surfaces <NUM>. The first air intake vents <NUM> are located rearward of the motor <NUM> and each include an entrance channel <NUM> defined by the lip <NUM> at an acute angle θ to the tool axis. Thus, the first air intake vents <NUM> are oriented at an acute angle to the tool axis so that air flows into the first air intake vents <NUM> along arrows A at the acute angle and then the end cap redirects the airflow in a direction in a generally opposite direction to air flow across and/or through the motor along arrows F. Air is also able to end the power tool <NUM> via a third air intake defined as a space <NUM> between the trigger <NUM> and the handle <NUM>. A set of exhaust vents <NUM> are disposed in the side surfaces <NUM> of the housing <NUM> forward of the motor <NUM> and adjacent or in line with the fan <NUM>.

When the fan <NUM> rotates during motor operation, air enters the housing through the first air intake vents <NUM> along arrow A. Air also enters the handle through the battery receptacle through the second air intake vents along arrow (similar to arrow B shown in <FIG>). Air also enters the housing through the space <NUM> in the trigger <NUM> along arrow C. The air from the first air intake vents <NUM> flows over and/or through the motor <NUM> along arrow F. The air from the second air intake vents flows over the control board and then mixes with the air from first air intake vents <NUM> to flow over and/or through the motor <NUM> (similar to airflows E and F shown in <FIG>). The air from the third air intake space <NUM> flows over the trigger and then mixes with the air from first air intake vents <NUM> to flow over and/or through the motor (similar to airflows G and F shown in <FIG>). All or most of the air that flows over and/or through the motor exits the housing <NUM> through the exhaust vents <NUM> along arrows H.

The wings <NUM> extend radially outward a second distance D2 from the axis X that is greater than the first distance D1 that the side surfaces <NUM> extend outward from the axis X. This inhibits a user's hand <NUM> from completely covering the first air intake vents <NUM> when the tool is being gripped with the palm <NUM> of the hand <NUM> on the end cap <NUM> and the thumb <NUM> and fingers <NUM> on the side surfaces <NUM>. The wings <NUM> also redirect air entering transverse to the axis to be parallel to the axis to flow over and/or through the motor. In addition, the outward projection of the wings <NUM> together with the bumpers <NUM> help to prevent direct impact onto the side surfaces <NUM> of the motor housing in the event the tool is dropped. This helps prevent damage to the housing and its internal components, including the motor.

Referring also to <FIG>, in accordance with the above-described examples, at least a majority (e.g., approximately <NUM>% to <NUM>%, such as approximately <NUM>% to <NUM>%) of the airflow enters the housing along arrows A and D through the first air intakes <NUM>, <NUM>, <NUM> (either only through the first intakes in the embodiments of <FIG> and <FIG> or in a combination of the first air intakes <NUM> and fourth air intakes <NUM> in the embodiment of <FIG>, e.g., with about <NUM>% of the airflow through the rear air vents) to cool the motor by flowing in the direction of arrow F to the exhaust vents where the air exits along arrow H. Meanwhile a smaller portion (e.g., approximately <NUM>% to <NUM>%, such as approximately <NUM>%) of the airflow enters the housing through the second air intakes <NUM>, <NUM>, <NUM> along arrow B, then flows along arrow E to cool the electronics on the control board, and then mixes with the airflow over and through the motor along arrow F to also cool the motor. An even smaller portion (e.g., approximately <NUM>% to <NUM>%) of the airflow enters the housing through the spaces <NUM>, <NUM>, <NUM> between the trigger and the handle along arrow C to cool the trigger switch and then is redirected along arrow G to mix with the airflow over and/or through the motor to cool the motor. The percentage breakdown of airflow may be configured to correspond to the relative amount of heat generated by each of the components of the power tool.

Example embodiments have been provided so that this disclosure will be thorough, and to fully convey the scope to those who are skilled in the art.

Terms of degree such as "generally," "substantially," "approximately," and "about" may be used herein when describing the relative positions, sizes, dimensions, or values of various elements, components, regions, layers and/or sections. These terms mean that such relative positions, sizes, dimensions, or values are within the defined range or comparison (e.g., equal or close to equal) with sufficient precision as would be understood by one of ordinary skill in the art in the context of the various elements, components, regions, layers and/or sections being described.

Claim 1:
A power tool comprising:
a housing (<NUM>) extending along a tool axis (X) with opposing lateral side surfaces (<NUM>) separated by a first distance (D1);
a motor (<NUM>) contained in the housing (<NUM>) and including a stator (<NUM>) that is stationary relative to the housing (<NUM>), a rotor (<NUM>) that rotates relative to the stator (<NUM>), a motor output shaft (<NUM>) rotatably driven by the stator (<NUM>), and a fan (<NUM>) coupled to the motor output shaft (<NUM>);
an end cap (<NUM>) coupled to a rear end portion of the housing (<NUM>);
at least one first intake vent (<NUM>; <NUM>) disposed axially rearward of the motor, the air intake vents (<NUM>; <NUM>) oriented transverse to the axis (X); and
an exhaust vent (<NUM>) defined in the housing (<NUM>) axially forward of the motor (<NUM>),
wherein:
the fan (<NUM>) is positioned axially forward of the motor (<NUM>) proximate the exhaust vent (<NUM>), such that upon actuation of the motor (<NUM>), air flows into the housing (<NUM>) through the at least one first intake vent along a first path, over or through the motor (<NUM>), and out of the exhaust vent (<NUM>);
characterized in that the end cap (<NUM>) has opposed lateral wings (<NUM>);
wherein the at least one first intake vent (<NUM>; <NUM>) disposed proximate at least one of the lateral wings; and
the opposed lateral wings (<NUM>) extend radially outward from the side surfaces by a second distance (D2) from the X axis that is greater than the first distance (D1), such that the wings (<NUM>) are configured to inhibit blockage of the at least one first intake vent (<NUM>; <NUM>).