Brushless motor assembly for a fastening tool

1. An electric brushless DC (BLDC) motor comprising:

an outer rotor assembly having a substantially-cylindrical metallic rotor body, a plurality of rotor magnets mounted within an inner surface of the rotor body, and a flywheel having a plurality of annular rings formed on an outer surface of the rotor body;

a molded structure formed within the rotor body formed on an inner surface of the rotor body to securely cover and retain the rotor magnets on the inner surface of the rotor body, the molded structure further comprising at least one radial member projecting inwardly from the main body towards a center of the outer rotor assembly, and a bearing support member having a substantially cylindrical shape in an axial direction of the outer rotor and supported by the at least one radial member; and

a stator assembly received inside the outer rotor assembly and mounted on a shaft,

wherein the at least one radial member is oriented radially in-line with at least a portion of the flywheel.

2. The electric motor of claim 1 , wherein the molded structure comprises at least one of a proxy, plastic, or resin material.

3. The electric motor of claim 1 , wherein the flywheel is integrally formed on the outer surface of the rotor body.

4. The electric motor of claim 1 , wherein the molded structure integrally comprises a radial member projecting inwardly from the main body towards a center of the outer rotor assembly, the radial member forming a sense magnet mount at an end of the rotor body, wherein the electric motor further comprises a sense magnet supported by the sense magnet mount.

5. The electric motor of claim 4 , further comprising an end cap affixed to an end of the outer rotor assembly opposite the stator assembly, the end cap including a positional sensor board disposed in close axial proximity to the sense magnet.

6. The electric motor of claim 1 , wherein the molded structure integrally comprises an axial fan formed at an end of the rotor body opposite the rotor magnets.

7. A power tool comprising a housing and an electric brushless DC (BLDC) motor according to claim 1 disposed within the housing.

8. An electric brushless DC (BLDC) motor comprising:

an outer rotor assembly having a substantially-cylindrical metallic rotor body, and a plurality of rotor magnets mounted within an inner surface of the rotor body;

a molded structure formed within the rotor body formed on an inner surface of the rotor body to securely cover and retain the rotor magnets on the inner surface of the rotor body, the molded structure further comprising at least one radial member projecting inwardly from the main body towards a center of the outer rotor assembly, and a bearing support member having a substantially cylindrical shape in an axial direction of the outer rotor and supported by the at least one radial member;

a stator assembly received inside the outer rotor assembly and fixedly mounted on a shaft; and

at least one bearing located within the bearing support member and mounted on the shaft to rotationally support the outer rotor assembly relative to the shaft.

9. The electric motor of claim 8 , wherein the molded structure comprises at least one of a proxy, plastic, or resin material.

10. The electric motor of claim 8 , the outer rotor assembly further comprising a flywheel integrally formed on an outer surface of the rotor body.

11. The electric motor of claim 8 , further comprising an end cap affixed to an end of the outer rotor assembly opposite the stator assembly, the end cap including a positional sensor board disposed in close axial proximity to the sense magnet.

12. The electric motor of claim 8 , wherein the molded structure integrally comprises an axial fan formed at an end of the rotor body opposite the rotor magnets.

13. A power tool comprising a housing and an electric brushless DC (BLDC) motor according to claim 8 disposed within the housing.