Power tool with compact transmission

Abstract

A power tool includes a housing and a motor in the housing with a rotor rotatable about a motor axis, a transmission assembly configured to transmit torque from the rotor to a tool output shaft, the transmission assembly including a first gear rotatable about the motor axis, a second gear rotatably driven by the first gear about a transverse output axis, and at least one planetary gear set driven by the second gear, and a cutting assembly including a blade mount rotatably driven by the tool output shaft and coupled to a cutting blade, a blade guard with an opening configured to expose a portion of the cutting blade, and a base plate transverse to the output axis for resting against a work surface, the cutting assembly is configured so that the cutting blade is able to flush cut a protruding member extending from the work surface.

Description

Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOPOWER TOOL WITH COMPACT TRANSMISSIONCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of and priority to each of U.S. Provisional Patent Application No. 63 / 777,521, filed on March 25, 2025, entitled Power Tool with Compact Transmission, and U.S. Patent Application No. 63 / 926,367, filed on November 26, 2025, entitled Power Tool with Compact Transmission.INCORPORATION BY REFERENCE

[0002] The disclosures of each of U.S. Provisional Patent Application No. 63 / 777,521, filed on March 25, 2025, entitled Power Tool with Compact Transmission, and U.S. Patent Application No. 63 / 926,367, filed on November 26, 2025, entitled Power Tool with Compact Transmission, are hereby incorporated by reference for all purposes as if set forth in their entireties.TECHNICAL FIELD

[0003] This application relates to power tools, and more specifically to powered cutting tools with improved compact transmissions.BACKGROUND

[0004] Power tools can be used for cutting, machining, and / or otherwise working a large assortment of materials and workpieces, for example, in commercial or home construct! on / repair, home improvement projects, craft hobbies, and other applications, to name a few. In order to provide effective access to a wide variety of work surfaces and job locations, it is desirable for a power tool to have a configuration that provides ease of access to selected materials and workpieces. It is also desirable that the power tool have a robust configuration that avoids unwanted shifting of components during operation. There is therefore a need for a power tool having improved construction and performance.1WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOSUMMARY

[0005] In an aspect, the disclosure is generally directed to a power tool, the power tool comprising a tool housing, a motor at least partially received in the tool housing, the motor having a rotor rotatable about a motor axis, a transmission assembly configured to transmit torque from the rotor to a tool output shaft, the transmission assembly comprising a first gear rotatable about the motor axis, a second gear rotatably driven by the first gear about an output axis transverse to the motor axis, and a first planetary gear set driven by the second gear, and a cutting assembly comprising a blade mount rotatably driven by the tool output shaft about the output axis and configured to be coupled to a cutting blade, a blade guard of the cutting blade, and a base plate transverse to the output axis and configured to rest against a work with an opening configured to expose a portion surface, wherein the cutting assembly is configured so that the cutting blade is able to flush cut a protruding member extending away from the work surface.

[0006] Implementations of this aspect may include one or more of the following features.

[0007] In some example implementations, the first planetary gearset comprises a first sun gear coupled to the second gear to rotate about the output axis. The first sun gear may define a central bore that at least partially receives the tool output shaft. The central bore may extend at least partially through the second gear. The tool output shaft may extend entirely through the first sun gear and the second gear and is supported by a rear output shaft bearing disposed on an opposite side of the second gear than the first planetary gearset. The rear output shaft bearing may be disposed axially rearward of the motor axis along the output axis and the first planetary gearset may be disposed axially forward of the motor axis along the output axis. The power tool may further comprise a front output shaft bearing configured to support the tool output shaft and disposed axially forward of the first planetary gearset.

[0008] In some example implementations, the power tool further comprises an inner bearing disposed in the central bore and configured to support the first sun gear. The power tool may further comprise an outer bearing configured to support the second gear, with the inner bearing at least partially nested inside the outer bearing.

[0009] In some example implementations, the first gear comprises a first bevel gear and the second gear comprises a second bevel gear.2WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0010] In some example implementations, the first planetary gearset comprises a plurality of first planet gears intermeshed with the first sun gear, the plurality of first planet gears coupled to a first planet carrier, and a ring gear surrounding the plurality of first planet gears. The power tool may further comprise a second planetary gearset axially forward of the first planetary gearset. The second planetary gearset may comprise a second sun gear driven by the first planet earner, a plurality of second planet gears intermeshed with the second sun gear, the plurality of second planet gears coupled to a second planet carrier, and the ring gear surrounding the plurality of second planet gears.

[0011] In some example implementations, a central bore extends through the second sun gear to at least partially receive the tool output shaft. The tool output shaft may comprise a body and at least a portion of the second planet carrier may be integral with the body of the tool output shaft. In some example implementations, at least a portion of the body of the tool output shaft has an outer diameter between about 10 mm and about 15 mm.

[0012] In some example implementations, the first gear, the second gear, the first planetary gearset, and the second planetary' gearset are arranged in series to provide a total gear reduction of between about 11:1 and about 14:1.

[0013] In some example implementations, the power tool further comprises a transmission housing portion of the tool housing coupled to the cutting assembly, the transmission housing portion configured to receive the transmission assembly. The transmission housing portion may comprise an interior cavity' with a volume between about 1.0E6 mm3and about 1.5E6 mm 3.

[0014] In some example implementations, the tool output shaft has an outer diameter and a ratio of an internal volume of the transmission housing portion to the outer diameter of the tool output shaft is between about 6.7E4 mm2and about 1.5E5 mm2.

[0015] In some example implementations, the transmission assembly further comprises a plurality of bearings in the interior cavity of the transmission housing portion each receiving a respective portion of the tool output shaft.

[0016] In some example implementations, the opening in the blade guard is configured to expose a blade with a radial girth of about 30 mm extending toward the output axis.3WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0017] In some example implementations, the power tool has a proximal end, a distal end, and a center of gravity between the proximal end and the distal end. A distance between the distal end and the center of gravity of the power tool may be between about 115 mm and about 130 mm.

[0018] In some example implementations, a distance between the proximal end and the center of gravity of the power tool is between about 220 mm and about 240 mm.

[0019] In some example implementations, a ratio of the distance between the distal end and the center of gravity to the distance between the proximal end and the center of gravity is between about 0.48 and about 0.59.

[0020] In some example implementations, the power tool comprises a total length of about 365 mm from the proximal end to the distal end, and the ratio of the total length of the power tool to the outer diameter of the tool output shaft is about 24.

[0021] In some example implementations, the power tool comprises a total length of about 353 from the proximal end to the distal end, and the ratio of the total length of the power tool to the outer diameter of the tool output shaft is about 23.53.

[0022] In another aspect, the disclosure is generally directed to a power tool comprising a tool housing, a motor at least partially received in the housing and configured to be energized to produce a rotational output about a motor axis, a tool output shaft coupled to an accessory holder, the tool output shaft configured to rotate about an output axis transverse to the motor axis upon energization of the motor, and a transmission assembly for transmitting rotational motion from the motor to the accessory holder, the transmission assembly comprising a first bevel gear configured to rotate about the motor axis, a second bevel gear intermeshed with the first bevel gear and configured to rotate about the output axis, and a planetary gearset operably coupled with the second bevel gear to transmit torque from the second bevel gear to the output shaft, the planetary gear set comprising a sun gear driven by the second bevel gear, a plurality of planet gears surrounding and intermeshed with the sun gear, a planet carrier to which the plurality of planet gears are coupled, and a ring gear surrounding and intermeshed with the plurality of planet gears, wherein the tool output shaft extends completely through a central opening in the sun gear and the second bevel gear, the tool output shaft supported by a rear bearing axially rearward of the second bevel gear along the output axis and a front bearing axially forward of the planetary gearset along the output axis.4WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0023] Implementations of this aspect may include one or more of the following features.

[0024] In some example implementations, the power tool may further comprise an inner bearing disposed in the central opening between the tool output shaft and the sun gear to support the second bevel gear. The power tool may further comprise an outer bearing configured to support an outer portion of the second bevel gear. The inner bearing may be at least partially nested in the outer bearing.

[0025] In some example implementations, the planetary gearset is a first planetary gearset and the transmission assembly further comprises a second planetary gearset axially forward of the first planetary gearset. The sun gear may be a first sun gear and the second planetary gearset may comprise a second sun gear driven by the planet carrier, wherein the tool output shaft extends completely through a central opening in the second sun gear and the front bearing is axially forward of the second planetary gearset along the output axis.

[0026] In another aspect, the disclosure is generally directed to a power tool comprising a motor housing portion, a motor at least partially received in the motor housing portion, the motor having a rotor rotatable about a motor axis, a transmission housing portion coupled to a front end portion of the motor housing portion, a transmission assembly at least partially received in an interior cavity of the transmission housing portion, the transmission assembly comprising a plurality of gears configured to transmit torque from the rotor to a tool output shaft rotatable about an output axis transverse to the motor axis, wherein a ratio of an interior volume of the interior cavity of the transmission housing portion to an outer diameter of the tool output shaft is between about 6.7E4 mm2and about 1.5E5 mm2, and a cutting assembly including a blade holder rotatably driven by the tool output shaft and configured to be coupled to a cutting blade.

[0027] Implementations of this aspect may include one or more of the following features.

[0028] In some example implementations, the interior volume of the interior cavity of the transmission housing portion is between about 1.0E6 mm3and about 1.5E6 mm3.

[0029] In some example implementations, the outer diameter of the tool output shaft is between about 10 mm and about 15 mm.

[0030] In another aspect, the disclosure is generally directed to a power tool comprising a transmission housing portion and a transmission assembly at least partially received in the5WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOtransmission housing portion for transmitting torque from a motor to an output shaft. The transmission assembly can include a first bevel gear configured to rotate about a motor axis, a second bevel gear intermeshed with the first bevel gear and configured to rotate about an output axis perpendicular to the motor axis, a first planetar}' gearset operably coupled with the second bevel gear, and a second planetary gearset operably coupled with at least a portion of the first planetary gearset. The first bevel gear and second bevel gear can be configured to provide a first gear reduction. The first planetary gear set can comprise a pl nral i t\ of gears configured to provide a second gear reduction. The second planetary gear set can comprise a plurality' of gears configured to provide a third gear reduction. The first gear reduction, second gear reduction, and third gear reduction combined produce a total gear reduction for the transmission assembly between about 11:1 and about 14:1.

[0031] Implementations of this aspect may include one or more of the following features.

[0032] The output shaft can extend completely through a central opening in the second bevel gear, the first planetary gearset, and the second planetary gearset. At least a portion of the transmission housing portion can comprise an inner diameter between about 48 mm and about 51 mm.

[0033] In some example implementations, the pow er tool can have a ratio of an outer diameter of the second bevel gear measured perpendicular to the output axis to an outer diameter of the output shaft between 2.80 and about 4.20. The power tool can also have a ratio of an inner diameter of the transmission housing portion measured perpendicular to the output axis to an outer diameter of the output shaft between about 3.20 and about 5.10.

[0034] In another aspect, the disclosure is generally directed to a pow er tool comprising a motor housing portion, a motor at least partially received in the motor housing portion, the motor having a rotor rotatable about a motor axis, a transmission housing portion coupled to a front end portion of the motor housing portion, a transmission assembly at least partially received in an interior cavity of the transmission housing portion and configured to transmit torque from the rotor to an output shaft rotatable about an output axis transverse to the motor axis, the transmission assembly comprising: a first bevel gear configured to rotate about the motor axis, a second bevel gear intermeshed with the first bevel gear and configured to rotate about the output axis, and a planetary gearset operably coupled with the second bevel gear to transmit torque from the second bevel gear to the output shaft, the planetary gear set comprising6WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOa sun gear driven by the second bevel gear, a plurality of planet gears surrounding and intermeshed with the sun gear, a planet carrier to which the plurality of planet gears are coupled, and a ring gear surrounding and intermeshed with the plurality of planet gears, wherein the tool output shaft extends completely through a central opening in the sun gear and the second bevel gear, the tool output shaft supported by a rear bearing axially rearward of the second bevel gear along the output axis and a front bearing axially forward of the planetary gearset along the output axis. A ratio of an interior diameter of the interior cavity7of the transmission housing portion to an outer diameter of the output shaft can be between about 3.20 and about 5.10. The power tool can further comprise a cutting assembly including a blade holder rotatably driven by the tool output shaft and configured to be coupled to a cutting blade.

[0035] Implementations of this aspect may include one or more of the following features.

[0036] In some example implementations, the power tool may further comprise an inner bearing disposed in the central opening between the tool output shaft and the sun gear to support the second bevel gear. The power tool may further comprise an outer bearing configured to support an outer portion of the second bevel gear. The inner bearing may be at least partially nested in the outer bearing.

[0037] In some example implementations, the planetary gearset is a first planetary7gearset and the transmission assembly further comprises a second planetary gearset axially forward of the first planetary gearset. The sun gear may be a first sun gear and the second planetary gearset may comprise a second sun gear driven by the planet carrier, wherein the tool output shaft extends completely through a central opening in the second sun gear.

[0038] In some example implementations, the blade holder comprises a blade mount and a clamp member secured to the output shaft such that the cutting blade is for being at least partially received between the blade mount and the clamp member.

[0039] In another aspect, the disclosure is generally directed to a power tool comprising a motor housing portion, a motor at least partially received in the motor housing portion, the motor having a rotor rotatable about a motor axis, a transmission housing portion coupled to a front end portion of the motor housing portion, a transmission assembly at least partially received in an interior cavity7of the transmission housing portion, the transmission assembly comprising a plurality of gears configured to transmit torque from the rotor to a tool output shaft rotatable about an output axis transverse to the motor axis, the plurality of gears7WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOcomprising a first gear rotatable about the motor axis and a second gear for being rotatably driven by the first gear about the output axis, the wherein a ratio of an outer diameter of the second gear to an outer diameter of the tool output shaft is between about 3.20 and about 5.10, and a cutting assembly including a blade holder rotatably driven by the tool output shaft and configured to be coupled to a cutting blade.

[0040] Implementations of this aspect may include one or more of the following features.

[0041] In some example implementations, the power tool may further comprise an inner bearing disposed in a central opening between the output shaft and a sun gear of the transmission assembly to support the sun gear. The power tool may further comprise an outer bearing configured to support an outer portion of the second gear of the transmission assembly. The inner bearing may be at least partially nested in the outer bearing.

[0042] In some example implementations, the blade holder comprises a blade mount and a clamp member secured to the tool output shaft such that the cutting blade is for being at least partially received between the blade mount and the clamp member.

[0043] In another aspect, a power tool comprises a tool housing, a motor at least partially received in the housing and configured to be energized to produce a rotational output about a motor axis, an output shaft coupled to an accessory holder, the output shaft configured to rotate about an output axis transverse to the motor axis upon energization of the motor, and a transmission assembly comprising a plurality of gears configured to transmit torque from the motor to the output shaft. The plurality of gears comprises a first bevel gear configured to rotate about the motor axis, a second bevel gear intermeshed with the first bevel gear and configured to rotate about the output axis, and a planetary gearset operably coupled with the second bevel gear to transmit torque from the second bevel gear to the output shaft, the planetary gear set comprising a sun gear driven by the second bevel gear, a plurality of planet gears surrounding and intermeshed with the sun gear, a planet carrier to which the plurality of planet gears are coupled, and a ring gear surrounding and intermeshed with the plurality of planet gears, wherein a ratio of an outer diameter of the ring gear to an outer diameter of the output shaft is between about 3.20 and about 5.10.

[0044] Implementations of this aspect may include one or more of the following features.

[0045] In some example implementations, the power tool further comprises an inner bearing disposed between the output shaft and the sun gear to support the sun gear. The power tool 8WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOmay further comprise an outer bearing configured to support an outer portion of the second bevel gear. The inner bearing may be at least partially nested in the outer bearing.

[0046] In some example implementations, the planetary gearset is a first planetary gearset and the transmission assembly further comprises a second planetary gearset axially forward of the first planetary' gearset.

[0047] In some example implementations, the sun gear may be a first sun gear and the second planetary gearset may comprise a second sun gear driven by the planet carrier, wherein the output shaft extends completely through a central opening in the second sun gear and the front bearing is axially forward of the second planetary gearset along the output axis.

[0048] In some example implementations, the first bevel gear and the second bevel gear are configured for providing a gear reduction of about 2:1. The first planetary gearset may be configured for providing a gear reduction of about 2.5:1. The second planetary gearset may be configured for providing a gear reduction of about 2.5:1.

[0049] In another aspect, a power tool comprises a tool housing, a motor at least partially received in the housing and configured to be energized to produce a rotational output about a motor axis, a transmission assembly configured to transmit torque from the motor to an output shaft, and a cutting assembly. The transmission assembly can include a first gear rotatable about the motor axis, a second gear rotatably driven by the first gear about an output axis transverse to the motor axis, and a planetary gearset driven by the second gear. The cutting assembly can include a blade mount rotatably driven by the output shaft about the output axis and configured to be coupled to a cutting blade, a blade guard with an opening configured to expose a portion of the cutting blade, and a base plate transverse to the output axis and configured to rest against a work surface. The cutting assembly can be configured so that the cutting blade is able to flush cut a protruding member extending away from the work surface while the base plate rests on the work surface. A vertical distance parallel to the output axis between the motor axis and a bottom surface of the base plate can be between about 65 mm and about 70 mm.

[0050] Implementations of this aspect may include one or more of the following features.

[0051] In some example implementations, the vertical distance between the motor axis and the bottom surface of the base plate is about 77 mm.9WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0052] In some example implementations, the power tool can further include a proximal end, a distal end, and a center of gravity between the proximal end and the distal end. A distance between the distal end and the center of gravity of the power tool can be between 120 mm and 130 mm. A distance between the proximal end and the center of gravity' of the power tool can be between about 230 mm and about 245 mm. A ratio of the distance between the distal end and the center of gravity and the distance between the proximal end and the center of gravity can be between about 0.49 and about 0.57.

[0053] In another aspect, a power tool comprises a tool housing, a motor at least partially received in the housing having a rotor rotatable about a motor axis, a transmission assembly configured to transmit torque from the rotor to an output shaft, and a cutting assembly. The transmission assembly can include a first gear rotatable about the motor axis, a second gear rotatably driven by the first gear about an output axis transverse to the motor axis, a first bearing supporting a first portion of the output shaft, a second bearing supporting a second portion of the output shaft, and a planetary gearset driven by the second gear. The cutting assembly can include a blade mount rotatably driven by the output shaft about the output axis and configured to be coupled to a cutting blade, a blade guard with an opening configured to expose a portion of the cutting blade, and a base plate transverse to the output axis and configured to rest against a work surface. The cutting assembly can be configured so that the cutting blade is able to flush cut a protruding member extending away from the work surface while the base plate rests against the work surface.

[0054] Implementations of this aspect may include one or more of the following features.

[0055] In some example implementations, the cutting assembly can further include a pivot pin. The base plate can be rotatable about the pivot pin around an axis parallel to and offset from the output axis to expose the blade mount for replacing the blade.

[0056] In some example implementations, the planetary gearset can include a sun gear coupled to the second gear to rotate about the output axis. The sun gear and the second gear can be integral. The sun gear can define a central bore that at least partially receives the output shaft therethrough. The central bore can also extend at least partially through the second gear.

[0057] In some example implementations, the second bearing can be disposed axially forward of the planetary gearset. The first bearing can be disposed axially rearward of the planetary gearset. The transmission assembly can also include a third bearing configured to support at10WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOleast a portion of the second gear. An inner diameter of the third bearing can be larger than an outer diameter of the sun gear. The second bearing can be disposed on an opposite side of the second gear than the planetary7gearset.

[0058] In some example implementations, the first bearing can be positioned to straddle the motor axis such that a first portion of the first bearing is axially rearward of the motor axis along the output axis and a second portion of the first bearing is axially forward of the motor axis along the output axis.

[0059] Aspects of the present disclosure provide for a compact transmission assembly that provides a power tool with ease of visibility and maneuverability in working spaces. A tool output shaft associated with the transmission assembly is sufficiently arranged and supported for withstanding flush cuts and other cutting operations.

[0060] These and other advantages and features, as well as further areas of applicability7, will be apparent from the description, the drawings, and the claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0061] According to common practice, the various features of the drawings discussed below are for illustrative purposes and are not necessarily draw n to scale. Some dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.

[0062] FIG. 1 is an upper isometric view of an example power tool according to example embodiments of the disclosure.

[0063] FIG. 2A is a lower isometric view of the power tool of FIG. 1.

[0064] FIG. 2B is another lower isometric view of the pow er tool of FIG. 1 that is similar to FIG. 2A. showing a base plate removed for clarity of illustration.

[0065] FIG. 3 is a top plan view of the power tool of FIG. 1.

[0066] FIG. 4 is a cross-sectional view of a portion of the distal end of the pow er tool of FIG.1.

[0067] FIG. 5 is another cross-sectional view of a portion of the distal end of the power tool of FIG. 1.11WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0068] FIG. 6 is an exploded view of the components of a transmission assembly and a cutting assembly of the power tool of FIG. 1 according to example embodiments of the disclosure.

[0069] FIG. 7 is an isometric view of an example output shaft of the transmission assembly of the power tool of FIG. 1 according to example embodiments of the disclosure.

[0070] FIG. 8 is a cross-sectional view of an example bevel gear and sun gear of the transmission assembly of the power tool of FIG. 1 according to example embodiments of the disclosure.

[0071] FIG. 9A is an exploded side view of an alternative construction of a bevel gear and sun gear for use with the transmission assembly of the power tool of FIG. 1 according to example embodiments of the disclosure.

[0072] FIG. 9B is a side view of the assembled bevel gear and sun gear of FIG. 9A.

[0073] FIG. 10 is an isometric view of an example transmission housing portion and cutting assembly of the power tool of FIG. 1 according to example embodiments of the disclosure.

[0074] FIG. 11 is a top plan view of the transmission housing portion and cutting assembly shown in FIG. 10.

[0075] FIG. 12 is a side view of the power tool of FIG. 1 with the battery pack removed.

[0076] FIG. 13 is another side view of the power tool of FIG. 1 with the battery pack inserted.

[0077] FIG. 14 is an enlarged plan view of section A-A from FIG. 13.

[0078] FIG. 15 is an enlarged plan view of section B-B from FIG. 13.

[0079] FIG. 16 is a schematic diagram of a protruding member extending away from a portion of a work surface for being cut with the power tool of FIG. 1 according to example embodiments of the disclosure.

[0080] FIG. 17 is a plan view of the debris path from a protruding member being cut with the power tool of FIG. 1 according to example embodiments of the disclosure.

[0081] FIG. 18 is an upper isometric view of another example power tool according to example embodiments of the disclosure.

[0082] FIG. 19 is a lower isometric view of the power tool of FIG. 18.

[0083] FIG. 20 is atop plan view of the power tool of FIG. 18.12WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0084] FIG. 21 is right side elevation view of the power tool of FIG. 18.

[0085] FIG. 22 A is a view of the guide shoes of the power tool of FIG. 18.

[0086] FIG. 22B is another view of the guide shoes of the power tool of FIG. 18.

[0087] FIG. 23 is a cross-sectional view of a portion of the distal end of the power tool of FIG.18.

[0088] FIG. 24 is another cross-sectional view of a portion of the distal end of the power tool of FIG. 18.

[0089] FIG. 25A is an isometric view of an example output shaft and portions of the transmission assembly of the power tool of FIG. 18 according to example embodiments of the disclosure.

[0090] FIG. 25B is a view of section E-E from FIG. 25 A.

[0091] FIG. 25C is an exploded view of the example output shaft and portions of the transmission assembly from FIG. 25 A.

[0092] FIG. 26A is an elevation view of an example bevel gear and sun gear of the transmission assembly of the power tool of FIG. 18 according to example embodiments of the disclosure.

[0093] FIG. 26B is a view of section F-F from FIG. 26A.

[0094] FIG. 27 A is an elevation view of an alternative example bevel gear and sun gear of the transmission assembly of the power tool of FIG. 18.

[0095] FIG. 27B is an isometric exploded view of the bearing seat and sealing members shown in FIG. 27A.

[0096] FIG. 28 is an exploded view some components of the cutting assembly of the power tool of FIG. 18 according to example embodiments of the disclosure.

[0097] FIG. 29A is an isometric view of an example transmission housing portion and cutting assembly of the power tool of FIG. 18 according to example embodiments of the disclosure.

[0098] FIG. 29B is a bottom plan view of the transmission housing portion and cutting assembly shown in FIG. 29 A.

[0099] FIG. 29C is another bottom plan view of the transmission housing portion and cutting assembly shown in FIG. 29A with the base plate rotated.13WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0100] FIG. 30A is an isometric view of another example transmission housing portion and cutting assembly of the power tool of FIG. 18 according to example embodiments of the disclosure.

[0101] FIG. 30B is a bottom plan view of the transmission housing portion and cutting assembly shown in FIG. 30A.

[0102] FIG. 30C is another bottom plan view of the transmission housing portion and cutting assembly shown in FIG. 30A with the base plate rotated.

[0103] FIG. 30D is a view of a possible hand position for using a power tool according to example embodiments of the disclosure.

[0104] FIG. 30E is a view of another possible hand position for using a power tool according to example embodiments of the disclosure.

[0105] FIG. 30F is an isometric view of another example transmission housing portion and cutting assembly of the power tool of FIG. 18 showing an exploded fastener retention system for the base plate of the power tool according to example embodiments of the disclosure.

[0106] FIG. 30G is a partial cross-sectional view of a portion of the example transmission housing portion and cutting assembly shown in FIG. 30F, showing the assembled fastener retention system secured to the base plate.

[0107] FIG. 30H is a partial cross-sectional view of a portion of the example transmission housing portion and cutting assembly shown in FIG. 30F, showing partial removal of the fastener from the base plate.

[0108] FIG. 31 is a side view of the power tool of FIG. 18.

[0109] FIG. 32 is another side view of the power tool of FIG. 18 with a battery pack inserted.

[0110] FIG. 33 is an isometric view of a debris bag adaptor coupled to the debris port of a power tool according to example embodiments of the disclosure.

[0111] FIG. 34 is another isometric view of the debris bag adaptor of FIG. 33 as removed from the debris port of the power tool.

[0112] FIG. 35 is an isometric view of the debris bag adaptor of FIG. 33 coupling a debris bag to a power tool according to example embodiments of the disclosure.14WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0113] FIG. 36 is an isometric view of a power tool with a retention clip for holding auxiliary tools according to example embodiments of the disclosure.

[0114] Corresponding parts are designated by corresponding reference numbers throughout the drawings.DETAILED DESCRIPTION

[0115] FIGS. 1-3 of the drawings show several views of a power tool 10, e.g., a cutting tool, according to example embodiments of the present disclosure. The power tool 10 may be either a corded (e.g., AC powered) or cordless (e.g., DC powered / battery operated) device.

[0116] In the embodiments shown, the power tool 10 is a cordless flush cutter (e.g., for cutting rebar or other elements that protrude from a work surface) that has a proximal end portion 11 (e.g., an end portion generally designated to be closest to a user or operator), a tool housing 12, and a distal end portion 13 (e.g., an end portion generally designated as a working end or end furthest from a user or operator). Near the proximal end portion 11 of the power tool 10, the tool housing 12 may at least partially define or be coupled to a battery interface 14 for coupling to a portable battery pack 16 or other power source. In the illustrated embodiment, the distal end portion 13 of the power tool 10 can be generally defined as the end portion of the tool opposing the proximal end portion 11.

[0117] The tool housing 12 includes a handle portion 15, a motor housing portion 20 that supports a power switch assembly 22, and a transmission housing portion 30 coupled to a distal end of the motor housing portion 20. In the example embodiments shown, the handle portion 15 and motor housing portion 20 are integral, but in other embodiments they may be separate components. In alternative embodiments, the housing may have a configuration similar to one or more configurations disclosed in PCT Application No. PCT / US24 / 60792, filed December 18, 2024, titled “Power Tool,” which is incorporated by reference in its entirety. A substantially circular blade guard 42 associated with a cutting assembly 40 may be connected to the transmission housing portion 30. As described herein, the blade guard 42 may selectively cover and selectively expose a portion of a cutting member such as a circular blade 44 or other tool head. In some embodiments, the blade guard 42 may form a portion of the tool housing 12 or transmission housing portion 30 may be separate from them.15WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0118] With continued reference to FIGS. 1-3, an optional side handle 31 may be integral with or removably attachable to the transmission housing portion 30 and presents an additional gripping structure at which the power tool 10 may be grasped and / or manipulated by a user or operator. In some embodiment, the side handle 31 may be repositionable relative to the tool housing 12, e.g.. via a mechanical fastener. For example, a threaded connection can be used whereby the side handle 31 is optionally inserted into a selected one of two or more different threaded openings 24 in the transmission housing portion 30 to allow the side handle 31 to be mounted to the transmission housing portion 30 at two or more different relative positions. In other embodiments, threaded openings can be provided in the side handle 31 to allow the side handle 31 to be mounted to various positions on the transmission housing portion 30. It will be understood a different configuration of threaded openings 24 may be provided in the tool housing 12 and / or side handle 31 for selective attachment in other mounting positions, or other types of mechanical joints may be used to attach the side handle 31 to the transmission housing portion 30.

[0119] The tool housing 12 may include a pair of clam shell halves 12a, 12b (FIG. 4) that may cooperate to define the motor housing portion 20 and a battery interface 14. The motor housing portion 20 may enclose a motor 50 (FIG. 4) and also provide a handle feature for a user or operator to grasp the power tool 10. In the illustrated embodiment, the motor housing portion 20 may have features and contours that allow a user to ergonomically grip / maneuver the power tool 10 in a manner that provides convenient access to the switch assembly 22 using one or more fingers. The example switch assembly 22 shown is a paddle-style switch adjacent with and coupled to the tool housing 12 via a pivot so as to be pressable at dual end portions thereof, though various other types of power switch assemblies could be substituted without departing from the disclosure.

[0120] As shown, in some embodiments, the power tool 10 is powered by the removable battery pack 16 which may be coupled to the battery interface 14 (e.g., with a portion of the battery pack 16 at least partially received within the battery interface 14). The battery pack 16 may be in electrical communication with internal electrical components of the power tool 10, (e.g., one or more wires, terminals, contacts, circuit boards, connectors, and control electronics) such that electrical power from the battery pack 16 may be supplied to the power tool 10.

[0121] For example, the battery pack 16 may supply electrical power to motor, sensors, lights, and / or other components of the power tool 10. The battery pack 16 may also supply power to 16WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOcontrol circuitry associated with the power tool 10 to effect various functions and processes thereof (e g., actuation of the switch assembly 22, speed control, and / or other functions). In some embodiments, the battery' pack 16 may include a plurality of cells composed, for example, Li-ion, lithium-ion phosphate (LPF), and / or another suitable cell chemistry.

[0122] It will be understood that additional or alternative configurations of power supply ing devices may be provided to supply electrical power to such components without departing from the disclosure. In some embodiments, the battery pack 16 may be provided with a predetermined voltage potential, such as 12V, 18V, 20V, 24V, 54V, 60V, etc. In some embodiments, the power tool 10 may be configured to receive battery' packs of varied sizes or voltages. For example, in an example embodiment, the power tool 10 may be configured to receive a battery pack with a maximum initial voltage of about 12V (measured without a workload) or a battery pack with a maximum initial voltage of about 20V (measured without a workload), so that the power tool 10 may operate w ith batteries of different voltage potentials.

[0123] The cutting assembly 40 may be fastened or otherwise mechanically coupled to the transmission housing portion 30 proximate the distal end portion 13 of the power tool 10. The cutting assembly 40 includes the blade guard 42 positioned extending around and at least partially circumscribing a circular blade 44. A base plate 45 may be removably attached to the blade guard 42 to at least partially cover the bottom portion of the circular blade 44. The base plate 45, as shown, may be generally planar such that it may rest on a work surface and guide the pow er tool 10 tow ard a member protruding from the work surface during cutting operations, e.g., flush cuts in which the protruding member is cut by the circular blade 44, though it will be understood that the base plate 45 may have a different configuration without departing from the disclosure.

[0124] The blade guard 42 and base plate 45 of the cutting assembly 40 each have a respective U-shaped or other slotted recessed portion therealong near the distal end portion 13 of the power tool 10 that are aligned to form an opening or blade opening 46 in the blade guard 42 / base plate 45 that exposes outer radial portions of the circular blade 44. While the blade opening 46 depicted in the example embodiment of FIGS. 1-3 is generally U-shaped, an opening with a different geometry' could be provided without departing from the disclosure. The blade opening 46 may expose a sufficient radial portion of the circular blade 44 to allow' for a desired depth of cut Cd of a working piece or protruding member extending from a work17WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOsurface, e.g., a metal rod such as a piece of rebar, a threaded rod, a screw, a bolt, an anchor, etc.

[0125] With reference to FIG. 16, an example protruding member M is illustrated extending from a work surface W. The protruding member M may be a length of metal, such as rebar extending from the work surface W, which may be concrete or another material in which the protruding member M extends. The protruding member M may have a diameter DM such that Cd> DM and such that the protruding member M may be at least partially received in the blade opening 46 of the power tool 10 for being at least partially cut by the blade. In some embodiments, the protruding member M may be up to and including #8 rebar, e.g., #6 rebar, #7 rebar, #8 rebar, etc. It will be understood that one or both of the work surface W and the protruding member M may be a different material or size without departing from the disclosure.

[0126] Referring again to FIGS. 1-3, a guide block 47 may be at least partially received in and supported extending from the blade guard 42 adjacent to the blade opening 46 to help guide the protruding member of a target working piece, e.g., rebar of a selected gauge, into the blade opening 46 and into contact with the circular blade 44. In this regard, the guide block 47 may be positioned abutting a side of the blade opening 46. As illustrated, the guide block 47 has a rectangular configuration. In other examples, the guide block 47 may have other configurations such as tapered or rounded, and there may be an additional guide block on the other side of the blade opening 46.

[0127] A debris port 48 may be at least partially defined in a radially outwardly-protruding section of the blade guard 42 at a location suitable to eject debris, e.g., chips, chunks, slivers, etc., of a working piece cut by the circular blade 44. In some embodiments, the debris port 48 may be positioned / oriented a sufficient distance away from the blade opening 46 so as to minimize, inhibit, and / or prevent interference with maneuvering of a portion of the power tool 10 proximate the distal end portion 13 relative to a working environment.

[0128] Still referring to FIGS. 1-3 and further referring to FIGS. 4-6, the transmission housing portion 30 of the tool housing 12 may be a hollow structure that may be mounted to and engaged with the motor housing portion 20 such that the transmission housing portion 30 is axially-fixed and non-rotatable relative to the motor housing portion 20.

[0129] The transmission housing portion 30 is configured and arranged to be bolted or otherwise attached to the distal or front side of the motor housing portion 20 of the tool housing18WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO12 at a housing flange 53 or other mating surface and configured to cover or shroud at least a portion of a transmission or transmission assembly 49 described in further detail below.

[0130] In some embodiments, some or all of the transmission assembly 49 may be in the form of a transmission where the final rotational output axis of the transmission assembly 49 is oriented transverse to (e.g., about 90 degrees) a first axis or motor axis 52. It will be understood that the final rotational axis of the transmission assembly 49 could be oriented more than 90 degrees or less than 90 degrees relative to the motor axis 52. As described further herein, the transmission assembly 49 may be configured to transmit torque from the motor 50 along the motor axis 52 to an output shaft oriented along a second axis or output axis 59.

[0131] FIG. 4 shows a cross-sectional view near the distal end portion 13 of the power tool 10 showing the internal components of the motor housing portion 20, the transmission housing portion 30, and the cutting assembly 40. FIG. 5 shows another cross-sectional view from the distal end portion 13 of the power tool 10, looking toward the proximal end portion 11 of the power tool 10. FIG. 6 show s an exploded view" of components of the transmission assembly 49 and the cutting assembly 40 in isolation for clarity7of illustration.

[0132] The motor housing portion 20 forms an interior cavity 21 into which an electric motor 50 (e.g., a brushless DC motor) configured to receive power from the battery pack 16 may be at least partially received. The motor 50 may be electrically coupled to the switch assembly 22 and the battery pack 16. The motor 50 includes a rotor 51 and a stator 55 that may be energized to cause rotation of the rotor 1 about the motor axis 52.

[0133] The rotor 51 may be integral with or coupled to a motor output shaft that extends from the motor 50 and that may form an input to the transmission assembly 49. In an example, the motor output shaft may be fixedly coupled to a first gear 54 such that the first gear 54 rotates with the motor output shaft. In this regard, in some embodiments, the first gear 54 may be coupled to an end of the motor output shaft and / or may at least partially receive a portion of the motor output shaft therethrough. In some embodiments, the motor output shaft extending from the motor 50 may be considered a part of the transmission assembly 49.

[0134] The first gear 54 is intermeshed with a second gear 56 that is rotatable about an output axis 59 that can be transverse (e.g., substantially perpendicular) to the motor axis 52. In this regard, the first gear 54 and the second gear 56 are configured and arranged to transmit torque from the motor output shaft driven by the motor 50 from the motor axis 52 to further19WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOdownstream components of the transmission assembly 49 along the output axis 59, e.g., at a transverse or right angle. In other embodiments, the output axis 59 may be at an angle less than or greater than 90 degrees to the motor axis 52.

[0135] In some embodiments, the gear ratio between the first gear 54 and the second gear 56 may be different than 1:1, e.g., such that the second gear 56 has a greater or lesser number of teeth than the first gear 54 and such that the second gear 56 rotates at a slower or faster speed than the first gear 54. In some embodiments, the gear ratio between the first gear 54 and the second gear 56 may be about 2: 1.

[0136] As a result of the foregoing arrangement, the first gear 54 and the second gear 56 may change the direction along which rotational motion is transmitted while also providing the mechanical advantage of an increase in torque so as to produce a first reduction stage for the transmission assembly 49. In some embodiments, the first gear 54 and second gear 56 are intermeshed bevel gears, e.g., an input bevel gear and an output bevel gear. The bevel gears may have straight cut or helical teeth. In other embodiments, the first gear 54 and second gear 56 may have a worm gear arrangement with a worm gear and a worm wheel. It will be understood that a different configuration of the first gear 54 and second gear 56 may be provided without departing from the disclosure.

[0137] As seen in FIGS. 4 and 5, a tool output shaft 58 may extend along the output axis 59 nearly the entire vertical length of the transmission housing portion 30, through a central bore 73 in the second gear 56, and at least partially into an interior space 65 at least partially defined by the blade guard 42. The tool output shaft 58 is rotatable independently of the second gear 56. A plurality of bearings may be provided to support the axial alignment of the tool output shaft 58 along the output axis 59 to balance the rotation of the tool output shaft 58 as well as to support a sufficient stiffness and resistance to deformation for facilitating implementations of the power tool 10 to cut rebar or other target work pieces of selected diameters. The plurality of bearings may be located or journalled in a volume V of an interior cavity 33 of the transmission housing portion 30 and each bearing may receive a respective portion of the tool output shaft 58 at least partially therethrough. Such bearings may be press fit or otherwise fixed within the transmission housing portion 30.

[0138] The compact size of the transmission assembly 49 can give the power tool 10 of the present disclosure a size advantage over other tools, allowing the tool to be advantageously20WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOshortened by spacing the distal end 57 of the first gear 54 closer to the output shaft 58. In some embodiments, the power tool 10 can have a length LR (see FIG. 4) between the distal end 57 of the first gear 54 and the center of the output shaft 58 on the output axis 59 in a range between and including about 10 mm and about 15 mm. In some embodiments, LR is about 13.5 mm.

[0139] In the illustrated embodiment, a rear output shaft bearing 62 can be disposed along the output axis 59 and having an annular configuration so as to at receive a portion of the tool output shaft 58 in the transmission housing portion 30 therethrough at a location axially rearward of the motor axis 52. As described herein, axially rearward refers to a direction along the output axis 59 further away from the cutting assembly 40 such that the rear output shaft bearing 62 is positioned vertically above the gearing of the transmission assembly 49 and above the motor output shaft.

[0140] The rear output shaft bearing 62 thus receives at least a portion of the tool output shaft 58 therein at a position axially rearward of the intermeshed first gear 54 and second gear 56 and positioned on a side of the second gear 56 opposite that of a first planetary gearset 70. The rear output shaft bearing 62 may be, for example, a ball bearing configured to transmit rearward and / or forward thrust loads from the tool output shaft 58 into the transmission housing portion 30 while minimizing, inhibiting, and / or preventing friction against the rotating tool output shaft 58 extending therethrough.

[0141] A front output shaft bearing 64 can be disposed in a portion of the transmission housing portion 30 along the output axis 59 at a location axially forw ard of the motor axis 52. As described herein, axially forward refers to a direction on the output axis 59 closer to the cutting assembly 40 such that the front output shaft bearing 64 is positioned vertically below the rotor 51. The front output shaft bearing 64 may receive at least a portion of the tool output shaft 58 therein. The front output shaft bearing 64 may be, for example, a ball bearing, a journal bearing, or a bushing configured to transmit thrust loads between the tool output shaft 58 and the cutting assembly 40 while minimizing, inhibiting, and / or preventing friction against the rotating tool output shaft 58 extending therethrough.

[0142] Still referring to FIGS. 4 and 5, the transmission assembly 49 in the transmission housing portion 30 includes one or more planetary gearsets that includes the first planetary gearset 70 driven by the second gear 56. The first planetary gearset 70 may be positioned along the output axis 59 at a location axially forward of the motor axis 52.21WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0143] The first planetary gearset 70 includes a first sun gear 72 coupled to the second gear 56 for rotating about output axis 59. In this regard, the first sun gear 72 has a body that at least partially defines a central bore 73 that at least partially receives the tool output shaft 58 therethrough.

[0144] The first planetary' gearset 70 also has a plurality of first planet gears 74 intermeshed with and arranged to orbit about the first sun gear 72. The plurality of first planet gears 74 may be coupled to a first planet carrier 76 positioned below the first planet gears 74 such that the first planet carrier 76 may rotate about the output axis 59 with the orbit of the first planet gears 74 about the first sun gear 72. The teeth of the first planet gears 74 may be intermeshed with interiorly-facing teeth of a ring gear 78 surrounding the plurality of first planet gears 74. The ring gear 78 may be non-rotatably coupled to the transmission housing portion 30 such that the first planet gears 74 travel an orbital path between the ring gear 78 and the first sun gear 72.

[0145] The first planetary gearset 70 produces a speed reduction for the transmission assembly 49, wherein the first planet carrier 76 rotates about the output axis 59 at a speed less than a speed of the second gear 56 rotating about the output axis 59.

[0146] The transmission assembly 49 in the transmission housing portion 30 may further have a second planetary' gearset 80 axially forward of the first planetary' gearset 70. The second planetary gearset 80 may be considered an output planetary’ stage. The second planetary gearset 80 is coaxially arranged with the second gear 56 and the first sun gear 72.

[0147] The second planetary gearset 80 includes a second sun gear 82 rotatable with the first planet carrier 76 for rotation about the output axis 59 upon rotation of the first planet carrier 76. As described further herein, the second sun gear 82 has a central bore 83 extending at least partially therethrough for at least partially receiving a portion of the tool output shaft 58. The central bore 83 of the second sun gear 82 may be coaxially arranged with the central bore 73 of the first sun gear 72. In some embodiments, the central bores 73, 83 may be considered a generally7axially7continuous central bore of the first sun gear 72 and the second sun gear 82 upon assembly of the transmission assembly 49.

[0148] The second planetary gearset 80 also has a plurality7of second planet gears 84 intermeshed with and orbiting around the second sun gear 82. The teeth of the plurality' of second planet gears 84 are surrounded by and intermeshed with the teeth of the ring gear 78 (or of a second ring gear that is non-rotatably coupled to the transmission housing portion 30)22WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOand are coupled to and supported on a second planet carrier 86 configured to rotate about the output axis 59. The second planetary gearset 80 produces an additional speed reduction for the transmission assembly 49, wherein the second planet carrier 86 rotates about the output axis 59 at a rotational speed less than a rotational speed of the first planet carrier 76 about the output axis 59.

[0149] The tool output shaft 58 may have a body 90 that is non-rotatably coupled to at least a portion of the second planet carrier 86 so as to rotate about the output axis 59 at the same speed as the second planet carrier 86. The tool output shaft 58 extends in the central bore 73 of the first sun gear 72 so as to extend at least partially therethrough. The tool output shaft 58 further at least partially extends through a central bore in the first planet carrier 76, and the central bore 83 in the second sun gear 82.

[0150] The body 90 of the tool output shaft 58 may further extend through an outer bearing 92 and an inner bearing 94 at least partially nested within the outer bearing 92 such that the outer bearing 92 and the inner bearing 94 are at least partially coextensive. In the illustrated embodiment, the outer bearing 92 may have the configuration of a ball bearing, a journal bearing, or a bushing, and the inner bearing 94 may have the configuration of a needle bearing, though one or both of the outer bearing 92 and the inner bearing 94 may have a different configuration without departing from the disclosure.

[0151] The outer bearing 92 may be positioned below the second gear 56 and above the ring gear 78 and extending around the first sun gear 72 so as to support the second gear 56 and to facilitate rotation of the second gear 56 and the first sun gear 72 when driven by the first gear 54.

[0152] The inner bearing 94 is at least partially received in the central bore 73 of the first sun gear 72 so as to be nested therein and radially positioned between the tool output shaft 58 and the first sun gear 72 to facilitate relative rotation. The inner bearing 94 supports the second gear 56 and the tool output shaft 58 and maintains the axial alignment of the tool output shaft 58 along the output axis 59. The inner bearing 94 therefore balances the rotation of the tool output shaft 58 as well as provides a sufficient stiffness and resistance to deformation for facilitating implementations of the power tool 10 to cut rebar or other working pieces of selected diameters.23WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0153] It should be noted that although the type of transmission assembly depicted and described herein is a three-stage, single-speed transmission (i.e., a single output speed and speed reduction through the bevel gears and first and second planetary gearsets), the present disclosure has applicability to other types of transmissions as well. In some embodiments, the transmission can be a two-speed transmission through the inclusion of a switch allowing a decoupling of one of the planetary stages by allowing one of the ring gears to spin freely. The transmission could also include a lesser or greater number of planetary gearsets. In some embodiments, the ring gear 78 may be selectively engageable between planetary gearsets 70, 80. In still other embodiments, the transmission assembly 49 may have or be configured for mechanical cooperation with a clutch mechanism configured to resist rotation of one or more components of the transmission.

[0154] Referring additionally to FIG. 6, the interior cavity 33 of the transmission housing portion 30 has the volume V configured to receive and enclose the components of the transmission assembly 49. An O-ring 98 may be disposed in the volume V of the interior cavity- 33 of the transmission housing portion 30 to seal lubrication therein and prevent outside contaminants from entering the transmission assembly 49.

[0155] The first planet carrier 76 may have a first top ring 100 and a top carrier 102 spaced apart from the first top ring 100 along the output axis 59 and between which the first planet gears 74 are supported. The first top ring 100 can be a backing plate that, in coordination with the top carrier 102, can facilitate free rotation of the first planet gears 74. The first planet carrier 76 may further have a plurality of first pins 104 mounted to the top ring 100 and the top carrier 102 and extending through a central portion of the respective first planet gears 74 such that each of the first planet gears 74 is rotatably supported about the respective first pin 104 and carried to rotate with the top ring 100 and the top carrier 102.

[0156] Similarly, the second planet carrier 86 may have a second top ring 103 and a plurality of second pins 106 mounted between the second top ring 103 and a carrier flange 107 defined along the body 90 of the tool output shaft 58 and extending radially outwardly from a remainder thereof. The second top ring 103 can be a backing plate that, in coordination with the carrier flange 107, can facilitate free rotation of the second planet gears 84. The second planet carrier 86 may further have a plurality7of second pins 106 mounted to the top ring 103 and the carrier flange 107 and extending through a central portion of the respective second planet gears 84 such that each of second planet gears 84 is rotatably supported about the respective second pin 24WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO106 and carried to rotate with the top ring 103 and the carrier flange 107 of the tool output shaft 58. In this regard, at least a portion of the second planet carrier 86 is integrally formed with the body 90 of the tool output shaft 58.

[0157] The transmission housing portion 30 may be coupled to a portion of the blade guard 42 of the cutting assembly 40 so as to avoid relative movement therebetween. The cutting assembly 40 may further include an accessory holder or blade mount 108 and a clamp member 110 which secure the circular blade 44 therebetween for rotation about the output axis 59. The blade mount 108 may be a generally convexly-arranged member with a central aperture at least partially receiving a lower portion of the tool output shaft 58 below the carrier flange 107. The clamp member 110 may be a similarly convexly -arranged member that nests within a lower portion of the blade mount 108 such that the blade mount 108 and clamp member 110 cooperate to position a central opening in the circular blade 44 over a lower flanged portion of the clamp member 110 and below the blade mount 108.

[0158] A blade locking screw 111 may be inserted through a washer 112 into a threaded opening in the lower end of the body 90 of the tool output shaft 58 to urge the washer 112 to press the clamp member 110 and the blade mount 108 together to secure the position of the circular blade 44 therebetween, with a lower edge of the blade mount 108 contacting an upper surface of the circular blade 44 and a lower surface of the circular blade 44 resting on a lower flanged portion of the clamp member 110.

[0159] The circular blade 44 may thus be accessed for installation, removal, replacement, maintenance, etc., by removal of the base plate 45 from the blade guard 42. The blade locking screw 111 may be threadably uncoupled from the tool output shaft 58, for example, with a fastener driver, and the washer 112 may be further removed to allow relative separation of the clamp member 110 and the blade mount 108 to free the circular blade 44.

[0160] FIG. 7 shows an enlarged view of the tool output shaft 58 according to the illustrated embodiment. The body 90 of the tool output shaft 58 may be an integral and / or monolithically-formed element having a generally cylindrical shape extending at least partially through the first planetary gearset 70 and the second planetary gearset 80 as described herein. In some embodiments, the tool output shaft 58 may extend completely through the central bore 73 in the first sun gear 72 and completely through the central bore 83 in the second sun gear 82.25WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0161] The body 90 of the tool output shaft 58 may include a (axially) rear portion 120, an (axially) forward portion 122, and the integral carrier flange 107 disposed between the rear portion 120 and the forward portion 122 along a mid-length portion 121. The rear portion 120 may have a reduced diameter approaching a shoulder 124 such that the tool output shaft 58 may be received in and seat against the rear output shaft bearing 62. The rear output shaft bearing 62 may thus support the rear portion 120 of the tool output shaft 58 to align the rear portion 120 of the tool output shaft 58 with the output axis 59.

[0162] The forward portion 122 of the body 90 of the tool output shaft 58 may include one or more locating features 126 configured to interface with corresponding elements of the blade mount 108 of the cutting assembly 40 such that the circular blade 44 (clamped between the blade mount 108 and clamp member 110) may rotate freely about the output axis 59 with the tool output shaft 58. As shown in FIGS. 4 and 5, the forward portion 122 may extend at least partially into a portion of the blade guard 42 of the cutting assembly 40 through and be supported by the front output shaft bearing 64 which aligns the forward portion 122 with the output axis 59.

[0163] The carrier flange 107 may be supported between the front output shaft bearing 64 and the second sun gear 82 and second planet gears 84 of the second planetary gearset 80. The earner flange 107 may also include a plurality of holes 109 extending partially or completely through the carrier flange 107 to receive the plurality of second pins 106 about which the second planet gears 84 are configured to rotate. In some embodiments, the body 90 of the tool output shaft 58 may be further tapered and / or stepped for increased support with corresponding components of the transmission assembly 49.

[0164] The tool output shaft 58 of the power tool 10 disclosed herein can be selected with a sufficient configuration to withstand selected applications of the power tool 10, for example, cutting applications for metal rods such as up to and including #6, #7, and #8 rebar. The tool output shaft 58 of the power tool 10 may thus be provided with sufficient structural stiffness within the transmission housing portion 30 to minimize, inhibit, and / or prevent relative movement of elements of the transmission assembly 49 in the transmission housing portion 30, for example, the position of the second gear 56 relative to the first gear 54. In some embodiments, the tool output shaft 58 may have a large outer diameter Dsalong the mid-length portion 121 thereof in a range between and including about 10 mm and about 15 mm. In some embodiments, the tool output shaft 58 may have the outer diameter Dsof about 15 mm.26WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0165] Accordingly, the relatively large outer diameter Dsof the tool output shaft 58 in cooperation with the arrangement of the rear output shaft bearing 62 and the front output shaft bearing 64 to support the alignment of the tool output shaft 58 along the output axis 59 under applied loads during the course of operation of the power tool 10, e.g., rebar cutting operations, provides an enhanced rigidity and stiffness to the tool output shaft 58 and the transmission assembly 49 as a whole.

[0166] In some embodiments, as shown in FIGS. 4-6, the second gear 56 and the first sun gear 72 may be integral and / or monolithically formed as a single component. As further depicted in FIG. 8, such an integral arrangement of the second gear 56 and the first sun gear 72 yields a transmission assembly 49 with a reduced number of individual parts and further contributes to increased rigidity and stiffness when torque is transmitted between a first reduction stage (i.e., between the first gear 54 and the second gear 56) and the first planetary gearset 70.

[0167] The cross-sectional view in FIG. 8 shows that the second gear 56 / first sun gear 72 may have a substantially cylindrical body 130 spanning axially forward from a bottom flange 132 of the second gear 56 to the teeth 134 of the first sun gear 72 with the central bore 73 extending therethrough. In this regard, and as show n, the central bore 73 of the first sun gear 72 extends upwardly through the body 130 to extend through each of the second gear 56 and the first sun gear 72. In this regard, the central bore 73 is common to both the second gear 56 and the first sun gear 72 so as to receive the tool output shaft 58 extending entirely therethrough.

[0168] The outer bearing 92 may be disposed around an outer surface 138 of the body 130 below the bottom flange 132 and above the teeth 134 to support and position the second gear 56 in the transmission assembly 49. The inner bearing 94 may be located in the central bore 73 of the body 130 and to provide free rotation along portions thereof to enable the difference in rotational speed between the second gear 56 and the tool output shaft 58.

[0169] In an alternative construction, as shown in FIGS. 9A and 9B, the second gear 56 and the first sun gear 72 can be separate components mechanically coupled together so as to provide a single assembly. This arrangement may simplify machining steps in the manufacturing process. The second gear 56 may have an outer sleeve 140 extending axially forward along the output axis 59. The first sun gear 72 may have an opposing inner barrel 142 concentric with the output axis 59 and the outer sleeve 140. The inner barrel 142 may have an outer27WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOdiameter sized slightly larger than a corresponding inner diameter of the outer sleeve 140 so the second gear 56 and the first sun gear 72 may have an interference fit when assembled, as shown in FIG. 9B.

[0170] It will be understood that the second gear 56 and the first sun gear 72 may have a different configuration without departing from the disclosure.

[0171] The gearing of the first, second, and third reduction stages of the transmission assembly 49, e.g., the reduction from the first gear 54 through the second gear 56, the reduction from the second gear 56 through the first planetary gearset 70, and the reduction from the first planetary gearset 70 through the second planetary gearset 80, respectively, together provide a desired degree of speed reduction from the motor 50. For example, the motor 50 may have a no load output speed of about 20,000 RPM which may be reduced to a target no-load speed of the tool output shaft 58 between and including about 1900 RPM and about 2100 RPM. Such total speed reduction provides the power tool 10 with a torque sufficient withstand cutting operations on metal rods such as up to and including #6, #7, and #8 rebar with a circular blade 44 having an about 110 mm - about 120 mm diameter.

[0172] The achieved degree of speed reduction for the pow er tool 10 can result in a tool output torque in a range between and including about 11.0 Nm and about 12.0 Nm. This range of output torque can occur at a peak power rating for the tool, as measured by Unit Watts Out (UWO). In some embodiments, the power tool 10 can have a maximum power output in a range between and including about 1200W and about 1400W. In some embodiments, the pow er tool 10 can have a maximum pow er output in a range between and including about 1250W and about 1350W. In some embodiments, the power tool 10 can have a maximum power output of about 1300W.

[0173] During the operation of the power tool 10, an initial drive torque is transmitted about the motor axis 52 from the rotor 51 of the motor 50 to the first gear 54, causing the second gear 56 to apply a first intermediate torque to the first sun gear 72. The first planet gears 74 rotate about their axes and orbit the first sun gear 72, and a resulting second intermediate torque is applied to the second sun gear 82 by the first planet carrier 76. The rotation of the second planet gears 84 about the second sun gear 82 produces a final output torque to be transmitted from the second planet carrier 86 to the tool output shaft 58. In this fashion, the initial drive28WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOtorque from the motor 50 is multiplied (and the initial drive speed reduced) in a predetermined manner according to the gear reduction ratio of the transmission assembly 49.

[0174] In some embodiments, the gear reduction of the first reduction stage between the first gear 54 and the second gear 56 is about 2:1. In some embodiments, the gear reduction of the second reduction stage in the first planetary gearset 70 is about 2.5:1. In some embodiments, the gear reduction of the third reduction stage in the second planetary gearset 80 is about 2.5:1.

[0175] In some embodiments, the first gear 54, the second gear 56, the first planetary gearset 70, and the second planetary gearset 80 are arranged in series to provide a total gear reduction for the three stages of between and including about 11:1 and about 14:1. In some embodiments, the total gear reduction for the three stages is about 13:1.

[0176] The arrangement in the embodiments disclosed herein allows the advantages of a stiff and compact transmission assembly 49 in the transmission housing portion 30. The nesting of the output shaft 58 with the planetary gearsets 70, 80 of the transmission assembly 49 (e.g., the output shaft 58 extending through the central bore 73 of the first sun gear 72 and the central bore 83 of the second sun gear 82) allows the output shaft 58 to be advantageously lengthened such that there is greater spacing between the supporting rear output shaft bearing 62 and the front output shaft bearing 64. The increased spacing can limit angular displacements of the output shaft 58 when the power tool 10 is under load, reducing wobble of the circular blade 44 and improving performance, especially when a carbide or cermet tipped blade is used in metal cutting applications.

[0177] In addition, the arrangement of the tool output shaft 58 at least partially received and extending through central openings in each of the second gear 56, the first sun gear 72, and the second sun gear 82 cooperate to reduce the volume V of the interior cavity 33 of the transmission housing portion 30. Additionally, the location of the rear output shaft bearing 62 axially rearward of the intermeshed first and second gears 54, 56, and the nesting of the inner bearing 94 within the outer bearing 92 collectively save space along the second axis 59 in the transmission housing portion 30.

[0178] As such, the distal end portion 13 of the power tool 10 as disclosed herein may be maneuvered by an operator or user into tightly spaced applications by virtue of the arrangement and compact profile of the transmission housing portion 30.29WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0179] In some embodiments, the compact transmission housing portion 30 as disclosed may have the volume V of the interior cavity 33 that is between and including about I 0E6 mm3and about 1.5E6 mm3, for example, between and including about 1.E61 mm3and about 1.4E6 mm3, between and including about 1.2E6 mm3and about 1.3E6 mm3, etc., and integer and noninteger values therebetween.

[0180] In this regard, the corresponding ratio of the volume V of the interior cavity 33 of the transmission housing portion 30 and the outer diameter Dsof the tool output shaft 58 may be between and including about 6.7E4 mm2and about 1.5E5 mm2.

[0181] FIGS. 10 and 11 illustrate further dimensional aspects related to the compact transmission of the described power tool 10 according to embodiments of the disclosure. The examples are shown with the transmission assembly 49 attached to the cutting assembly 40 as together these assemblies will geometrically determine accessibility to tight spaces at the distal end portion 13 of the power tool 10.

[0182] The power tool 10 may have a height LI defined as the vertical distance parallel to the output axis 59 between the bottom of the base plate 45 and the top of the transmission housing portion 30. In some embodiments, LI is in a range between and including about 105 mm and about 110 mm. In some embodiments, LI is about 108 mm.

[0183] The power tool 10 may have a first width L2 defined as the horizontal distance transverse to the output axis 59 between a distal edge 146 of the blade guard 42 and a proximal edge 148 of the housing flange 53. In some embodiments, L2 is in a range between and including about 105 mm and about 110 mm. In some embodiments, L2 is about 108 mm.

[0184] The power tool 10 may have a second width L3 defined as the horizontal distance transverse to each of the motor axis 52 and the output axis 59 corresponding to an outer diameter of the circular blade guard 42. In some embodiments, L3 is in a range between and including about 125 mm and about 130 mm. In some embodiments, L3 is about 128 mm.

[0185] The power tool 10 may have a radial depth of cut Cd defined as the horizontal distance transverse to each of the motor axis 52 and the output axis 59 between a distal edge 150 of the circular blade 44 and a proximal edge 152 of the blade opening 46 in the blade guard 42. In some embodiments, Q is in a range between and including about 25 mm and about 30 mm. In some embodiments, Cd is about 27 mm.30WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0186] The disclosed transmission arrangement also allows the length of the power tool 10 to be advantageously reduced, resulting in reduced weight and improved ergonomics of use (e.g., flexibility and portability). The power tool 10 may generally be designed to be operated with one hand on the tool housing 12 and another on the side handle 31, though it will be understood that various grip arrangements are available to suit different use cases.

[0187] In some embodiments, the tool housing 12 itself may have two or more different grip positions. For example, referring to FIG. 12, the power tool 10 may have a forward grip position where, for example, at least an operator or user’s index and middle finger are centered on a first grip section 160 of the tool housing 12 located axially forward of the switch assembly 22 and the switch is actuated by one or more of the pinky finger or ring finger. The power tool 10 may further have a rear grip position where, for example, a user's hand is centered on a second grip section 162 of the tool housing 12 located axially rearward of the switch assembly 22 and the switch assembly 22 is actuated by one or more fingers. As described herein, axially forward refers to a direction on the motor axis 52 towards the distal end portion 13 of the power tool 10, and axially rearward refers to a direction on the motor axis 52 towards the proximal end portion 11 of the power tool 10.

[0188] FIGS. 12 and 13 also illustrates some further dimensional aspects related to the advantageously shortened power tool as related to the center of gravity CG of the described powder tool 10 betw een the proximal end portion 11 and the distal end portion 13 thereof. These dimensional aspects have been experimentally determined according to embodiments of the disclosure. The relationships have been determined with and without a standard 5Ah battery pack 16 received in the battery interface 14 so as to compare the balance of the unloaded tool weight and system weight during operating conditions (e.g., system weight = weight of the pow er tool 10 and the battery pack 16). In some embodiments, the w eight of the power tool 10 without the battery pack 16, e g., the bare tool weight, can be between and including about 2 kg and about 3 kg. e.g., about 2.55 kg.

[0189] Referring to FIG. 12, the power tool 10 may have a distance L4 defined as the horizontal distance parallel to the motor axis 52 between the center of gravity CG of the power tool 10 and the distal edge 146 of the blade guard 42 (i.e., the distal end portion of the power tool 10). In some embodiments, L4 is in a range between and including about 115 mm and about 130 mm. In some embodiments, L4 is about 123 mm.31WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0190] The power tool 10 may have a distance L5 defined as the horizontal distance parallel to the motor axis 52 between the center of gravity CG of the power tool 10 and the leading edge 164 (i.e., the most axially forward / distal edge) of the power switch assembly 22. In some embodiments, L5 is in a range between and including about 70 mm and about 90 mm. In some embodiments, L5 is about 80 mm.

[0191] The power tool 10 may have a distance L6 defined as the horizontal distance parallel to the motor axis 52 between the center of gravity CG of the power tool 10 and the geometric center 166 of the second grip portion 162 as measured parallel to the motor axis 52. In some embodiments, L6 is in a range between and including about 65 mm and about 80 mm. In some embodiments, L6 is about 73 mm.

[0192] The power tool 10 may have a distance L7 defined as the horizontal distance parallel to the motor axis 52 between the center of gravity CG of the power tool 10 and the trailing edge 168 (i.e., the most axially rearward / proximal edge or proximal end) of the tool housing 12. In some embodiments, £7 is in a range between and including about 220 mm and about 240 mm. In some embodiments, L 7 is about 230 mm.

[0193] The compact size of the transmission assembly 49 allows the power tool 10 to be balanced such that, in some embodiments, a ratio of the distance L4 to the distance £7 is in a range between and including about 0.48 and about 0.59. In some embodiments, the ratio of the distance L4 to the distance £7 is about 0.53.

[0194] Referring to FIG. 13, the dimensional aspects were determined for the power tool 10 with a battery pack 16 for comparison with those of FIG. 12. The power tool 10 may have a distance 1.8 defined as the horizontal distance parallel to the motor axis 52 between the center of gravity CG of the power tool 10 with the battery pack 16 inserted and the distal edge 146 of the blade guard 42. In some embodiments, L8 is in a range between and including about 170 mm and about 190 mm. In some embodiments, L8 is about 178 mm.

[0195] The power tool 10 may have a distance L9 defined as the horizontal distance parallel to the motor axis 52 between the center of gravity CG of the power tool 10 with the battery pack 16 inserted and the leading edge 164 of the power switch assembly 22. In some embodiments, L9 is in a range between and including about 20 mm and about 30 mm. In some embodiments, L9 is about 24 mm.32WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0196] The power tool 10 may have a distance LIO defined as the horizontal distance parallel to the motor axis 52 between the center of gravity CG of the power tool 10 with the battery pack 16 and the geometric center 166 of the second grip portion 162 as measured parallel to the motor axis 52. In some embodiments, LIO is in a range between and including about 95 mm and about 115 mm. In some embodiments. LIO is about 107 mm.

[0197] The power tool 10 may have a distanceZ77 defined as the horizontal distance parallel to the motor axis 52 between the center of gravity CG of the power tool 10 with the battery pack 16 and the trailing edge 170 (i.e., the most axially rearward / proximal edge or proximal end) of the battery pack 16. In some embodiments, Lil is in a range between and including about 220 mm and about 240 mm. In some embodiments, Lil is about 233 mm.

[0198] The compact size of the transmission assembly 49 allows the power tool 10 to be balanced such that, in some embodiments, a ratio of the distance L8 to the distance Lil (of the power tool 10 and the battery pack 16) is in a range between and including about 0.71 and about 0.86. In some embodiments, the ratio of the distance L8 to the distance Lil is about 0.76.

[0199] In some examples, the power tool 10 may have an overall length without a battery pack 16 of about 365 mm. The ratio of the overall length of the power tool 10 without a battery¬ pack 16 and the outer diameter Dsof the tool output shaft 58 may be about 24.

[0200] The compact size of the high-reduction transmission assembly 49 of the power tool 10 allows the overall size of the transmission housing portion 30 to be advantageously reduced while maintaining a stiffness sufficient to perform large diameter cuts. FIGS. 14 and 15 illustrates some additional dimensional aspects of the described power tool 10. FIG. 14 is a cross-section view of section A-A from FIG. 13 taken through an upper portion of the transmission housing portion 30. FIG. 15 is a cross-section view of section B-B from FIG. 13 taken through a lower portion of the transmission housing portion 30.

[0201] The power tool 10 may have a diameter DI defined as the outer diameter of the second gear 56 as measured perpendicular to the output axis 59. In some embodiments, the diameter DI is in a range between and including about 38 mm and about 42 mm. In some embodiments, the diameter DI is about 20 mm.

[0202] The power tool 10 may have a diameter D2 defined as the inner diameter of the transmission housing portion 30 as measured perpendicular to the output axis 59. In some 33WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOembodiments, where the ring gear 78 is non-rotatably coupled to the transmission housing portion 30, the diameter D2 can also correspond to the outer diameter of the ring gear 78. In some embodiments, the diameter D2 is in a range between and including about 48 mm and about 51 mm. In some embodiments, the diameter DI is about 50 mm.

[0203] The compact size of the transmission assembly 49 and the transmission housing portion 30 allows the power tool 10 to be sized such that, in some embodiments, a ratio of the diameter DI to the outer diameter Dsof the tool output shaft 58 is in a range between and including about 2.8 and about 4.20.

[0204] Similarly, in some embodiments the power tool to a ratio of the diameter 1)2 to the outer diameter Dsof the tool output shaft 58 is in a range between and including about 3.20 and about 5.10. In some embodiments, the ratio of the diameter D2 to the diameter Dsis about 3.33.

[0205] The foregoing power tool 10 described herein may thus be activated by an operator or user to flush cut a protruding member extending outwardly from a work surface. In some embodiments, the protruding member and work surface and be the protruding member M and the work surface W illustrated in FIG. 16. In some embodiments, the base plate 45 of the power tool 10 may be rested upon the work surface W and advanced toward the protruding member M such that the protruding member M may be received in the blade opening 46 for being cut by the circular blade 44. As the protruding member M is cut, debus and chips can follow a generally circular path at least partially around the inner circumference of the blade guard 42 until reaching and being ejected from debris port 48, as shown by the arrows in FIG.17. In some embodiments, the debris port 48 may extend substantially tangent to the blade guard 42 and the axis of rotation of the circular blade 44 around the output axis 59 so as to expel debris and chips radially away from the protruding member M and distally away from the operator or user.

[0206] In this regard, and with reference again to FIGS. 1-13, the operator or user may grasp the tool housing 12, and, optionally, the side handle 31, and may actuate the switch assembly 22 to activate the motor 50. For example, pressing an end or portion of the switch assembly 22 may cause an electric circuit to close, may actuate a controller associated with one or more field effect transistors (FETs), etc., to cause electrical power to be supplied from the battery pack 16 or another power source to the motor 50.34WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0207] In some embodiments, the switch assembly 22 may be provided with a quick release feature, in which disengagement of the switch assembly 22 by the operator or user results in substantially immediate deactivation of the motor 50.

[0208] Due to the paddle-style, e.g., pivotable, arrangement of the switch assembly 22, multiple points therealong are presented for the user or operator to activate the power tool 10, which may provide for enhanced versatility in gripping the power tool 10, especially in working environments in which space constraints are provided.

[0209] Upon energization of the motor 50. a torque may be applied by the rotor 51 to the first gear 54 to rotate about the motor axis 52. The second gear 56 intermeshed with the first gear 54 is thus driven to rotate about the output axis 59.

[0210] As the first sun gear 72 of the first planetary gearset 70, which is integrally formed with or otherwise coupled to the second gear 56, is driven to rotate thereby, the plurality of first planet gears 74 intermeshed therealong are caused to orbit about the first sun gear 72 and cause rotation of the first planet carrier 76 coupled thereto.

[0211] Rotation of the first planet carrier 76 causes rotation of the second sun gear 82 of the second planetary gearset 80, which in turn causes the plurality of second planet gears 84 intermeshed therealong to orbit about the second sun gear 82 and drive rotation of the second planet carrier 86.

[0212] Since the second planet carrier 86 is integrally formed with and / or otherw ise coupled to the body 90 of the tool output shaft 58 at the carrier flange 107, the tool output shaft 58 is thus driven to rotate about the output axis 59. As the blade mount 108 and clamp member 110 are coupled to the tool output shaft 58, with the circular blade 44 held therebetween, the circular blade 44 is thus driven to rotate about the output axis 59 with the output shaft 59.

[0213] As the circular blade 44 is driven to rotate by the motor 50 and transmission assembly 49 as described herein, the portion thereof exposed in the blade opening 46 defined by the blade guard 42 and the base plate 45 may be presented to engage a protruding member extending from a work surface to effect one or more cutting operations with the power tool 10, e.g., flush cutting of rebar or other protruding member(s) extending from a work surface.

[0214] The compact configuration of the transmission assembly 49 in the transmission housing portion 30 described herein provides the power tool 10 with ease of visibility and35WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOmaneuverability with regard to such cutting operations, with a sufficient torque output through the tool output shaft 58 to provide the circular blade 44 w ith the power needed to cut a variety of protruding members that may include, but are not limited to, metal rods such as up to and including #6, #7, and #8 rebar.

[0215] It will be understood that power tools described herein can be provided in different configurations without departing from the disclosure.. Another exemplary embodiment of a power tool 210 according to the disclosure is shown in FIGS. 18-32. It will be understood that operation of the power tool 210 and associated removable battery pack can be generally the same as previously described for pow er tool 10. It is contemplated that one or more of the below -described mechanisms and features of power tool 210 may also be applied to power tool 10 and vice versa. Where the same or similar, like or similar features are designated with like or similar reference numerals.

[0216] In the various views of the embodiment shown in FIGS. 18-21, the power tool 210 is a cordless flush cutter having a proximal end portion 211 , a tool housing 212, and a distal end portion 213. As described herein, proximal generally designates that portion of the power tool closer to / in the direction of an operator, and distal generally designates that portion of the power tool further from / in the direction away from an operator. Proximally, the tool housing 212 may at least partially define a battery interface 214 for coupling to a portable battery pack 16 or other powder source.

[0217] The tool housing 212 includes a handle portion 215, a motor housing portion 220 supporting a power switch assembly 222, and a transmission housing portion 230 coupled to a distal end of the motor housing portion 220. Optional side handle 231 may be removably attachable to the transmission housing portion 230 and presents an additional gripping structure for a user or operator. The side handle 231 may be repositionable relative to the tool housing 212, e.g., via a mechanical fastener.

[0218] The example switch assembly 222 shown is a paddle-style switch adjacent with and coupled to the tool housing 212 with a pivot so as to be pressable at dual end portions thereof. As with power tool 10, power tool 210 is powered by a removable battery pack 16 coupled to the battery interface 214.

[0219] The cutting assembly 240 includes the blade guard 242, a debris port 248, a base plate 245 attached to the blade guard 242 that is in a generally planar orientation such that it may36WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOrest on a work surface and guide the power tool 210 toward a member protruding from the work surface during cutting operations. Internal to the blade guard can be a blade holder 308 (FIG. 24) structured like that of power tool 10 (e.g., a blade mount and a clamp member secured to the tool output shaft). The base plate 245 may follow the contours of the blade guard 242 in a plane parallel to the cutting blade 244 and transverse to the output axis 259. The base plate 245 may also be rotatable relative to the blade guard 242 via a pivot pin 261 for blade changes, as described in further detail below. The blade guard 242 and base plate 245 can each have a recessed portion forming a blade opening 246 for exposing outer radial portions of the circular blade 244.

[0220] In some embodiments, the cutting assembly 240 can include one or more guide shoes positioned for directing a workpiece along a cutting path into the blade opening 246 of the power tool 210. The example power tool 210 shown in FIGS. 18-21 and further in FIGS. 22A and 22B has a longitudinal guide shoe 247a and a transverse guide shoe 247b movable attached to the blade guard 242 approximate the distal end portion 213. The longitudinal guide shoe 247a can be slidable proximally and distally relative to the blade guard 242 and the transverse guide shoe 247b can be slidable laterally (i.e. , to the left and right) relative to the blade guard 242. In some embodiments, the longitudinal guide shoe 247a and the transverse guide shoe 247b can have a slot translatable about a fastener to allow7each guide shoe to telescope relative to the blade guard 242. FIG. 22A shows the longitudinal guide shoe 247a partially extended distally from the blade guard 242. FIG. 22B shows the transverse guide shoe 247b fully extended laterally into the blade opening 246. The guide shoe(s) allow a user or operator to control the position of a workpiece in a straight line relative to the cutting blade to reduce or avoid binding or tool kick.

[0221] Referring now to FIG. 23 and FIG. 24, the compact size of the transmission of the power tool 210 allows the overall size of the transmission housing portion 230 to be advantageously reduced. FIG. 23 is a side cross-section view of section C-C from FIG. 20. FIG. 24 is a cross-section view7of section D-D from FIG. 21 taken through a central portion of the transmission housing portion 230 looking proximally.

[0222] The motor housing portion 220 can house an electric motor 250 electrically coupled to the switch assembly 222 and powered by, e.g., battery7pack 16. The motor 250 includes a rotor 251 (e.g.. a motor output shaft) and a stator 255 that may be energized to cause rotation of the rotor 251 about the motor axis 252. The rotor 251 can form an input to the transmission 37WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOassembly 249 through a first gear 254 such that the first gear 254 at least partially receives a portion of the rotor 251 therethrough. The first gear 254 is intermeshed with a second gear 256 that is rotatable about an output axis 259 such that the first gear 254 and the second gear 256 transmit torque from the motor 250 to further downstream components of the transmission assembly 249. The power tool 210 can also have a tool output shaft 258 extending through a central bore 273 in the second gear 256 (such that output shaft 258 rotates independently of second gear 256) and downward into an interior space 265 of the blade guard 242. The output axis 259 may be perpendicular to, or at an angle less than or greater than 90 degrees to the motor axis 252 of the power tool 210.

[0223] As with power tool 10, the first gear 254 and second gear 256 of power tool 210 can be intermeshed bevel gears. Likewise, the gear ratio between the first gear 254 and the second gear 256 may be 1:1, or may be different than 1:1 such that the second gear 256 rotates at a slower or faster speed than the first gear 254. For example, in some embodiments, the gear reduction ratio between the first gear 254 and the second gear 256 can be between about 3:1 and about 4:1, for example, between about 3.1: 1 and about 3.9:1, between about 3.2:1 and about 3.8:1, between about 3.3:1 and about 3.7:1, between about 3.4:1 and about 3.6:1, about 3.5:1, etc. In some embodiments, the gear ratio between the first gear 254 and the second gear 356 can be about 3.625:1.

[0224] With continued reference to FIG. 23 and FIG. 24 and further reference to FIGS. 25 A-C, the illustrated embodiments of power tool 210 include a planetary gearset 270 driven by the second gear 256 and positioned along the output axis 259 at a location axially forward of the motor axis 252. As described herein, axially forward refers to a direction on the output axis 259 toward the cutting assembly 240, and axially rearward refers to a direction on the output axis 259 away from the cutting assembly 240.

[0225] The planetary gearset 270 includes a sun gear 272 coupled to the second gear 256 for rotating about output axis 259 and a plurality of planet gears 274 intermeshed with and orbiting the sun gear 272. Each of the planet gears 274 can be coupled to planet carrier 276 that is integrally formed with and / or otherwise coupled to a portion of the tool output shaft 258 (i.e., a circumferential flange as shown) by a pin 304 (FIG. 25B). The teeth of the planet gears 274 may be intermeshed with interiorly -facing teeth of a ring gear 278 surrounding the plurality of planet gears 274. The ring gear 278 may be non-rotatably coupled to the transmission housing38WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOportion 230 such that the planet gears 274 travel an orbital path between the ring gear 278 and the sun gear 272.

[0226] The planetary gearset 270 can produce a speed reduction for the transmission assembly 249, wherein the output shaft 258 (as driven by the pins 304 of the planet gears 274) rotates about the output axis 259 at a speed less than a speed of the second gear 256 rotating about the output axis 259. In some embodiments, the single planetary’ gearset 270 of power tool 210 can have an overall gear reduction less than the gear reduction used for power tool 10, giving power tool 210 a higher output speed and thus sustained higher cutting speeds relative to the power tool 10. the reduction from the second gear 256 through the planetary’ gearset 270 may provide a desired degree of speed reduction from the motor 250. The gear reduction ratio may be between and including about 10:1 and about 12:1, for example, between about 10.1:1 and about 11.9:1, between about 10.2:1 and about 11.8:1, between about 10.3:1 and about 11.7:1, between about 10.4:1 and about 11.6:1, between about 10.5:1 and about 11.5:1, between about 10.6:1 and about 11.4:1, between about 10.7:1 and about 11.3:1, between about 10.8:1 and about 11.2:1, between about 10.9:1 and about 11.1:1, about 11.0:1, and integer and noninteger values therebetween. For example, the motor 250 may have a no-load output speed of between and including about 26,000 RPM and about 27,000 RPM, for example, between about 26,100 RPM and about 26,900 RPM, between about 26,200 RPM and about 26,800 RPM, between about 26,300 RPM and about 26,700 RPM. between about 26.400 RPM and about 26.600 RPM, about 26,500 RPM, and integer and non-integer values therebetween, which may be reduced to a target no-load speed of the tool output shaft 258 between and including about 2,200 RPM and about 2,500 RPM, for example, between about 2,300 RPM and about 2,400 RPM, and integer and non-integer values therebetween.

[0227] Referring still to FIGS. 25A-25C, the output shaft 258 of power tool 210 can be substantially similar to the output shaft 58 of power tool 10, having a generally cylindrical body 290 with a stepped configuration including a (axially) rear portion 320, a mid-length portion 321, and an (axially) forward portion 322. The planet carrier 276 may be at least partially formed by a flange of the output shaft 258 that may include a plurality’ of holes 309 therethrough to receive the plurality of pins 304 about which the planet gears 274 are configured to rotate. In some embodiments, the planet carrier 276 can be formed integrally with the body 290 of the output shaft 258. In other embodiments, the planet carrier 276 is a separate annular component that is secured to the output shaft 258 via a press fit or other39WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOsuitable forming process. The output shaft 258 may have one or more locating features (e.g., a notch, a groove, etc.) for locating the planet carrier 276 axially on the body 290 such that the first gear 254, the second gear 256, and the planetary gearset 270 maintain alignment in the transmission housing portion 230.

[0228] A top carrier 300 may be provided spaced apart from the planet carrier 276 along the output axis 259 and between which the planet gears 274 are supported. The top earner 300 can be a backing plate that can facilitate free rotation of the planet gears 274. In this regard, the top carrier 300 can include a plurality of openings through which the pins 304 can be at least partially received for rotation with the orbital path of the planet gears 274 when the transmission assembly 249 is driven.

[0229] In some embodiments, the compact arrangement of the transmission assembly 249 of power tool 210 can allow for higher cutting speeds with limited rotational mass. For example, diameter Ds along the mid-length portion 321 of the output shaft 258 of power tool 210 can be in a range between and including about 9 mm and about 12 mm, for example, between about 10 mm and about 11 mm, and integer and non-integer values therebetween. In some embodiments, the tool output shaft 258 may have the outer diameter Ds of between and including about 9 mm and about 11 mm, for example, about 10 mm, and integer and noninteger values therebetween.

[0230] Referring again to the cross-sectional views of FIG. 23 and FIG. 24, in the illustrated embodiment, a first bearing 262 (e.g., a rear output shaft bearing) can be disposed along the output axis 259 and having an annular configuration so as to at receive a portion of the tool output shaft 258 therethrough. At least a portion of the first bearing 262 can be in register with the motor axis 252 at a position approximate the intermeshed first gear 254 and second gear 256 and positioned on a side of the second gear 256 opposite that of the planetary gearset 270. In this way, the first bearing 262 is positioned to straddle the motor axis 252 such that a first portion of the first bearing 262 is axially rearward of the motor axis 252 along the output axis 259 and a second portion of the first bearing 262 is axially forward of the motor axis 252 along the output axis 259. The first bearing 262 may be, for example, a needle bearing or bushing journaled within a recess in the transmission housing portion 230.

[0231] A second bearing 264 (e.g., a front output shaft bearing) can be disposed in a portion of the transmission housing portion 230 along the output axis 259 at a location axially forward40WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOof the motor axis 252 and axially forward of the planetary gearset 270. In this regard, the second bearing 264 is disposed on the opposite side of the planetary gearset 270 from the second gear 256. The second bearing 264 may receive at least a portion of the tool output shaft 258 therein. The second bearing 264 may be, for example, a bushing, a ball bearing, or a journal bearing configured to transmit radial loads between the tool output shaft 258 and the cutting assembly 240 while minimizing, inhibiting, and / or preventing friction against the rotating tool output shaft 258 extending therethrough.

[0232] Axially between the first bearing 262 and the second bearing 264, the output shaft 258 can be supported mid-span by an intermediate sleeve, bearing, or bushing 263 positioned radially about the output axis 259 between the second gear 256 and the output shaft 258. At least a portion of the intermediate bushing 263 can be nested within a third bearing 292(e.g., an outer bearing) such that the third bearing 292 and the intermediate bushing 263 are at least partially coextensive. The third bearing 292 can be positioned forward of the second gear 256 and rearward of the ring gear 278 so as to support the second gear 256 and to facilitate rotation of the second gear 256 and the sun gear 272 when driven by the first gear 254. The third bearing 292 can be supported by a bearing seat 293 fixedly secured in an interior cavity 233 of the transmission housing portion 230. In some embodiments, an inner diameter of the third bearing 292 is larger than an outer diameter of the sun gear 272.

[0233] FIG. 26A shows a subassembly including the second gear 256 / first sun gear 272 of power tool 210. FIG. 26B is a side cross-section view of section F-F from FIG. 26A. The combination of the second gear 256 and sun gear 272 can have a substantially cylindrical body 330 spanning axially forward from a bottom flange 332 of the second gear 256 to the teeth 334 of the sun gear 272 with the central bore 273 extending therethrough. In this regard, and as shown, the central bore 273 of the sun gear 272 extends upwardly through the body 330 to extend through each of the second gear 256 and the sun gear 272. In this regard, the central bore 273 is common to both the second gear 256 and the sun gear 272 so as to receive the tool output shaft 258 extending entirely therethrough. Some portions of the central bore 273 may also have differing inner diameters to as to axially locate stepped portions of the output shaft 258.

[0234] The third bearing 292 may be disposed around an outer surface 338 of the body 330 below the bottom flange 332 and above the teeth 334 to support and position the second gear 256 in the transmission assembly 249. The bearing seat 293 can have an annular cross-section 41WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOwith an L-shape (FIG. 27) into which the third bearing 292 is at least partially received. The intermediate bushing 263 may be located in the central bore 273 of the body 330 and to provide free rotation along a portion of the output shaft 258 to enable the difference in rotational speed between the second gear 256 and the tool output shaft 258.

[0235] In this regard, at least a portion of the intermediate bushing 263 can be nested within the third bearing 292, and at least a portion of the third bearing 292 can be nested within the bearing seat 293. In some embodiments, an inner diameter of the intermediate bushing 263 can be less than an inner diameter of the sun gear 272.

[0236] FIG. 27A is a side elevation view of an alternative exemplary embodiment of a subassembly including a second gear 2567first sun gear 272’ of the powder tool 210 according to an alternative exemplary embodiment of the disclosure. FIG. 27B is an isometric view showing sealing members 295 exploded away from the second gear 256' and first sun gear 272’. The second gear 2567first sun gear 272’ can be generally similar to the second gear 256 / first sun gear 272 described above, but can include a bearing seat 293’ with one or more circumferential grooves 294 formed therealong for at least partially receiving a respective sealing member 295 therein. In some embodiments, the sealing members 295 can be O-rings, e.g., annular rubber bodies configured to frictionally engage one or more surfaces of the transmission assembly 249 of the power tool 210. One or both of the sealing members 295 can be a different arrangement of a polymeric body without departing from the disclosure. The sealing members 295 can be arranged to firmly support the second gear 2567first sun gear 272’ in the transmission assembly 249 and maintain a position of the second gear 2567first sun gear 272’ during operation of the power tool 210, for example, during operations in which vibrations are generated while the tool is under load. The sealing members 295 can thus beneficially stabilize the transmission assembly of the power tool 210 to facilitate efficient and uninterrupted operation.

[0237] FIG. 28 shows an exploded view' of select components in the blade guard 242 of power tool 210. Fasteners 243 inserted in the interior space 265 of the blade guard 242 spaced around the output axis 259 can be used to secure the blade guard 242 to the transmission housing portion 230 via threaded connections (e.g., with nuts, threaded bosses, etc.). Four such fasteners 243 are show n clocked around the output axis 259, although a lesser or greater number of fasteners can also be provided without departing from the disclosure. It will be understood that the fasteners 243 are located axially rearward of the circular blade 244 and the base plate 42WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO245 along the output axis 259 (see, e.g., FIGS. 23 and 24). An O-ring 298 and a retaining ring 299 can be coaxial with the ring gear 278 in the interior space 265 of the blade guard 242. The O-ring 298 can minimize, inhibit, and / or prevent egress of grease and / or lubricants from the transmission assembly 249 into the cutting assembly 240, while similarly avoiding the entry' of contaminants from the cutting assembly 240 into the transmission assembly 249 to extend the life of components contained therein.

[0238] As noted previously herein, the base plate 245 of the cutting assembly 240 can be rotatable relative to the blade guard 242 about a pivot pin 261. The pivot pin 261 can have an axis of rotation parallel to and offset from the output axis 259. The arrangement allows the base plate 245 to be retained on the power tool 210 during blade changes such that teardown and replacement can be performed more rapidly without separating and reattaching components.

[0239] FIGS. 29A-29C illustrate an embodiment where the base plate 245 can be pivoted about the pivot pin 261 to expose the blade 244 and its retaining screw 280 to remove and replace the blade 244, while retaining the base plate 245 on the blade guard 242 As shown, two retaining fasteners 340 can be removably positioned along either side of the blade opening 246. Retaining fasteners 340 can be inserted parallel to the output axis 259 through the top of the blade guard 242 and at least partially into engagement with the base plate 245 such that when threadably engaged, base plate 245 is fixed in place relative to the blade guard 242 for operation of the power tool. Retaining fasteners 340 can be screws with hex heads or socket heads accessible from above the blade guard 242, though the retaining fasteners 340 can have a different configuration without departing from the disclosure. Removing or loosening the retaining fasteners 340 can allow the base plate 245 to be rotated about the pivot pin 261 (FIG.29C) such that blade retaining screw' 280 can be accessed and removed to enable the circular blade 244 to be removed. With reference again to FIG. 23, pivot pin 261 can be a pin for engaging the blade guard 242 while allowing the base plate 245 to rotate relative to the pivot pin 261. Once the circular blade 244 has been changed, the base plate 245 can be rotated back about the pivot pin 261 such that the retaining fasteners 340 can be reinstalled or tightened. It will be noted that in this configuration, the base plate 245 may rotate one or both of clockwise and / or counterclockwise about the pivot pin 261.

[0240] FIGS. 30A-30F illustrate another embodiment in which the base plate 245 can be pivoted about the pivot pin 261 to expose the blade 244 and its retaining screw 280 to remove 43WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOand replace the blade 244, while retaining the base plate 245 on the blade guard 242. The embodiment in FIGS. 30A-30C can be substantially similar to that shown in FIGS. 29A-29C with the exception that retaining fasteners 340’ are inserted in the opposite direction from the bottom of the cutting assembly 240 through the base plate 245 such that they are accessible beneath the base plate 245. Removing or loosening of the retaining fasteners 340' can allow the base plate 245 to be rotated about the pivot pin 261 (FIG. 30C) such that blade retaining screw 280 can be accessed and removed to remove the circular blade 244. Once the circular blade 244 has been changed, the base plate 245 can be rotated back about the pivot pin 261 such that the retaining fasteners 340’ can be reinstalled or tightened. It will be noted that in this configuration, the base plate 245 may rotate one or both of clockwise and / or counterclockwise about the pivot pin 261.

[0241] In some embodiments, the tool housing 212 (and similarly tool housing 12 of power tool 10) may have a grip portion allowing for two or more different hand positions for a user’s hand. For example, referring to FIG. 30D, the power tool 210 may have a forw ard grip position where, for example, at least an operator or user’s index and middle finger of one or both hands H are centered on a first hand position 260 of the tool housing 212 located axially forward of the switch assembly 222 and the switch is actuated by one or more of a pinky finger and / or ring finger. The pow er tool 210 may further have a rear grip position where, for example, a user’s hand is centered on a second hand position 267 of the tool housing 212 (FIG. 30E) located axially rearward of the switch assembly 222 and the switch assembly 222 is actuated by one or more fingers such as an index and / or middle finger. The different hand positions can allow7a user to choose a position based on comfort or the constraints of a job location.

[0242] FIGS. 30F-30H illustrate another embodiment in which the base plate 245 can be pivoted about the pivot pin 261 to remove and replace the blade 244 while retaining the retaining the retaining fasteners at least partially within the blade guard 242. Retaining fasteners 340” can be at least partially threaded along the shank, i.e.. at threaded portion 342, for securing to a threaded portion of the base plate 245 during operation of the power tool. The exploded view7in FIG. 30F illustrates that retaining fasteners 340” can be part of a fastener retention assembly 341 such that, when unthreaded from the base plate 245 the retaining fasteners 340” remain at least partially coupled to the cutting assembly 240 while the base plate 245 is rotated. As such, the fastener retention assembly 341 avoids full separation of the retaining fasteners 340” from the power tool during blade changes or other maintenance, for44WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOexample, such that the retention fasteners 340” can be easily tracked and handled without concern for loss and associated operational down times, etc.

[0243] FIG. 30G is a partial cross-sectional view of a portion of a power tool, e.g., the power tool 210, showing a retaining fastener 340’ ’ threadably secured to the base plate 245. FIG. 30H is a partial cross-section view of the portion of the pow er tool showing the retaining fastener 340” at least partially separated from the base plate 245 but retained by the remainder of the fastener retention assembly 341. The fastener retention assembly 341 can further include a washer 343, a compliant member 344 (e g., a spring), and a sleeve member 345. In some embodiments, the fastener retention assembly 341 can be considered separate from the retaining fastener 340”. As shown, the sleeve member 345 can have an upper flange to provide a seat for the washer 343, and which forms a lower shoulder or step that rests upon an outer surface of the blade guard 242 such that a downwardly-extending portion of the sleeve member 345 extends into the blade guard 242.

[0244] The compliant member 344 can be located in an annular chamber positioned radially between in interior surface of the sleeve member 345 and an outer surface of the retaining fastener 340”. When the threaded portion 342 of the retaining fastener 340” is threaded into the base plate 245, the compliant member 344 is axially compressed. When the threaded portion 342 of the retaining fastener 340” is unthreaded from the base plate 245, the preload of the compliant member 344 is released and the compliant member 344 expands along the axis of the retaining fastener 340” so as to bias the retaining fastener 340” upward and away from the base plate 245. The threaded portion 342 of the retaining fastener 340” can have an outer diameter greater than the inner diameter of the sleeve member 345 such that an upper surface of the threaded portion 342 of the retaining fastener 340” contacts a lower surface of the sleeve 345 to provide a vertical limit of travel of the retaining fastener 340” is raised. The retaining fasteners 340” are thus captured between the sleeve 345 and a portion of the base plate 245 and cannot be fully removed from the blade guard 242.

[0245] As such, FIGS. 2A, 2B, and 17 show an embodiment where the base plate 45 of the power tool is completely removable from the blade guard 42 and the retaining screws 43 are inserted from the bottom of the power tool 10 and are flush with the base plate 45 when tightened. FIGS. 18-20, 29A-29C and 30F-30H show7an embodiment where the base plate 245 of the power tool pivots about a pivot pin 261 and is attached and secured by captured screws 340 that are inserted from the top of the blade guard 242. Finally, FIGS. 30B-30D show an 45WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOembodiment where the base plate 245 pivots about a pivot pm 261 and the screws 340’ are inserted from the bottom of and are completely removable from the power tool. Still other configurations for securing the base plate to the power tool will also be recognized by those of skill in the art.

[0246] FIGS. 31 and 32 illustrate some further aspects related to the power tool 210 similar to that provided for power tool 10 described above (FIGS. 12 and 13). Thus, relationships related to the center of gravity CG for power tool 210 have been determined in the same fashion as with power tool 10 so as to compare the balance of the tool weight and system weight with a standard 5Ah battery’ pack 16 (e.g., system weight = weight of the power tool 210 and the battery pack 16) (Fig. 32) and without the battery' pack 16 (Fig. 31). In some embodiments, the weight of the power tool 210 without the battery pack 16. e.g., the bare tool weight, can be between and including about 2 kg and about 3 kg, for example, between about 2.1 kg and about 2.9 kg, between about 2.2 kg and about 2.8 kg, between about 2.3 kg and about 2.7 kg, between about 2.4kg and about 2.6kg, about 2.5 kg, and integer and non-integer values therebetween. In some embodiments, the bare tool weight can be about 2.55 kg.

[0247] Referring to FIG. 31, the single planetary gearset 270 of power tool 210 allows for an advantageously slimmer profile for improved ergonomics proximate the distal end portion 213 of the power tool 210. The power tool 210 can have a vertical distance L12 parallel to the output axis 259 between the motor axis 252 and a bottom surface 311 of the base plate 245 in a range between and including about 65 mm and about 70 mm, for example, between about 66 mm and about 69 mm, between about 67 mm and about 68 mm. and integer and non-integer values therebetween. In some embodiments, L12 is about 68 mm.

[0248] Referring still to FIG. 31. the power tool 210 may have a distance LI 3 defined as the horizontal distance parallel to the motor axis 252 between the center of gravity CG of the power tool 210 and the distal edge 363 of the blade guard 242 (i.e., the distal end portion 213 of the power tool 210). In some embodiments, L13 is in a range between and including about 120 mm and about 130 mm, for example, between about 121 mm and about 129 mm, between about 122 mm and about 128 mm, between about 123 mm and about 127 mm, between about 124 mm and about 126 mm, between about 124 mm and about 126 mm, about 125 mm, and integer and non-integer values therebetween. In some embodiments, LI 3 is about 126 mm.46WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0249] The power tool 210 may have a distanced 14 defined as the horizontal distance parallel to the motor axis 252 between the center of gravity CG of the power tool 210 and the leading edge 364 (i.e., the most axially forward / distal edge) of the power switch assembly 222. In some embodiments, L14 is in a range between and including about 50 mm and about 65 mm, for example, between and including about 51 mm and about 64 mm. between about 52 mm and about 63 mm, between about 53 mm and about 62 mm, between about 54 mm and about 61 mm, between about 54 mm and about 60 mm, between about 55 mm and about 59 mm, between about 56 mm and about 58 mm, about 57 mm, and integer and non-integer values therebetween. In some embodiments. L14 is about 58 mm.

[0250] The power tool 210 may have a distance LI 5 defined as the horizontal distance parallel to the motor axis 252 between the center of gravity CG of the power tool 210 and the rear end 266 of the motor switch assembly 222 as measured parallel to the motor axis 252. In some embodiments, LI 5 is in a range between and including about 145 mm and about 160 mm, for example, between and including about 146 mm and about 159 mm, between about 147 mm and about 158 mm, between about 148 mm and about 157 mm, between about 149 mm and about 156 mm, between about 149 mm and about 156 mm, between about 150 mm and about 155 mm, between about 151 mm and about 154 mm, between about 152 mm and about 153 mm, and integer and non-integer values therebetween. In some embodiments, L15 is about 152 mm.

[0251] The powertool 210 may have a distance LI 6 defined as the horizontal distance parallel to the motor axis 252 between the center of gravity CG of the power tool 210 and the trailing edge 268 (i.e., the most axially rearward / proximal edge or proximal end) of the tool housing 212. In some embodiments, L16 is in a range between and including about 230 mm and about 245 mm, for example, betw een and including about 231 mm and about 244 mm, betw een about 232 mm and about 243 mm, between about 233 mm and about 242 mm, between about 234 mm and about 241 mm. between about 235 mm and about 240 mm. between about 236 mm and about 239 mm, between about 237 mm and about 238 mm, and integer and non-integer values therebetw een. In some embodiments, L16 is about 236mm.

[0252] The compact size of the transmission assembly 249 allow s the power tool 210 to be balanced such that, in some embodiments, a ratio of the distance LI 3 to the distance L16 is in a range between and including about 0.49 and about 0.57, for example about 0.50 and about 0.56. between about 0.51 and about 0.55, between about 0.52 and about 0.54, about 0.53, and 47WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOinteger and non-integer values therebetween. In some embodiments, the ratio of the distance L13 to the distance LI 6 is about 0.53.

[0253] Referring to FIG. 32, the dimensional aspects were determined for the power tool 210 with a 5 Ah batten pack 16 for comparison with those of FIG. 31. The power tool 210 may have a distance LI 7 defined as the horizontal distance parallel to the motor axis 252 between the center of gravity CG of the power tool 210 with the battery pack 16 inserted and the distal edge 363 of the blade guard 242. In some embodiments, LI 7 is in a range between and including about 180 mm and about 195 mm, for example, between about 181 mm and about 194 mm, between about 182 mm and about 193 mm, between about 183 mm and about 192 mm, between about 184 mm and about 191 mm, between about 185 mm and about 190 mm, between about 186 mm and about 189 mm, between about 187 mm and about 188 mm, and integer and non-integer values therebetween. In some embodiments, LI 7 is about 189 mm.

[0254] In some embodiments, with the battery pack 16 inserted, the center of gravity CG of the power tool 210 may be approximately aligned with the leading edge 364 of the power switch assembly 222. In other embodiments, with the battery7pack 16 inserted, there may be a small distance L18 defined as the horizontal distance parallel to the motor axis 252 between the center of gravity CG of the power tool 210 and the leading edge 364 of the power switch assembly 222. In some embodiments, LI 8 is in a range between and including about 0.1mm and about 10mm, for example between about 0 mm and about 9 mm, between about 1 mm and about 8 mm, between about 2 mm and about 7 mm, between about 3 mm and about 6 mm, between about 4 mm and about 5 mm, and integer and non-integer values therebetween. In some embodiments, L18 is about 5 mm.

[0255] The power tool 210 may have a distance L19 defined as the horizontal distance parallel to the motor axis 252 between the center of gravity CG of the power tool 210 with the battery pack 16 and the rear end 266 of the motor switch assembly 222 as measured parallel to the motor axis 252. In some embodiments, L19 is in a range between and including about 90 mm and about 100 mm, for example between about 91 mm and about 99 mm, between about 92 mm and about 98 mm, between about 93 mm and about 97 mm, between about 94 mm and about 96 mm, and integer and non-integer values therebetween. In some embodiments, L19 is about 95 mm.48WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0256] The power tool 210 may have a distance L20 defined as the horizontal distance parallel to the motor axis 252 between the center of gravity CG of the power tool 210 with the battery pack 16 and the trailing edge 170 (i.e., the most axially rearward / proximal edge or proximal end) of the battery pack 16. In some embodiments, L20 is in a range between and including about 220 mm and about 240 mm, for example, between about 221 mm and about 239 mm, between about 222 mm and about 238 mm, between about 223 mm and about 237 mm, between about 224 mm and about 236 mm, between about 225 mm and about 235 mm, between about 226 mm and about 234 mm, between about 227 mm and about 233 mm, between about 228 mm and about 232 mm, about 229 mm. and integer and non-integer values therebetween. In some embodiments, L20 is about 233 mm.

[0257] The compact size of the transmission assembly 249 allows the power tool 210 to be balanced such that, in some embodiments, a ratio of the distance L17 to the distance L20 (of the power tool 210 and the battery pack 16) is in a range between and including about 0.80 and about 0.91, for example, between about 0.81 and about 0.90, between about 0.82 and about 0.89, between about 0.83 and about 0.88, between about 0.84 and about 0.87, between about 0.85 and about 0.86, and integer and non-integer values therebetween. In some embodiments, the ratio of the distance L17 to the distance L20 is about 0.86.

[0258] As a result, like transmission assembly 49, the compact configuration of the transmission assembly 249 in the transmission housing portion 230 provides the powder tool 210 with improved ergonomics, visibility, and maneuverability with regard to cutting operations, w ith a sufficient torque output to cut a variety of protruding members.

[0259] The arrangement of bearings associated with the tool output shafts of the described power tools 10, 210 provides positional stability’ thereto, e.g.. resistance to linear shifting, tilt, and / or deformation within the transmission assembly, such that the power tool has a robust configuration suitable for application on various job sites. Additionally, while the arrangement of the transmission assemblies and associated advantages have been described herein with regard to power tools 10, 210 having a cutting assembly, it will be understood that the transmission assemblies could be adapted for use with other types of power tools, for example, but not limited to, a drill / driver, an impact driver, an angle grinder, a flush cutter, a right angle drill, or other similar tool.49WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0260] FIG. 33 and FIG. 34 illustrate a debris bag adaptor 370 configured to facilitate engagement and disengagement of a debris bag 371 (FIG. 35) from the debris port 248 of the power tool 210 (or debris port 48 of power tool 10). Alternatively, some other compatible collection module, such as a vacuum hose, can also be connected to the adaptor 370. In the illustrated embodiment, debris port 48 can have a rib 372 projecting therefrom for being selectively received in a corresponding slot 374 of adaptor 370.

[0261] With additional reference to FIG. 35, the debris bag 371 or other collection structure can be attached to a neck 375 of the adaptor 370 by cinching such as with a draw string, zip tie, and / or other attachment feature. A user who wishes to remove or replace the debris bag 371 could remove the adaptor 370 by rotating or lifting the adaptor 370 such that the rib 372 of the debris port 48 withdraws from the slot 374 of the adaptor 370. The adaptor 370 and debris bag 371 can thus be conveniently removed in tandem from the debris port 48 of the power tool 10 without involving manipulation of the cinch or other attachment feature of the debris bag 371, facilitating quicker detachment and / or reattachment of a debris bag 371 from the power tool.

[0262] Referring to FIG. 36, the power tool 210 can further include a retention clip 380 attached to a side of the transmission housing portion 230 for conveniently holding an auxiliary tool 382. The auxiliary tool 382 can be, for example, a hex key for loosening and tightening the socket head cap screws (the retaining fasteners 340) securing the base plate 245 to the blade housing 242. The clip 380 can have an upper section and a lower section configured to elastically deform and grip the auxiliary tool 382 for ease of secure storage of the auxiliary tool 382 in the retention clip 380 and retrieval therefrom, e.g., such that the clip 380 can at least partially deform and resiliently return to a resting configuration when subject to external forces associated with manipulation of the auxiliary tool 382 by a user. An opening or boss 384 can be located in a side of the transmission housing for receiving at least a portion of the auxiliary tool 382 therein to inhibit movement during use or handling of the power tool. Such at least partial positioning of the auxiliary tool 382 in the boss 384 can further reduce or eliminate gaps between portions of the power tool 210 and the auxiliary tool 382, for example, that would otherwise present narrow regions that could catch or snag on a surrounding environment.

[0263] Alternatively, or in addition, those of skill in the art will recognize the clip 380 (and / or multiple clips) can be configured to hold other auxiliary tools. For example, the auxiliary tools could consist of one or more of screwdriver heads, spanner wrenches, nut drivers, and the like.50WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO

[0264] In some embodiments, an additional retention clip 380 could be provided in a different location on the power tool 210. For example, an additional retention clip 380 could be positioned on an opposite side of the transmission housing portion 230, i.e., on the side of the power tool 210 with the debris port 248. Such additional retention clip 380 can provide a user multiple locations at which an auxiliary tool 382 can be stored and / or retrieved, and / or can provide a location for storing an additional auxiliary' tool.

[0265] 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. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0266] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0267] The terms “distal"’ and “proximal” are used throughout the preceding description and are meant to refer to a positions and directions relative to a user. As such, “distal” or distally” refer to a position distant to or a direction away from the user. Similarly, “proximal” or “proximally” refer to a position near or a direction towards the user.

[0268] When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it may be directly on, engaged, connected, or coupled51WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOto the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0269] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer, or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of the example embodiments.

[0270] 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.

[0271] Numerous modifications may be made to the example implementations described above. These and other implementations are within the scope of this application.52WBD (US) 4933-4391-3113v4

Claims

Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOWhat is claimed is:

1. A power tool, comprising:a tool housing;a motor at least partially received in the tool housing, the motor having a rotor rotatable about a motor axis;a transmission assembly configured to transmit torque from the rotor to an output shaft, the transmission assembly compnsing a first gear rotatable about the motor axis, a second gear rotatably driven by the first gear about an output axis transverse to the motor axis, and a planetary gear set driven by the second gear; anda cutting assembly comprising a blade mount rotatably driven by the output shaft about the output axis and configured to be coupled to a cutting blade, a blade guard with an opening configured to expose a portion of the cutting blade, and a base plate transverse to the output axis and configured to rest against a work surface,wherein the cutting assembly is configured so that the cutting blade is able to flush cut a protruding member extending away from the work surface.

2. The power tool of claim 1. wherein the first planetary gearset comprises a first sun gear coupled to the second gear to rotate about the output axis.

3. The power tool of claim 2, wherein the first sun gear defines a central bore that at least partially receives the output shaft.

4. The power tool of claim 3, wherein the central bore extends at least partially through the second gear.

5. The power tool of any one of claims 2-4, wherein the output shaft extends entirely through the first sun gear and the second gear and is supported by a rear output shaft bearing disposed on an opposite side of the second gear than the first planetary gearset.

6. The power tool of claim 5, wherein the rear output shaft bearing is disposed axially rearward of the motor axis along the output axis and the first planetary’ gearset is disposed axially forward of the motor axis along the output axis.53WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO7. The power tool of any one of claims 1-6, further comprising a front output shaft bearing configured to support the output shaft and disposed axially forward of the first planetary gearset.

8. The power tool of any one of claims 3-6, further comprising an inner bearing disposed in the central bore and configured to support the first sun gear.

9. The power tool of claim 8, further comprising an outer bearing configured to support the second gear, the inner bearing at least partially nested inside the outer bearing.

10. The power tool of any one of claims 1-9, wherein the first gear comprises a first bevel gear and the second gear comprises a second bevel gear.

11. The power tool of claim 3, wherein the first planetary gearset comprises a plurality of first planet gears intermeshed with the first sun gear, the plurality of first planet gears coupled to a first planet carrier, and a ring gear surrounding the plurality of first planet gears.

12. The power tool of claim 11. further comprising a second planetary gearset axially forward of the first planetary gearset.

13. The power tool of claim 12, wherein the second planetary gearset comprises a second sun gear driven by the first planet carrier, a plurality of second planet gears intermeshed with the second sun gear, the plurality of second planet gears coupled to a second planet carrier, and the ring gear surrounding the plurality of second planet gears.

14. The power tool of claim 12, wherein a central bore extends through the second sun gear to at least partially receive the output shaft.

15. The power tool of any one of claims 13 or 14, wherein the output shaft comprises a body and at least a portion of the second planet carrier is integral with the body of the output shaft.

16. The power tool of any one of claims 1-15, wherein at least aportion of the body of the output shaft has an outer diameter between about 10 mm and about 15 mm.

17. The power tool of any one of claims 12-16, wherein the first gear, the second gear, the first planetary gearset, and the second planetary gearset are arranged in series to provide a total gear reduction of between about 11:1 and about 14:1.54WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO18. The power tool of any one of claims 1-17, further comprising a transmission housing portion coupled to the tool housing and the cutting assembly, the transmission housing portion configured to receive the transmission assembly.

19. The power tool of claim 18, wherein the transmission housing portion comprises a cavity' with an internal volume between about 1.0E6 mm3and about 1.5E6 mm3.

20. The power tool of any one of claims 18-19, wherein the output shaft has an outer diameter and a ratio of an internal volume of the transmission housing portion to the outer diameter of the output shaft is between about 6.7E4 mm2and about 1.5E5 mm2.

21. The power tool of any one of claims 18-20, wherein the transmission assembly further comprises a plurality of bearings in the intenor cavity of the transmission housing portion each receiving a respective portion of the output shaft.

22. The power tool of any one of claims 1-21, wherein the opening in the blade guard has a radial girth of about 30 mm extending toward the output axis.

23. The power tool of any one of claims 1 -22, having a proximal end, a distal end, and a center of gravity between the proximal end and the distal end.

24. The power tool of claim 23, wherein a distance between the distal end and the center of gravity' of the power tool is betw een about 115 mm and about 130 mm.

25. The power tool of any one of claims 23160-24, wherein a distance between the proximal end and the center of gravity of the pow er tool is between about 220 mm and about 240 mm.

26. The power tool of claim 1 or claim 23, wherein a ratio of the distance between the distal end and the center of gravity and the distance between the proximal end and the center of gravity is between about 0.48 and about 0.59.

27. The power tool of any one of claims 23-26, wherein the power tool comprises a total length of about 353 mm from the proximal end to the distal end, and the ratio of the total length of the pow er tool to the outer diameter of the output shaft is about 23.53.

28. A power tool, comprising:a tool housing;55WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOa motor at least partially received in the housing and configured to be energized to produce a rotational output about a motor axis;an output shaft coupled to an accessory holder, the output shaft configured to rotate about an output axis transverse to the motor axis upon energization of the motor; anda transmission assembly for transmitting rotational motion from the motor to the accessory holder, the transmission assembly comprising:a first bevel gear configured to rotate about the motor axis;a second bevel gear intermeshed with the first bevel gear and configured to rotate about the output axis; anda planetary7gearset operably coupled with the second bevel gear to transmit torque from the second bevel gear to the output shaft, the planetary gear set comprising a sun gear driven by the second bevel gear, a plurality of planet gears surrounding and intermeshed with the sun gear, a planet carrier to which the plurality of planet gears are coupled, and a ring gear surrounding and intermeshed with the plurality of planet gears,wherein the output shaft extends completely through a central opening in the sun gear and the second bevel gear, the output shaft supported by a rear bearing axially rearward of the second bevel gear along the output axis and a front bearing axially forward of the planetary gearset along the output axis.

29. The power tool of claim 28, further comprising an inner bearing disposed in the central opening betw een the output shaft and the sun gear to support the sun gear.

30. The power tool of claim 29, further comprising an outer bearing configured to support an outer portion of the second bevel gear.

31. The pow er tool of claim 30, wherein the inner bearing is at least partially nested in the outer bearing.

32. The pow er tool of any one of claims 28-31, wherein the planetary gearset is a first planetary gearset and the transmission assembly further comprises a second planetary gearset axially forward of the first planetary gearset.56WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO33. The power tool of claim 32, wherein the sun gear is a first sun gear and the second planetary gearset comprises a second sun gear driven by the planet carrier, wherein the output shaft extends completely through a central opening in the second sun gear and the front bearing is axially forward of the second planetary gearset along the output axis.

34. A power tool, comprising:a motor housing portion;a motor at least partially received in the motor housing portion, the motor having a rotor rotatable about a motor axis;a transmission housing portion coupled to a front end portion of the motor housing portion;a transmission assembly at least partially received in an interior cavity of the transmission housing portion, the transmission assembly comprising a plurality of gears configured to transmit torque from the rotor to an output shaft rotatable about an output axis transverse to the motor axis, wherein a ratio of an interior volume of the interior cavity of the transmission housing portion to an outer diameter of the output shaft is between about 67 mm2and about 150 mm2; anda cutting assembly including a blade holder rotatably driven by the output shaft and configured to be coupled to a cutting blade.

35. The power tool of claim 34, wherein the interior volume of the interior cavity of the transmission housing portion is between about 1.0E6 mm3and about 1.5E6 mm3.

36. The power tool of claim 34, wherein the outer diameter of the output shaft is between about 10 mm and about 15 mm.

37. A power tool, comprising:a transmission housing portion; anda transmission assembly at least partially received in the transmission housing portion for transmitting torque from a motor to an output shaft, the transmission assembly comprising:a first bevel gear configured to rotate about a motor axis;57WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOa second bevel gear intermeshed with the first bevel gear and configured to rotate about an output axis, the first bevel gear and second bevel gear configured to provide a first gear reduction;a first planetary7gearset operably coupled with the second bevel gear, the first planetary gear set comprising a plurality of gears configured to provide a second gear reduction; anda second planetary gearset operably coupled with at least a portion of the first planetary gearset, the second planetary gear set comprising a plurality of gears configured to provide a third gear reduction;wherein the first gear reduction, second gear reduction, and third gear reduction combined produce a total gear reduction for the transmission assembly between about 11:1 and about 14:1;wherein the output shaft extends completely through a central opening in the second bevel gear, the first planetary gearset, and the second planetary7gearset; and wherein at least a portion of the transmission housing portion comprises an inner diameter between about 48 mm and about 51 mm.

38. The power tool of claim 37, wherein a ratio of an outer diameter of the second bevel gear measured perpendicular to the output axis to an outer diameter of the output shaft is between 2.80 and about 4.20.

39. The power tool of any one of claims 37-38, wherein a ratio of an inner diameter of the transmission housing portion measured perpendicular to the output axis to an outer diameter of the output shaft is between about 3.20 and about 5.10.

40. A power tool, comprising:a motor housing portion;a motor at least partially received in the motor housing portion, the motor having a rotor rotatable about a motor axis;a transmission housing portion coupled to a front end portion of the motor housing portion;58WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOa transmission assembly at least partially received in an interior cavity of the transmission housing portion and configured to transmit torque from the rotor to an output shaft rotatable about an output axis transverse to the motor axis, the transmission assembly comprising:a first bevel gear configured to rotate about the motor axis;a second bevel gear intermeshed with the first bevel gear and configured to rotate about the output axis; anda planetary7gearset operably coupled with the second bevel gear to transmit torque from the second bevel gear to the output shaft, the planetary gear set comprising a sun gear driven by the second bevel gear, a plurality of planet gears surrounding and intermeshed with the sun gear, a planet carrier to which the plurality of planet gears are coupled, and a ring gear surrounding and intermeshed with the plurality of planet gears,wherein the output shaft extends completely through a central opening in the sun gear and the second bevel gear, the output shaft supported by a rear bearing axially rearward of the second bevel gear along the output axis and a front bearing axially forward of the planetary gearset along the output axis; wherein a ratio of an interior diameter of the interior cavity of the transmission housing portion to an outer diameter of the output shaft is between about 3.20 and about 5.10; anda cutting assembly including a blade holder rotatably driven by the output shaft and configured to be coupled to a cutting blade.

41. The power tool of claim 40, further comprising an inner bearing disposed in the central opening between the output shaft and the sun gear to support the sun gear.

42. The power tool of any one of claims 40-41, further comprising an outer bearing configured to support an outer portion of the second bevel gear.

43. The power tool of claim 42, wherein the inner bearing is at least partially nested in the outer bearing.59WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO44. The power tool of any one of claims 40-43, wherein the planetary gearset is a first planetary gearset and the transmission assembly further comprises a second planetary gearset axially forward of the first planetary gearset.

45. The power tool of any one of claims 40-44, wherein the sun gear is a first sun gear and the second planetary gearset comprises a second sun gear driven by the planet carrier, wherein the output shaft extends completely through a central opening in the second sun gear.

45. The power tool of any one of claims 40-44, wherein the blade holder comprises a blade mount and a clamp member secured to the output shaft such that the cutting blade is for being at least partially received between the blade mount and the clamp member.

46. A power tool, comprising:a motor housing portion;a motor at least partially received in the motor housing portion, the motor having a rotor rotatable about a motor axis;a transmission housing portion coupled to a front end portion of the motor housing portion;a transmission assembly at least partially received in an interior cavity of the transmission housing portion, the transmission assembly comprising a plurality of gears configured to transmit torque from the rotor to an output shaft rotatable about an output axis transverse to the motor axis, the plurality of gears comprising a first gear rotatable about the motor axis and a second gear for being rotatably driven by the first gear about the output axis, wherein a ratio of an outer diameter of the second gear to an outer diameter of the tool output shaft is between about 3.2 and about 5.1; anda cutting assembly including a blade holder rotatably driven by the output shaft and configured to be coupled to a cutting blade.

47. The power tool of claim 46, further comprising an inner bearing disposed in a central opening between the output shaft and a sun gear of the transmission assembly to support the sun gear.

48. The power tool of claim 46 or claim 47, further comprising an outer bearing configured to support an outer portion of the second gear of the transmission assembly.60WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO49. The power tool of any one of claims 46-48, wherein the inner bearing is at least partially nested in the outer bearing.

50. The power tool of any one of claims 46-50, wherein the blade holder comprises a blade mount and a clamp member secured to the output shaft such that the cutting blade is for being at least partially received between the blade mount and the clamp member.

51. A power tool, comprising:a tool housing;a motor at least partially received in the housing and configured to be energized to produce a rotational output about a motor axis;an output shaft coupled to an accessory holder, the output shaft configured to rotate about an output axis transverse to the motor axis upon energization of the motor; anda transmission assembly comprising a plurality' of gears configured to transmit torque from the motor to the output shaft, the plurality of gears comprising:a first bevel gear configured to rotate about the motor axis;a second bevel gear intermeshed with the first bevel gear and configured to rotate about the output axis; anda planetary gearset operably coupled with the second bevel gear to transmit torque from the second bevel gear to the output shaft, the planetary gear set comprising a sun gear driven by the second bevel gear, a plurality of planet gears surrounding and intermeshed with the sun gear, a planet carrier to which the plurality of planet gears are coupled, and a ring gear surrounding and intermeshed with the plurality of planet gears,wherein a ratio of an outer diameter of the ring gear to an outer diameter of the output shaft is between about 3.20 and about 5.10.

52. The power tool of claim 51 , further comprising an inner bearing disposed between the output shaft and the sun gear to support the sun gear.

53. The power tool of claim 52, further comprising an outer bearing configured to support an outer portion of the second bevel gear.61WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WO54. The power tool of claim 53, wherein the inner bearing is at least partially nested in the outer bearing.

55. The power tool of claim 51 , wherein the planetary gearset is a first planetary gearset and the transmission assembly further comprises a second planetary7gearset axially forward of the first planetary7gearset.

56. The power tool of claim 51 or claim 55, wherein the sun gear is a first sun gear and the second planetary gearset comprises a second sun gear driven by the planet carrier, wherein the output shaft extends completely through a central opening in the second sun gear and the front bearing is axially forward of the second planetary gearset along the output axis.

57. The power tool of claim 51 or claim 55, wherein the first bevel gear and the second bevel gear are configured for providing a gear reduction of about 2: 1.

58. The power tool of any one of claim 51, claim 55, or claim 57, wherein the first planetary7gearset is configured for providing a gear reduction of about 2.5:1.

59. The power tool of any one of claim 51, claim 55, claim 57, or claim 59, wherein the second planetary gearset is configured for providing a gear reduction of about 2.5:1.

60. A power tool, comprising:a tool housing;a motor at least partially received in the housing and configured to be energized to produce a rotational output about a motor axis;a transmission assembly configured to transmit torque from the motor to an output shaft, the transmission assembly comprising a first gear rotatable about the motor axis, a second gear rotatably driven by the first gear about an output axis transverse to the motor axis, and a planetary gearset driven by the second gear; anda cutting assembly comprising a blade mount rotatably driven by the output shaft about the output axis and configured to be coupled to a cutting blade, a blade guard with an opening configured to expose a portion of the cutting blade, and a base plate transverse to the output axis and configured to rest against a work surface;62WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOwherein the cutting assembly is configured so that the cutting blade is able to flush cut a protruding member extending away from the work surface while the base plate rests against the work surface; andwherein a vertical distance parallel to the output axis between the motor axis and a bottom surface of the base plate is between about 65 mm and about 70 mm.

61. The power tool of any one of claim 60, wherein the vertical distance between the motor axis and the bottom surface of the base plate is about 68 mm.

62. The power tool of any one of claim 60, further comprising a proximal end, a distal end, and a center of gravity between the proximal end and the distal end.

63. The power tool of any one of claim 60 or claim 62, wherein a distance between the distal end and the center of gravity of the power tool is between about 120 mm and about 130 mm.

64. The power tool of any one of claim 60, claim 62. claim 63, wherein a distance between the proximal end and the center of gravity of the power tool is between about 230 mm and about 245 mm.

65. The power tool of any one of claim 60, claim 62, claim 63, or claim 64, wherein a ratio of the distance between the distal end and the center of gravity and the distance between the proximal end and the center of gravity is between about 0.49 and about 0.57.

66. A power tool, comprising:a tool housing;a motor at least partially received in the tool housing, the motor having a rotor rotatable about a motor axis;a transmission assembly configured to transmit torque from the rotor to an output shaft, the transmission assembly comprising a first gear rotatable about the motor axis, a second gear rotatably driven by the first gear about an output axis transverse to the motor axis, a planetary gearset driven by the second gear, and a first bearing supporting a first portion of the output shaft and a second bearing supporting a second portion of the output shaft; anda cutting assembly comprising a blade mount rotatably driven by the output shaft about the output axis and configured to be coupled to a cutting blade, a blade guard with an opening63WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WOconfigured to expose a portion of the cutting blade, and a base plate transverse to the output axis and configured to rest against a work surface,wherein the cutting assembly is configured so that the cutting blade is able to cut a protruding member extending away from the work surface while the base plate rests against the work surface.

67. The power tool of claim 66, the cutting assembly further comprising a pivot pin, wherein the base plate is rotatable about the pivot pin around an axis parallel to and offset from the output axis to expose the blade mount for replacing the blade.

68. The power tool of claim 66, wherein the planetary gearset comprises a sun gear coupled to the second gear to rotate about the output axis.

69. The power tool of claim 66 or claim 68, wherein the sun gear and the second gear are integral.

70. The power tool of claim 66 or claim 68, wherein the sun gear defines a central bore that at least partially receives the output shaft therethrough.

71. The power tool of any one of claim 66, claim 68, or claim 70, wherein the central bore extends at least partially through the second gear.

72. The power tool of claim 66, the second bearing is disposed axially forward of the planetary gearset.

73. The power tool of claim 66 or claim 72, wherein the first bearing is disposed axially rearward of the planetary' gearset74. The power tool of claim 66 or claim 72, further comprising a third bearing configured to support at least a portion of the second gear.

75. The power tool of any one of claim 66, claim 72, or claim 74, wherein an inner diameter of the third bearing is larger than an outer diameter of the sun gear.

76. The power tool of any one of claim 66, claim 72, or claim 74, the second bearing disposed on an opposite side of the second gear than the planetary’ gearset.

77. The power tool of any one of claim 66, claim 72, claim 74, or claim 76, wherein the first bearing is positioned to straddle the motor axis such that a first portion of the first64WBD (US) 4933-4391-3113v4Title: POWER TOOL WITH COMPACT TRANSMISSIONApplicant: Black & Decker Inc.SBD Ref. No. P-WO-TN-2024-0044WBD Ref. No. SI 22995 1070WObearing is axially rearward of the motor axis along the output axis and a second portion of the first bearing is axially forward of the motor axis along the output axis.65WBD (US) 4933-4391-3113v4

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