Abstract: An SRE fan has a hub, a carrier extending outwardly of the hub and a plurality of vanes on a first side of the carrier. The carrier has a second side opposite the first side that is configured to contact an engagement surface of a rotor segment. Channels are provided on the second side of the carrier. Rotor coil leads are surrounded by respective compressible insulated sleeves and are each routed through respective channels. The geometry of the channels is adapted to cooperate with the engagement surface of the rotor to enclose the channels and establish a uniform channel depth. The depth is selected to be less than an uncompressed diameter of the sleeves so as to provide a measure of compression when the fan contacts the rotor, holding the leads in place.

Abstract: Disclosed is an apparatus 10 and method of ultrasonic injection molding a plastic part including: providing plastic pellets 12; passing the pellets into a defined space 14 in an ultrasonic horn apparatus 16; applying ultrasonic energy to the horn thereby permitting flow of the melted plastic; applying a force to a plunger 18 which forces the melted plastic into a mold 24 of a desired shape; and recovering the desired part.