Abstract: Provided is a rotor assembly for a brushless direct current motor. The rotor assembly includes an insert which fits within an outer rotor cup. The insert locates the position of the magnets and secures them with extended features. Curved fan blades are integrated into the insert to provide improved airflow and cooling during rotation. The insert has features incorporated to reduce overall noise caused by air flow by having smooth transitions between mating surfaces and joints. A trench is incorporated within the insert to provide an overflow catch for excess adhesive when the magnet segments are “glued” into place.

Abstract: Provided is a rotor assembly for a brushless direct current motor. The rotor assembly includes an insert which fits within an outer rotor cup. The insert locates the position of the magnets and secures them with extended features. Curved fan blades are integrated into the insert to provide improved airflow and cooling during rotation. The insert has features incorporated to reduce overall noise caused by air flow by having smooth transitions between mating surfaces and joints. A trench is incorporated within the insert to provide an overflow catch for excess adhesive when the magnet segments are “glued” into place.