Abstract: A stator for use in an electric motor is disclosed. The stator comprises an annular core, a plurality of wedges, and a plurality of wedge-retaining structures. The core includes a plurality of arcuately spaced apart teeth. Each of the teeth includes a generally radial leg and a head projecting from the leg to present a pair of arcuately spaced apart head ends. A slot opening is defined between the opposed head ends of each adjacent pair of teeth. Each of the wedges is received within a corresponding slot opening. Each wedge-retaining structure is at least in part fixed relative to the core and cooperates with a respective one of the wedges to compressibly retain the respective wedge between the head ends.

Abstract: An outer rotor motor is provided for use in a machine. The motor includes a rotor and a stator. A control board assembly configured to control at least one operational characteristic of the motor is mounted at least in part radially inside the stator.

Abstract: A rotor for an outer rotor-type motor is provided. The rotor includes a metallic coupler and a polymeric frame molded over at least part of the metallic coupler.

Abstract: A rotor for an outer rotor-type motor is provided. The rotor includes a metallic coupler and a polymeric frame molded over at least part of the metallic coupler.

Abstract: A stator comprises a cavity formed into the insulator of the windings. The non-wound wire sections that extend from the windings and the electrical conductors attached thereto are housed within the cavity. A cap locks onto the stator insulator and prevents the non-wound sections of wire from migrating out of the cavity.

Abstract: A stator of an electric motor or generator comprises a core formed of ferromagnetic material having a plurality of teeth arranged circumferentially about an axis. In one aspect of the invention, at least one retaining member connects the end portions of at least two of the teeth to each other in a manner inhibiting relative movement between said tooth end portions. By inhibiting relative movement between said tooth end portions, vibration is reduced. Vibration can also be reduced by welding interior surfaces of a core to each other. Reducing the vibration reduces the noise emissions of the stator during operation.

Abstract: A stator or rotor of an electric motor or generator comprises a core formed of ferromagnetic material having a plurality of teeth arranged circumferentially about an axis. In one aspect of the invention, at least one retaining member connects the end portions of at least two of the teeth to each other in a manner inhibiting relative movement between said tooth end portions. By inhibiting relative movement between said tooth end portions, vibration is reduced. Vibration can also be reduced by welding interior surfaces of a core to each other. Reducing the vibration reduces the noise emissions of the rotor or stator during operation.

Abstract: An outer rotor motor is provided for use in a machine. The motor includes a rotor and a stator. A control board assembly configured to control at least one operational characteristic of the motor is mounted at least in part radially inside the stator.

Abstract: A rotor for an outer rotor-type motor is provided. The rotor includes a metallic coupler and a polymeric frame molded over at least part of the metallic coupler.

Abstract: Mounting structure is provided for support of a motor within a machine. More particularly, the mounting structure is configured for the support of a stator within the machine, with the mounting structure preventing axial and rotational movement of the stator relative thereto.

Abstract: A mounting cap is provided for use with an insulated stator of an outer rotor motor. The mounting cap is configured to support the stator and is fixed to the stator to prevent relative rotation therebetween. The mounting cap includes mounting structure configured to fix the mounting cap to the machine, such that the stator is fixed to and supported on the machine by the mounting cap. Furthermore, the mounting cap is configured to facilitate routing of wiring associated with the stator.

Abstract: A stator comprises a ferromagnetic core having teeth. The stator also comprises first and second insulator members. The first and second insulating members collectively encircle each of the teeth of the core. The first insulating member comprising a plurality of mounting bosses spaced circumferentially from each other about the axis. Each of the mounting bosses has first and second retaining surfaces. The first and second retaining surfaces face axially opposite directions from each other and are exposed and are unobstructed by the second insulating member.

Abstract: An overmolded-type rotor for an outer rotor-type electric motor, wherein, in addition to a backing ring and magnets, a metallic coupler that comprises an inner axial surface configured to interface with a shaft to be driven by the rotor and an outer axial surface that corresponds to a multiplicity of outer teeth is overmolded with a polymer frame.

Abstract: An overmolded-type rotor for an outer rotor-type electric motor, wherein, in addition to a backing ring and magnets, a metallic coupler that comprises an inner axial surface configured to interface with a shaft to be driven by the rotor and an outer axial surface that corresponds to a multiplicity of outer teeth is overmolded with a polymer frame.

Abstract: A stator comprises a ferromagnetic core having teeth. The stator also comprises first and second insulator members. The first and second insulating members collectively encircle each of the teeth of the core. The first insulating member comprising a plurality of mounting bosses spaced circumferentially from each other about the axis. Each of the mounting bosses has first and second retaining surfaces. The first and second retaining surfaces face axially opposite directions from each other and are exposed and are unobstructed by the second insulating member.

Abstract: A stator comprises a cavity formed into the insulator of the windings. The non-wound wire sections that extend from the windings and the electrical conductors attached thereto are housed within the cavity. A cap locks onto the stator insulator and prevents the non-wound sections of wire from migrating out of the cavity.

Abstract: A stator or rotor of an electric motor or generator comprises a core formed of ferromagnetic material having a plurality of teeth arranged circumferentially about an axis. In one aspect of the invention, at least one retaining member connects the end portions of at least two of the teeth to each other in a manner inhibiting relative movement between said tooth end portions. By inhibiting relative movement between said tooth end portions, vibration is reduced. Vibration can also be reduced by welding interior surfaces of a core to each other. Reducing the vibration reduces the noise emissions of the rotor or stator during operation.

Abstract: A motor includes a rotor having at least one magnet. A stator includes multiple teeth and a sensor adjacent the magnet, or adjacent an air gap that is defined between the rotor and the stator. The majority of the teeth are identical in shape, or at least substantially identical. However, there is at least one distinct tooth (from among the teeth) that has a recess shaped to receive the sensor or a sensor housing. Thus, the distinct tooth has a different shape than the majority of the teeth to accommodate the sensor or sensor assembly.

Abstract: A horizontal axis washing machine includes an integrated motor and controller assembly. The controller is mounted to the electric motor with the controller positioned under a tub of the washing machine. The tub provides drip protection for the controller during operation of the washing machine. Additional embodiments include a motor and controller assembly in which a heat producing component of the controller is thermally coupled to a heat sink. The heat sink is positioned on an endshield of the electric motor and/or external to a housing of the motor controller. A stator of the electric motor can include one or more magnet wires attached directly to a connector for the motor controller.

Abstract: A stator for an electric machine includes stator teeth with powder coat insulation covering a portion of each tooth. An end cap with a routing element is positioned on one side of the stator. Wire extends around and contacts the powder coat insulation on the stator teeth and is routed via the routing element.