Abstract: A method of manufacturing a stator core including stacking a plurality of teeth into a plurality of stacks, said teeth are obtained from a jigsaw pattern of said teeth, said teeth are substantially identical to each other in size, each said tooth is substantially T-shaped via two arms protruding sideways from a leg, said teeth substantially aligning with each other in each said stack; winding said stacks with a plurality of windings; placing said stacks along a perimeter of a polygonal inner surface of a ferromagnetic tube, said inner surface defining an inner space within said tube, each side of said polygonal inner surface corresponding to each said stack and contacting the bases of said legs of each said stack; inserting a shaft into said inner space, the top surfaces of said arms facing said shaft; vacuum encapsulating said inner space in an epoxy resin; removing said shaft.

Abstract: Method of manufacturing a stator core includes stacking a plurality of substantially T-shaped teeth obtained from a jigsaw pattern of said teeth into a plurality of stacks. In each said stack, said teeth are substantially aligned with each other. Said method includes winding said stacks with a plurality of windings and placing said stacks along the perimeter of a polygonal outer surface of a ferromagnetic tube having an inner channel. Each side of said outer surface corresponds to each said stack and contacts the bases of said legs of each said stack. Said method includes inserting said stacks and said tube into an inner space defined by an annular inner surface of a mold and a shaft into said channel. Said stacks are stationed along the circumference of said inner surface. Said method includes vacuum encapsulating said inner space in epoxy resin and removing said mold and shaft.

Abstract: A fan assembly with an impeller and shroud for application in a vehicle cooling system. The fan is powered by an external rotor brushless direct current (BLDC) motor having an electronic controller positioned away from the BLDC on an outer shroud wall with a plurality of ducts drawing an airflow from a static lower pressure created by the impeller, the airflow streaming over a heat sink disposed on the controller, exiting through a shroud. The static lower pressure air is pulled by a centrifugal fan and skewed magnets inside the motor through a plurality of ducts in a shroud hub, cooling the BLDC, maintaining low resistance for high efficiency. The BLDC is integrated into the assembly, having a stator fixed in the shroud hub and a rotor directly fused to the impeller, the shroud and impeller forming the BLDC motor without a housing, allowing the motor to easily dissipate heat.

Abstract: A fan assembly with impeller and shroud for application in a vehicle cooling system. The fan is powered by an external rotor brushless direct current (BLDC) motor having an electronic controller positioned away from the BLDC on an outer shroud wall with a plurality of ducts drawing an airflow from a static lower pressure created by the impeller, the airflow streaming over a heat sink disposed on the controller, exiting through a shroud. The static lower pressure air is pulled by a centrifugal fan and skewed magnets inside the motor through a plurality of ducts in a shroud hub, cooling the BLDC, maintaining low resistance for high efficiency. The BLDC is integrated into the assembly, having a stator fixed in the shroud hub and a rotor directly fused to the impeller, the shroud and impeller forming the BLDC motor without a housing, allowing the motor to easily dissipate heat.