Abstract: A stator and armature assembly 12 is provided for a permanent magnet DC motor. The assembly includes an armature 13 having a lamination core 14 and windings 15, and a stator structure 16 associated with the armature. The armature is constructed and arranged to rotate with respect to the stator structure. The stator structure includes at least one permanent magnet 22 providing a certain flux, and at least one wound core structure 17 having a core 18 and a coil 19 wound about the core so as to define an alternate pole with respect to the permanent magnet. When current to the coil is controlled, flux of the stator structure 16 can be increased or decreased relative to the certain flux. In this way a motor can operate at different speeds.

Abstract: A stator and armature assembly 12 is provided for a permanent magnet DC motor. The assembly includes an armature 13 having a lamination core 14 and windings 15, and a stator structure 16 associated with the armature. The armature is constructed and arranged to rotate with respect to the stator structure. The stator structure includes at least one permanent magnet 22 providing a certain flux, and at least one wound core structure 17 having a core 18 and a coil 19 wound about the core so as to define an alternate pole with respect to the permanent magnet. When current to the coil is controlled, flux of the stator structure 16 can be increased or decreased relative to the certain flux. In this way a motor can operate at different speeds.

Abstract: A stator and armature assembly 12 is provided for a permanent magnet DC motor. The assembly includes an armature 13 having a lamination core 14 and windings 15, and a stator structure 16 associated with the armature. The armature is constructed and arranged to rotate with respect to the stator structure. The stator structure includes at least one permanent magnet 22 providing a certain flux, and at least one wound core structure 17 having a core 18 and a coil 19 wound about the core so as to define an alternate pole with respect to the permanent magnet. When current to the coil is controlled, flux of the stator structure 16 can be increased or decreased relative to the certain flux. In this way a motor can operate at different speeds.

Abstract: A stator and armature assembly 12 is provided for a permanent magnet DC motor. The assembly includes an armature 13 having a lamination core 14 and windings 15, and a stator structure 16 associated with the armature. The armature is constructed and arranged to rotate with respect to the stator structure. The stator structure includes at least one permanent magnet 22 providing a certain flux, and at least one wound core structure 17 having a core 18 and a coil 19 wound about the core so as to define an alternate pole with respect to the permanent magnet. When current to the coil is controlled, flux of the stator structure 16 can be increased or decreased relative to the certain flux. In this way a motor can operate at different speeds.

Abstract: A method of linking commutator bars of a commutator for a motor wherein N is the number of magnetic poles of the motor and N is an even integer greater than 2. The method include a) arranging a plurality of commutator bars to be generally equally spaced in a circular arrangement to define the commutator, each commutator bar having a tang extending therefrom, b) contacting an end of a continuous, insulated conductive member to a tang, c) moving the member to contact a second tang which is disposed at an angle of 720°/N from the previously contacted tang to form a link, and when N is greater than four, repeating this step until N/2−1 links are created, d) moving the member to contact a tang which is immediately adjacent to the second tang contacted in step (c) such that the member defines a bridging portion between the adjacent tangs, e) repeating steps (c) and (d) and until all tangs have been contacted by the member, and f) cutting the bridging portion between adjacent tangs.

Abstract: A choke 10, for suppressing radio-frequency interference of a brush-type motor, includes a single wire having a portion 15 wound about a coil axis A to define a plurality of coils 14 including two outermost coils 16 and 18. An attaching structure 20 extends from each outermost coil and is disposed generally transverse with respect to the coil axis. Each attaching structure is constructed and arranged to be inserted through an associated opening in a supporting structure and to be bent so as secure the choke to the supporting structure. An elongated end portion 22 extends from each attaching structure so as to be spaced from and generally parallel to the coil axis. The elongated end portions extend in opposite directions. One of the elongated end portions is constructed and arranged to be directly electrically connected to an electrical connector of a motor and the other of the elongated end portions is constructed and arranged to be in electrical connection with a brush of the motor.

Abstract: A choke 10, for suppressing radio-frequency interference of a brush-type motor, includes a single wire having a portion 15 wound about a coil axis A to define a plurality of coils 14 including two outermost coils 16 and 18. An attaching structure 20 extends from each outermost coil and is disposed generally transverse with respect to the coil axis. Each attaching structure is constructed and arranged to be inserted through an associated opening in a supporting structure and to be bent so as secure the choke to the supporting structure. An elongated end portion 22 extends from each attaching structure so as to be spaced from and generally parallel to the coil axis. The elongated end portions extend in opposite directions. One of the elongated end portions is constructed and arranged to be directly electrically connected to an electrical connector of a motor and the other of the elongated end portions is constructed and arranged to be in electrical connection with a brush of the motor.

Abstract: A choke 10, for suppressing radio-frequency interference of a brush-type motor, includes a single wire having a portion 15 wound about a coil axis A to define a plurality of coils 14including two outermost coils 16 and 18. An attaching structure 20 extends from each outermost coil and is disposed generally transverse with respect to the coil axis. Each attaching structure is constructed and arranged to be inserted through an associated opening in a supporting structure and to be bent so as secure the choke to the supporting structure. An elongated end portion 22 extends from each attaching structure so as to be spaced from and generally parallel to the coil axis. The elongated end portions extend in opposite directions. One of the elongated end portions is constructed and arranged to be directly electrically connected to an electrical connector of a motor and the other of the elongated end portions is constructed and arranged to be in electrical connection with a brush of the motor.

Abstract: A choke 10, for suppressing radio-frequency interference of a brush-type motor, includes a single wire having a portion 15 wound about a coil axis A to define a plurality of coils 14 including two outermost coils 16 and 18. An attaching structure 20 extends from each outermost coil and is disposed generally transverse with respect to the coil axis. Each attaching structure is constructed and arranged to be inserted through an associated opening in a supporting structure and to be bent so as secure the choke to the supporting structure. An elongated end portion 22 extends from each attaching structure so as to be spaced from and generally parallel to the coil axis. The elongated end portions extend in opposite directions. One of the elongated end portions is constructed and arranged to be directly electrically connected to an electrical connector of a motor and the other of the elongated end portions is constructed and arranged to be in electrical connection with a brush of the motor.

Abstract: An electric motor 10 includes a motor housing 12 defining an internal cavity 15. A brush card assembly 24, a commutator 26 and an armature assembly 18 are provided in the cavity 15. The commutator 26 cooperates with the brush card assembly 24 to resupply electric current to the armature assembly 18. Permanent magnet structure 44 is provided in the housing 12 to generate a magnetic field to cause rotation of the armature assembly 18. A FET 52 is mounted with respect to the housing 16 so as to be in heat exchange relation therewith. A gate terminal G of the FET is constructed and arranged to receive pulse width modulation output from an electronic control unit 64 which is remote from the motor so as to enable able the motor to operate at more than one speed. A method of integrating a FET in a motor is also provided.

Abstract: A cooling module 10 of short axial length includes a fan 18 having a plurality of blades 16. A shroud structure 12 is spaced from and generally adjacent to the blades 16. A brushless electric motor 22 rotates the blades 16. The motor 22 includes a heat sink structure 24 coupled to the shroud structure 12 and defines a base of the motor 22. A shaft 32 is fixed to the heat sink structure 24. A rotor 34 is mounted for rotation with respect to the shaft 32. The fan 18 is coupled to the rotor 34. Magnets 48 are fixed in relation to the rotor 34. A lamination core 56 is fixed to the heat sink structure 24. A winding is wound about the lamination core 56 and is operatively associated with the magnets 48.

Abstract: A brushless electric motor 26 includes a stator assembly 32 defining an interior chamber 38. The stator assembly includes a stator core 34 and windings 36. The windings and at least a portion 44 of the stator core are in open communication with the interior chamber. A rotor assembly 42 is provided in the interior chamber. An electronic control unit 60 is coupled to the stator assembly and has an upper surface 62 in communication with the interior chamber. A fluid flow path structure 64 is constructed and arranged to permit fluid to pass from an inlet in the stator assembly and enter the interior chamber so that the rotor assembly, the windings, and the portion of said stator core are submerged in the fluid for cooling the rotor assembly, the windings, and the portion of the stator core. Fluid also contacts the upper surface of the electronic control unit to cool the electronic control unit. Fluid isolating structure 74′ prevents fluid from contacting an end 81 of the windings.

Abstract: A cooling system for a vehicle having a liquid-cooled engine is provided. The cooing system includes a heat exchanger constructed and arranged to be mounted in spaced relation with respect to the engine for cooling the liquid by air directed from a front side of the heat exchanger through a rear side of the heat exchanger. Duct structure is coupled to the rear side of the heat exchanger so as to cover at least a portion of the rear side, and to receive at least a portion of air exiting the rear side of the heat exchanger. The duct structure is mounted with respect to the heat exchanger so that a portion of the duct structure extends beyond bounds of a sidewall of the heat exchanger. At least one radial-flow type fan is mounted in the extending portion of duct structure such that air flowing through the heat exchanger and the duct structure is pulled by the fan so as to exit generally at the sidewall of the heat exchanger. A motor is operatively coupled to the fan to drive the fan.

Abstract: A brushless pump-motor has a pump housing having an impeller chamber with an impeller in the impeller chamber. A motor assembly is coupled to the pump housing. The motor assembly includes a stator assembly having a plurality of core members. A connecting structure couples the plurality of core members with respect to each other to form a generally annular core assembly such that adjacent core members are disposed in non-contacting relation. Windings are operatively associated with the core members. The stator assembly has an interior portion defining a rotor chamber and a rotor assembly is disposed in the rotor chamber. The connecting structure has a partition portion constructed and arranged to isolate the windings from the rotor chamber. A shaft is provided on which the rotor assembly and impeller are mounted. The shaft includes a hollow portion in open communication with the rotor chamber.

Abstract: A brushless water pump motor includes a pump housing having an impeller chamber with an impeller disposed therein, and a motor assembly coupled at a first end thereof to the pump housing. The motor assembly includes a stator assembly having laminations and windings, the stator having an interior portion defining a rotor chamber in which a rotor assembly is disposed. There is a partition structure provided between the rotor assembly and the stator assembly for isolating the stator assembly from the rotor chamber, and the partition structure has a wall in communication with the rotor chamber. The pump/motor assembly further includes a hollow shaft in communication with the rotor chamber, such that the rotor assembly and impeller are mounted on the hollow shaft. A bearing structure is operatively associated with the hollow portion of the shaft for supporting the shaft for rotational movement.

Abstract: A vehicle engine cooling system includes a coupling assembly to be connected to and rotated by a vehicle engine output shaft. An electric motor includes a motor shaft having first and second ends. An impeller is coupled to the first end of the motor shaft. A clutch structure is integral with the electric motor and includes an input member carried by the second end of the motor shaft for rotation therewith. An end of the coupling structure is operatively associated with the input member to cause rotation of the input member upon rotation of the coupling assembly. An electro-magnet structure is disposed about the input member. The clutch structure also includes output structure having a mounting member fixed to the motor shaft. A movable element, including magnetically permeable material, is mounted with respect to the mounting member for rotational movement therewith and for movement between a non-engaging position and an engaging position. A spring biases the movable element towards the non-engaging position.

Abstract: An ultra quiet electric motor includes a drive shaft, bearing structure rotatably supporting the drive shaft, and an armature assembly and commutator each fixed on the drive shaft. A motor housing is disposed around the armature assembly and has an open end portion. A permanent magnet structure is disposed between the motor housing and the armature. Brush structure is provided having a pair of brush support arms each guiding a generally crescent-shaped brush. Each of the brushes contacts the commutator. A noise absorbing housing is defined by a plurality of walls and is disposed generally around the brush structure. Noise absorption material covers at least a portion of at least one of the walls of the noise absorbing housing. An end cap is fixed to the motor housing to close the open end portion thereof. The structure of the motor is such that during operation, a decibel rating of approximately 32 dbA is generated.

Abstract: A heat exchanger module, a cooling fan module, a pump/fan module, and an electronics system control module are joined together in assembly to form a total cooling assembly for an automotive vehicle that is powered by an internal combustion engine. The cooling fan module is disposed directly behind the rear face of the radiator, and contains an electric motor-driven fan that draws ambient air across the radiator. At time of installation in a vehicle, the assembly is "dropped into" the vehicle engine compartment and secured in place. An electric motor-driven coolant pump module that pumps engine coolant through the engine and radiator, and an electronics system control module that controls the operation of the fan and pump motors also mount on the cooling fan module. When the vehicle has an air conditioning system, and/or turbo-charged engine, one and/or two additional heat exchangers form part of the heat exchanger module. The cooling fan module may comprise an axial flow fan or a ducted radial flow fan.

Abstract: A brushless pump-motor has a pump housing having an impeller chamber with an impeller in the impeller chamber. A motor assembly is coupled to the pump housing. The motor assembly includes a stator assembly having a plurality of core members. A connecting structure couples the plurality of core members with respect to each other to form a generally annular core assembly such that adjacent core members are disposed in non-contacting relation. Windings are operatively associated with the core members. The stator assembly has an interior portion defining a rotor chamber and a rotor assembly is disposed in the rotor chamber. The connecting structure has a partition portion constructed and arranged to isolate the windings from the rotor chamber. A shaft is provided on which the rotor assembly and impeller are mounted. The shaft includes a hollow portion in open communication with the rotor chamber.

Abstract: A high speed electric motor for automotive applications that is designed to effectively minimize vibration of its component parts and thus suppress noise generated during its operation. The motor incorporates acoustic engineering principles including surface vibration control, acoustic radiation efficiency, active intensity field control and noise control using acoustic materials to reduce overall vibration of the motor components and the motor noise sensed by the passenger of the vehicle.