Abstract: The invention proposes an electric motor having a rotor, a rotor and a process for manufacturing a rotor for an electric motor, in which the manufacturing complexity is considerably reduced in comparison with the prior art. This object is achieved by virtue of the fact that, in the rotor, a plastics connection (11, 12) is provided between the return plate (2) and the rotor shaft (1). This plastics connection (11, 12) between the return plate (2) and the rotor shaft (1) is produced in accordance with the manufacturing process according to the invention by injection-molding.

Abstract: Electric motor components are formed of a conductive loaded resin-based material. The conductive loaded resin-based material comprises micron conductive powder(s), conductive fiber(s), or a combination of conductive powder and conductive fibers in a base resin host. The percentage by weight of the conductive powder(s), conductive fiber(s), or a combination thereof is between about 20% and 50% of the weight of the conductive loaded resin-based material. The micron conductive powders are metals or conductive non-metals or metal plated non-metals. The micron conductive fibers may be metal fiber or metal plated fiber. Further, the metal plated fiber may be formed by plating metal onto a metal fiber or by plating metal onto a non-metal fiber. Any platable fiber may be used as the core for a non-metal fiber. Superconductor metals may also be used as micron conductive fibers and/or as metal plating onto fibers in the present invention.

Abstract: A plurality of stator segments 20 are linked together by a phase change material 22 enabling simplified winding and higher slot fill. Once wound this continuous structure can be formed into a toroidal core 17 for a stator assembly 40 used to make a motor 100. In a preferred embodiment, a monolithic body 42 of phase change material substantially encapsulates the conductors and holds the stator segments 20 in contact with each other in the toroidal core 17. Hard disc drives using the motor 100, and methods of constructing the motor 100 are also disclosed.

Abstract: A rotor for a permanent magnet motor of an outer rotor type having a plurality of permanent magnets and disposed around a stator includes a frame, an annular iron core combined integrally with the frame, and a plurality of insertion holes formed in the core so that the permanent magnets are inserted in the insertion holes respectively. The frame, the core and the permanent magnets are combined integrally with one another by a synthetic resin. Each insertion hole includes a magnet disposing portion in which the permanent magnet is disposed, a space portion located in at least one of circumferential both ends of each permanent magnet disposed in the magnet disposing portion, and a positioning portion positioning each permanent magnet in the magnet disposing portion, and the molten synthetic resin is poured into the space portion.

Abstract: For many applications, it is desirable to use fans which weigh less than 30 grams and are driven by electric motors not more than a few centimeters in size. Mass-producing products this small, which nevertheless must be extremely reliable, poses unique manufacturing challenges, which are best overcome by an improved structure which is susceptible to automation. Preferably, the fan motor is electronically commutated and has an internal stator (50) and an external rotor (22) supported on a central rotor shaft (34). The shaft is journaled within a bearing tube (70) supporting first and second rotor bearings (72, 76). By injection-molding the bearing tube (70) with first and second axial extensions (90?, 90?), the extensions can hold the bearings in place and insure uniform manufacturing quality and a desirably long service life. One of the extensions can also be shaped to abut against a circuit board (46) which supports components which control commutation.

Abstract: The invention relates to a device for the insulation of the stator slots of an electric machine that has a stator having a plurality of stator poles and stator slots located between the stator poles, comprising an insulating body that has moldings adapted to the shape of the stator slots and can be slid onto the stator in an axial direction, and a cover piece that can be connected to an end face of the insulating body, in order after the windings have been applied to the insulating body, to carry the windings (36) at the end face of the stator and to cover them.

Abstract: In a method for manufacturing an electric motor, a cylindrical stator core circumferentially dividable into a plurality of core components is inserted into a circular internal surface of a motor housing. In this case, the motor housing is heated to be expanded thermally thereby enlarge circular internal surface thereof. Then, the stator core is fit over the external surface of an, insertion guide head of a generally cylindrical shape, and the insertion guide head is moved ward toward the thermally expanded motor housing secured on a fixed table to insert the stator re inside the motor housing. When the insertion guide head reaches a predetermined axial position inside the motor housing, a pressing mechanism incorporated in the insertion guide head is operated to press the core components on the circular internal surface of the motor using.

Abstract: An electric motor has an armature and a stators. The armature has a lamination stack having slots therein. An internal shaft extends coaxially through the lamination stack. A plurality of magnet wires are wound in the slots of the lamination stack. A commutator is disposed on the armature shaft to which ends of the magnet wires are electrically coupled. The internal is shaft coupled to an external pinion and bearing journal by an insulated coupling. The magnet wires are at least partially encased in thermally conductive plastic. The magnet wires can have a layer of heat activated adhesive that is activated when the plastic is molded. Slots in the lamination stack can include slot liners formed of thermally conductive plastic. A fan can be formed when the thermally conductive plastic is molded to encapsulate the magnet wires. A power tool has the electric motor.

Abstract: The brushless direct current motor comprises a housing 10, a stator 13 and a rotor 11 within the housing, windings on the stator, sensors for sensing the position of the rotor relative to the stator and electronic circuitry for switching the current in the windings in response to outputs from the sensors to cause the rotor to rotate relative to the stator. The sensors and at least a part of the electronic circuitry are encapsulated in an electrically insulating and fuel resistant material in a container within the housing.

Abstract: In a rotary electric machine, each stator coil includes a bobbin that is fitted to one of teeth of a stator core and a phase coil is wound around the bobbin. Each bobbin includes a bobbin terminal for connecting opposite ends of the phase coil. A stator housing includes an insert mold and a plurality of stator terminals embedded in the insert mold to be connectable to an outside electric device. Each stator terminal has a first contact portion and each bobbin terminal has a second contact portion in contact with the first contact portion when the stator core is accommodated in the stator housing.

Abstract: A magneto-generator, a method of manufacturing the same and a resin molding die for manufacturing the same. In the magneto-generator, a guard ring is omitted with the performance of the magneto-generator being enhanced. The magneto-generator is manufactured by making use of a resin molding die (21) having an outer peripheral surface (21d) to be positioned in opposition to an inner peripheral surface of a flywheel (11) and projections (21a) provided in the outer peripheral surface (21d) for holding a plurality of magnets (12) at predetermined positions, respectively. The magnets (12) are positioned and held stationarily at predetermined positions by the aforementioned projections, respectively, and spaces defined between the resin molding die (21) and the inner peripheral surface of the flywheel (11) are filled with a resin. After hardening of the resin, the resin molding die (21) is detached from the flywheel (11).

Abstract: The invention is a fan for an alternator adapted to be coupled in rotation to the alternator rotor, and being of the type comprising a wheel part and a plurality of fan blades (47, 48) extending from the latter, the fan being moulded in a plastics material on an insert (50) which is preferably of metal and which constitutes the wheel part of the fan and is arranged to provide fastening of the fan on the rotor, being configured so as to constitute a means for increasing the mechanical strenght of the fan; the insert (50, 65) includes at least a portion of a blade (48, 69) of the fan. The invention is useful in the manufacture of a high power cooling fan for a motor vehicle alternator.

Abstract: The invention proposes a method of making a rotor (12) for a rotary electrical machine, the rotor including a core (14) on which there is formed at least one electrical winding (16) comprising at least one electrically conductive element (18) which is coated with an outer bonding layer (32), of the type in which the winding step is followed by a step of change of state which causes softening of the bonding material to take place and which then causes it to solidify once more, characterized in that the winding of the conductive element (18) is carried out on the convex outer cylindrical wall (40) of a tubular element (42) of the core, and in that, after the said step of change of state, the tubular element (42) is assembled on a core body (44) in such a way as to minimize the temperature gradient in the winding (16) during the step of change of state.

Abstract: A motor has a stator substantially encapsulated within a body of thermoplastic material; and one or more solid parts used in the motor either within or near the body. The thermoplastic material has a coefficient of linear thermal expansion such that the thermoplastic material contracts and expands at approximately the same rate as the one or more solid parts. In another aspect, a motor for a hard disc drive comprises at least one conductor, at least one magnet, at least one bearing and a shaft; and a monolithic body of thermoplastic material substantially encapsulating the at least one conductor. The bearing is either encapsulated in the thermoplastic material, housed in a hollow cylindrical insert encapsulated in the thermoplastic material, or secured in a bore formed in the body of thermoplastic material. The motor has improved shock resistance.

Abstract: A rotor assembly for an electric motor includes a spoke permanent magnet rotor and a shaft connected thereto. The spoke permanent magnet rotor has an axis of rotation, permanent magnet material, and ferro-magnetic material. The permanent magnet material extends outwardly relative to the axis of rotation to form a plurality of outwardly extending spoke portions of permanent magnet material. The ferro-magnetic material is positioned adjacent to the outwardly extending spoke portions of permanent magnet material. The shaft supports the spoke permanent magnet rotor for rotation about the axis of rotation. The permanent magnet material may circumferentially surround the axis of rotation to form a center portion of permanent magnet material. Further, the axis of rotation may pass through the permanent magnet material. The spoke permanent magnet rotor may be formed using a compaction process and/or an injection molding process.

Abstract: A highly reliable resin-molded stator not suffering insulation breakdown between the different phases of the stator coils even when the operation mode where the output of a rotary machine using a resin-molded stator in which a stator coil wound around a plurality of slots and a stator coil provided at the stator core end are resin-molded is to be increased from the level under a stopped status to the maximum achievable level within a short time is repeated. Also disclosed is a method of manufacturing such a stator, and a rotary machine using the same.

Abstract: An end bell for a motor has a base plate, a bearing and a molded insert to couple the bearing to the base plate. The end bell with molded insert is durable, light weight and has good anti-corrosion properties. The bearing is held in relation to the base plate while the molded insert is disposed. A post-mold machining operation can be used to both size the bearing hole to the motor shaft but also to align the hole in relation to the base plate. Bushings and fasteners for assembly of the end bell to the motor housing and supplemental supports may be pre-attached to the base plate, molded into the molded insert or added in a post-mold operation. Deformations in the end bell may be used to couple the molded insert to the end bell.

Abstract: The present invention provides an inner rotor electric motor, in which the stator core is divided into a plurality of stator segments extending in an axial direction which are accommodated in corresponding stator casing segments. The stator segments are preferably constructed in an identical manner; the corresponding stator casing segments are also preferably substantially identical to each other. Means of connection to mechanically connect the stator segments and the corresponding stator casing segments is provided as well as means of electrically coupling the phase windings.

Abstract: In a method of manufacturing a rotor of an electric motor to be arranged inside a stator, a permanent magnet is formed in a ring-shape, and a rotating shaft and the permanent magnet are concentrically arranged in a mold. Then, a rubber material in a fluid state is poured into a space between the permanent magnet and the rotating shaft to vulcanize and mold a cushioning member having predetermined hardness. The permanent magnet and the rotating shaft are integrally coupled through the cushioning member.

Abstract: A rotating electric machine comprises: a stator including a stator iron core having a plurality of slots and a stator winding incorporated in the plurality of slots; and a rotor rotatably disposed in the stator via a clearance; wherein a mold (i.e., a slot insulator) made of an insulating resin is brought into close contact with the surface of a projection (i.e., a tooth core) of the stator iron core, formed between the adjacent slots, the thickness of the mold at a portion of the projection wound with the stator winding being smaller than that of the mold at other portions. Thus, it is possible to provide the rotating electric machine in which thermal resistance generated between the stator winding and the stator iron core can be reduced, thermal transmittance of heat generated in the stator winding to the stator iron core can be enhanced, and the cooling efficiency of the stator winding can be enhanced.

Abstract: A stator assembly for an electric motor includes a stator housing, a flux ring inserted into the stator housing after the stator housing is formed and a plurality of magnets on an inner surface of the flux ring. Overmold material is molded around the magnets in the flux ring, such as by injection molding. The overmold material secures the magnets to the flux ring and the flux ring to the housing. In an aspect, the overmold material is molded to form at least one of a commutator end or rear bearing support, front bearing support and fan baffle.

Abstract: A method of manufacturing a watertight brushless fan motor includes first, combining a stator assembly with a stator and a circuit substrate, a case, a die, and an annular member. The stator assembly is mounted on the bearing supporting cylindrical section of the case. The bearing supporting cylindrical section is engaged and the die and annular member are fixed to the case. An insulating resin is poured into the die to mold spaces between the plate-like section and the bearing supporting cylindrical section so that the stator and the circuit substrate are included inside. The resin may be poured under low vacuum. With this arrangement, the watertight brushless fan motor is provided that can prevent occurrence of a crack in the outer surface of the molded part due to molding shrinkage of the insulating resin or expansion and shrinkage of the insulating resin caused by a change in ambient temperature.

Abstract: The present invention relates to a motor that allows connection terminals to be stably fastened to a bobbin. The motor includes at least one lead wire wound around a bobbin of a stator to form a coil, at least one power line electrically connected to the lead wire to supply power to the lead wire, at least one connection terminal to connect the lead wire to the power line, a terminal holding part provided at a portion of the bobbin to place the connection terminal, at least one terminal receiving hole provided in the terminal holding part to allow the connection terminal connected to the power line to be inserted and connected to the lead wire, and a fastening member to accommodate the connection terminal connected to the power line therein and to be fastened to the terminal holding part so as to keep the connection terminal mounted in the terminal receiving hole.

Abstract: A lead-wire-fixing attachment for fixing a lead wire is provided in a lead-wire-fixed portion arranged in a stator core, and a lead wire is connected to a stator-winding mounting board by way of a through-hole provided at the upper end of the lead-wire-fixing attachment. The through-hole is formed by notches provided at a location where the first attachment and second attachment contact each other. An inlet passage through which a potting material is poured, outlet passages through which the potting material runs out, base portions which are inscribed in the inside wall of the lead-wire-fixed portion are formed in the upper portion of the lead-wire-fixing attachment. The lead wire is made to pass through the through-hole and the lead-wire-fixing attachment is inserted in the lead-wire-fixed portion, and then they are fixed by using a potting material.

Abstract: Magnet wires wound in slots in a lamination stack of a dynamoelectric machine are encapsulated, in whole or in part, with plastic. The plastic may be thermally conductive and have features molded therein that enhance heat transfer. The plastic may stiffen the armature and increase its critical speed. Characteristics of the plastic, its geometry and its distribution may be varied to adjust spinning inertia and resonant frequency of the armature. The magnet wires may be compressed into the slots, by application of iso-static pressure or by the pressure of the plastic being molded around them. Larger magnet wire can then be used which increases the power of the electric motor using the armature having the larger magnet wire. A two or three plate mold may be used to mold the plastic around the armature. Balancing features can be molded in place. The plastic can have a base polymer that is a blend of two or more polymers and various thermally conductive fillings.

Abstract: The rotating electric machine has a stator coil wound around a stator, a magnetic pole and a signal rotor fixed to a rotor, and a detection stator, disposed opposite to the signal rotor, for detecting the rotational position of the rotor, characterized by further comprising an adjuster for adjusting the position of the signal rotor or the detection stator by supplying a direct current to a predetermined phase of the stator coil and then a direct current to a different phase from the predetermined phase to rotate the rotor by a predetermined angle or more and constrain the rotor.

Abstract: A cylinder/magnet assembly for a field of an electric machine, such as a stator of a brush type motor or a rotor of a brushless motor, alternator or generator, is formed by stamping a blank to form anchors extending upwardly from a surface of the blank and stamping holes in the blank where first and second portions of the anchors meet an inner surface of the cylinder to facilitate rolling of the cylinder from the blank. After a cylinder is rolled from the blank, pre-formed magnets are placed around an inner surface of the cylinder and plastic molded around the magnets and anchors to secure the magnets to the cylinder. In an aspect of the invention, the holes act as magnetic chokes. In another aspect of the invention, the anchors are formed as flux spreaders. In another aspect of the invention, the north and south poles of a cylinder and magnet assembly have unequal distribution angles.

Abstract: A stator of an electric motor is formed by inserting pre-formed magnets on a cylinder having anchors and plastic is molded around the magnets and anchors to secure the magnets to a surface of the cylinder, forming a cylinder/magnet assembly. A pilot feature is formed in at least one endwall of the plastic molding when it is molded. An end plate is located with respect to the cylinder/magnet assembly by mating a corresponding pilot feature of the end plate with the pilot feature in the endwall of the plastic molding. In another aspect of the invention, magnets are inserted into magnet receiving pockets of a cylinder and plastic molded therearound with the magnet pockets holding the magnets in place during molding of the plastic. In another aspect of the invention, the north and south poles of a cylinder and magnet assembly have unequal distribution angles. In another aspect of the invention, the north and south poles of a cylinder and magnet assembly have unequal numbers of magnets.

Abstract: The invention relates to a brushless electric motor comprising a stator, which has pole elements, and a rotor, which is mounted rotatably in relation to the stator and comprises magnet poles of magnetic powder material bonded to form a body and a back yoke body carrying the magnet poles, the magnet poles being formed by at least one molded magnetic body, which is molded with a back yoke side onto the back yoke body.

Abstract: A mixer/stirrer motor-reducer (e.g. as part of a mixer, stirrer or similar building machine), includes an electric motor (2) and a reducer (3) kinematically connected to the motor via a gear train (4, 6, 8) and with a relevant output shaft (9) intended for moving a mixing tank (10; 110). The motor-reducer (1) is provided with a box-shaped shell (15) made of insulating material. The shell (15) is open laterally, is able to include the casing (12) of the electric motor (2), is closable by a flange (19) and is made of electrically insulating material and is interposed between the motor (2) and the reducer (3).

Abstract: A highly reliable resin-molded stator not suffering insulation breakdown between different phases of stator coils even when the operation mode is repeated where the output of a rotary machine using a resin-molded stator is to be increased from the level under a stopped status to the maximum achievable level within a short time. Also provided are methods of manufacturing such a stator, and a rotary machine using the same. The a resin-molded stator of the invention comprises a stator core, electrically insulated stator coils wound around the plurality of slots or protrusions provided in the axial direction of the stator core, and molding resin with which are molded the stator core and the stator coils located at the aforementioned slots or protrusions. At the stator core end, non-adhesive structure is established between the molding resin and at least one of the end faces of the stator core.

Abstract: A motor comprises a baseplate, a shaft supported by said baseplate, a stator assembly having windings, the stator being rigidly attached to said baseplate, and injection molded thermoplastic material encapsulating said windings. In one embodiment, the stator is coreless. In other embodiments, the stator has a core and the core is substantially encapsulated by the thermoplastic material. In preferred embodiments, the thermoplastic material secures the stator to the baseplate or forms the baseplate.

Abstract: The invention relates to a drive arrangement with a unit comprising stator, rotor and fixed bearing in which a shaft of the motor is mounted, housed in a motor housing. An injection molded piece comprises a plug piece on an external annular piece, which comprises a branch supply line, connected to the coil of the stator and a sensor line connected to a sensor circuit board, whereby said sensor circuit board comprises at least one sensor. The injection molded piece further comprises an inner annular piece in which the fixed bearing is arranged on the side axially opposed to the shaft output of the drive arrangement.

Abstract: An electric traction motor for a vehicle including a housing, a wound stator field located in the housing, a rotor magnetically interacting with the wound stator field, high energy magnets configured in the rotor, and low energy magnets configured in the rotor.

Abstract: A motor is constructed from a stator assembly including a stator having multiple conductors that create a plurality of magnetic fields when electrical current is conducted by the conductors and a body of a phase change material such as a thermoplastic substantially encapsulating the stator. A rotatable hub having a magnet connected thereto is in operable proximity to the stator. The motor also includes a shaft, a bearing surrounding the shaft and one of the bearing or shaft being fixed to the stator assembly and the other of the bearing or shaft being fixed to the rotatable hub. Hard disc drives using the motor, and methods of developing and constructing the motor and hard disc drives are also disclosed.

Abstract: An electric motor includes a motor casing, a stator assembly, a rotor shaft assembly, first and second end bells, respectively, attached to each end of the motor casing, and an electrical inlet in the motor casing for supplying power to the motor. The motor further includes a first bearing assembly housed in the first end bell and a second bearing assembly housed in the second end bell. Both bearing assemblies and support the rotor shaft assembly and seal the interior of the motor casing from moisture. The motor also includes a heat-conductive solid resin that encapsulates the stator assembly.

Abstract: A cylindrical magnet ring assembly having a cylinder magnet flux ring (102) formed with a plurality of inwardly projecting anchors (108); a plurality of permanent magnets (104), wherein the magnet can be formed with step portions (112) in the inner radial surface; a molded plastic member (106) being molded around the magnets and anchors to secure the magnets to a surface of the cylinder flux ring. There are several variations of the embodiments of the invention. Few embodiments are the following: in one aspect of the invention, magnets are inserted into magnet molded around an assembly ring (806) and the molded plastic secures the assembly ring to the flux ring; in another aspect, there are two assembly rings, a first assembly ring (is inserted into the one side of the cylinder flux ring then the second assembly ring is inserted into the other side of the cylinder flux ring and mated to the first assembly ring, after that the molded plastic secures the two assembly rings.

Abstract: An improved synchronous electric motor incorporating a stator and large current terminal unit made into a single unit with solidified molding resin thus a separate casing is unnecessary and thus the constitution is simplified. The large current terminal unit and a magnetic pole position detector are located on opposite sides of the stator, with the former mounted on one end of the shaft of a cooperating rotor and with the other on the other end of the rotor shaft, and they are fixed in solidified molding resin to form a single body.

Abstract: A process for preparing an over molded motor stator structure comprises constructing a bobbin assembly; constructing an intermediate stator assembly including assembling the bobbin assembly to a stator core having an internal and external diameter; disposing the intermediate stator assembly into a mold fixture comprising a cover half and an ejector half that includes an inner ejector core and a moveable plate; loading a bearing carrier into the mold fixture; closing the cover half causing the moveable plate to travel within the mold; injecting a unitizing material into the mold fixture to encapsulate the intermediate stator assembly and form an over molded motor stator structure. The moveable plate travels within the mold fixture so as prevent coating of the stator laminations external diameter. A tight tolerance relationship between the inner ejector core and the stator lamination inner diameter prevents the internal diameter from being encapsulated by the unitizing material.

Abstract: A permanent magnet DC motor 10 having electro-magnetic interference (EMI) suppression includes a metal motor housing 12 and a brush card assembly 34. The brush card assembly includes brushes 20 and leads 24 constructed and arranged to be coupled with a source of power to power the motor. A brush card housing 14 has a first portion 18 housing the brushes and a second portion 22, integral with the first portion, and housing the leads. A printed circuit board 26 is mounted with respect to the second portion of the housing and carries at least one electro-magnetic interference (EMI) suppression component 30 constructed and arranged to suppress EMI generated by the motor. The leads are electrically connected to the printed circuit board so that current can be provided through the printed circuit board to the brushes.

Abstract: In a motor, a shaft passes through a magnet of a rotor and is fixed to the magnet by way of a rotor sleeve formed by resin-molding between the magnet and the shaft. A resin-molded boss is fixed to a front end of a stator, has a center hole, and defines an inner surface continuous from the center hole and beveled so as to obliquely face a front end of the rotor sleeve. A plurality of bearing balls are rotatably disposed between the front end of the rotor sleeve and the beveled inner surface of the boss, thereby constituting a ball bearing which rotatably supports the shaft. Thus, the shaft is prevented from bowing, whereby the motor achieves a high rotational accuracy of the shaft without an additional bearing attached separately.

Abstract: A brushless motor includes a highly reliable thrust-receiving member that simplifies the machining and assembling of parts and prevents deformation of the bearing and leakage of lubricating oil. A stator base has a cylindrical portion serving as a base portion of a bearing housing of the motor. The cylindrical portion is integral with the stator base. A sleeve bearing is pressed in and mounted in a fixed condition on the inner side of the cylindrical portion. A stator core consisting of a conductive wire is mounted in a fixed condition on the outer side of the cylindrical portion, thereby forming a stator. A thrust-receiving portion for the rotary shaft is molded integrally with the stator base at the opening of the cylindrical portion by outsert and resin integral molding, this thrust-receiving portion serving to receive the end of the rotary shaft opposite to the output end thereof.

Abstract: A motor includes a stator having multiple conductors that create a plurality of magnetic fields when electrical current is conducted through the conductors. The stator has a pair of opposing end surfaces in contact with each other forming a toroidal core. A monolithic body of phase change material substantially encapsulates the conductors and holds said toroidal core in place. The stator is formed by laminating strips together to form a linear core preform, winding wire around poles extending from a side of the core preform, then rolling the preform to bring its two ends together to form the toroidal core. Hard disc drives using the motor, and methods of constructing the motor and hard disc drives are also disclosed.

Abstract: An electric motor having an armature which includes a coating of thermally conductive plastic applied in a conventional injection molding process. The armature also includes a fan which is integrally formed from the thermally conductive plastic applied to the armature. This completely eliminates the need to apply one or more coatings of a trickle resin to the armature. It also eliminates the need to separately form and secure a fan by a suitable adhesive to the armature, which together significantly simplifies the manufacturing and cost of the armature. The plastic coating also better fills the spaces between the magnet wires, thus promoting even more efficient cooling and better holding of the magnet wires stationary relative to one another. The thermally conductive plastic coating may be mixed with other suitable materials to provide a density approximately equal to the magnet wires. This eliminates the need to balance the armature after the injection molding step.

Abstract: A molded motor has a motor frame molded by covering a stator made from a straight core, with a molding resin. The straight core has a stack of laminas each having a plurality of tees projecting from one long side of a belt-shaped back yoke and a V-shaped cut formed between every two adjoining tees along the back yoke and on a side from which the tees project. The straight core has an insulating layer thereon, formed by pre-molding from an insulating resin, excluding at least an inner periphery of each tee. The straight core also has a winding formed about each tee having the insulating layer formed thereon. The stator is formed by bending the straight core at cuts made therein into an arcuate or annular shape, and joining the opposite ends of the back yokes to each other by welding or adhesion.

Abstract: An impeller and at least a portion of a cooperating peripheral volute may be integrated into, and preferably are integrally injection molded with, concentric outer rotor and inner stator assemblies, respectively, to achieve a low profile precision impeller mechanism based on an improved brushless d.c. motor with low length (L) to diameter (D) ratio and suitable for use in a variety of other applications. In one practical embodiment of such a motor, a rotating cap has an inner circumference which is molded about an outer ferromagnetic back ring that in turn supports a permanently magnetized ring shaped rotor magnet having a number of poles of alternating polarity defined about its inner circumference and separated by a relatively small cylindrical air gap from the outwardly projecting radially oriented selectively magnetized poles of a fixed stator assembly. In one exemplary embodiment, the rotor may have 8 poles and the stator may have 9 poles.

Abstract: An on-vehicle AC generator that comprises a rotor; and a stator including a cylindrical stator iron core in which a plurality of slots extending in axial direction of a shaft are formed to be circumferentially aligned, and which is fitted to and supported in a case to contain the rotor therein, and a stator winding wound about the slot of the stator iron core, and which possesses a high rigidity to secure no deformation by force applied at the time of being fitted to the case. An insulating resin having adhesive properties is applied to an entire surface of the coil end portions. A corner portion formed by outer circumferential surface of the bottom of the coil end portions and an end face in axial direction of the stator iron core is also filled with the adhesive insulating resin.

Abstract: In the stator of a electric rotary machine in which heat conductive insulation resin is filled at the end portions of a stator coil, the material of a stator core, the stator coil, the heat conductive insulation resin and a frame is selected such that a linear thermal expansion coefficient ?1 of the stator core, a linear thermal expansion coefficient ?2 of the stator coil, a linear thermal expansion coefficient ?3 of the heat conductive insulation resin being filled and a linear thermal expansion coefficient ?4 of the frame satisfy a relation that ?1<?2 <?4 ??3. A cooling medium path is integrally formed within the frame made from aluminum through die casting molding.

Abstract: A resin composition having high thermal conductivity and excellent moldability and a method of producing the same is provided. The composition includes 40 vol % or more of a matrix resin, 10 to 55 vol % of a thermally conductive filler dispersed in the matrix resin and the balance of a low-melting point alloy connecting the thermally conductive filler to each other and having a melting point not higher than 500° C. The proportion of the volume ratio of the low-melting point alloy to that of the thermally conductive filler is set in a range from 1/30 to 3/1.

Abstract: A permanent magnet DC motor 10 having electromagnetic interference (EMI) suppression includes a metal motor housing 12 and a brush card assembly 34. The brush card assembly includes brushes 20 and leads 24 constructed and arranged to be coupled with a source of power to power the motor. A brush card housing 14 has a first portion 18 housing the brushes and a second portion 22, integral with the first portion, and housing the leads. A printed circuit board 26 is mounted with respect to the second portion of the housing and carries at least one electromagnetic interference (EMI) suppression component 30 constructed and arranged to suppress EMI generated by the motor. The leads are electrically connected to the printed circuit board so that current can be provided through the printed circuit board to the brushes.