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Patent Searching and Data


Title:
A STATOR ASSEMBLY WITH AN OVERMOLDING THAT SECURES MAGNETS TO A FLUX RING AND THE FLUX RING TO A STATOR HOUSING
Document Type and Number:
WIPO Patent Application WO2004055956
Kind Code:
A3
Abstract:
A stator assembly (30) for an electric motor includes a stator housing (32), an expandable flux ring (34) inserted into the stator housing and a plurality of magnets (36) on an inner surface of the flux ring. Overmold material (84) is molded around the magnets in the flux ring, such as by injection molding. The pressure of the overmold material as it is being molded expands the flux ring pressing the flux ring into engagement with the stator housing. The overmold material secures the magnets to the flux ring and the flux ring to the housing. One of the flux ring and stator housing has a dimple (88) that engages a hole (90) in the other of the flux ring and stator housing to align the flux ring and stator housing. In an aspect, the overmold material is molded to form at least one of a commutator end or rear bearing support (102), front bearing support (103) and fan baffle (104). In an aspect, the overmold material is molded to form a keying feature. The keying feature can be slots (95, 96) of different widths between magnetic poles of the stator assembly. In an aspect, the flux ring and housing are preformed as a unit by stamping them from blanks and rolling them together. In a variation, the flux ring blank is rolled first to form the flux ring and the housing blank rolled around the flux ring with the flux ring acting as a rolling arbor.

Inventors:
ORTT EARL M (US)
AGNES MICHAEL J (US)
DU HUNG (US)
Application Number:
US0339145W
Publication Date:
May 18, 2006
Filing Date:
December 10, 2003
Export Citation:
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Assignee:
BLACK & DECKER INC.
ORTT, EARL, M.
AGNES, MICHAEL, J.
DU, HUNG
International Classes:
B25F5/00; H02K1/00; H02K1/12; H02K1/17; H02K1/18; H02K5/00; H02K5/08; H02K5/173; H02K15/03; H02K23/04; H02K; (IPC1-7): H02K1/04; H02K1/14; H02K1/17; H02K1/18; H02K1/27; H02K5/02; H02K5/04; H02K5/15; H02K15/02; H02K15/14; H02K21/06; H02K21/26; H02K21/28; H02K23/04
Foreign References:
US5268607A1993-12-07
US5861695A1999-01-19
US5475276A1995-12-12
US5783888A1998-07-21
US4015154A1977-03-29
US4873461A1989-10-10
US4682066A1987-07-21
US4935655A1990-06-19
Other References:
See also references of EP 1588469A4
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