Motor controller can with synthetic housing and metal heat sink

An electric motor comprising:

• a rotor rotatable about an axis;
• a stator;
• and
• a motor housing including a controller can comprising a synthetic can housing and a metal insert thermal conductor,
• said synthetic can housing defining a slot,
• said metal insert thermal conductor being inserted into the slot,
• said metal insert thermal conductor comprising a flange inserted into the slot,
• said slot being defined adjacent a first side of the metal insert thermal conductor,
• said synthetic can housing defining a second slot adjacent a second side of the metal insert thermal conductor opposite of the first side,
• said metal insert thermal conductor comprising a second flange inserted into the second slot,
• said first and second flanges engaging with respective ones of the first and second slots to restrict circumferential movement of the metal insert thermal conductor with respect to the synthetic can housing.

An electric motor comprising:

• a rotor rotatable about an axis;
• a stator;
• and
• a motor housing including a controller can comprising a synthetic can housing and a metal insert thermal conductor,
• said synthetic can housing defining a slot,
• said metal insert thermal conductor being inserted into the slot,
• said controller can presenting an exposed surface area facing an external heat sink space,
• said metal insert thermal conductor presenting between ten percent (10%) and forty percent (40%) of the exposed surface area.

An electric motor comprising:

• a rotor rotatable about an axis;
• a stator;
• and
• a motor housing including a controller can comprising a synthetic can housing and a metal insert thermal conductor,
• said synthetic can housing defining a slot,
• said metal insert thermal conductor being inserted into the slot,
• said synthetic can housing including an end plate comprising a thermally insulative material,
• said metal insert thermal conductor comprising thermally conductive material,
• said thermally insulative material having a thermal conductivity at least four (4) times less than a thermal conductivity of the thermally conductive material.

An electric motor comprising:

• a rotor rotatable about an axis;
• a stator;
• a motor housing including a controller can comprising a synthetic can housing and a metal insert thermal conductor, and
• a controller including a printed circuit board and at least one electronic component,
• said metal insert thermal conductor being thermally connected to the controller,
• said synthetic can housing defining a slot,
• said metal insert thermal conductor being inserted into the slot,
• said synthetic can housing including an end plate,
• said printed circuit board being mounted to a spacer at least partly disposed between the printed circuit board and the end plate,
• said spacer comprising a ground mounting pad in electrical communication with the metal insert thermal conductor.

An electric motor comprising:

• a rotor rotatable about an axis;
• a stator;
• and
• a motor housing including a controller can comprising a synthetic can housing and a metal insert thermal conductor,
• said synthetic can housing defining a slot,
• said metal insert thermal conductor being inserted into the slot,
• said metal insert thermal conductor having an outer surface comprising a plurality of heat transfer fins.

An electric motor comprising:

• a rotor rotatable about an axis;
• a stator;
• and
• a motor housing including a controller can comprising a synthetic can housing and a metal insert thermal conductor,
• said synthetic can housing defining a slot,
• said metal insert thermal conductor being inserted into the slot,
• said can housing comprising a skirt, wherein said skirt defines a plurality of arcuately-spaced drainage holes.