Compact brushless motor including in-line terminals

A motor comprising:

• a stator including a stator core, a plurality of stator windings, and a routing insulator provided at an axial end of the stator core to electrically insulate the stator core from the plurality of stator windings;
• a rotor rotatably received within the stator and including a rotor shaft extending along a longitudinal axis and a plurality of permanent magnets;
• and
• a plurality of stator terminals supported by the routing insulator and extending away from the stator, each stator terminal including:
• a main body having a first portion mounted at or near an outer periphery of the routing insulator and a second portion extending angularly-inwardly from a first side of the first portion, a tang portion folded over the second portion of the main body and receiving a portion of a magnet wire therein to make an electrical connection with at least one of the stator windings, and a terminal pin projecting axially from a second side of the first portion.

A motor comprising:

• a stator including a stator core and a plurality of stator windings;
• a rotor rotatably received within the stator and including a rotor shaft extending along a longitudinal axis and a plurality of permanent magnets;
• a routing insulator mounted on the stator core and including an annular body and plurality of inwardly-projecting teeth configured to electrically insulate the stator core from the plurality of stator windings;
• and
• a plurality of stator terminals mounted on the routing insulator, each stator terminal including a main body extending over the annular body of the routing insulator at an angular width of approximately at least 33 degrees relative to a center of the stator core along a circumferential direction, a tang portion folded over the main body to receive a portion of a magnet wire therein to make an electrical connection with at least one of the stator windings, and a terminal pin extending axially in a direction away from the stator core;
• wherein the stator terminals are fully contained within an outer envelope of the stator defined by an outer circumferential surface of the stator core, and
• wherein the main body of each stator terminal includes a first portion and a second portion, wherein, from an axial viewpoint, the first portion is radially outward of a gap formed between adjacent inwardly-projecting teeth of the routing insulator, and the second portion is radially aligned with a first stator winding of the plurality of stator windings that is adjacent the gap.