Circuit board assembly for compact brushless motor

A motor assembly comprising:

• a stator including a stator core, a plurality of stator windings, and a routing insulator configured 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;
• a plurality of stator terminals supported by the end insulator and extending away from the stator;
• and
• a circuit board including a plurality of mounting regions arranged to be mounted on and electrically connect to the plurality of stator terminals, the circuit board having a plurality of conductive traces facilitating interconnections between the plurality of stator windings;
• and
• a bearing bridge including a body forming a center pocket arranged to support a bearing of the rotor shaft, wherein the bearing bridge is received at least partially within the routing insulator and is located between the circuit board and the rotor core along the longitudinal axis.

A motor assembly comprising:

• a stator including a stator core, a plurality of stator windings, and a routing insulator configured to electrically insulate the stator core from the plurality of stator windings, the routing insulator including an annular body extending away from the stator core and a plurality of non-conductive axial posts extending from the annular body opposite the stator core;
• 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 circuit board having a plurality of conductive traces facilitating interconnections between the plurality of stator windings,
• wherein the circuit board is mounted in contact with the plurality of non-conductive axial posts of the routing insulator such that a portion of the plurality of non-conductive axial posts extends past the circuit board along the longitudinal axis in a direction away from the stator core, the plurality of stator windings is wound from a continuous magnet wire having cross-over portions between the adjacent stator windings, and the cross-over portions extend in contact with the plurality of non-conductive axial posts to make electrical connections directly with metal parts of the circuit board.