Brushless direct current motor for power tools
AssigneeMilwaukee Electric Tool Corporation
InventorsAndrew T. Beyerl, Keith Boulanger, Matthew R. Bailey, Carl B. Westerby
Life of this patent
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Abstract
A method of manufacturing a brushless electric motor including providing a stator that includes a core defining a plurality of stator teeth, positioning a rotor within the stator, coupling a stator end cap to an end of the core, winding a plurality of coils on the plurality of stator teeth, and overmolding a plurality of coil contact plates within the stator end cap. The coil contact plates short-circuit diagonally opposite coils on the stator.
Claims20
A method of manufacturing a brushless electric motor, the method comprising:
- providing a stator that includes a core defining a plurality of stator teeth;
- positioning a rotor within the stator;
- coupling a stator end cap to an end of the core;
- winding a plurality of coils on the plurality of stator teeth;
- and
- overmolding a plurality of coil contact plates within the stator end cap, wherein the plurality of coil contact plates short-circuit diagonally opposite coils on the stator.
A method of manufacturing a brushless electric motor, the method comprising:
- providing a stator that includes a core defining a plurality of stator teeth and a recess;
- positioning a rotor within the stator;
- coupling a stator end cap to an end of the core;
- aligning the stator end cap to the end of the core by receiving a projection of the stator end cap in a recess of the core;
- and
- winding a plurality of coils on the plurality of stator teeth and end cap teeth of the stator end cap.
A method of manufacturing a brushless electric motor, the method comprising:
- providing a stator that includes a core defining a plurality of stator teeth;
- positioning a rotor within the stator;
- coupling a stator end cap to an end of the core;
- winding a plurality of coils on the plurality of stator teeth;
- inserting a plurality of coil contact plates within a groove of the stator end cap;
- maintaining an air gap between adjacent coil plates of the plurality of coil contact plates via a plurality of ribs in the groove;
- and
- applying a resin layer to the stator end cap and the plurality of coil contact plates.
Dependencies are inferred from the claim text.