Synchronous reluctance motor having a stator with stacked laminations and a method of construction

A motor comprising:

• a plurality of pre-wound stator segments having a plurality of winding sections and a plurality of bobbins, each pre-wound stator segment of the plurality of pre-wound stator segments comprising:
• stacked tooth laminations that form a core portion and a tooth portion;
• a bobbin of the plurality of bobbins that is slidably positioned over the tooth portion of the stacked tooth laminations;
• and
• a respective winding section of the plurality of winding sections that is positioned around the bobbin;
• wherein:
• each pre-wound stator segment is coupled to two adjacent pre-wound stator segments to form an outer ring with each tooth portion extending inward, wherein each core portion forms a portion of the outer ring;
• and
• the plurality of winding sections are coupled to form at least one phase winding of the plurality of pre-wound stator segments, wherein the at least one phase winding defines a plurality of stator poles that are configured to be selectively energized.

A method for forming a rotor for an electric motor, the method comprising:

• forming rotor laminations having reluctance sections removed from each of the rotor laminations;
• stacking the rotor laminations to form a rotor body, wherein connecting webs of the reluctance sections are aligned to define reluctance voids within the rotor body;
• disposing opposing end caps on the rotor body to enclose the reluctance voids and maintain spaces of the reluctance voids;
• and
• overmolding the rotor body with an overmold material, wherein the opposing end caps prevent infiltration of the overmold material into the spaces of the reluctance voids.