Method of manufacturing a motor element of an electric motor

A method of manufacturing an inside out salient pole stator of an electric motor having a ferromagnetic circuit including a set of poles having pole faces, said poles being adapted to receive electrical windings thereon and being spaced radially from a shaft carrier mounting means comprising:

• providing a strip of lightly insulated ferromagnetic material shaped with poles extending from a yoke portion;
• winding said strip of ferromagnetic material edgewise and helically thereby providing a plurality of radially outwardly directed laminated poles extending from a radially disposed yoke and having radially outward facing pole faces thereon thereby forming a ferromagnetic circuit, adjacent laminations being separated only by said light insulation;
• providing a plastics injection molding die having walls defining a cavity for receiving injection molding plastics material including wall portions defining a part of said cavity for forming a shaft carrier mounting means, and a cylindrical face therein;
• fixing said ferromagnetic circuit as an integral unit in said plastics injection molding die with said pole faces in closely fitting relationship against said cylindrical face of said die;
• injecting a plastics material into said die cavity thereby forming a plastics molding having said ferromagnetic circuit, except said pole faces, embedded therein, a shaft carrier mounting means and a web between said embedded ferromagnetic circuit and said shaft carrier mounting means as parts thereof;
• cooling said plastics material;
• and
• holding said pole faces and shaft carrier mounting means in fixed position relative to each other thereby maintaining substantial concentricity between said pole faces and said shaft carrier mounting means during said cooling of said plastics material.