Method for manufacturing a claw pole stator structure

Abstract

A multipole brushless DC motor stator is formed with a pair of complementary opposable claw pole stator structures in which each of the stator structures comprises a stator base formed of a plurality of stacked sheet metal laminations. A plurality of stator pole members extend from the stator base and are formed by compression molding of a ferromagnetic material. In one form, the ferromagnetic material is molded in situ on the stator base by positioning the stator base in a compression mold having the slots in which a powdered or flaked ferromagnetic material can be positioned and compressed by a die. In another form, the ferromagnetic pole members may be independently compression molded of powdered or flaked ferromagnetic material and then adhesively bonded to the stacked laminations forming the stator base. In either method, the stacked laminations are formed with a plurality of receptacles for receiving one end of each of the stator poles and holding the stator poles to the stator base.

Dependencies are inferred from the claim text.