Direct current electric motor which eliminates outer case and places brushes and chokes in space efficient locations

A motor and fan structure comprising:

• a direct current motor assembly comprising:
• a stator assembly including a flux plate and permanent magnet structure mounted on the flux plate, the flux plate defining one end of the motor assembly and defining a magnetic flux path of the motor assembly, and
• a generally cylindrical armature assembly defining another end of the motor assembly, the armature assembly being radially wound with wire windings, and an outermost part of the armature assembly and at least a portion of the wire windings being exposed to the environment, and
• a fan including a generally cylindrical hub receiving and covering the exposed outermost part and the portion of the windings of the armature assembly, the hub having a plurality of blades extending therefrom.

A method of providing a fan and motor structure, the method including:

• providing of direct current motor assembly comprising:
• a stator assembly including a flux plate and permanent magnet structure mounted on the flux plate, the flux plate defining one end of the motor assembly and defining a magnetic flux path of the motor assembly, and
• a generally cylindrical armature assembly defining another end of the motor assembly, the armature assembly being radially wound wire with windings, and an outermost part and at least a portion of the wire windings of the armature assembly being exposed to the environment,
• providing a fan including a generally cylindrical hub sized to receive the outermost part and the portion of the windings of the armature assembly, the hub having a plurality of blades extending therefrom, and
• using the fan as a cover by inserting the exposed outermost part of the armature assembly and portion of the wire windings into the hub so that the hub covers the outermost part and portion of the windings, thereby preventing exposure thereof to the environment.

A method of assembling a direct current motor including:

• providing a stator assembly including a flux plate and four permanent magnets mounted on the flux plate in a manner to define a generally circular outline and defining first and second pairs of spaces between adjacent magnets, the flux plate defining one end of the motor assembly and defining a magnetic flux path of the motor assembly,
• placing a pair of brushes into the first pair of spaces by placing each brush in an associated space of said first pair of spaces,
• placing a pair of chokes into the second pair of spaces by placing each choke in an associated space of said second pair of spaces, and
• providing an armature assembly adjacent to the stator assembly to define another end of the motor assembly, the armature assembly being radially wound with windings, with an outermost part and at least a portion of the windings of the armature assembly being exposed to the environment.