Combination fan-flywheel-pulley assembly and method of forming

A fan-flywheel-pulley assembly for use in conjunction with an electric motor, the assembly comprising:

• a pulley positioned about a central axis;
• a flywheel coupled to the pulley and positioned about the central axis, the flywheel including an outer circumferential flywheel surface at least partially defining a plurality of circumferentially spaced openings, and wherein a portion of the flywheel extends circumferentially about a cylindrical wall unit of the motor from an inner diameter to an outer diameter, wherein the portion creates a baffle positioned in close proximity to the cylindrical wall unit to limit a gap between the baffle and the cylindrical wall unit;
• and
• a radial fan disposed within the flywheel and positioned about the central axis including a plurality of blades, wherein each of the plurality of blades extends at least from the inner diameter to the outer diameter of the flywheel so that one of the plurality of openings are positioned between each adjacent blade of the plurality of blades;
• wherein the pulley, the flywheel, and the radial fan are integrally formed.

An electric motor comprising:

• a shaft rotatably mounted about a central axis;
• a housing enclosing the motor and including a cylindrical wall unit having a front plate connected to a front end of the cylindrical wall unit and a back plate connected to a back end of the cylindrical wall unit;
• and
• an integral fan-flywheel-pulley assembly coupled to the shaft including:
• a pulley including a circumferential pulley surface extending along the central axis;
• a flywheel coupled to the pulley and positioned about the central axis and extending circumferentially from an inner diameter to an outer diameter, the flywheel including an outer circumferential flywheel surface at least partially defining a plurality of circumferentially spaced openings and further including a baffle extending over and in close proximity to the cylindrical wall unit of the motor to reduce leakage of air between the baffle and the cylindrical wall unit and thereby improve air flow through the motor;
• and
• a radial fan disposed within the flywheel and positioned about the central axis including a plurality of blades, wherein each of the plurality of blades are curved and extend at least from the inner diameter to the outer diameter of the flywheel so that one of each of the plurality of circumferentially spaced openings are positioned between each adjacent blade of the plurality of blades, and wherein the radial fan draws air through the motor;
• wherein the pulley, the flywheel, and the radial fan are integrally formed.