Rotor shaft coupling

A rotor comprising:

• a shaft;
• a support member having a peripheral portion and an interior rim, the interior rim defining a central opening that receives and fixedly coupled to the shaft, wherein the shaft is substantially coaxial with the support member;
• the shaft has a groove that forms a securing flange at the end of the shaft nearest the support member;
• the interior rim having first and second portions, the first portion of the interior rim being less than 360 degrees around the shaft, the first portion of the interior rim being spaced in a first direction from the peripheral portion, the second portion of the interior rim being spaced in a second direction from the peripheral portion,
• the first and second directions being substantially parallel to the shaft,
• the first and second directions being different directions so that ends of the first portion and ends of the second portion are spaced from each other in a direction that is substantially parallel to the shaft;
• an impeller or propeller coupled to the support member;
• a fill material that secures the impeller or propeller to the securing flange of the shaft and the first and second portions;
• and
• an annular magnet circumscribing an interior of the support member.

A motor comprising:

• a stator;
• the stator having a circuit board, an arbor, and a plurality of coils, wherein the circuit board includes a magnetic sensor so that the flow of current to the plurality of coils can be controlled;
• a shaft, wherein the shaft has a groove that forms a securing flange at the end of the shaft nearest the support member;
• and
• a rotor having a support member, an impeller or propeller coupled to the support member and an annular magnet circumscribing an interior of the support member, the support member having a peripheral portion and an interior rim, the interior rim defining a central opening, the interior rim also diverging from the peripheral portion, the interior rim having a first portion and a second portion, the first portion diverging downwardly and the second portion diverging upwardly from the peripheral portion relative to a horizontal so that ends of the first portion are spaced from ends of the second portion in a direction substantially parallel with the shaft;
• the shaft being fixedly coupled to the support member within the central opening of the support member, the first portion of the interior rim being less than 360 degrees around the shaft,
• the shaft also being rotatably coupled with the stator.

A fan assembly comprising:

• a housing;
• a motor having a stator;
• the stator having a circuit board and an arbor, wherein the circuit board includes a magnetic sensor so that the flow of current to the plurality of coils can be controlled;
• a rotor having a support member having a peripheral portion and an interior rim, the interior rim defining a central opening;
• a plurality of diverging members extending from the support member, wherein the plurality of diverging members extend from the peripheral portion;
• a shaft fixedly coupled to the support member within the central opening of the support member, the diverging members extending toward the shaft, each diverging member extending less than 360 degrees around the shaft, at least one of the diverging members diverging downwardly and at least one of the diverging members diverging upwardly from the peripheral portion relative to a horizontal so that ends of the diverging members are spaced from each other in a direction that is substantially parallel to the shaft, and wherein the plurality diverging members that define the central opening and diverge from the peripheral portion terminate at the interior rim;
• wherein the shaft has a groove that forms a securing flange at the end of the shaft nearest the support member;
• a bearing above the stator and a bearing below the stator, wherein the bearings are secured within the arbor to receive the rotor shaft;
• an impeller or propeller coupled to the support member;
• an annular magnet circumscribing an interior of the support member;
• a fill material that secures the impeller or propeller to the shaft and the plurality of diverging members, wherein the fill material fills the central opening and is formed over at least a portion of the diverging member;
• wherein the securing flange acts as an anchor to secure the shaft to the fill material;
• and
• wherein the rotor and motor are located in the housing.