A fan assembly having a reduced dimension formed by several modifications is described. The fan assembly includes a stator having stator coils positioned within a recessed portion of a pillow that receives the motor. The stator may include wire connections positioned between adjacent stator coils and designed to terminate wires of the stator coils. The wire terminations may be on a protrusion or a post positioned between adjacent stator coils, or alternatively, the wire terminations may be disposed on protruding features of a bushing. The protrusion may be formed from an electrically conductive material and electrically connected to a motor control circuit via a flexible printed circuit. In some embodiments, the protrusion is part of an electrically neutral stator bushing having several pins. Also, a gap region between the bushing and a flange feature is designed to improve an adhesive joint.

An alternator with a longer stationary coil support or bobbin and rotor axial and components thereof are provided.

An alternator with a longer stationary coil support or bobbin and rotor axial and components thereof are provided.

A bobbin for electrically insulating the stator core from a coil wire to be wound around the bobbin includes: a coil winding portion around which the coil wire is to be wound; and a terminal fixing portion to which a winding starting end portion and a winding finishing end portion of the coil wire are to be fixed. The terminal fixing portion includes a first groove configured to guide a winding starting section extending from the winding starting end portion of the coil wire to a winding starting position of the coil winding portion and a second groove configured to guide a winding finishing section extending from a winding finishing position of the coil winding portion to the winding finishing end portion of the coil wire to intersect the winding starting section when seen in an axial direction.

An electric machine includes an annular stator and a rotor disposed within the stator. The stator has a multiplicity of stator segments in a circumferential direction. Each of the stator segments has one or more inner grooves, disposed in the region of the inner circumference of the stator segment, and a winding window which is disposed in the region of the outer circumference of the stator segment. A stator winding is wound in toroidal fashion around the stator segment. The winding window is partially surrounded at its radial outer side by stator segment outer arms in such a way that a radially directed outer gap extending from the winding window to the outer circumference of the stator segment is formed between the stator segment outer arms.

A motor includes binding pins around which a coil lead wire is wound, and an end on one side in an axial direction of the binding pin and the coil lead wire are fixed to a surface facing one side in the axial direction of a substrate. An insulator assembly includes a substrate receiver contacting with the substrate from the other side in the axial direction. A heat sink is fixed to a cover, and an end on the other side in the axial direction of the heat sink presses down the integrated circuit mounted on the substrate toward the other side in the axial direction. The heat sink and the substrate receiver are disposed at positions where the heat sink and the substrate receiver overlap each other as viewed in the axial direction.

A motor includes binding pins around which a coil lead wire is wound, and an end on one side in an axial direction of the binding pin and the coil lead wire are fixed to a surface facing one side in the axial direction of a substrate. An insulator assembly includes a substrate receiver contacting with the substrate from the other side in the axial direction. A heat sink is fixed to a cover, and an end on the other side in the axial direction of the heat sink presses down the integrated circuit mounted on the substrate toward the other side in the axial direction. The heat sink and the substrate receiver are disposed at positions where the heat sink and the substrate receiver overlap each other as viewed in the axial direction.

A lamination for use in an electric machine stator includes a body having a generally circular outer periphery and a generally circular inner periphery, spaced from the outer periphery and a plurality of spaced apart teeth extending inwardly from the circular inner periphery. Each of said teeth define opposed inner edges thereof. The lamination includes a first pair of tips extending tangentially in opposed directions from the inner edge of one of said teeth and a second pair of tips extending tangentially in opposed directions from the inner edges of another one of said teeth. A tip of the first pair of tips and a tip of the second pair of tips define a first configuration having a first gap therebetween and defining a second configuration having a second gap therebetween. The first gap being substantially less than the second gap.

A three-dimensional magnet structure (6) made up of a plurality of individual magnets (4), the magnet structure (6) having a thickness that forms its smallest dimension, the magnet structure (6) incorporating at least one mesh (5a) exhibiting mesh cells each one delimiting a housing (5) for a respective individual magnet (4), each housing (5) having internal dimensions just large enough to allow an individual magnet (4) to be inserted into it, the mesh cells being made from a fibre-reinforced insulating material, characterized in that a space is left between the housing (5) and the individual magnet (4), which space is filled with a fibre-reinforced resin, the magnet structure (6) comprising a non-conducting composite layer coating the individual magnets (4) and the mesh structure (5a).

A three-dimensional magnet structure (6) made up of a plurality of individual magnets (4), the magnet structure (6) having a thickness that forms its smallest dimension, the magnet structure (6) incorporating at least one mesh (5a) exhibiting mesh cells each one delimiting a housing (5) for a respective individual magnet (4), each housing (5) having internal dimensions just large enough to allow an individual magnet (4) to be inserted into it, the mesh cells being made from a fibre-reinforced insulating material, characterized in that a space is left between the housing (5) and the individual magnet (4), which space is filled with a fibre-reinforced resin, the magnet structure (6) comprising a non-conducting composite layer coating the individual magnets (4) and the mesh structure (5a).