Various embodiments relate to a motor in which a structure of an insulator is improved. The motor includes an insulator module coupled to a top face of a stator core. The insulator module includes: each power terminal unit connected to each of 3-phases power lead wires; a neutral terminal unit connected to a neutral point of a coil; and an insulator body for achieving insulations between the power and neutral terminal units and the stator core, and between the power and neutral terminal units, wherein the power terminal unit and the neutral terminal unit are positioned at different vertical levels.

An electric motor includes three busbars in contact at end surfaces thereof and including ring-segment-shaped base portions to provide electrical connection of the busbars. The base portion of a first busbar is in a first plane and the base portion of a second busbar is in a second plane. The base portion of the first busbar extends clockwise from the terminal of the first busbar and the base portion of the second busbar extends counterclockwise from the terminal of the second busbar. Terminals of the first and second busbars are spaced apart with the terminal of the third busbar between the first and third terminals. The third busbar includes a first region extending clockwise from its terminal and lying in the second plane and a second region extending counterclockwise from its terminal and lying in the first plane.

In a brushless motor including a stator core and a rotor which rotates with respect to the stator core, a coil support wall supports a coil wound around a core main body part from a radially inner side of the core main body part. A first wall part and a second wall part constituting the coil support wall are connected to each other at an angle at a portion of a tooth tip part protruding from a tooth main body part along a circumferential direction of the core main body part, and a thickness dimension of the second wall part is equal to or larger than a thickness dimension of the first wall part along a radial direction of the core main body part.

A brushless DC motor (BLDC) includes a stator having a ring-shaped body with multiple stator posts extending axially outward from the ring-shaped body. A plurality of stator windings are each wound about a corresponding one of the stator posts. A rotor support structure is positioned radially inward of the multiple stator posts. A rotor including a shaft is received in the rotor support structure. A first rotor disk is fixed to a first end of the shaft. At least a first set of magnets is disposed about the rotor disk and positioned radially adjacent to the stator posts such that the first set of magnets and the stator windings define a first radial flux flowpath. A second set of magnets positioned relative to the stator posts in one of an axial adjacency or a radial adjacency such that a second flux flowpath is defined.

A stator for an electric machine comprises a cylindrical core defining an inner cylindrical surface and an outer cylindrical surface with a plurality of slots formed between the inner cylindrical surface and the outer cylindrical surface. Windings are positioned on the cylindrical core. The leads of the windings include a plurality of inner leads associated with conductors in an inner layer of the slots and a plurality of outer leads associated with conductors in an outer layer of the slots. A bus bar assembly includes a plurality of inner bus bars and a plurality of outer bus bars, the plurality of inner bus bars connected to the plurality of inner leads, and the plurality of outer bus bars connected to the plurality of outer leads. The plurality of outer bus bars are positioned radially outward from the end turns of the windings and radially inward from the outer cylindrical surface.

A modular DC motor includes a stator module having a stator core. The stator core has a ring-shaped base defining an axis and a plurality of stator posts protruding axially outward from the ring shaped based. A plurality of coils are wound around the stator posts. Each stator post extends axially beyond the corresponding coil. A shaft support is radially inward of the stator ring shaped base and is connected to the ring-shaped base. The shaft support is configured to support a rotor shaft relative to the stator core. The stator module is configured to receive one of a plurality of rotor modules. An operation of the modular DC motor is dependent on the physical configuration of the received one of the plurality of rotor modules. Each rotor module in the plurality of rotor modules has a distinct magnetic configuration from each other rotor module in the plurality of rotor modules.

An apparatus and methods are provided for a segmented stator comprising over-molded windings and an incorporated bus bar for a multi-phase electric motor. The segmented stator comprises a plurality of stator segments that are arranged into a circular configuration. Each stator segment comprises a divided core that includes a core back portion and a core tooth portion. An insulator is disposed on at least the core tooth portion, and a winding of magnet wire is disposed on the insulator. An over-molded encapsulation is applied to fixate the divided core and the winding. A bus bar is incorporated into the stator segments and placed into electrical communication with the windings. The bus bar includes annular conductors that may be over-molded such that the bus bar is encapsulated within the segmented stator. Connectors coupled with the bus bar are configured for passing an electric current to the stator segments.

A method for manufacturing an electro-mechanical device includes creating a plurality of substrates using a first additive manufacturing process. Each of the substrates includes a polymeric material. The substrates include a first substrate and a second substrate. The first substrate includes a first main body and defines a protrusion extending from the first main body. The second substrate includes a second main body and a recess defined in the second main body. The method includes coupling the first substrate to the second substrate by inserting the protrusion into the recess such that the protrusion elastically deforms to an elastically averaged configuration. The protrusion and the recess together form an elastic averaging coupling. The method includes creating a plurality of electrically conductive components using a second additive manufacturing process and then coupling the electrically conductive components to at least one of the substrates.

One aspect of a pump of the present invention includes a rotor rotatable about a central axis, a stator assembly located radially outside the rotor and surrounding the rotor, a pump unit connected to a first side in an axial direction of the rotor, a support member including a rotor accommodating portion, the rotor accommodating portion being located radially inside the stator assembly and accommodates the rotor therein, and a resin housing in which the stator assembly and the support member are molded. The rotor accommodating portion includes a lid portion that covers the rotor from a second side in the axial direction, and a tubular portion that is located between the rotor and the stator assembly in a radial direction and is open to the first side in the axial direction. The stator assembly includes a stator core having an annular shape, a plurality of coils mounted on the stator core, and a stator cover that covers the plurality of coils.

A power tool is provided including a gear case having a spindle, a motor case connected to a rear end of the gear case along a longitudinal axis; a handle portion extending from a rear end of the motor case along the longitudinal axis; a motor housed inside the motor case; a fan in rotational connection with the motor; at least one air intake arranged at least one of the motor case or the handle portion near the rear end of the motor case; and a power module including power switches for driving the motor and a heat sink. The power module is housed in at least one of the motor case or the handle portion near the rear end of the motor case such that rotation of the fan causes air flow to enter through the air intake and flow near the heat sink and through the motor.