A stator assembly for a brushless DC motor includes a stator core including stator poles and an outer surface, at least one magnet wire wound on the poles forming stator windings, and a bus bar including a non-conductive mount and conductive terminals. Each conductive terminal includes: a main portion and a tang portion extending from a first longitudinal end of the main portion. At least a contact portion of the at least one magnet wire is wrapped around the tang portion and fused to make an electric connection to the conductive terminal. The tang portion has a smaller lateral width than the main portion and is folded over the main portion to capture the contact portion of the at least one magnet wire. A power wire supply electric power to the motor is coupled to the conductive terminal proximate the second longitudinal end of the main portion.

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 axial field rotary energy device can include a rotor comprising an axis of rotation and a magnet. In addition, a stator can be coaxial with the rotor. The stator can include a plurality of stator segments that are coupled together about the axis. Each stator segment can include a printed circuit board (PCB) having a PCB layer comprising a coil. Each stator segment also can include only one electrical phase. The stator itself can include one or more electrical phases.

A high voltage electric machine and power distribution system including one or more of such electric machines are provided. In one aspect, a high voltage electric machine includes a stator, a rotor, and a housing encasing at least a portion of the stator and rotor. The stator is modularized into cascaded voltage stator modules. The stator modules are galvanically isolated from one another by intermodular separators. At least one intermodular separator is positioned between each adjacent pair of stator modules. The stator modules are also galvanically isolated from the housing by a housing separator. The housing separator is positioned between the stator modules and the housing. Each stator module has an associated set of windings that are wound only within their associated stator module.

A stator assembly for a brushless DC motor includes a stator core defining poles and having an outer surface, at least one magnet wire wound on the poles forming phases, and a bus bar including a non-conductive mount arranged on the outer surface and conductive terminals. Each conductive terminal includes: a main portion mounted on the non-conductive mount substantially parallel to the longitudinal axis of the motor, a tang portion folded over the main portion from a first longitudinal end of the main portion, and a connection tab at a second longitudinal end of the main portion. At least a contact portion of the at least one magnet wire is wrapped around the tang portion and fused to make an electric connection to the conductive terminal, and the connection tab is arranged to makes electric contact with a wire supplying electric power to the motor.

An electric motor is provided including: a stator assembly having a lamination stack defining poles and magnet wires wound on the poles, and a rotor rotatably arranged inside the stator assembly. A mount having a curved profile and made of non-conductive material is provided. Conductive terminals are mounted on and secured to a first surface of the mount, the conductive terminals being separated and insulated from each other via portions of the mount. A second surface of the mount opposite the first surface is mounted over to an outer surface of the lamination stack in contact therewith to align the plurality of conductive terminals longitudinally along the outer surface of the lamination stack.

An electric motor is disclosed having a detachable stator tooth. In some implementations, coil windings of the electric motor may be coupled to one or more drivers independently of other coil windings. A method of repairing and manufacturing an electric motor having a detachable stator tooth is also disclosed.

A two degree-of-freedom electromagnetic machine includes an inner stator, a plurality of stator windings, an outer stator, a voice coil winding, a rotor, a plurality of spin magnets, and a plurality of tilt magnets. The plurality of stator windings, when electrically energized, impart a torque on the rotor that causes the rotor to rotate, relative to the inner and outer stators, about a first rotational axis, and the voice coil winding, when electrically energized, imparts a torque on the rotor that causes the rotor to rotate, relative to the inner and outer stators, about a second rotational axis that is perpendicular to the first rotational axis.

The present disclosure provides hybrid stator core components for an axial flux motor stator and methods for making the same. The hybrid stator core component includes a molded soft magnetic composite material and a laminated component. In one variation, a laminated insert comprising a plurality of insulated layers is non-releasably seated within a molded soft magnetic composite material. In another variation, a hybrid stator core component has a molded soft magnetic composite core and a laminated shell comprising a plurality of layers disposed around at least a portion of the molded soft magnetic composite core.

The purpose of the present invention is to ensure reliability and installation space reduction of crossover wires of an axial gap type rotary electric machine. An axial gap type rotary electric machine having: a stator which is constructed by annularly arranging multiple core units about an axis of rotation, each of the core units having at least a core, windings disposed around the outer periphery of the core, and crossover wires leading out from the windings; at least one rotor which faces an axial end surface of the cores with a gap therebetween; and a rotary shaft which rotates along with the rotor. The axial end surface side and the outer diameter side of the stator, is provided with multiple wiring support sections, each having an arc-shaped base part extending in a rotational direction along the annular shape of the outer diameter side of the stator, wherein the base part has a length extending over the outer diameter-side end surfaces of two or more adjoining core units and a predetermined axial width, and is equipped with multiple axial grooves for guiding the crossover wires in the rotational direction which are disposed on the opposite surface of the base from the rotary shaft. The rotary electric machine has a molding resin for integrally molding the wiring support sections with the stator.