Method for forming an electric motor having armature coated with a thermally conductive plastic

摘要

A method for forming an electric motor includes providing a stator and an armature having a lamination stack with slots therein in which magnet wires are wound. Thermally conductive plastic is molded over at least a portion of the armature to at least partially encase the magnet wires and to mold a fan. The fan is molded without any portion of the fan extending into the slots in the lamination stack of the armature to increase the volume in the slots in which the magnet wires can be wound and the magnet wires are wound in this increased volume when they are wound in the slots in the lamination stack to increase a power rating of the electric motor beyond what is normally attainable with a fan component having portions extending into the slots in the lamination stack.