Magnet assembly for a motor and method of making same

摘要

A cylinder/magnet assembly for a field of an electric machine, such as a stator of a brush type motor or a rotor of a brushless motor, alternator or generator, is formed by inserting pre-formed magnets on a cylinder having anchors. Plastic is molded around the magnets and anchors to secure the magnets to a surface of the cylinder. In another aspect of the invention, magnets are inserted into magnet pockets of an assembly ring. The assembly ring is inserted into a cylinder and plastic molded around the assembly ring and magnets to secure the assembly ring and magnets to the cylinder. In another aspect of the invention, magnets are inserted in a first assembly ring which is then inserted in one side of a cylinder. A second assembly ring is inserted into the other side of the cylinder and mated to the first assembly ring. Plastic is molded around the assembly rings and magnets to secure them to the cylinder. In another aspect of the invention, magnets are inserted into magnet receiving pockets of a cylinder and plastic molded therearound. In another aspect of the invention, the north and south poles of a cylinder and magnet assembly have unequal distribution angles. In another aspect of the invention, the north and south poles a cylinder and magnet assembly have unequal numbers of magnets. In another aspect of the invention, the anchors are also formed as flux spreaders. In another aspect of the invention, flux spreaders are disposed on inner surfaces of the magnets of each pole of a cylinder and magnet assembly. In another aspect of the invention, the foregoing aspects are used in a stator of a motor. In another aspect of the invention, such a stator is used in a power tool. <IMAGE>