AU2003293467B2 - A stator assembly with an overmolding that secures magnets to a flux ring and the flux ring to a stator housing - Google Patents

Description

A STATOR ASSEMBLY WITH AN OVERMOLDING THAT SECURES MAGNETS TO A FLUX RING AND THE FLUX RING TO A STATOR HOUSING CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is related to U.S. Patent Application No. 10/468,643 filed August 20, 2003, which is a 371 National Phase filing of PCT International Application PCTIUS02/05029 filed February 22, 2002 (International Publication Number WO 02/068235 A2) which claims the 10 benefit of U.S. Provisional Application No. 60/271,141 filed February 23, 2001.

This application claims the benefit of U.S. Provisional Application No. 60/433,496 filed December 13, 2002. The disclosures of the above applications are incorporated herein by reference.

FIELD OF THE INVENTION [0002] The present invention relates to electric motors, and more particularly to stator assemblies for electric motors.

BACKGROUND OF THE INVENTION >0 [0003] In the construction of stator assemblies for permanent magnet electric motors, magnets are retained within the stator assembly. For example, in a brush-type permanent magnet electric motor, magnets are retained on a stator housing or a separate flux ring within the stator housing. This generally requires gluing or adhering each individual magnet to the flux ring or stator housing.

[0004] Various types of adhesives have been used to adhere the magnets to the metallic surface. It is possible that a sudden shock to the electric motor will destroy the bond between the magnet and the flux ring or stator housing. This would result in movement of the magnet within the stator assembly. The magnet itself could even break. As a result, the electric motor ceases to properly function.

[0005] It is known in the art to provide an anchor in the flux ring or stator housing. Magnetic material is then injection molded on the flux ring or P OPER\D0,1261220 29 1w 07 sp a dom-26 I2007 -2stator housing and is retained in position by the anchor. Such an anchor system is disclosed in U.S. Patent No. 6,522,042 issued February 18, 2003 entitled Anchoring System for Injection Molded Magnets on a Flux Ring or Motor Housing and in U.S. Application Serial No. 09/764,004 filed January 17, 2001 entilted Achoring System for Injection Molded Magnets on a Flux Ring or Motor Housing.

However, a disadvantage of the anchoring systems described in the aboveidentified patent applications is that they require the use of injection molded magnetic material. This is typically the most expensive type of magnetic material per unit flux.

I0 SUMMARY OF THE INVENTION [0006] Accordingly, the present invention provides a stator assembly, comprising: a housing; a flux ring disposed on an inner surface of the housing wherein the housing and the flux ring are separately formed and the flux ring is disposed on the inner surface of the housing after the housing is formed, the flux ring including anchors extending radially inwardly; a plurality of permanent magnets disposed around an inner surface of the flux ring between the anchors; and a material overmolded around the plurality of magnets and the anchors to secure the magnets to the flux ring and to secure the flux ring to the housing.

[0007] In another aspect, there is provided a stator assembly, comprising: a housing; a flux ring disposed on an inner surface of the housing wherein the housing and the flux ring are separately formed and the flux ring is disposed on the inner surface of the housing after the housing is formed; a material overmolded around the plurality of magnets to secure the magnets to the flux ring and to secure the flux ring to the housing; and P \OPERO )M116122019 07 Wp.3 doc-26/10120( -3- 0 the flux ring including a seam that allows the flux ring to be compressed for Cc insertion into the housing during assembly, the overmold material expanding the flux ring against the housing.

[0008] In another aspect of the invention, there is provided a stator C 5 assembly comprising: c- a housing; Sa flux ring disposed within the housing, the flux ring having a seam that C- allows the flux ring to be compressed for insertion into the housing during assembly; a plurality of permanent magnets disposed around an inner surface of the flux ring, each magnet disposed between at least two anchors extending radially inwardly from an inner surface of the flux ring; and a material overmolded around the plurality of magnets and the anchors to secure the magnets to the flux ring, to secure the flux ring to the housing by expanding the flux ring against the housing and to prevent the flux ring from compressing by filling the seam of the flux ring.

[0009] In another aspect of the invention, there is provided a stator assembly comprising: a housing; a flux ring disposed on an inner surface of the housing wherein the housing and the flux ring are separately formed and the flux ring is disposed on the inner surface of the housing after the housing is formed; a plurality of permanent magnets disposed around an inner surface of the flux ring; a material overmolded around the plurality of magnets to secure the magnets to the flux ring; and at least one of a rear bearing support, front bearing support and fan baffle integrally formed of the overmold material during molding of the overmold material.

[0010] In another aspect of the invention, there is provided a power tool comprising: a housing; and P \OPERDI-'1261,R220O 29 J, O7 spa3 doC.-2/IOf207 -3a- ,1 0 a motor disposed within the housing and having an output coupled to a c transmission, the motor having a stator assembly having a flux ring disposed on an inner surface of a stator housing wherein the stator housing and the flux ring are separately formed and the flux ring is disposed on the inner surface of the stator housing after the stator housing is formed, the flux ring including anchors Sextending radially inwardly; a plurality of permanent magnets disposed around an inner surface of the Sflux ring between the anchors, and a material overmolded around the plurality of magnets and the anchors to secure the magnets to the flux ring and secure the flux ring to the stator housing.

[0011] In another aspect of the invention there is provided a power tool comprising: a housing; and a motor disposed within the housing and having an output coupled to a transmission, the motor having a stator assembly having a flux ring disposed on an inner surface of a stator housing wherein the stator housing and the flux ring are separately formed and the flux ring is disposed on the inner surface of the stator housing after the stator housing is formed, a plurality of permanent magnets disposed around an inner surface of the flux ring, a material overmolded around the plurality of magnets to secure the magnets to the flux ring and secure the flux ring to the stator housing, the flux ring including a seam that allows the flux ring to be compressed for insertion into the housing during assembly of the stator assembly, the overmold material expanding the flux ring against the stator housing.

[0012] In another aspect, there is provided a power tool comprising: a housing; and a motor disposed within the housing and having an output coupled to a transmission, the motor having a stator assembly having a flux ring disposed on an inner surface of a stator housing wherein the stator housing and the flux ring are separately formed and the flux ring is disposed on the inner surface of the stator housing after the stator housing is formed, a plurality of permanent magnets P \OPER\OM 2618220 29 J. O7 Ipa3 do.-26/ IO2O7 -3b- 0 disposed around an inner surface of the flux ring, a material overmolded around 0 the plurality of magnets and the anchors to secure the magnets to the flux ring and secure the flux ring to the stator housing, and at least one keying feature is formed in the overmold material between magnetic poles of the stator assembly, the keying feature including slots formed in the overmold material between the magnetic poles when the overmold material is molded with widths of at least two of the slots being different.

[0013] In another aspect of the invention, there is provided a method for constructing a permanent magnet stator assembly comprising: inserting a flux ring having a seam into a housing; inserting a plurality of permanent magnets on an inner surface of the flux ring; and injecting a material around the permanent magnets in the flux ring so that the material at least partially overmolds the permanent magnets to secure the permanent magnets to the flux ring and expand the flux ring against the housing to secure the flux ring to the housing.

[0014] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for the purposes of illustration only and are not intended to limit the scope of the iinvention.

BRIEF DESCRIPTION OF THE DRAWINGS [0015] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: [0016] Figure 1 is a cross-sectional view of a power tool according to the present invention; [0017] Figure 2 is a perspective view of a stator assembly of the power tool of Figure 1; P.IOPERDI-{I26I822O 29)vn07 spa3 don.9/IMM(J7 3c 0[0018] Fig. 3 is a cross-section view of the stator assembly of Fig. 2 0 taken along the line 3-3.

[0019] Fig. 4 is a perspective view of a flux ring of the stator assembly of Fig. 2; WO 2004/055956 PCT/US2003/039145 [0020] Fig. 5 is a perspective view of a stator can or housing of the stator assembly of Fig. 2; [0021] Fig. 6 is a perspective view of the flux ring of Fig. 4 received in the stator can of Fig. [0022] Fig. 7 is a perspective view of a variation of the flux ring of Fig.

4 showing a flux ring with interlocking fingers; [0023] Fig. 8 is a cross-sectional view of an alternative configuration of the stator assembly of Fig. 2; [0024] Fig. 9 is a perspective view of an electric motor having an alternative configuration of the stator assembly of Fig. 2; [0025] Fig. 10 is a cross-sectional view of the electric motor of Fig. 9 taken along the line 10 [0026] Fig. 11 is a perspective view of an alternative stator assembly; and [0027] Fig. 12 is a perspective view of still another alternative stator assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0028] The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

[0029] Referring now to Figure 1, a power tool 10 is shown. The power tool 10 is illustrated as a drill, however, any type of power tool may be used in accordance with the present invention. The power tool 10 includes a housing 12 which surrounds a motor 14. An activation member 16 is coupled with the motor and a power source 18. The power source 18 includes either a power cord (AC current) or includes a battery (DC current) (not shown). The motor 14 is coupled with an output 20 that includes a transmission 22 and a chuck 24. The chuck 24 is operable to retain a tool (not shown).

[0030] The motor includes a stator assembly 30. The stator assembly includes a stator housing 32, a flux ring 34 and magnets 36. The flux ring 34 is an expandable or split flux ring. An armature 40 includes a shaft 42, a rotor 44 WO 2004/055956 PCT/US2003/039145 and a commutator 50 coupled with the shaft 42. The rotor 44 includes laminations 46 and windings 48. The motor 14 also includes end plates 52 and 54. End plate 52 includes a front bearing 56 which supports one end of a shaft 42. The shaft 42 is coupled with a pinion 60 that is part of the output Brushes 62 and 64 are associated with the commutator 50. A rear bearing 70 is also coupled with the end plate 54 to balance rotation of the shaft 42.

[0031] Referring now to Figs. 2 6, the stator assembly 30 is described in further detail. Stator housing 32 and flux ring 34 are illustratively made of soft magnetic material, such as cold rolled steel. The flux ring 34 has anchors 80 extending radially inward. The magnets 36 are disposed around an inner surface 82 of the flux ring 34 between anchors 80. An overmolding 84 secures the magnets 36 to flux ring 34 as described in more detail in WO 02/068235 A2.

[0032] The flux ring 34 is discontinuous having a seam 86 extending therealong. The seam 86 enables the flux ring 34 to be compressed for insertion into the stator housing 32. When flux ring 34 is assembled in stator assembly the seam 86 is preferably disposed over one of magnetic poles P 1

P

2 of the stator assembly 30 to minimize magnetic losses. In the configuration of Figs. 2 6, the flux ring 34 includes a projection or dimple 88 that engages a hole 90 in the stator housing 32. Alternatively, as shown in Fig. 8, the stator housing 32 includes a projection or dimple 92 that engages a hole 94 in the flux ring 34.

Engagement of the dimple 88,92 and hole 90,94 provides proper alignment of the flux ring 34 during assembly of the stator assembly 30. The dimple 88,92 and hole 90,94 are illustratively at ninety degrees to seam 86 to provide sufficient displacement of dimple 88 or hole 94, as applicable, in flux ring 34 with respect to stator housing 32 when flux ring 34 is compressed so that when flux ring 34 is uncompressed, dimple 88 will be urged into hole 90 (or hole 94 around dimple 92). Alternatively, the dimple 88, 92 and hole 90, 94 are ideally centered over one of the magnetic poles P 1

P

2 to reduce magnetic losses. Overmolding 84 is formed so there are slots 95, 96 on diametrically opposite sides of flux ring 34 between the overmolding 84 around magnets 36 of pole P 1 and the overmolding 84 around magnets 36 of pole P2. Slots 95, 96 illustratively extend WO 2004/055956 PCT/US2003/039145 axially along inner surface 82 of flux ring 34 between poles P 1 and P 2 Slots 96 may be gaps in the overmolding 84 or regions of reduced thickness in the overmolding 84. In the illustrative embodiment, stator assembly 30 has one pair of magnetic poles, with one of poles P 1 and P 2 thus being a North pole and the other being a South pole. It should be understood that stator assembly 30 could have more than one pair of North and South poles.

[0033] To assemble the stator assembly 30, stator housing 32 and flux ring 34 are each preformed. In this regard, stator housing 32 illustratively has interlocking fingers 33 as shown in Fig. 5. The flux ring 34 is slightly compressed and inserted into the stator housing 32 as shown in Fig. 6. The dimple 88,92 engages the hole 90,94 as described above. The magnets 36 are placed against the inner surface 82 of the flux ring 34 and are positioned between the anchors 80. The magnets 36 can be lightly magnetized so they are retained against the inner surface 82 of flux ring 34 during assembly.

[0034] Overmold material 83, such as plastic, is injection molded into the stator assembly 30 to form the overmolding 84. During the injection molding process, the pressure of the overmold material 83 pushes against the magnets 36 and flux ring 34, expanding the flux ring 34 against the stator housing 32.

The overmold material 83 fills the seam 86 of flux ring 34 and surrounds the magnets 36. Expansion of the flux ring 34 against the stator housing 32 provides the retention force for retaining the flux ring 34 within the stator housing 32. Further, because the overmolding 84 fills the seam 86 of the flux ring 34, compression of the flux ring 34 in the stator housing 32 is prevented after the overmold material 83 hardens, thus preventing the removal of flux ring 34 from the stator housing 32. The engagement of the dimple 88, 92 and hole 90, 94, held in place by the overmolding 84, further secures the flux ring 34 to the stator housing 32. The diameter and true position of the overmolding 84 are maintained closely relative to the inside diameter of the stator housing 32 to reduce tolerance stack-ups to the armature 40 (Fig. It should be understood that there can be more than one dimple/hole arrangement in flux ring 34 and stater housing 32.

WO 2004/055956 PCT/US2003/039145 [0035] In an aspect of the invention, slot 95 is wider than slot 96. This limits to two the orientations in which stator assembly 30 can be placed in a magnetizer (not shown) used to magnetize magnets 36 after stator assembly is assembled. That is, the difference in the widths of slots 95 and 96 provide a keying feature that keys stator assembly 30 to the magnetizer. If the widths of slot 95 and 96 were the same, stator assembly 30 could be placed in the magnetizer in four orientations. That is, either end of stator assembly 30 could be placed in the magnetizer in two orientations that are 180 degrees apart. By forming the keying feature in the overmolding 84, each end of the stator assembly 30 can be placed in the magnetizer in only one orientation, reducing to two the orientations in which the stator assembly 30 can be placed in the magnetizer. This makes sensing of the stator assembly 30 in the magnetizer fixture more robust and eliminates the possibility of magnetizing backwards due to placing the stator assembly 30 in the magnetizer in the wrong orientation. It should be understood that in stator assemblies having more than two poles, preferably the width of only one of the slots between the poles would be different than the widths of the rest of the slots between the poles to key the stator assembly to the magnetizer.

[0036] In an aspect of the invention, the stator housing 32 and the flux ring 34 are preassembled as a unit according to an alternative assembly method.

More specifically, the stator housing 32 and flux ring 34 are formed of separate blanks, such as steel blanks, and in this regard, the edges of the seams of flux ring 34 and stator housing 32 are formed to have interlocking fingers, such as interlocking fingers 33 shown in Fig. 5 for stator housing 32 and interlocking fingers 37 shown in Fig. 7 for flux ring 34. One or more holes 94 are stamped into the flux ring and matching mating dimple(s) 92 stamped in the stator housing 32, or vice-versa. The stator housing 32 and flux ring 34 are lain together in their fiat, pre-rolled states with the holes and dimples engaged. The stator housing 32 and flux ring 34 are rolled and the seam of the flux ring 34 interlocks as does the seam of the stator housing 32. The holes and dimples maintain alignment of the stator housing 32 and flux ring 34 during the rolling process.

WO 2004/055956 PCT/US2003/039145 [0037] In an alternative, the flux ring 34 can be rolled first and the stator housing 32 rolled about the flux ring 34. In this case, the flux ring 34 acts as a rolling arbor. Additionally, the holes and dimples maintain alignment as the stator housing 32 is rolled about the flux ring 34. According to another alternative, the stator housing 32 and flux ring 34 can be spot-welded together to form a sub-assembly. Regardless of how the stator housing 32 and flux ring 34 are assembled together, injection of the overmold material 83 not only secures the magnets 36 to the flux ring 34 but also secures the flux ring 34 to the stator housing 32 through the pressure exerted on the flux ring 34 therein.

[0038] The stator assembly 30 of the present invention provides significant advantages in both assembly and manufacture of the power tool In particular, the stator assembly 30 eliminates the need for welding equipment to secure the components together. The expansion of flux ring 34 against stator housing 32 induced by injection of the overmold material 83 secures the flux ring 34 to stator housing 32 and the overmolding 84 also secures the magnets to flux ring 34. The interlocking of the dimple/hole arrangement(s) further secure the flux ring 34 to the stator housing 32. Further, injection of the overmold material 83 reduces tolerance stack-ups, improving ease of assembly. As a result, manufacturing equipment and floor space is reduced entailing cost savings.

Another advantage of reduced tolerance stack-ups is that the magnet can be placed closer to the armature 40 thus maximizing motor performance. The keying feature provided by the different widths of slots 95, 96 improve the placement of stator assembly 30 in the magnetizer.

[0039] Turning now to Figs. 9 and 10, an electric motor 98 having a further embodiment of the stator assembly 30, indicated generally by reference numeral 100, is shown. The stator assembly 100 includes the stator housing 32, flux ring 34, and permanent magnets 36 as shown in the stator assembly 30 of Figs. 2 6. The stator assembly 100 further includes an integrally molded commutator end or rear bearing support 102 and an integrally molded fan baffle 104. An armature, such as armature 40 (Fig. is received in stator assembly 100. A fan 112 is affixed at one end of shaft 42 of armature 40 and is disposed within fan baffle 104. An insulative sleeve 114 may illustratively be disposed 4 between shaft 42 and laminations 46 and between shaft 42 and commutator An end plate (not shown in Figs. 9 and 10), such as end plate 52 (Fig. is affixed to fan baffle 104.

[0040] The rear bearing support 102 includes a cap 106 integrally molded from the overmold material 83. The cap 106 includes a pocket 108 for S receiving rear bearing 70 (Fig. Integrally forming the cap 106 as part of the overmolding 84 from the overmold material 83 eliminates the need for separate fasteners to fix the rear bearing support 102 to the stator housing 32. The fan baffle 104 is likewise integrally molded from the overmold material 83.

[0041] Tumlng now to Fig. 11, an alternate embodiment of stator assembly 100 is shown and generally indicated by reference numeral 100'.

Stator assembly 100' is substantially similar to the stator assembly 100 shown in Figs. 9 and 10, however, only the rear bearing support 102 is integrally molded as part of the overmolding 84 from the overmold material 83. Alternatively, a front bearing support 103 (shown in phantom in Fig. 11) for engaging a front bearing, such as bearing 56 (Fig. may be integrally molded in a manner substantially similar to the rear bearing support 102.

[0042] With reference to Fig. 12, another altemrnate embodiment of stator assembly 100 is illustrated and generally indicated by reference numeral !0 100". Stator assembly 100" is substantially similar to the stator assembly 100 shown in Figs. 9 and 10, however, only the fan baffle 104 is integrally molded as part of overmolding 84 from the overmold material 83.

[0043] By integrally molding the commutator end bearing support 102 and the fan baffle 104 as part of overmolding 84, further assembly and costs savings may be realized.

[0044] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.

P:\OPER\SASUul-Dc 05\12618220 Ispa doc29/08/05 Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that that prior art forms part of the common general knowledge in Australia.

Claims (48)

1. A stator assembly, comprising: a housing; a flux ring disposed on an inner surface of the housing wherein the housing and the flux ring are separately formed and the flux ring is disposed on the inner surface of the housing after the housing is formed, the flux ring including anchors extending radially inwardly; a plurality of permanent magnets disposed around an inner surface of the flux ring between the anchors; and a material overmolded around the plurality of magnets and the anchors to secure the magnets to the flux ring and to secure the flux ring to the housing.

2. A stator assembly, comprising: a housing; a flux ring disposed on an inner surface of the housing wherein the housing and the flux ring are separately formed and the flux ring is disposed on the inner surface of the housing after the housing is formed; a material overmolded around the plurality of magnets to secure the magnets to the flux ring and to secure the flux ring to the housing; and the flux ring including a seam that allows the flux ring to be compressed for insertion into the housing during assembly, the overmold material expanding the flux ring against the housing.

3. The stator assembly of claim 2 wherein the seam of the flux ring is filled with the overmold material during molding of the overmold material, the overmold material upon hardening preventing the flux ring from compressing.

4. The stator assembly of claim 2 wherein the stator assembly has a plurality of magnetic poles, the seam of the flux ring aligned with one of the magnetic poles. P \OPER IMQ6 I 1 220 29 J n 07 spa3 dc.29.r20(07 -12- O

5. The stator assembly of claim 2, wherein one of the flux ring and the housing 0 includes at least one projection and the other of the flux ring and the housing includes at least one hole, the projection being received in the hole to align the flux ring in the housing.

6. The stator assembly of claim 5, wherein the projection and hole of the flux ring and housing are disposed about ninety degrees from the seam of the flux ring.

7. The stator assembly of claim 1, further including at least one of a rear bearing support, front bearing support and fan baffle integrally formed of the overmold material during molding of the overmold material.

8. The stator assembly of claim 1, further including a rear bearing support integrally formed of the overmold material during molding of the overmold material, the rear bearing support including a cap having a pocket therein for receiving a rear bearing.

9. The stator assembly of claim 1, wherein the overmold material is a plastic.

10. The stator assembly of claim 1, wherein at least one keying feature is formed in the overmold material between magnetic poles of the stator assembly.

11. The stator assembly of claim 10 wherein the keying feature includes slots formed in the overmold material between the magnetic poles with widths of at least two of the slots being different.

12. The stator assembly of claim 1, wherein the plurality of magnets includes four magnets, the stator assembly having a first magnetic pole defined by two of the magnets that are adjacent to each other and a second magnetic pole defined by the other two of the magnets that are adjacent to each other, the overmold material molded to have a first slot between the magnets of the first and second P \OPERHAI26'IK22O 29 Jn (17 sp.3 doc-2611012(~)7 -13- O magnetic poles on a first side of the flux ring and a second slot between the magnets of the first and second magnetic poles on a second side of the flux ring that is diametrically opposed to the first side of the flux ring, the first and second slots having different widths.

13. A stator assembly comprising: (-i Cc a housing; 0 a flux ring disposed within the housing, the flux ring having a seam that allows the flux ring to be compressed for insertion into the housing during assembly; a plurality of permanent magnets disposed around an inner surface of the flux ring, each magnet disposed between at least two anchors extending radially inwardly from an inner surface of the flux ring; and a material overmolded around the plurality of magnets and the anchors to secure the magnets to the flux ring, to secure the flux ring to the housing by expanding the flux ring against the housing and to prevent the flux ring from compressing by filling the seam of the flux ring.

14. The stator assembly of claim 13 wherein one of the flux ring and the housing includes at least one projection and the other of the flux ring and the housing includes at least one hole in which the at least one projection is received, the seam of the flux ring aligned with a first magnetic pole of the stator assembly.

The stator assembly of claim 14 wherein the projection and hole of the flux ring and housing disposed about ninety degrees from the seam of the flux ring.

16. The stator assembly of claim 14 wherein the projection and hole of the flux ring and housing are aligned with a second magnetic pole of the stator assembly. P OPERDID)f1619R2) 29 07 p.3 d.2(J10r(XU7 -14- O

17. The stator assembly of claim 13, wherein at least one keying feature is Cformed in the overmold material between magnetic poles of the stator assembly, the keying feature including slots formed in the overmold material between magnetic poles of the stator assembly when the overmold material is molded with widths of at least two of the slots being different.

18. A stator assembly comprising: Sa housing; a flux ring disposed on an inner surface of the wherein the housing and the flux ring are separately formed and the flux ring is disposed on the inner surface of the housing after the housing is formed; a plurality of permanent magnets disposed around an inner surface of the flux ring; a material overmolded around the plurality of magnets to secure the magnets to the flux ring; and at least one of a rear bearing support, front bearing support and fan baffle integrally formed of the overmold material during molding of the 0vermold material.

19. A power tool comprising: a housing; and a motor disposed within the housing and having an output coupled to a transmission, the motor having a stator assembly having a flux ring disposed on an inner surface of a stator housing wherein the stator housing and the flux ring are separately formed and the flux ring is disposed on the inner surface of the stator housing after the stator housing is formed, the flux ring including anchors extending radially inwardly; a plurality of permanent magnets disposed around an inner surface of the flux ring between the anchors, and a material overmolded around the plurality of magnets and the anchors to secure the magnets to the flux ring and secure the flux ring to the stator housing. P \OPER\Olr1'261822 29 Jw 07 spa3 doc-.26/102IO c C.) O

20. A power tool comprising: a housing; and a motor disposed within the housing and having an output coupled to a transmission, the motor having a stator assembly having a flux ring disposed on an inner surface of a stator housing wherein the stator housing and the flux ring Sare separately formed and the flux ring is disposed on the inner surface of the stator housing after the stator housing is formed, a plurality of permanent magnets Sdisposed around an inner surface of the flux ring, a material overmolded around the plurality of magnets to secure the magnets to the flux ring and secure the flux ring to the stator housing, the flux ring including a seam that allows the flux ring to be compressed for insertion into the housing during assembly of the stator assembly, the overmold material expanding the flux ring against the stator housing.

21. The power tool of claim 20 wherein the seam of the flux ring is filled with the overmold material that prevents the flux ring from compressing.

22. The power tool of claim 20 wherein the seam is aligned-with a magnetic pole of the stator assembly.

23. The power tool of claim 20, wherein one of the flux ring and the housing includes at least one projection and the other of the flux ring and the housing includes at least one hole in which the projection is received to align the flux ring in the housing.

24. The power tool of claim 23, wherein the projection and hole of the flux ring and housing are disposed about ninety degrees from the seam of the flux ring. The power tool of claim 23, wherein the stator assembly includes at least one of a rear bearing holder, front bearing holder and fan baffle integrally formed of the overmold material during molding of the overmold material.

P'OPEROH 126h18220 29 Jn 07 sp.1dc -1I6//07 -16- O

26. The power tool of claim 23, wherein the overmold material is a plastic.

27. A power tool comprising: a housing; and a motor disposed within the housing and having an output coupled to a transmission, the motor having a stator assembly having a flux ring disposed on an inner surface of a stator housing wherein the stator housing and the flux ring Sare separately formed and the flux ring is disposed on the inner surface of the stator housing after the stator housing is formed, a plurality of permanent magnets disposed around an inner surface of the flux ring, a material overmolded around the plurality of magnets and the anchors to secure the magnets to the flux ring and secure the flux ring to the stator housing, and at least one keying feature is formed in the overmold material between magnetic poles of the stator assembly, the keying feature including slots formed in the overmold material between the magnetic poles when the overmold material is molded with widths of at least two of the slots being different.

28. A method for constructing a permanent magnet stator assembly comprising: inserting a flux ring having a plurality of anchors extending radially inward into a housing; inserting a plurality of permanent magnets between the anchors; and injecting a material around the permanent magnets in the flux ring so that the material at least partially overmolds the permanent magnets to secure the permanent magnets to the flux ring and expand the flux ring against the housing to secure the flux ring to the housing.

29. The method of claim 28, wherein the flux ring includes a seam that allows the flux ring to be compressed and inserting the flux ring into the housing includes compressing the flux ring before inserting into the housing, inserting the flux ring into the housing while the flux ring is compressed and allowing the flux ring to expand against the housing once it has been inserted into the housing. P \OPERD)H1I26182220 29 Jwi 07 spa3 dm-26.I W7 -17- O

30. The method of claim 29, and further including preventing the flux ring from c compressing by injecting the material so that it fills the seam of the flux ring, the material hardening in the seam and preventing the flux ring from compressing. \O 5

31. The method of claim 28, further including aligning the flux ring in the t' housing by inserting the flux ring in the housing so that a projection in one of the housing and flux ring extends into a hole in the other of the flux ring and the Shousing.

32. The method of claim 28, further including injecting the material so that it forms at least one of a rear bearing holder, a front bearing holder and a fan baffle.

33. The method of claim 28, further including injecting the material to form at least one keying feature by forming slots in the material between magnetic poles of the stator assembly with widths of at least two of the slots being different.

34. The method of claim 28, and further including preassembling the housing and flux ring as a unit by: stamping the housing and flux ring from separate blanks, the separate blanks each stamped to have interlocking fingers on opposed ends; stamping at least one hole in one of the housing and flux ring blanks and stamping at least one projection in the other of the housing and flux ring blanks; laying the housing and flux ring blanks together with the at least one hole and the at least one projection engaging each other; and rolling the housing and flux ring blanks so that the fingers of the housing blank interlock and the fingers of the flux ring blank interlock. The method of claim 34 and further including spot-welding the flux ring and housing together.

P IOPER\XI)- 1261220 29 J 07 pl do.2611'0007 -18- O

36. The method of claim 28, and further including preassembling the housing Cand flux ring as a unit by: rolling the flux ring from a blank; and rolling the housing from a blank where the housing blank is rolled around the flux ring with the flux ring acting as a rolling arbor.

37. The method of claim 36 wherein one of the flux ring and housing blanks is stamped to have at least of one projection and the other of the flux ring and housing blanks is stamped to have at least one hole therein, the at least one projection engaging the at least one hole during the rolling of the housing blank about the flux ring.

38. The method of claim 36 wherein the flux ring and further including spot- welding the flux ring and housing together.

39. A method for constructing a permanent magnet stator assembly comprising: inserting a flux ring having a seam into a housing; inserting a plurality of permanent magnets on an inner surface of the flux ring; and injecting a material around the permanent magnets in the flux ring so that the material at least partially overmolds the permanent magnets to secure the permanent magnets to the flux ring and expand the flux ring against the housing to secure the flux ring to the housing.

40. The method of claim 39 including preventing the flux ring from compressing by injecting the material so that it fills the seam of the flux ring, the material hardening in the seam and preventing the flux ring from compressing.

41. The method of claim 40, further including aligning the flux ring in the housing by inserting the flux ring in the housing so that a projection in one of the housing and flux ring extends into a hole in the other of the flux ring and the P %OPFROHI I 'b I N220 '9)91 -0pS doc26 I/017 tIA--- O O housing.

42. The method of claim 40, further including injecting the material so that it "-forms at least one of a rear bearing holder, a front bearing holder and a fan baffle.

43. The method of claim 39, further including injecting the material to form at Cleast one keying feature by forming slots in the material between magnetic poles of the stator assembly with widths of at least two of the slots being different.

44. The method of claim 39, and further including preassembling the housing and flux ring as a unit by: stamping the housing and flux ring from separate blanks, the separate blanks each stamped to have interlocking fingers on opposed ends; stamping at least one hole in one of the housing and flux ring blanks and stamping at least one projection in the other of the housing and flux ring blanks; laying the housing and flux ring blanks together with the at least one hole and the at least one projection engaging each other; and rolling the housing and flux ring blanks so that the fingers of the housing blank interlock and the fingers of the flux ring blank interlock.

The method of claim 44 and further including spot-welding the flux ring and housing together.

46. A stator assembly substantially as hereinbefore described with referenced to the accompanying drawings.

47. A power tool substantially as hereinbefore described with referenced to the accompanying drawings.

48. A method substantially as hereinbefore described with referenced to the accompanying drawings.