阅读说明：本技术 具有直线定子齿的轴向磁通电机 (Axial flux machine with linear stator teeth ) 是由 J·B·赫尔 于 2020-09-14 设计创作，主要内容包括：一种用于器具的轴向磁通电机包括定子轭。多个定子齿从定子轭沿轴向方向延伸,并且围绕中心旋转轴线定位。每个定子齿包括沿轴向方向延伸并且形成“T”形构件的多个叠片。多个定子齿用聚合材料包覆成型,以限定多个轴向定子磁极。至少一个绕组围绕多个轴向定子磁极延伸。环形转子围绕定子轭的中心旋转轴线旋转。转子定位在多个轴向定子磁极的轴向端附近。(An axial-flux electric machine for an appliance includes a stator yoke. A plurality of stator teeth extend in an axial direction from the stator yoke and are positioned about the central axis of rotation. Each stator tooth includes a plurality of laminations extending in an axial direction and forming a "T" shaped member. The plurality of stator teeth are overmolded with a polymeric material to define a plurality of axial stator poles. At least one winding extends around the plurality of axial stator poles. The annular rotor rotates about a central axis of rotation of the stator yoke. The rotor is positioned near an axial end of the plurality of axial stator poles.)

1. An electric motor, comprising:

a stator yoke;

a plurality of stator teeth extending axially from the stator yoke, each stator tooth comprising a first linear member and a second linear member, wherein the plurality of stator teeth are overmolded with a polymeric material to define a plurality of axial stator poles;

at least one winding extending around the plurality of axial stator poles; and

a rotor that rotates about a central axis of the stator yoke, wherein the rotor is positioned near an axial end of the plurality of stator teeth.

2. The motor according to claim 1, wherein the rotor is coupled with a rotating member that rotationally operates around the central axis.

3. The motor of claim 1, wherein the first and second linear members comprise a plurality of laminations oriented perpendicular to the stator yoke.

4. The motor of claim 3, wherein the first linear member and the second linear member are positioned to form an extruded "T" shape extending from the stator yoke.

5. The motor of claim 1, wherein the plurality of axial stator poles are overmolded with the polymeric material to define a single flexible unit that is slidably engaged with the stator yoke.

6. The motor of claim 5, wherein the single flexible unit comprises a plurality of living hinges positioned between adjacent ones of the plurality of axial stator poles.

7. The motor of claim 1, wherein the rotor is a ring magnet coupled to a fan blade.

8. The motor of claim 6, wherein the stator yoke is made of powdered metal and includes a plurality of holes for receiving the plurality of stator teeth.

9. The electric motor of any one or more of claims 1 to 8, further comprising a second overmold extending around the plurality of axial stator poles and the stator yoke.

10. An axial-flux electric machine for an appliance, the axial-flux electric machine comprising:

a stator yoke;

a plurality of stator teeth extending in an axial direction from the stator yoke and positioned about a central axis of rotation, wherein each stator tooth comprises a plurality of laminations extending in the axial direction and forming a "T" shaped member, wherein the plurality of stator teeth are overmolded with a polymeric material to define a plurality of axial stator poles;

at least one winding extending around the plurality of axial stator poles;

an annular rotor that rotates about the central axis of rotation of the stator yoke, wherein the rotor is positioned near an axial end of the plurality of axial stator poles.

11. The axial-flux electric machine of claim 10, wherein the "T" shaped member includes a first linear member and a second linear member, and wherein the plurality of laminations of the first and second linear members are in a parallel orientation.

12. The axial-flux electric machine of claim 10, wherein the plurality of axial stator poles are overmolded with the polymeric material to define a single flexible unit that is slidably engaged with the stator yoke.

13. The axial-flux electric machine of claim 12, wherein the polymeric material of the single flexible unit includes a plurality of living hinges positioned between adjacent ones of the plurality of axial stator poles.

14. The axial-flux electric machine of claim 10, further comprising:

a second overmold extending around the plurality of axial stator poles and the stator yoke.

15. The axial-flux electric machine of claim 10, wherein the rotor is a ring magnet coupled to fan blades.

16. The axial-flux electric machine of claim 10, wherein the stator yoke is made of powdered metal and includes a plurality of holes for receiving the plurality of stator teeth.

17. The axial-flux electric machine of claim 10, wherein the axial stator poles are coupled with a structural housing for a fluid pump, and wherein the rotor is disposed within the structural housing and the axial stator poles are at least partially external to the structural housing.

18. The axial-flux electric machine of any one or more of claims 10-17, wherein the rotor is coupled with a rotating member that operates rotationally about the central axis.

19. A method for forming an axial-flux electric machine, the method comprising:

joining a plurality of first laminations to form a first linear member;

joining the plurality of second laminations to form a second linear member;

positioning the first and second linear members in a "T" configuration to define stator teeth;

disposing an overmolding material on the first and second linear members to define axial stator poles; and

positioning the axial stator poles within a stator yoke to form a stator core.

20. The method of claim 19, wherein the step of disposing the overmold material on the first and second linear members includes disposing the overmold material on a plurality of stator teeth in a configuration, the method further comprising:

forming the elongated configuration into a circular configuration for positioning within the stator yoke.

Technical Field

The device belongs to the field of electric motors and, more specifically, is an axial flux machine comprising stator teeth having a rectilinear configuration with a generally "T" shaped configuration.

Disclosure of Invention

According to one aspect of the present disclosure, an electric motor includes a stator yoke. A plurality of stator teeth extend axially from the stator yoke. Each stator tooth includes a first linear member and a second linear member. The plurality of stator teeth are overmolded with a polymeric material to define a plurality of axial stator poles. At least one winding extends around the plurality of axial stator poles. The rotor rotates about a central axis of the stator yoke. The rotor is positioned near an axial end of the plurality of stator teeth.

According to another aspect of the present disclosure, an axial-flux motor for a laundry appliance includes a stator yoke. A plurality of stator teeth extend in an axial direction from the stator yoke and are positioned about a central axis of rotation. Each stator tooth includes a plurality of laminations extending in the axial direction and forming a "T" shaped member. The plurality of stator teeth are overmolded with a polymeric material to define a plurality of axial stator poles. At least one winding extends around the plurality of axial stator poles. An annular rotor rotates about the central axis of rotation of the stator yoke. The rotor is positioned near an axial end of the plurality of axial stator poles.

In accordance with yet another aspect of the present disclosure, a method for forming an axial-flux electric machine includes joining a plurality of first laminations to form a first linear member. The plurality of second laminations are joined to form a second linear member. Positioning the first and second linear members in a "T" configuration to define a stator tooth. An overmold material is disposed on the first and second linear members to define axial stator poles. Positioning the axial stator poles within a stator yoke to form a stator core.

These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.

Drawings

In the drawings:

FIG. 1 is a front view of a laundry appliance incorporating an aspect of an axial-flux motor;

FIG. 2 is a side perspective view of an aspect of a stator core of an axial-flux electric machine, and without showing windings;

FIG. 3 is a cross-sectional view of the stator core of FIG. 2 taken along line III-III;

FIG. 4 is a side perspective view of a single axial stator pole showing "T" shaped stator teeth and a polymer overmold;

FIG. 5 is a cross-sectional perspective view of a structural assembly incorporating an aspect of an axial-flux electric machine and showing axial stator poles incorporated within a structural housing;

FIG. 6 is a side perspective view of an aspect of a plurality of axial stator poles, shown formed in a linear configuration and including a plurality of living hinges;

FIG. 7 is a partially exploded perspective view of a plurality of axial stator poles manipulated in a circular configuration and positioned to be mounted on a stator yoke to form a stator core of an axial-flux electric machine;

FIG. 8 is a cross-sectional view of an aspect of an axial-flux electric machine and illustrating positioning of a rotor with respect to a stator core of the axial-flux electric machine;

FIG. 9 is a schematic cross-sectional view of an axial stator pole showing the configuration of windings extending around the axial stator pole; and

fig. 10 is a linear flow chart illustrating a method for forming an axial-flux electric machine.

The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein.

Detailed Description

The present embodiment illustrated resides primarily in combinations of method steps and apparatus components related to an axial flux motor. Accordingly, the apparatus components and method steps have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like reference numerals in the description and drawings denote like elements.

For purposes of the description herein, the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," and derivatives thereof shall relate to the disclosure as oriented in fig. 1. Unless otherwise specified, the term "front" shall mean that the element is closer to the surface of the intended viewer, and the term "rear" shall mean that the element is further from the surface of the intended viewer. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

The terms "comprises," "comprising," "includes" or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, elements recited in the singular and proceeded with the word "comprise … …" do not exclude the presence of additional identical elements in the process, method, article, or apparatus that comprises the same elements.

With respect to fig. 1-8, reference numeral 10 generally designates an axial-flux motor incorporated within an implement 12 for operating various mechanical assemblies 14 within the implement 12. In general, axial-flux motor 10 may be used within a laundry appliance 12 for operating components having low voltage requirements, such as fluid pumps, fans, and other similar components. According to various aspects of the apparatus, electric motor 16 in the form of axial-flux electric machine 10 includes a stator yoke 18 and a plurality of stator teeth 20 extending axially from stator yoke 18. Each stator tooth 20 includes a first linear member 22 and a second linear member 24. The plurality of stator teeth 20 are overmolded with a polymeric material 26 to define a plurality of axial stator poles 28. These axial stator poles 28 engage the stator yoke 18 to define a stator core 30. At least one winding 32 extends around the plurality of axial stator poles 28. Typically, a plurality of windings 32 are positioned about the axial stator poles 28 to define a single phase motor or a multi-phase motor for use within the laundry appliance 12. The rotor 34 rotates about a central axis 36 of the stator yoke 18. The rotor 34 is positioned adjacent an axial end 38 of the plurality of stator teeth 20. Accordingly, when the windings 32 are energized by selectively applying the current 40, the stator core 30 generates a magnetic field that cooperates with the magnetic material of the rotor 34 to produce an electromotive force 42 that rotates the rotor 34 relative to the stator core 30.

Because rotor 34 is positioned at axial ends 38 of plurality of stator teeth 20, axial-flux electric machine 10 typically occupies a small, compact space 72 for use within a smaller assembly. Within these assemblies, the rotor 34 may be attached to a rotating member 44 that operates rotationally about the central axis 36 of the stator yoke 18 and the stator core 30. The rotating member 44 may be in the form of an impeller of a fluid pump, a fan blade, or other similar rotating member 44 that may be used within an appliance 12, such as a laundry appliance.

Referring now to fig. 3 and 4, the first linear member 22 and the second linear member 24 forming each stator tooth 20 include a plurality of laminations 50 oriented perpendicular to the stator yoke 18. In this manner, the first linear member 22 includes a first set 52 of laminations 50 attached together in a layered configuration, and the second linear member 24 includes a second set 54 of laminations 50 also attached together in a layered configuration to form the first linear member 22 and the second linear member 24. The laminations 50 can be adhered together, attached together via fasteners, overmolded together, and coupled via other similar mechanisms and methods. These first and second linear members 22, 24 are positioned in a perpendicular configuration relative to each other to form an extruded "T" shape extending from the stator yoke 18 in the axial direction 56. The orientation of the laminations 50 extending in the axial direction 56 from the stator yoke 18 directs magnetic flux from the energized windings 32 to the rotor 34 to generate an electromotive force 42 that operates the rotor 34 relative to the stator. Generally, the various laminations 50 are oriented in a similar orientation such that the first and second sets 52, 54 of laminations 50 are parallel to one another. In this parallel configuration, the first and second linear members 22, 24 maintain a "T" shape that forms each stator tooth 20. These laminations 50 are typically made of a ferromagnetic material (such as iron) that can be made by using a plurality of stamped laminations 50 that are adhered to one another to form the first and second linear members 22, 24.

In conventional axial flux machines, the stator teeth are typically in the form of triangular prisms with laminations extending axially from the stator yoke. To form such triangular teeth, each of the laminations must be of a different size to accommodate the triangular shape that flares outward and away from the center of the stator yoke. Accordingly, in conventional axial magnetomotive machines, each stator tooth comprises a large number of individually sized laminations which must be oriented in a particular configuration to achieve the triangular shape of the stator tooth. This process is very time consuming, expensive, and can result in a significant waste of resources.

Within axial-flux electric machine 10 as described herein, first linear member 22 and second linear member 24 are positioned to form a "T" shaped configuration of stator teeth 20. When the windings 32 are applied to the polymer overmold 70 of the axial stator poles 28, a space 72 (shown in fig. 9) may remain between the windings 32 and the polymer overmold 70 of the axial stator poles 28. These spaces 72 may result in a reduction in electromotive force 42, which may result in a low voltage efficiency, or may require a slightly increased current 40, which may need to be delivered to windings 32 of axial-flux motor 10. Because axial-flux electric machine 10 is used in an installation having very small electrical requirements, the voltage that may result therefrom may be inefficient representing only a small percentage of the already low electrical requirements. Also, axial-flux electric machine 10 described herein is typically used for low-voltage machines that require low-speed operation during use.

As shown in fig. 2-9, the first and second linear members 22, 24 of the stator teeth 20 include a first set 52 and a second set 54 of laminations 50 that are positioned in a rectangular pattern and combine to define a "T" shape for each stator tooth 20. It is contemplated that the first linear member 22 and the second linear member 24 may comprise the same dimensions such that a single size lamination 50 is required for each of the first linear member 22 and the second linear member 24. It is also contemplated that the first linear member 22 and the second linear member 24 may have different widths and may include a different number of laminations 50 such that the first linear member 22 and the second linear member 24 may have different sizes. In each of these configurations, first and second linear members 22, 24 are formed from stacked similar and uniformly sized laminations 50 that are positioned in an axial direction 56 relative to stator yoke 18 to form stator core 30 of axial-flux electric machine 10. By using uniformly sized laminations 50 for each of first and second linear members 22, 24, the manufacture of stator teeth 20 of axial-flux electric machine 10 is a more efficient operation that results in less waste and use of resources.

In accordance with various aspects of the apparatus, axial-flux electric machine 10 described herein may be coupled with a controller 80 to provide consistent speed or variable speed operation with respect to a fan, fluid pump, or other similar mechanical assembly 14. Such speed variation may be used to provide quiet night operation, such as a night drying function that allows the fan blades to operate at low speeds during long periods of idle. Moreover, the smaller footprint of axial-flux electric machine 10 allows axial-flux electric machine 10 to be positioned within limited space 72. Such a limited space 72 can be found between the tub of the laundry appliance 12 and the outer cabinet of the laundry appliance 12.

As shown in fig. 2-9, the laminations 50 of the stator teeth 20 may be made of a ferromagnetic material, such as steel, powdered metal, and other similar ferrous materials commonly used in electric stators. In addition, the stator yoke 18 may also be made from a variety of materials that may include powdered metal, steel, and other similar materials. The stator yoke 18 may also be formed from a plurality of stacked laminations 50.

As shown in fig. 5, axial-flux electric machine 10 may be coupled with a structural housing 90 for a component, such as a fluid pump, fan, or other similar component. Stator core 30 of axial-flux electric machine 10 may be overmolded with a polymeric material 26, such as Bulk Molding Compound (BMC), to attach stator core 30 to structural shell 90. In such embodiments, the stator core 30 may include a second overmold 92 in the form of a BMC that extends around the plurality of axial stator poles 28 and the stator yoke 18 for attaching the stator core 30 to the structural shell 90. It is also contemplated that the stator core 30 may be integrated within a structure, wherein the axial stator poles 28 may extend at least partially into or through a portion of the structural housing 90 of the machine assembly 14.

Referring again to fig. 5, the rotor 34 may be positioned near the axial ends 38 of the plurality of axial stator poles 28 when the stator core 30 is attached to the structural shell 90. As shown in fig. 5, the rotor 34 may be positioned within the structural shell 90 and the stator core 30 may be positioned at least partially outside of the structural shell 90. During operation of axial-flux electric machine 10, an electromotive force 42 is transmitted to rotor 34 via windings 32 and axial stator poles 28 for forming an electromagnetic field and generating electromotive force 42 that operates rotor 34 relative to the stator. As described above, the electromotive force 42 may be used to operate the rotor 34, which is attached to various rotating items, such as fan blades, impellers of fluid pumps, and other similar items. These items are typically lightweight such that only a minimum amount of current 40 is required to generate a magnitude of electromotive force 42 for operating rotor 34 and a rotating member 44 coupled with rotor 34.

By way of example and not limitation, as shown in FIG. 5, the magnets 94 of the rotor 34 may be overmolded as part of the fan blade assembly. In such embodiments, the fan blade assembly may be attached to a bearing that positions the fan blade assembly's rotor 34 near the axial ends 38 of the plurality of axial stator poles 28. Accordingly, when windings 32 of axial-flux electric machine 10 are energized, the resulting electromotive force 42 operates magnets 94 (such as ring magnets 94) of rotor 34 to rotate about the central axis of rotation. In turn, operation of the rotor 34 causes the fan blades to rotate about the same axis of rotation. In certain aspects of the device, the magnets 94 of the rotor 34 may include various configurations. These configurations may include, but are not limited to, halbach arrays, single piece ring magnets, multiple magnets forming a ring, magnet assemblies with back iron for rotor 34, and other similar configurations.

Where rotor 34 is used as part of a fan blade assembly, the configuration of axial-flux electric machine 10 may be used in conjunction with a fan blade having an increased pitch of each of the blades due to the increased speed of rotor 34 and the fan blade. The increased pitch may be useful in avoiding clogging by lint particles present within the laundry appliance 12 during operation. The increased pitch of the individual fan blades leaves more space 72 for lint particles to pass through the individual fan blades to prevent clogging.

Referring again to fig. 2-9, first and second linear members 22, 24 are shown with respect to each stator tooth 20 of axial-flux electric machine 10. It is contemplated that additional linear members may be used to create additional steps 100 and corresponding spaces 72 within each stator tooth 20. Typically, each stator tooth 20 will include a first linear member 22 and a second linear member 24 positioned with the laminations 50 generally parallel to each other. The first and second linear members 22, 24 are also positioned to create a "T" shape of the stator teeth 20.

Referring again to fig. 1-9, axial-flux electric machine 10 for use in laundry appliance 12 includes a stator yoke 18 and a plurality of stator teeth 20 extending from stator yoke 18 in an axial direction 56. The stator teeth 20 are positioned about a central axis of rotation, and each stator tooth 20 includes a plurality of laminations 50 that extend in an axial direction 56 to form a "T" shaped member. As described above, the "T" shaped member is generally formed by a first linear member 22 and a second linear member 24 that are vertically oriented relative to each other to form a "T" shape. In this "T" shape, the laminations 50 of the first and second linear members 22, 24 are parallel to each other throughout the stator tooth 20. The plurality of stator teeth 20 are overmolded with a polymeric material 26 to define a plurality of axial stator poles 28 extending in an axial direction 56 from the stator yoke 18. The windings 32 may then be positioned around the plurality of axial stator poles 28 in a single phase or a multiple phase configuration. The configuration of windings 32 and controller 80 for delivering various currents 40 to these windings 32 may result in a single speed axial-flux motor 10 or a variable speed axial-flux motor 10.

The annular rotor 34 is configured to include a magnet 94 that rotates about a central axis of rotation of the stator yoke 18. The rotor 34 is positioned near an axial end 38 of the plurality of axial stator poles 28. With this configuration, the magnetic field generated by energizing the winding 32 causes the electromotive force 42 that operates the rotor 34 with respect to the stator core 30. Axial-flux motor 10 may be controlled as a variable speed motor and operated in both a clockwise and counterclockwise direction in various configurations of the device. Axial-flux motor 10 may also be configured as a single-speed, unidirectional motor or a variable-speed, unidirectional motor.

Referring now to fig. 2-4, each axial stator pole 28 may be independently manufactured and inserted into a respective one 122 of a plurality of holes 122 defined in the stator yoke 18. In such a configuration, the first and second linear members 22, 24 are positioned within the mold and the polymer overmold 70 is positioned around the stator teeth 20 to create the axial stator pole 28. Each axial stator pole 28 may include a spacer flange 110 that engages a yoke surface 112 of the stator yoke 18 and also helps to laterally position each axial stator pole 28 relative to an adjacent axial stator pole 28. To secure the axial stator poles 28 to the stator yoke 18, a second overmold 92 may be positioned about the plurality of axial stator poles 28 and the stator yoke 18 to form an integral assembly of the stator core 30.

Referring now to fig. 6 and 7, the plurality of axial stator poles 28 are overmolded with the polymeric material 26 to define a single flexible unit 120 that may be slidably engaged within a bore 122 defined in the stator yoke 18. In such embodiments, the stator teeth 20 may be positioned in an elongated and generally linear configuration 124, and the polymeric material 26 may be overmolded when the stator teeth 20 are in the linear configuration 124. Each of the axial stator poles 28 may be coupled via a living hinge 126 that allows the plurality of axial stator poles 28 to be manipulated from a linear configuration 124 to a circular configuration 128 for insulation within the stator yoke 18. As shown in fig. 6, each living hinge 126 is positioned between adjacent axial stator poles 28 to allow manipulation of this linear configuration 124 of axial stator poles 28.

In this linear configuration 124 of the axial stator poles 28, the process of positioning the windings 32 may be completed. In the linear configuration 124, as shown in fig. 6, the mechanism for positioning the windings 32 may operate along a linear path of the axial stator poles 28. Once the positioning of the windings 32 is complete, the linear configuration 124 of the axial stator teeth 20 may be manipulated with the windings 32 into a circular configuration 128 for positioning on the stator yoke 18. The process of adding the windings 32 when the axial stator poles 28 are in the linear configuration 124 is simpler and more efficient than positioning the windings 32 on radially positioned stator teeth 20.

As shown in fig. 7, the axial stator poles 28 and windings 32 may be formed in a circular shape such that each stator tooth 20 may be inserted into a corresponding hole defined in the stator yoke 18. With this configuration, the axial stator pole 28 may be formed as a single flexible unit 120 that may be manipulated and installed as a single piece within the stator yoke 18. As with the other embodiments, this assembly may then be secured by using a second overmold 92 that surrounds the axial stator teeth 20 and stator yoke 18 to form an integral structure of the stator core 30.

Having described various aspects of axial-flux electric machine 10 and referring now to fig. 1-10, a method 400 for forming various aspects of axial-flux electric machine 10 is disclosed. According to the method 400, a plurality of first laminations 50 are joined to form a first linear member 22 (step 402). A plurality of second laminations 50 are joined to form a second linear member 24 (step 404). As described above, the first and second linear members 22, 24 may be of similar size or of different sizes. When the sizes are different, the difference in size may be accomplished by including a different number of similarly sized laminations 50 within the first linear member 22 and the second linear member 24. The difference in size may also be accomplished by differently sized laminations 50 used to form the first linear member 22 and the second linear member 24.

Referring again to fig. 1-10, according to the method 400, the first and second linear members 22, 24 are positioned in a "T" configuration to define the stator teeth 20 (step 406). An overmold material is then disposed on the first and second linear members 22, 24 to define the axial stator poles 28 (step 408). The axial stator poles 28 may then be positioned within the stator yoke 18 to form the stator core 30 (step 410). As described above, the process of placing the overmolding material on the first and second linear members 22, 24 may be accomplished by overmolding each tooth independently. Alternatively, a set of teeth may be overmolded to form an elongated assembly of axial stator teeth 20, which may be manipulated to fit within the stator yoke 18. In each of these examples, the first and second linear members 22, 24 extend at least partially through the material of the stator yoke 18.

In accordance with various aspects of the apparatus, axial-flux electric machine 10 may be used in a wide variety of mechanisms and appliances 12. Such mechanisms may include, but are not limited to, fans, air handlers, blowers, fluid pumps, and other similar mechanical devices. These devices may be incorporated into a wide range of appliances 12, which may include, but are not limited to, laundry appliances, dishwashers, refrigerators, freezers, gadgets, countertop appliances, air handlers, water heaters, ovens, and other similar residential and commercial appliances and fixtures.

According to another aspect of the present disclosure, an electric motor includes a stator yoke. A plurality of stator teeth extend axially from the stator yoke. Each stator tooth includes a first linear member and a second linear member. The plurality of stator teeth are overmolded with a polymeric material to define a plurality of axial stator poles. At least one winding extends around the plurality of axial stator poles. The rotor rotates about a central axis of the stator yoke. The rotor is positioned near an axial end of the plurality of stator teeth.

According to another aspect, the rotor is coupled with a rotating member that operates rotationally about the central axis.

According to yet another aspect, the first and second linear members include a plurality of laminations oriented perpendicular to the stator yoke.

According to another aspect of the present disclosure, the first and second linear members are positioned to form an extruded "T" shape extending from the stator yoke.

According to another aspect, the plurality of axial stator poles are overmolded with the polymeric material to define a single flexible unit that is slidably engaged with the stator yoke.

According to yet another aspect, the single flexible unit includes a plurality of living hinges positioned between adjacent ones of the plurality of axial stator poles.

According to another aspect of the disclosure, a second overmold extends around the plurality of axial stator poles and the stator yoke.

According to another aspect, the rotor is a ring magnet coupled to fan blades.

According to yet another aspect, the stator yoke is made of powdered metal and includes a plurality of holes for receiving the plurality of stator teeth.

According to another aspect of the present disclosure, an axial-flux electric machine for an appliance includes a stator yoke. A plurality of stator teeth extend in an axial direction from the stator yoke and are positioned about a central axis of rotation. Each stator tooth includes a plurality of laminations extending in the axial direction and forming a "T" shaped member. The plurality of stator teeth are overmolded with a polymeric material to define a plurality of axial stator poles. At least one winding extends around the plurality of axial stator poles. An annular rotor rotates about the central axis of rotation of the stator yoke. The rotor is positioned near an axial end of the plurality of axial stator poles.

According to another aspect, the "T" shaped member includes a first linear member and a second linear member, and wherein the plurality of laminations of the first and second linear members are in a parallel orientation.

According to yet another aspect, the rotor is coupled with a rotating member that operates in rotation about the central axis.

According to another aspect of the present disclosure, the plurality of axial stator poles are overmolded with the polymeric material to define a single flexible unit that is slidably engaged with the stator yoke.

According to another aspect, the polymeric material of the single flexible unit includes a plurality of living hinges positioned between adjacent ones of the plurality of axial stator poles.

According to yet another aspect, a second overmold extends around the plurality of axial stator poles and the stator yoke.

According to another aspect of the present disclosure, the rotor is a ring magnet coupled to fan blades.

According to another aspect, the stator yoke is made of powdered metal and includes a plurality of holes for receiving the plurality of stator teeth.

According to yet another aspect, the axial stator poles are coupled with a structural housing for a fluid pump, and the rotor is disposed within the structural housing, and the axial stator poles are at least partially external to the structural housing.

In accordance with another aspect of the present disclosure, a method for forming an axial-flux electric machine includes joining a plurality of first laminations to form a first linear member. The plurality of second laminations are joined to form a second linear member. Positioning the first and second linear members in a "T" configuration to define a stator tooth. An overmold material is disposed on the first and second linear members to define axial stator poles. Positioning the axial stator poles within a stator yoke to form a stator core.

According to another aspect, the step of disposing the overmold material on the first and second linear members includes disposing the overmold material on a plurality of stator teeth in a configuration. The method further includes forming the elongated configuration into a circular configuration for positioning within the stator yoke.

One of ordinary skill in the art will understand that the described disclosure and construction of other components is not limited to any particular materials. Other exemplary embodiments of the present disclosure disclosed herein may be formed from a variety of materials, unless otherwise described herein.

For the purposes of this disclosure, the term "coupled" (in all its forms, coupled, etc.) generally refers to two components (electrical or mechanical) joined to one another either directly or indirectly. Such engagement may be fixed in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Unless otherwise specified, such engagement may be permanent in nature, or may be removable or releasable in nature.

It is also important to note that the construction and arrangement of the elements of the present disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or other elements of the connectors or systems may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or components of the system may be constructed of any of a variety of materials that provide sufficient strength or durability in any of a variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

It will be understood that any described process or step within a described process may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The example structures and processes disclosed herein are for purposes of illustration and are not to be construed as limiting.