Electric motor and power tool

Abstract

An electric motor and a power tool may include a rotor assembly including a rotor shaft. An electric motor may include a stator assembly including a plurality of stator segments arranged adjacent to each other in a circumferential direction of the stator assembly, at least one stator segment including: a core having a core yoke portion and a core tooth portion; an insulator at least partially covering the core and having an insulator yoke and insulator teeth; a stator segment yoke portion formed by the core yoke portion and the insulator yoke portion; a stator segment tooth portion formed by the core tooth portion and the insulator tooth portion; and a stator winding extending around the stator segment teeth, the stator winding including a wire lead. The insulator yoke includes a seat portion defining a wire recess. The wire recess at least partially accommodates the wire lead.

Description

[0001] Cross - reference to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 513,042, filed on July 11, 2023, the entire content of which is incorporated herein by reference. Technical field

[0003] The present disclosure relates to electric motors, and more particularly to stators for electric motors. Background art

[0004] A stator for an electric motor can be formed by a plurality of annular stator segments arranged in a tubular shape. Summary of the invention

[0005] In some aspects, the techniques described herein relate to an electric motor that includes: a rotor assembly including a rotor shaft; a stator assembly including a plurality of stator segments arranged adjacent to each other circumferentially in the stator assembly, at least one stator segment including: a core having a core yoke portion and a core tooth portion; an insulator at least partially covering the core and having an insulator yoke portion and an insulator tooth portion; a stator segment yoke portion formed by the core yoke portion and the insulator yoke portion; a stator segment tooth portion formed by the core tooth portion and the insulator tooth portion; and a stator winding extending around the stator segment tooth portion, the stator winding including a wire lead; and a busbar assembly coupled to the stator assembly and configured to be electrically connected to the stator winding, the busbar assembly including an injection - molded body and a plurality of conductors; wherein the insulator yoke portion of the at least one stator segment includes a support portion that axially protrudes away from the core yoke portion of the at least one stator segment, the support portion defining an inner surface facing the insulator tooth portion, an outer surface facing away from the insulator tooth portion, and a top surface facing away from the core yoke portion; wherein the support portion defines a wire notch that is recessed into the inner surface and extends axially in the axial direction of the electric motor; and wherein the wire notch at least partially houses the wire lead.

[0006] In some embodiments, the wire notch extends axially from the top surface of the support portion to a notch bottom wall located near an axial end face of the core yoke portion.

[0007] In some aspects, the techniques described herein relate to an electric motor that includes: a rotor assembly including a rotor shaft; and a stator assembly including a plurality of stator segments arranged adjacent to each other in the circumferential direction of the stator assembly, at least one stator segment including: a core having a core yoke portion and a core tooth portion; an insulator at least partially covering the core and having an insulator yoke portion and an insulator tooth portion; a stator segment yoke portion formed by the core yoke portion and the insulator yoke portion; a stator segment tooth portion formed by the core tooth portion and the insulator tooth portion; and a stator winding extending around the stator segment tooth portion and including a wire lead; wherein the insulator yoke portion of the at least one stator segment includes a support portion that axially protrudes away from the core yoke portion of the at least one stator segment, the support portion defining an inner surface facing the insulator tooth portion, an outer surface facing away from the insulator tooth portion, and a top surface facing away from the core yoke portion; wherein the support portion defines a first wire notch that is recessed into the top surface and extends in the radial direction of the electric motor from the inner surface to the outer surface; wherein the support portion further defines a second wire notch that is recessed into the inner surface and extends in the axial direction of the electric motor, the first wire notch communicating with the second wire notch; and wherein the first wire notch and the second wire notch each at least partially accommodate the wire lead.

[0008] In some embodiments, the second wire notch extends in the axial direction from the top surface of the support portion to a second notch bottom wall that is located near an axial end face of the core yoke portion.

[0009] In some aspects, the technology described herein relates to a power tool that includes: a housing; and an electric motor received within the housing, the electric motor including: a rotor assembly including a rotor shaft; a stator assembly including a plurality of stator segments arranged adjacent to each other circumferentially of the stator assembly, at least one stator segment including: a core having a core yoke portion and a core tooth portion; an insulator at least partially covering the core and having an insulator yoke portion and an insulator tooth portion; a stator segment yoke portion formed by the core yoke portion and the insulator yoke portion; a stator segment tooth portion formed by the core tooth portion and the insulator tooth portion; and a stator winding extending around the stator segment tooth portion, the stator winding including a wire lead; wherein the electric motor further includes a bus bar assembly coupled to the stator assembly and configured to be electrically connected to respective stator windings, the bus bar assembly including an injection molded body and a plurality of conductors; wherein the insulator yoke portion of the at least one stator segment includes a support portion axially protruding away from the core yoke portion of the at least one stator segment, the support portion defining an inner surface facing the insulator tooth portion, an outer surface facing away from the insulator tooth portion, and a top surface facing away from the core yoke portion; wherein the support portion defines a wire notch recessed into the inner surface and extending axially of the electric motor; and wherein the wire notch at least partially receives the wire lead.

[0010] In some embodiments, the wire notch extends axially from the top surface of the support portion to a notch bottom wall located near an axial end face of the core yoke portion, and the wire notch is open radially and axially of the electric motor.

[0011] In some aspects, the technology described herein relates to an electric motor that includes: a rotor assembly including a rotor shaft; a stator assembly including: a core having a core yoke, core teeth extending from the core yoke, and a core crown attached to the core teeth and positioned opposite the core yoke; an insulator at least partially covering the core, the insulator having an insulator yoke at least partially covering the core yoke, insulator teeth at least partially covering the core teeth, and an insulator crown at least partially covering the core crown; a stator winding extending around the insulator teeth, the stator winding including a wire lead; and a busbar assembly coupled to the stator assembly and configured to be electrically connected to the stator winding, the busbar assembly including an injection molded body and a plurality of conductors; wherein the insulator yoke includes a support portion axially protruding away from the core yoke, the support portion defining an inner surface facing the insulator crown, an outer surface facing away from the insulator crown, and a top surface facing away from the core yoke; wherein the support portion defines a wire notch recessed into the inner surface and extending axially in the axial direction of the electric motor; and wherein the wire notch at least partially houses the wire lead.

[0012] In some embodiments, the wire notch is radially open towards the insulator crown.

[0013] In some embodiments, the wire notch is also axially open away from the core yoke.

[0014] In some embodiments, the wire notch is a second wire notch, and the support portion further defines a first wire notch recessed into the top surface and extending radially in the electric motor from the inner surface to the outer surface.

[0015] In some embodiments, the second wire notch extends axially from the top surface of the support portion to a second notch bottom wall located near the axial end face of the core yoke.

[0016] In some embodiments, the wire notch extends axially from the top surface of the support portion to a notch bottom wall located near the axial end face of the core yoke, and the wire notch is radially open and axially open in the axial direction of the electric motor.

[0017] In some aspects, the techniques described herein relate to an electric motor that includes: a rotor assembly including a rotor shaft; and a stator assembly including: a core having a core yoke, core teeth extending from the core yoke, and a core crown attached to the core teeth and positioned opposite the core yoke; an insulator at least partially covering the core, the insulator having an insulator yoke at least partially covering the core yoke, insulator teeth at least partially covering the core teeth, and an insulator crown at least partially covering the core crown; and a stator winding extending around the insulator teeth, the stator winding including a wire lead; wherein the insulator yoke includes a support portion that axially protrudes away from the core yoke, the support portion defining an inner surface facing the insulator crown, an outer surface facing away from the insulator crown, and a top surface facing away from the core yoke; wherein the support portion defines a first wire notch that is recessed into the top surface and extends in a radial direction of the electric motor from the inner surface to the outer surface; wherein the support portion further defines a second wire notch that is recessed into the inner surface and extends in an axial direction of the electric motor; and wherein the first wire notch and the second wire notch each at least partially receive the wire lead.

[0018] In some embodiments, the second wire notch extends in the axial direction from the top surface of the support portion to a second notch bottom wall that is located near an axial end face of the core yoke.

[0019] Other features and aspects of the present disclosure will become apparent by considering the following detailed description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 is a perspective view of a power tool according to one embodiment.

[0021] Figure 2 is Figure 1 a perspective view of an electric motor of the power tool.

[0022] Figure 3 and Figure 4 is Figure 2 an exploded perspective view of the electric motor.

[0023] Figure 5 is an illustration Figure 2 of a perspective view of a stator assembly of the electric motor.

[0024] Figure 6 is an illustration Figure 5 of a partial exploded perspective view of the stator assembly.

[0025] Figure 7 is an illustration Figure 5Partial exploded perspective view of the stator assembly with parts removed.

[0026] Figure 8 and Figure 9 is an illustration Figure 5 of a perspective view of a part of the stator assembly.

[0027] Figure 10 is an illustration Figure 2 of a perspective view of the busbar assembly of an electric motor.

[0028] Figure 11 is an illustration Figure 10 of an exploded perspective view of the busbar assembly.

[0029] Figure 12 is taken along Figure 2 line 12 - 12 of Figure 2 a perspective cross - sectional view of the electric motor.

[0030] Figure 13 is a perspective view of a stator assembly according to another embodiment.

[0031] Figure 14 is Figure 13 an exploded perspective view of the stator assembly.

[0032] Figure 15 and Figure 16 is Figure 13 a perspective view of a part of the stator assembly.

[0033] Figure 17 is a perspective view of a stator assembly according to another embodiment.

[0034] Figure 18 is an illustration Figure 17 of a partial exploded perspective view of the stator assembly.

[0035] Figure 19 is a perspective view of a stator assembly according to another embodiment.

[0036] Figure 20 is a perspective view of a stator assembly according to another embodiment.

[0037] Figure 21 is a perspective view of an electric motor according to another embodiment.

[0038] Figure 22 is taken along Figure 21 line 22 - 22 of Figure 21 a cross - sectional view of the electric motor.

[0039] Figure 23 is a side view of an electric motor according to another embodiment.

[0040] Figure 24 and Figure 25 is Figure 23 A partial perspective view of a stator assembly of an electric motor.

[0041] Figure 26 is according to another embodiment of Figure 24 A partial perspective view of a portion of a stator assembly.

[0042] Figure 27 is according to another embodiment of Figure 24 A partial perspective view of a portion of a stator assembly.

[0043] Figure 28 is according to another embodiment of Figure 24 A partial perspective view of a portion of a stator assembly.

[0044] Figure 29 is a perspective view of an electric motor according to another embodiment.

[0045] Figure 30 is Figure 29 A top view of an electric motor with a portion removed.

[0046] Figure 31 is Figure 29 A partial perspective view of an electric motor.

[0047] Figure 32 is Figure 29 A perspective view of a molded insulator of a bus bar assembly of an electric motor.

[0048] Figure 33 is a perspective view of a portion of an electric motor according to another embodiment.

[0049] Figure 34 is Figure 33 A partial exploded perspective view of an electric motor.

[0050] Figure 35 illustrates Figure 33 A side view of a bus bar assembly of an electric motor.

[0051] Figure 36 is Figure 35 A plan view of a bus bar assembly.

[0052] Figure 37 is Figure 35 An exploded perspective view of a bus bar assembly.

[0053] Figure 38 is Figure 35 An exploded plan view of a bus bar assembly with a portion removed.

[0054] Figure 39Is a perspective view of a portion of an electric motor according to another embodiment.

[0055] Figure 40 Is Figure 39 A partial exploded perspective view of the electric motor.

[0056] Figure 41 Illustrates Figure 39 A side view of the busbar assembly of the electric motor.

[0057] Figure 42 Is Figure 41 A plan view of the busbar assembly.

[0058] Figure 43 Is Figure 41 An exploded perspective view of the busbar assembly.

[0059] Figure 44 Is Figure 41 An exploded plan view of the busbar assembly with a portion removed.

[0060] Figure 45 Is a perspective view of a portion of an electric motor according to another embodiment.

[0061] Figure 46 Is Figure 45 A partial exploded perspective view of the electric motor.

[0062] Figure 47 Illustrates Figure 45 A side view of the busbar assembly of the electric motor.

[0063] Figure 48 Is Figure 47 A plan view of the busbar assembly.

[0064] Figure 49 Is Figure 47 An exploded perspective view of the busbar assembly.

[0065] Figure 50 Is Figure 47 An exploded plan view of the busbar assembly with a portion removed.

[0066] Figure 51 Is a perspective view of a portion of an electric motor according to another embodiment.

[0067] Figure 52 Is Figure 51 A partial exploded perspective view of the electric motor.

[0068] Figure 53 Illustrates Figure 51 A side view of the busbar assembly of the electric motor.

[0069] Figure 54 IsFigure 53 Plan view of the busbar assembly.

[0070] Figure 55 is Figure 53 Exploded perspective view of the busbar assembly.

[0071] Figure 56 is Figure 53 Exploded plan view of the busbar assembly with some parts removed.

[0072] Figure 57 Perspective view of a part of an electric motor according to another embodiment.

[0073] Figure 58 is Figure 57 Exploded perspective view of the electric motor.

[0074] Figure 59 illustrates Figure 57 Side view of the busbar assembly of the electric motor.

[0075] Figure 60 is Figure 59 Plan view of the busbar assembly.

[0076] Figure 61 is Figure 59 Exploded perspective view of the busbar assembly.

[0077] Figure 62 is Figure 59 Exploded plan view of the busbar assembly with some parts removed.

[0078] Figure 63 illustrates the Figure 57 Perspective view of the busbar assembly of the electric motor according to another embodiment.

[0079] Figure 64 Perspective view of a part of an electric motor according to another embodiment.

[0080] Figure 65 is Figure 64 Exploded perspective view of the electric motor.

[0081] Figure 66 is Figure 64 Perspective view of the stator segment of the electric motor.

[0082] Figure 67 is Figure 66 Top view of the stator segment with some parts removed.

[0083] Figure 67A is Figure 64 Partial perspective view of the stator segment of the electric motor.

[0084] Figure 68 is Figure 66 a partial perspective view of the stator segment of

[0085] Figure 69 is Figure 66 a partial perspective view of the stator segment of

[0086] Figure 70 is a cross-sectional view of the stator segment of Figure 68 taken along line 70-70 of Figure 66 of

[0087] Before explaining in detail any embodiments of the present disclosure, it is to be understood that the present disclosure is not limited in its application to the details of the construction and arrangement of components set forth in the following description or illustrated in the following drawings. The present disclosure is capable of other embodiments and of being practiced or carried out in various ways. Further, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. Detailed Description

[0088] Figure 1 and Figure 2 illustrate a power tool 10, such as, for example, a drill, a rotary impact tool, etc. The power tool 10 includes a housing 12 and an electric motor 14. The power tool 10 is operable with a battery pack 16 that is removably coupled to a battery receptacle 18 located at the bottom end of the housing 12. The battery pack 16 includes a plurality of battery cells (not shown) that are electrically connected to provide the desired output (e.g., nominal voltage, current capacity, etc.) of the battery pack 16. When the battery pack 16 is coupled to the battery receptacle 18, the electric motor 14 receives power from the battery pack 16.

[0089] In some embodiments, the power tool 10 may include a power cord for electrically connecting the motor 14 to an alternating current (AC) power source. However, the battery pack 16 is the preferred means for powering the power tool 10 because cordless power tools can be used in locations where other power sources are not available.

[0090] Referring to Figures 2 to 4, the illustrated electric motor 14 is a brushless direct current (“BLDC”) motor having a stator assembly 20 and a rotor assembly 22 that is rotatable relative to the stator assembly 20 about an axis 24. The rotor assembly 22 includes a rotor body 26 and a fan 28 each supported on a rotor shaft 30. The fan 28 is located adjacent a first or front end 32 of the motor 14. The stator assembly 20 includes a central cavity 34 that receives the rotor assembly 22 rotatable about the axis 24. The motor 14 also includes a bus bar assembly 36 and a printed circuit board assembly (PCBA) 38 that are each coupled to the stator assembly 20 at a second or rear end 40 of the motor 14 opposite the front end 32.

[0091] Referring Figures 5 to 9 , the stator assembly 20 is a segmented stator assembly 20 that, in the illustrated embodiment, includes six stator segments 42 disposed within a tubular housing 44. Each stator segment 42 includes a core 46, an overmolded insulator 48, and a stator winding 50. Adjacent stator segments 42 are interconnected via a notch and projection interlock 52. Specifically, each stator segment 42 includes a longitudinally extending notch 54 disposed in a first circumferential end face 56 and a longitudinally extending projection 58 that projects from a second circumferential end face 60. The notch 54 of one stator segment 42 receives the projection 58 of an adjacent stator segment 42 to align the two adjacent stator segments 42.

[0092] The tubular housing 44 surrounds the disposed stator segments 42 to hold the stator segments 42 together. Specifically, the tubular housing 44 includes a tubular wall 62 that defines an inner cavity 64, and the stator segments 42 are received into the inner cavity 64 such that the tubular wall 62 converges about the stator segments 42. In one example, the tubular housing 44 can be heated to expand the outer diameter of the tubular wall 62, and then the tubular housing 44 can be pressed onto the stator segments 42. When the tubular housing 44 cools, the tubular wall 62 contracts about the stator segments 42 to secure the assembly. In the illustrated embodiment, the tubular housing 44 also includes mounting tabs 66 that radially extend outward from the tubular wall 62, each mounting tab 66 defining a mounting aperture 68 that is configured to receive a fastener (e.g., a screw) for securing the motor 14 to, for example, a gearbox (not shown).

[0093] Referring Figure 8 , each overmolded insulator 48 includes a mounting portion 70 that projects toward the rear end 40 of the motor 14. Each mounting portion 70 defines an axially extending threaded aperture 72 that receives a first fastener 74 or a second fastener 76 to secure the bus bar assembly 36 and the PCBA 38 to the stator assembly 20 ( Figure 3 and Figure 4 ).

[0094] Referring Figure 10 andFigure 11 , the busbar assembly 36 includes three annular conductors 78 extending generally circumferentially around the motor 14, and an overmolded body 80 that fixedly supports the annular conductors 78. Each conductor 78 includes two shanks 82 disposed at opposite ends of the conductor 78 and a terminal 84 extending axially along the motor 14. Each terminal 84 is mechanically and electrically connected to the PCBA 38. Specifically, the PCBA 38 includes a plurality of small holes 85 corresponding to the positions of the terminals 84 ( Figure 3 and Figure 12 ). During assembly, the terminals 84 are inserted into the small holes 85 and soldered to the PCBA 38 to mechanically and electrically connect the terminals 84 to the PCBA 38. Each stator winding 50 includes a pair of leads 86 ( Figure 8 ) connected to adjacent shanks 82 of the conductor 78. The leads 86 can be soldered or fused to the shanks 82. In this way, the conductor 78 electrically connects the stator winding 50 to the PCBA 38. The PCBA 38 receives power from the battery pack 16 and selectively applies current to the winding 50, causing the rotor shaft 30 to rotate about the axis 24.

[0095] The overmolded body 80 includes a central hub 88 that defines a central small hole or bearing pit 90 for receiving the rotor bearing 92 ( Figures 10 to 12 ). The rotor bearing 92 receives the rotor shaft 30 to rotatably support the rotor assembly 22. The overmolded body 80 also includes radial arms 94 extending radially outward from the central hub 88. In some embodiments, the number of radial arms 94 corresponds to the number of mounting portions 70 of the stator assembly 20. In the illustrated embodiment, the overmolded body includes six radial arms 94 corresponding to the six mounting portions 70 of the six stator segments 42. Each radial arm 94 defines a first small hole 96 that aligns with the threaded small hole 72 of the corresponding mounting portion 70.

[0096] Referring to Figure 3 and Figure 12, the busbar assembly 36 is fixed to the mounting portion 70 of the stator assembly 20 via the first fastener 74 and the second fastener 76, and the PCBA 38 is fixed to the stator assembly 20 via the second fastener 76. The PCBA 38 includes a second small hole 98 that extends through the PCBA 38 and corresponds to the first small holes 96 of the other circumferentially radial arms 94. Thus, the radial arm 94 includes a first radial arm 94a and a second radial arm 94b. The first radial arm 94a is directly coupled to the mounting portion 70 via the first fastener 74. The second radial arm 94b is coupled to the mounting portion 70 and the PCBA 38 via the second fastener 76. More specifically, the first fastener 74 is received in the first small hole 96 of the first radial arm 94a and fastened to the threaded small hole 72 to fix the first radial arm 94a to the mounting portion 70. The second fastener 76 is received in the second small hole 98 of the PCBA 38 and the first small hole 96 of the second radial arm 94b, and fastened to the threaded small hole to fix the PCBA 38 and the second radial arm 94 to the mounting portion 70. Thus, the busbar assembly 36 is fixed to each mounting portion 70 of each stator segment 42 and supports the rotor bearing 92 to center the rotor assembly 22 relative to the stator assembly 20.

[0097] Referring to Figure 3 , Figure 4 and Figure 12 , the PCBA 38 includes a printed circuit board (PCB) 95 and a heat sink 97 fixed to the PCB 95. The heat sink 97 includes a plurality of recesses 97a, and the overmolded body 80 includes a plurality of axially extending protrusions 80a that are received in the corresponding recesses 97a to align the PCBA 38 with the busbar assembly 36.

[0098] Figures 13 to 16 Illustrate a stator assembly 120 in another embodiment according to the present disclosure. The stator assembly 120 is similar to the above-described stator assembly 20 and includes a structure substantially the same as that of the stator assembly 20. Also, the stator assembly 120 can operate with each of the above-described rotor assembly 22, busbar assembly 36, and PCBA 38. The feature parts and elements of the stator assembly 120 similar to those of the stator assembly 20 are given the same reference numerals "plus 100". It should be understood that the feature parts of the stator assembly 120 not explicitly described below have the same characteristics as those of the stator assembly 20.

[0099] Referring to Figure 13 and Figure 14, the stator assembly 120 is coupled to the busbar assembly 36 and the PCBA 38 via a first fastener 74 and a second fastener 76 in the same manner as the connection of the stator assembly 20 described above. And, the stator assembly 120 similarly includes stator segments 142 arranged end-to-end. However, the stator assembly 120 does not include a tubular housing. Instead, the stator segments 142 are laser welded at each notch and protrusion interlock 152 to hold the stator segments 142 together. Further, the stator segments 142 are not uniform, but include a first stator segment 142a and a second stator segment 142b arranged in an alternating sequence ( Figure 15 and Figure 16 ). More specifically, each first stator segment 142a is connected to a second stator segment 142b at each circumferential end. Each first stator segment 142a includes mounting ribs 121 that project radially outward and extend longitudinally along the axis. Each mounting rib 121 defines a mounting aperture 123 that receives a fastener for mounting the stator assembly 120 to, for example, a gearbox (not shown). The second stator segment 142b does not include mounting ribs, but includes an axially extending groove that receives a portion of the overmolded insulator 148.

[0100] Figure 17 and Figure 18 Illustrate a stator assembly 220 according to another embodiment of the present disclosure. The stator assembly 220 is similar to the stator assembly 20, stator assembly 120 described above, and includes substantially the same structure. And, the stator assembly 220 is capable of operating with the rotor assembly 22 described above. The features and elements of the stator assembly 220 that are similar to those of the stator assembly 20 and stator assembly 120 are given the same reference numerals “plus 200”. It should be understood that the features of the stator assembly 220 that are not explicitly described below have the same characteristics as the features of the stator assembly 20.

[0101] The stator assembly 220 includes stator segments 242 laser welded at each notch and protrusion interlock device 252 to secure the stator segments 242 together. Each stator segment 242 includes an external groove 225 formed in the outer circumferential surface of the core 246 and extending longitudinally in the axial direction. The stator assembly 220 can be mounted inside the housing 12. In this regard, the housing 12 may be provided with longitudinal ribs (not shown) that project inwardly within the housing 12 and are received into the grooves 225 to secure the stator assembly 220 against rotation relative to the housing 12. Additionally, the stator assembly 220 is capable of operating with the PCBA 238, which includes peripheral notches 227 formed at intervals around the periphery of the PCBA 238. Each notch 227 can accommodate two adjacent leads 286 of the stator winding 250. The leads 286 can be directly soldered to pads provided within the notch 227 to directly electrically connect the leads 286 to the PCBA 238. Since the leads 286 are directly secured to the PCBA 238, there is no need to provide a separate bus bar assembly. The PCBA 238 also includes a second small hole 298 that houses a fastener 229, which fastens to at least a portion of the mounting portion 270 to secure the PCBA 238 to the axial end of the stator assembly 220.

[0102] Figure 19 Illustrate a stator assembly 320 according to another embodiment of the present disclosure. The stator assembly 320 is similar to the above-described stator assembly 20 and includes substantially the same structure. Also, the stator assembly 320 is capable of operating with the above-described rotor assembly 22. The features and elements of the stator assembly 320 that are similar to those of the stator assembly 20 are given the same reference numerals “plus 300”. It should be understood that the features of the stator assembly 320 not explicitly described below have the same characteristics as the features of the stator assembly 20.

[0103] Similar to the segmented stator assembly 20 described above, the stator assembly 320 is a segmented stator assembly 320 which, in the illustrated embodiment, includes six stator segments 342 disposed within a tubular housing 344. However, unlike the stator assembly 20, the stator assembly 320 is not coupled to a bus bar assembly at its axial ends. Instead, the stator assembly 320 further includes a terminal plate assembly 353 directly injection molded onto an outer circumferential surface 356 of a tubular wall 362 of the tubular housing 344. In the illustrated embodiment, the terminal plate assembly 353 includes three conductors 360 extending generally longitudinally along the outer circumferential surface 356. Each conductor 360 includes a winding connection portion 364 disposed near an axial end of the stator assembly 320 and a terminal 368 extending axially away from the winding connection portion 364 of the stator assembly 320. The winding connection portion 364 is mechanically and electrically connected to leads of respective pairs of windings 350, and each terminal 368 is electrically connected to a PCBA (not shown). Thus, the conductors 360 electrically connect the stator windings 350 to the PCBA which receives power from the battery pack 16 and selectively applies current to the windings 350 to cause the rotor shaft 30 to rotate about the axis 24. The conductors 360 may be supported on the outer circumferential surface 356 by an injection molded material (such as a resin) which electrically insulates the conductors 360 from the tubular housing 344 and from the cores 346 of the stator segments 342.

[0104] Figure 20 Illustrate a stator assembly 420 according to another embodiment of the present disclosure. The stator assembly 420 is similar to the stator assembly 120 described above and includes substantially the same structure. Also, the stator assembly 420 is capable of operating with the rotor assembly 22 described above. Features and elements of the stator assembly 420 that are similar to those of the stator assembly 120 are given the same reference numerals “plus 300”. It should be understood that features of the stator assembly 420 that are not explicitly described below have the same characteristics as those of the stator assembly 120.

[0105] Similar to the segmented stator assembly 120 described above, the stator assembly 420 is a segmented stator assembly 420 which, in the illustrated embodiment, includes six stator segments 442 that are laser welded at each notch and protrusion interlock 452 to secure the stator segments 442 together. However, unlike the stator assembly 120, the stator assembly 420 is not coupled to the busbar assembly at its axial ends. Instead, the stator assembly 420 further includes a terminal board assembly 453 that is directly injection molded onto the outer circumferential surface 456 of the core 446 of one of the stator segments 442. In the illustrated embodiment, the terminal board assembly 453 includes three conductors 460 that extend generally longitudinally along the outer circumferential surface 456. Each conductor 460 includes a winding connection portion 464 disposed near the axial end of the stator assembly 420 and a terminal 468 that extends axially away from the winding connection portion 464 of the stator assembly 420. The winding connection portion 464 is mechanically and electrically connected to the leads of each pair of windings 450, and each terminal 468 is electrically connected to a PCBA (not shown). In this way, the conductors 460 electrically connect the stator windings 450 to the PCBA which receives power from the battery pack 16 and selectively applies current to the windings 450 to cause the rotor shaft 30 to rotate about the axis 24. The conductors 460 may be supported on the outer circumferential surface 456 by an injection molded material (e.g., resin) that electrically insulates the conductors 460 from the core 446 of the stator segment 442. In some embodiments, the overlapping injection molded insulator 448 of the stator segment 442 may be formed with a terminal board portion 472 that supports the conductors 460.

[0106] Figure 21 and Figure 22 Illustrate a segmented stator assembly 520 according to another embodiment of the present disclosure. The stator assembly 520 is similar to the stator assembly 120 described above and includes substantially the same structure. Also, the stator assembly 520 is capable of operating with the rotor assembly 22 described above. The features and elements of the stator assembly 520 that are similar to those of the stator assembly 120 are given the same reference numerals “plus 400”. It should be understood that the features of the stator assembly 520 that are not explicitly described below have the same characteristics as the features of the stator assembly 120.

[0107] Similar to the segmented stator assembly 120 described above, the stator assembly 520 is a segmented stator assembly 520 which, in the illustrated embodiment, includes six stator segments 542 that are laser welded at each notch and protrusion interlock 552 to secure the stator segments 542 together. In an alternative embodiment (not shown), the stator segments 542 may alternatively be disposed within a tubular housing, such as the stator assembly 20 described above ( Figure 3) of the tubular housing 44. Each stator segment 542 includes a core 546, an overmolded insulator 548, and a stator winding 550. The stator segments 542 are not uniform, but rather include first stator segments 542a and second stator segments 542b arranged in an alternating sequence. Each first stator segment 542a is connected to a second stator segment 542b at each circumferential end.

[0108] The busbar assembly 536 is coupled to an axial end of the stator assembly 520. The busbar assembly 536 includes three annular conductors 578 and an overmolded body 580 that fixedly supports the conductors 578. Each conductor 578 includes a shank 582 disposed at one end of the conductor 578 and a terminal 584 formed at an opposite end of the conductor 578. The overmolded body 580 includes a disk portion 581 that supports the shank 582 and a terminal plate portion 583 that extends axially away from the disk portion 581 at a peripheral edge of the disk portion 581. The terminal plate portion 583 supports the terminal 584. The disk portion 581 also includes mounting tabs 594 that engage a mounting portion 570 defined by the overmolded insulator 548 of the first stator segment 542a. The mounting tabs 594 can be fixed to the mounting portion 570 via, for example, threaded fasteners.

[0109] Each terminal 584 is electrically connected to a PCBA (e.g., via a wire; not shown) that receives power from the battery pack 16 ( Figure 1 ) and selectively applies current to the stator winding 550. Each winding 550 includes a pair of leads 586 that are connected to adjacent shanks 582 of the conductor 578. In this way, the conductor 578 electrically connects the stator winding 550 to the PCBA 538.

[0110] The disk portion 581 of the overmolded body 580 defines a central aperture or bearing pit 590 that houses the rotor bearing 92 ( Figure 3 ). The rotor bearing 92 houses the rotor shaft 30 of the rotor assembly 22 ( Figure 3 ) to rotatably support the rotor assembly 22. Since the busbar assembly 536 is fixed to each mounting portion 570 of each first stator segment 542a and further supports the rotor bearing 592, the busbar assembly 536 centers the rotor assembly 22 relative to the stator assembly 520.

[0111] Figures 23 to 25 Illustrating a stator assembly 620 according to another embodiment of the present disclosure. The stator assembly 620 is similar to the stator assembly 120 described above and includes substantially the same structure. Also, the stator assembly 620 is capable of operating with the rotor assembly 22 described above. The like features and elements of the stator assembly 620 and the stator assembly 120 are given the same reference numerals “plus 500”. It should be understood that the features of the stator assembly 620 that are not explicitly described below have the same characteristics as the features of the stator assembly 120.

[0112] Similar to the segmented stator assembly 120 described above, the stator assembly 620 is a segmented stator assembly 620 which, in the illustrated embodiment, includes six stator segments 642 that are laser welded to each other at the notch and projection interlock means 652 to secure the stator segments 642 together. In an alternative embodiment (not shown), the stator segments 642 may alternatively be disposed within a tubular housing, such as the tubular housing 44 of the stator assembly 20( Figure 3 ). Each stator segment 642 includes a core 646, an overmolded insulator 648, and a stator winding 650.

[0113] The stator assembly 620 is capable of operating with a PCBA 638 coupled to the axial ends of the stator assembly 620. The PCBA 638 receives power from the battery pack 16( Figure 1 ) and selectively applies current to the stator winding 650. Each overmolded insulator 648 defines a pair of notches 685 at the axial ends, and an L-shaped conductive terminal 678 is overmolded into the overmolded insulator 648 adjacent to each notch 685. A first leg 687 of the terminal 678 extends radially outward from the overmolded insulator 648, and a second leg 689 of the terminal 678 extends axially away from the overmolded insulator 648. Each lead 686 of each winding 650 is bent into the corresponding notch 685 and electrically connected to the corresponding first leg 687 of the terminal 678 (e.g., via laser welding). The second leg 689 of the terminal 678 is mechanically and electrically coupled to the PCBA 638 (e.g., via soldering). In some embodiments, the soldered connection between the PCBA 638 and the terminal 678 is sufficient to mechanically secure the PCBA 638 to the stator assembly 620.

[0114] Referring to Figure 26 , in another embodiment, the stator assembly 620 may alternatively include stator segments 642a that include overmolded conductive terminals 678a, each having a vertical shank 687a instead of the radially extending first leg described above. Each vertical shank 687a is folded over the corresponding lead 686 of the stator winding 650 and welded. The second leg (not shown) of the terminal 678a is soldered to the PCBA 638 in a manner similar to that described above( Figure 23 ).

[0115] Referring to Figure 27 , in another embodiment, the stator assembly 620 may alternatively include stator segments 642b that include overmolded conductive terminals 678b, each defining a fill slot 691. The leads 686 of the stator winding 650 are pressed into the fill slots 691 to form an electrical connection. The second leg 689b of the terminal 678b is soldered to the PCBA 638 in a manner similar to that described aboveFigure 23 )。

[0116] Referring to Figure 28 , in another embodiment, the stator assembly 620 may alternatively include a stator segment 642c that includes injection-molded conductive terminals 678c, each conductive terminal having a clamping weld groove 693. The leads 686 of the stator winding 650 are pressed into the clamping weld grooves 693 and welded to form an electrical connection. The second leg 689c of the terminal 678c is soldered to the PCBA 638 in a manner similar to the above-described manner ( Figure 23 )。

[0117] Figures 29 to 32 Illustrated is a segmented stator assembly 720 in accordance with another embodiment of the present disclosure. The stator assembly 720 is similar to the above-described stator assembly 520 and includes substantially the same structure. Also, the stator assembly 720 is capable of operating with the above-described rotor assembly 22. Features and elements of the stator assembly 720 that are similar to those of the stator assembly 520 are given the same reference numerals “plus 200”. It should be understood that features of the stator assembly 720 that are not explicitly described below have the same characteristics as those of the stator assembly 520.

[0118] Similar to the above-described segmented stator assembly 520, the stator assembly 720 is a segmented stator assembly 720 that, in the illustrated embodiment, includes six stator segments 742 that are laser welded at each notch and protrusion interlock device 752 to secure the stator segments 742 together. In an alternative embodiment (not shown), the stator segments 742 may alternatively be disposed within a tubular housing, such as the tubular housing 44 of the above-described stator assembly 20 ( Figure 3 )。Each stator segment 742 includes a core 746, an overlapping injection-molded insulator 748, and a stator winding 750. The stator segments 742 are not uniform but include first stator segments 742a and second stator segments 742b that are arranged in an alternating order. Each first stator segment 742a is connected to a second stator segment 742b at each circumferential end.

[0119] A busbar assembly 736 is coupled to an axial end of the stator assembly 720. The busbar assembly 736 includes three annular conductors 778 and an overlapping injection-molded body 780 that fixedly supports the conductors 778. The overlapping injection-molded body 780 is injection-molded over the arranged conductors 778 such that a portion of each conductor 778 extends generally within the overlapping injection-molded body 780.

[0120] Figure 30An exemplary segmented stator assembly 720 is illustrated, where the overmolded body 780 is removed to expose the annular conductors 778. Each conductor 778 includes two pairs of tangs 782 that project radially outward, or both radially and tangentially outward, from the overmolded body 780. The two pairs of conductors 778 are disposed at circumferentially opposite sides of the annular conductor 778. Each tang 782 is connected to a lead 786 of an adjacent stator winding 750( Figure 31 ).

[0121] Referring Figure 31 , each overmolded insulator 748 defines a pair of notches 785 at an axial end. Each notch 785 is located adjacent to a corresponding tang 782. Each lead 786 of each winding 750 is bent into the corresponding notch 785 and electrically connected to the corresponding tang 782 (e.g., via laser welding). Also, each tang 782 is bent toward the notch 785 (i.e., axially) to bring the tang 782 into contact with the lead 786.

[0122] Each conductor 778 further includes a terminal 784 that projects radially outward, or at least both radially and tangentially outward, from the overmolded body 780. Each terminal 784 is electrically connected to a PCBA (e.g., via a wire; not shown) that receives power from the battery pack 16( Figure 1 ) and selectively applies current to the stator windings 750. Thus, the conductor 578 electrically connects the stator windings 550 to the PCBA 538.

[0123] Referring Figure 29 and Figure 32 , the overmolded body 780 includes a generally disk-shaped disk portion 781 from which mounting tabs 794 project radially outward. The mounting tabs 794 engage mounting portions 770 defined by the overmolded insulators 748 of the first stator segment 742a. The mounting tabs 794 can be fixed to the mounting portions 770 via, for example, threaded fasteners.

[0124] The overmolded body 780 includes a central annular wall 755 that extends axially away from the disk portion 781 and toward the rotor assembly 22( Figure 3 ). The annular wall 755 and the disk portion 781 together define a central aperture or bearing pit 790 that houses the rotor bearing 92( Figure 29 ). The rotor bearing 92 houses the rotor shaft 30( Figure 3 ) of the rotor assembly 22 to rotatably support the rotor assembly 22. Since the busbar assembly 736 is fixed to each mounting portion 770 of each stator segment 742a and further supports the rotor bearing 792, the busbar assembly 736 centers the rotor assembly 22 relative to the stator assembly 720. The disk portion 781 also includes a plurality of vent holes 757( Figure 32)。Ventilation holes 757 allow the cooling air flow generated by the fan 28 ( Figure 3 ) to pass through the busbar assembly 736.

[0125] Figures 33 to 38 Illustrates a portion of an electric motor 814 according to another embodiment of the present disclosure. The motor 814 includes a segmented stator assembly 820, which is similar to the stator assembly 120 described above and includes substantially the same structure. Also, the stator assembly 820 is capable of operating with the rotor assembly 22 described above. The features and elements of the stator assembly 820 that are similar to those of the stator assembly 120 are given the same reference numerals “plus 700”. It should be understood that the features of the stator assembly 820 not explicitly described below have the same characteristics as the features of the stator assembly 120.

[0126] Similar to the segmented stator assembly 120 described above, the stator assembly 820 is a segmented stator assembly 820 which, in the illustrated embodiment, includes six stator segments 842 that are laser welded at each notch and protrusion interlock device 852 to secure the stator segments 842 together. In an alternative embodiment (not shown), the stator segments 842 may alternatively be disposed within a tubular housing, such as the tubular housing 44 of the stator assembly 20 ( Figure 3 ). Each stator segment 842 includes a core 846, an overmolded insulator 848, and a stator winding 850. The stator segments 842 are not uniform but include first stator segments 842a and second stator segments 842b arranged in an alternating sequence. Each first stator segment 842a is connected to a second stator segment 842b at each circumferential end.

[0127] The motor 814 includes a busbar assembly 836 coupled to an axial end of the stator assembly 820. The busbar assembly 836 includes six annular conductors 878 and an overmolded body 880 that fixedly supports the conductors 878. Each conductor 878 includes two shanks 882 disposed at two opposite ends of the conductor 878 and a terminal 884 formed at one of the ends of the conductor 878 and positioned adjacent to one of the two shanks 882. The overmolded body 880 includes mounting tabs 894 that engage mounting portions 870 defined by the overmolded insulators 848 of the first stator segments 842a. The mounting tabs 894 can be fixed to the mounting portions 870 via, for example, threaded fasteners.

[0128] Each terminal 884 is electrically connected to a PCBA (e.g., via wires; not shown) that receives power from the battery pack 16 ( Figure 1 ) and selectively applies current to the stator windings 850. Each winding 850 includes a pair of leads 886 that are connected to two adjacent shanks 882 of the conductor 878. In this manner, the conductors 878 electrically connect the stator windings 850 to the PCBA.

[0129] The overmolded body 880 defines a central hole or bearing pit 890 that houses the rotor bearing 92( Figure 3 ). The rotor bearing 92 houses the rotor shaft 30 of the rotor assembly 22( Figure 3 ) to rotatably support the rotor assembly 22. Since the busbar assembly 836 is fixed to each mounting portion 870 of each stator segment 842a and further supports the rotor bearing 92, the busbar assembly 836 centers the rotor assembly 22 relative to the stator assembly 820.

[0130] The PCBA 839 (such as a rotor position sensor circuit board) is coupled to the overmolded body 880 of the busbar assembly 836. The PCBA 839 is generally annular and is received into a corresponding centrally located annular recess 841 defined in the overmolded body 880 and secured to the overmolded body by threaded fasteners. The PCBA 839 covers at least a portion of the bearing pit 890.

[0131] Referring to Figure 35 and Figure 36 , the busbar assembly 836 includes a total of twelve shanks 882 that are circumferentially equally spaced around the perimeter of the overmolded body 880. In other embodiments (not shown), fewer or more shanks may also be contemplated, and the number of shanks may be twice the number of stator windings such that each shank is connected to a corresponding lead of a stator winding. In the illustrated embodiment, the busbar assembly 836 also includes six terminals 884 provided in three pairs 884a - 884c (i.e., three sets 884a - 884c of double terminals 884). The three pairs 884a - 884c are circumferentially spaced from each other around the perimeter of the overmolded body 880. In the illustrated embodiment, each set 884a - 884c is spaced approximately 120 degrees from the other sets 884a - 884c as measured about the central axis 824 of the motor 814.

[0132] As Figure 35 shown, the overmolded body 880 includes a first axial surface 823 that extends at a first axial end of the overmolded body and a second axial surface 825 that extends at a second axial end of the overmolded body. The first axial surface 823 faces the stator assembly 820, and the second axial surface 825 faces away from the stator assembly 820. The shanks 882 each project from the first axial surface 823 and extend partially axially and partially radially. That is, each shank 882 extends generally toward the stator assembly 820 and extends radially outward. Each shank 882 also includes a V - shaped notch 827 defined in the distal end of the shank between two adjacent forks 829. The corresponding leads 886 of adjacent stator windings 850( Figure 33) is received into the notch 827 and mechanically attached, such as by laser welding, to the shank 882 between the fork heads 829. As Figure 35 As further shown, each shank 882 is also generally located within the same axial region of the motor 814. Specifically, the ends of each fork head 829 of each shank 882 together define a first plane 831 that extends perpendicular to the central axis 824.

[0133] Each terminal 884 projects from the second axial surface 825 of the overmolded body 880 and is generally L-shaped, having a first leg 833 that extends axially and a second leg 835 that extends radially. The second legs 835 of each terminal 884 are generally located within the same axial region of the motor 814. Specifically, the second legs 835 of each terminal 884 together define a second plane 837 that is perpendicular to the central axis 824 and extends parallel to the first plane 831.

[0134] Figures 39 to 44 Illustrating a portion of an electric motor 914 according to another embodiment of the present disclosure. The motor 914 includes the segmented stator assembly 820 described herein in connection with Figures 33 to 38 and is capable of operating with the rotor assembly 22 described herein in connection with Figures 2 to 4 and Figure 12 .

[0135] The motor 914 includes a busbar assembly 936 coupled to the axial end of the stator assembly 920. The busbar assembly 936 includes six annular conductors 978 and an overmolded body 980 that fixedly supports the conductors 978. Each conductor 978 includes two shanks 982 disposed at two opposite ends of the conductor 978 and a terminal 984 formed at one of the ends of the conductor 978 and positioned adjacent to one of the two shanks 982. The overmolded body 980 includes mounting tabs 994 that engage mounting portions 870 defined by the overmolded insulators 848 of the first stator segments 842a. The mounting tabs 994 can be fixed to the mounting portions 870, such as by threaded fasteners.

[0136] Each terminal 984 is electrically connected to a PCBA (e.g., via a wire; not shown), which receives power from the battery pack 16 ( Figure 1 ) and selectively applies current to the stator windings 850. The leads 886 of the windings 850 are connected to two adjacent shanks 982 of the conductor 978. In this way, the conductor 978 electrically connects the stator windings 850 to the PCBA.

[0137] The overmolded body 980 defines a central hole or bearing pit 990 that houses the rotor bearing 92 ( Figure 3 ). The rotor bearing 92 houses the rotor assembly 22 ( Figure 3) The rotor shaft 30 rotatably supports the rotor assembly 22. Since the busbar assembly 936 is fixed to each mounting portion 870 of each stator segment 842a and further supports the rotor bearing 92, the busbar assembly 936 centers the rotor assembly 22 relative to the stator assembly 820.

[0138] A PCBA 939 (such as a rotor position sensor circuit board) is coupled to the overmolded body 980 of the busbar assembly 936. The PCBA 939 is generally annular and is received within a corresponding centrally located annular recess 941 defined in the overmolded body 980 and secured to the overmolded body by threaded fasteners. The PCBA 939 covers at least a portion of the bearing pit 990.

[0139] As Figure 41 shown, the overmolded body 980 includes a first axial surface 923 extending at a first axial end of the overmolded body and a second axial surface 925 extending at a second axial end of the overmolded body. The first axial surface 923 faces the stator assembly 820, and the second axial surface 925 faces away from the stator assembly 820. The overmolded body 980 also includes a circumferential outer surface 943 extending between the first axial surface 923 and the second axial surface 925. The shanks 982 each project generally radially from the circumferential outer surface 943. Each shank 982 includes a hook portion 945 extending generally circumferentially. The respective leads 886 ( Figure 33 ) of adjacent stator windings 850 are received by and contact the hook portions 945 and are mechanically attached to the hook portions, for example, by laser welding. In other embodiments, the leads 886 may be attached to the hook portions 945 by other means (such as soldering, ultrasonic welding, crimping, etc.). As Figure 41 further shown, each shank 982 is also generally located within the same axial region of the motor 814. Specifically, each hook portion 945 of each shank 982 together defines a first plane 931 extending perpendicular to the central axis 924.

[0140] In the illustrated embodiment, the busbar assembly 936 includes six terminals 984 that are grouped together on one lateral side of the overmolded body 980. Each terminal 984 projects from the second axial surface 925 of the overmolded body 980 and includes a leg 935 extending in a laterally outward direction perpendicular to the central axis 924. Each leg 935 extends generally parallel to each other. The longitudinal extent of each leg 935 together defines a second plane 937 that is perpendicular to the central axis 924 and extends parallel to the first plane 931. Additionally, the distal ends 947 of each leg 935 are laterally aligned with each other. Specifically, the distal ends 947 terminate along a line L that is perpendicular to the central axis 924 and perpendicular to the laterally outward direction. Further, as Figure 42As shown, the busbar assembly 936 can be divided into four equal radial quadrants A - D, each quadrant starting from the central axis 924. The leg 935 of each terminal 984 is located within a single quadrant A.

[0141] Figures 45 to 50 Illustrates all or part of an electric motor 1014 according to another embodiment of the present disclosure. The motor 1014 includes the segmented stator assembly 820 described herein in connection with Figures 33 to 38 and is capable of operating with the rotor assembly 22 described herein in connection with Figures 2 to 4 and Figure 12 .

[0142] The motor 1014 includes a busbar assembly 1036 coupled to the axial end of the stator assembly 820. The busbar assembly 1036 includes three annular conductors 1078 ( Figures 49 to 50 ) and an overmolded body 1080 that fixedly supports the conductors 1078. Each conductor 1078 includes four winding connection terminals or leads 1082 disposed at two opposite ends of the conductor 1078, and a power connection terminal 1084 that projects from the conductor 1078. The overmolded body 1080 includes three mounting arms 1094 that project radially from the central region of the body 1080 and are spaced apart at equal intervals around the circumference of the body. The mounting arms 1094 engage mounting portions 870 defined by the overmolded insulators 848 of the first stator segment 842a. The mounting arms 1094 can be fixed to the mounting portions 870 via, for example, threaded fasteners.

[0143] Each terminal 1084 is electrically connected to a PCBA (e.g., via wires; not shown), which receives power from the battery pack 16 ( Figure 1 ) and selectively applies current to the stator windings 850. The leads 886 of the windings 850 are connected to two adjacent leads 1082 of the conductor 1078. In this way, the conductor 1078 electrically connects the stator windings 850 to the PCBA.

[0144] The overmolded body 1080 defines a central hole or bearing pit 1090 that houses the rotor bearing 92 ( Figure 3 ). The rotor bearing 92 houses the rotor shaft 30 of the rotor assembly 22 ( Figure 3 ) to rotatably support the rotor assembly 22. Since the busbar assembly 1036 is fixed to each mounting portion 870 of each stator segment 842a and further supports the rotor bearing 92, the busbar assembly 1036 centers the rotor assembly 22 relative to the stator assembly 820.

[0145] The PCBA 1039 (such as a rotor position sensor circuit board) is connected to the overmolded body 1080 of the busbar assembly 1036. The PCBA 1039 is generally annular and is received in a corresponding centrally located annular recess 1041 defined in the overmolded body 1080 and is fixed to the overmolded body by threaded fasteners. The PCBA 1039 covers at least a portion of the bearing pit 1090.

[0146] As Figure 47 shown, the overmolded body 1080 includes a first axial surface 1023 extending at a first axial end of the overmolded body and a second axial surface 1025 extending at a second axial end of the overmolded body. The first axial surface 1023 faces the stator assembly 820, and the second axial surface 1025 faces away from the stator assembly 820. The overmolded body 1080 also includes a circumferential outer surface 1043 extending between the first axial surface 1023 and the second axial surface 1025. The shanks 1082 each project generally radially from the circumferential outer surface 1043. Each shank 1082 includes a forked end 1045 at its distal end and is generally planar in shape. The respective leads 886 ( Figure 45 ) of adjacent stator windings 850 are received by and contact the forked ends 1045 and are mechanically attached to the forked ends, such as by laser welding. In other embodiments, the leads 886 may be attached to the forked ends 1045 by other means (such as soldering, ultrasonic welding, crimping, etc.). As Figure 47 further shown, each shank 1082 is also generally located within the same axial region of the motor 1014. Specifically, each shank 1082 lies within and defines a first plane 1031 extending perpendicular to the central axis 1024. As Figure 47 shown, the shanks 1082 are spaced apart around the circumference of the overmolded body 1080 at generally equal intervals. Thus, the angle A is measured at the center around the central axis 1024 between any two adjacent shanks 1082. In the illustrated embodiment, the busbar assembly 1036 includes twelve shanks 1082, and the angle A is approximately 30 degrees.

[0147] In the illustrated embodiment, the busbar assembly 1036 includes three power connection terminals 1084 projecting axially 1037 from the second axial surface 1025 of the overmolded body 1080. Each terminal 1084 is formed as a straight leg perpendicular to the central axis 1024. All terminals 1084 are generally parallel to each other and extend perpendicular to the first plane 1031.

[0148] The busbar assembly 1036 is configured to provide a parallel delta winding configuration for the motor 1014. Specifically, when the leads 886 of the winding 850 forming each coil are connected to the corresponding fork-shaped ends 1045 of the respective nearest pins 1082, the windings 850 are arranged in a parallel delta winding configuration.

[0149] Figures 51 to 56 Illustrates a portion of an electric motor 1114 according to another embodiment of the present disclosure. The motor 1114 includes the segmented stator assembly 820 described herein in connection with Figures 33 to 38 and is capable of operating with the rotor assembly 22 described herein in connection with Figures 2 to 4 and Figure 12 .

[0150] The motor 1114 includes a busbar assembly 1136 coupled to an axial end of the stator assembly 820. The busbar assembly 1136 includes six annular conductors 1178 ( Figure 55 and Figure 56 ) and an overlapping injection molded body 1180 that fixedly supports the conductors 1178. Each conductor 1178 includes two winding connection terminals or pins 1182 disposed at two opposite ends of the conductor 1178 and a power connection terminal 1184. The overlapping injection molded body 1180 includes three mounting arms 1194 that radially project from a central region of the body 1180 and are spaced apart at equal intervals around the circumference of the body. The mounting arms 1194 engage mounting portions 870 defined by overlapping injection molded insulators 848 of the first stator segment 842a. The mounting arms 1194 can be fixed to the mounting portions 870 via, for example, threaded fasteners.

[0151] Each terminal 1184 is electrically connected to a PCBA (e.g., via a wire; not shown) that receives power from the battery pack 16 ( Figure 1 ) and selectively applies current to the stator windings 850. The two leads 886 of each winding 850 forming each coil are connected to two adjacent pins 1182 of the conductor 1178. In this way, the conductor 1178 electrically connects the stator windings 850 to the PCBA.

[0152] The overlapping injection molded body 1180 defines a central hole or bearing pit 1190 that houses the rotor bearing 92 ( Figure 3 ). The rotor bearing 92 houses the rotor shaft 30 of the rotor assembly 22 ( Figure 3 ) to rotatably support the rotor assembly 22. Since the busbar assembly 1136 is fixed to each mounting portion 870 of each stator segment 842a and further supports the rotor bearing 92, the busbar assembly 1136 centers the rotor assembly 22 relative to the stator assembly 820.

[0153] The PCBA 1139 (such as a rotor position sensor circuit board) is coupled to the overlapping injection molded body 1180 of the bus bar assembly 1136. The PCBA 1139 is generally annular and is received into a corresponding centrally located annular recess 1141 defined in the overlapping injection molded body 1180 and is secured to the overlapping injection molded body by threaded fasteners. The PCBA 1139 covers at least a portion of the bearing pit 1190.

[0154] As Figure 53 shown, the overlapping injection molded body 1180 includes a first axial surface 1123 extending at a first axial end of the overlapping injection molded body and a second axial surface 1125 extending at a second axial end of the overlapping injection molded body. The first axial surface 1123 faces the stator assembly 820, and the second axial surface 1125 faces away from the stator assembly 820. The overlapping injection molded body 1180 also includes a circumferential outer surface 1143 extending between the first axial surface 1123 and the second axial surface 1125. The shanks 1182 each project generally radially from the circumferential outer surface 1143. Each shank 1182 includes a forked end 1145 at its distal end and is generally planar in shape. The respective leads 886 ( Figure 51 ) of adjacent stator windings 850 are received by and contact the forked ends 1145 and are mechanically attached to the forked ends, such as by laser welding. In other embodiments, the leads 886 may be attached to the forked ends 1145 by other means (such as soldering, ultrasonic welding, crimping, etc.). As Figure 53 further shown, each shank 1182 is also generally located within a different axial region of the motor 1114. Specifically, some of the shanks 1182 are located within and define a first plane 1131a, other shanks 1182 are located within and define a second plane 1131b, other shanks 1182 are located within and define a third plane 1131c, and still other shanks 1182 are located within and define a fourth plane 1131d. Each of the first plane 1131a, the second plane 1131b, the third plane 1131c, and the fourth plane 1131d is parallel to one another and extends perpendicular to the central axis 1124 and is axially spaced from one another at a particular interval. As Figure 54 shown, the shanks 1182 are spaced apart at generally equal intervals about the circumference of the overlapping injection molded body 1180. Thus, the angle A is measured at the center about the central axis 1124 between any two adjacent shanks 1182. In the illustrated embodiment, the bus bar assembly 1136 includes twelve shanks 1182 and the angle A is approximately 30 degrees.

[0155] In an exemplary embodiment, the busbar assembly 1136 includes six terminals 1184 that are grouped together on one lateral side of the overlapping molded body 1180. The terminals 1184 include four first terminals 1184a that project axially 1137 from the second axial surface 1125 of the overlapping molded body 1180. Each terminal 1184a is formed as a straight leg perpendicular to the central axis 1124. All of the first terminals 1184a are generally parallel to each other and extend perpendicular to the first plane 1131a. The terminals 1184 also include two second terminals 1184b that project radially outward from the circumferential surface 1143 of the overlapping molded body 1180 in a direction perpendicular to the central axis 1124. Both of the two second terminals 1184b are located in the first plane 1131a that extends perpendicular to the central axis 1124.

[0156] The busbar assembly 1136 is configured to provide a ΔY winding configuration for the motor 1014. Specifically, when the leads 886 of the windings 850 forming each coil are connected to the corresponding fork-like ends 1145 of the respective nearest pins 1182, the windings 850 are arranged in a ΔY-shaped winding configuration.

[0157] Figures 57 to 62 All or part of an electric motor 1214 according to another embodiment of the present disclosure is illustrated. The motor 1214 includes the segmented stator assembly 820 described herein in connection with Figures 33 to 38 and is capable of operating with the rotor assembly 22 described herein in connection with Figures 2 to 4 and Figure 12 The motor 1214 includes a busbar assembly 1236 that is coupled to the axial end of the stator assembly 820. The busbar assembly 1236 includes three annular conductors 1278 (

[0158] ) and an overlapping molded body 1280 that fixedly supports the conductors 1278. Each conductor 1278 includes four winding connection terminals or pins 1282 disposed at two opposite ends of the conductor 1278, and a power connection terminal 1284 that projects from the conductor 1278. The overlapping molded body 1280 includes three mounting arms 1294 that project radially from the central region of the body 1280 and are spaced apart at equal intervals around the circumference of the body. The mounting arms 1294 engage mounting portions 870 defined by the overlapping molded insulators 848 of the first stator segments 842a. The mounting arms 1294 can be fixed to the mounting portions 870 via, for example, threaded fasteners. Figures 61 to 62 Each terminal 1284 is electrically connected to a PCBA (e.g., via a wire; not shown), which is powered from the battery pack 16 (

[0159] via, for example, a wire; not shown), which is powered from the battery pack 16 ( Figure 1)Receives electrical power and selectively applies current to the stator winding 850. Leads 886 of the winding 850 are connected to two adjacent pins 1282 of the conductor 1278. In this way, the conductor 1278 electrically connects the stator winding 850 to the PCBA.

[0160] The overmolded body 1280 defines a central hole or bearing pocket 1290 that houses the rotor bearing 92( Figure 3 )). The rotor bearing 92 houses the rotor shaft 30 of the rotor assembly 22( Figure 3 ) to rotatably support the rotor assembly 22. Since the busbar assembly 1236 is fixed to each mounting portion 870 of each stator segment 842a and further supports the rotor bearing 92, the busbar assembly 1236 centers the rotor assembly 22 relative to the stator assembly 820.

[0161] The PCBA 1239 (such as a rotor position sensor circuit board) is coupled to the overmolded body 1280 of the busbar assembly 1236. The PCBA 1239 is generally annular and is received in a corresponding centrally located annular recess 1241 defined in the overmolded body 1280 and fixed to the overmolded body by a threaded fastener. The PCBA 1239 covers at least a portion of the bearing pocket 1290.

[0162] As Figure 59 shown, the overmolded body 1280 includes a first axial surface 1223 extending at a first axial end of the overmolded body and a second axial surface 1225 extending at a second axial end of the overmolded body. The first axial surface 1223 faces the stator assembly 820, and the second axial surface 1225 faces away from the stator assembly 820. The overmolded body 1280 also includes a circumferential outer surface 1243 extending between the first axial surface 1223 and the second axial surface 1225. The pins 1282 each project generally radially from the circumferential outer surface 1243. Each pin 1282 includes a forked end 1245 at its distal end and is generally planar in shape. The corresponding leads 886 of adjacent stator windings 850( Figure 45 ) are received and contacted by the forked ends 1245 and are mechanically attached to the forked ends, for example, by laser welding. In other embodiments, the leads 886 may be attached to the forked ends 1245 by other means (such as soldering, ultrasonic welding, crimping, etc.). As Figure 47 further shown, each pin 1282 is also generally located within the same axial region of the motor 1214. Specifically, each pin 1282 is located within and defines a first plane 1231 that extends perpendicular to the central axis 1224. As Figure 60As shown, the shank feet 1282 are spaced apart at substantially equal intervals around the circumference of the overmolded body 1280. Thus, the angle A is measured at the center around the central axis 1224 between any two adjacent shank feet 1282. In the illustrated embodiment, the busbar assembly 1236 includes twelve shank feet 1282, and the angle A is approximately 30 degrees.

[0163] In the illustrated embodiment, the busbar assembly 1236 includes three power connection terminals 1284. Each terminal 1284 projects from the second axial surface 1225 of the overmolded body 1280 and includes a leg 1235 that extends radially outward perpendicular to the central axis 1224. The longitudinal extents of each leg 935 together define a second plane 1237 that is perpendicular to the central axis 1224 and extends parallel to the first plane 1231.

[0164] Figure 63 An illustration of a busbar assembly 1236 according to another embodiment is shown. Figure 63 The busbar assembly 1236 of Figures 57 to 62 is substantially similar to the busbar assembly 1236 of Figure 63 but differs in terms of the power connection terminals. Specifically, the busbar assembly 1236 of

[0165] includes three modified conductors 1278a having three power connection terminals 1284a that project axially 1238 from the second axial surface 1225 of the overmolded body 1280. Each terminal 1284a is formed as a straight leg perpendicular to the central axis 1224. All the terminals 1284 extend substantially parallel to each other.

[0166] Figures 64 to 70 An illustration of all or part of an electric motor 1314 according to another embodiment of the present disclosure is shown. The motor 1314 includes a segmented stator assembly 1320 that is substantially similar to the segmented stator assembly 820 described herein in connection with Figures 33 to 38 The motor 1314 also includes that described herein in connection with Figures 2 to 4 and Figure 12The rotor assembly 22 described or can operate with the rotor assembly. Features and elements of the stator assembly 1320 that are similar to those of the stator assembly 820 are given the same reference numeral "plus 500". The following disclosure will focus on the differences between the stator assembly 1320 and the stator assembly 820. Specifically, the following disclosure will focus on the arrangement of the first wire notch 1302a and the second wire notch 1302b in the overlapping injection-molded insulator 1348 of each stator segment among the plurality of stator segments 1342 of the stator assembly 1320. It should be understood that features of the stator assembly 1320 that are not explicitly described below have the same characteristics as those of the stator assembly 820. In addition, although the arrangement of the first wire notch 1302a and the second wire notch 1302b is described in connection with the stator assembly 1320, the notch arrangement can also be incorporated into any embodiment of the stator assemblies described herein (e.g., stator assemblies 20, 120, 420, 520, 620, 720, and 820) to achieve the same or similar benefits as described below.

[0167] The motor 1314 also includes the busbar assembly Figures 57 to 62 described herein. The busbar assembly 1236 is coupled to the stator assembly 1320 in a manner similar to that described herein for the stator assembly 820. Alternatively, in other arrangements (not shown) of the electric motor 1314, the stator assembly 1320 can alternatively be coupled to and operate with any one of the other busbar assemblies described herein (e.g., busbar assemblies 36, 536, 736, 836, 936, 1036, and 1136).

[0168] The stator assembly 1320 is a segmented stator assembly that includes, in the illustrated embodiment, six stator segments 1342 that are laser welded to each other at each notch and projection interlock 1352 to secure the stator segments 1342 together. In an alternative embodiment (not shown), the stator segments 1342 are not laser welded to each other but are alternatively arranged within a tubular housing (such as the tubular housing 44 of the stator assembly 20 Figure 3 ) described above). In the illustrated embodiment, each stator segment 1342 includes a core 1346, an overlapping injection-molded insulator 1348, and a coil or stator winding 1350. The stator segments 1342 are not uniform but include first stator segments 1342a and second stator segments 1342b that are arranged in an alternating order circumferentially. Each first stator segment 1342a is connected to a second stator segment 1342b at each circumferential end (i.e., at the notch and projection interlock 1352).

[0169] The overmolded insulator 1348 of the first stator segment 1342a defines a mounting portion 1370 that engages a mounting arm 1294 formed on the overmolded body 1280 of the bus bar assembly 1236 to secure the bus bar assembly 1236 to the stator assembly 1320. The mounting arm 1294 can be secured to the mounting portion 1370 via, for example, threaded fasteners.

[0170] Figure 66 and Figure 67 Illustrated is one of the second stator segments 1342b of the stator assembly 1320. Each second stator segment 1342b includes an annular stator segment yoke 1304a, a stator segment tooth 1304b that radially projects from a central region of the stator segment yoke 1304a, and a stator segment crown 1304c at an end of the stator segment tooth 1304b opposite the stator segment yoke 1304a. In the illustrated embodiment, the stator segment tooth 1304b radially projects inwardly from the stator segment yoke 1304a in a direction toward the central axis 1324 ( Figure 64 ) of the assembled electric motor 1314. A winding slot 1306 is defined between the stator segment yoke 1304a and the stator segment crown 1304c and on each lateral side and each axial end of the stator segment tooth 1304b. The winding slot 1306 houses the coil stator winding 1350. The stator segment yoke 1304a, the stator segment tooth 1304b, and the stator segment crown 1304c are each formed from corresponding portions of the core 1346 and the overmolded insulator 1348. Specifically, the stator segment yoke 1304a is formed from an insulator yoke 1348a of the overmolded insulator 1348 and a core yoke 1346a of the core 1346. The stator segment tooth 1304b is formed from an insulator tooth 1348b of the overmolded insulator 1348 and a core tooth 1346b of the core 1346. The stator segment crown 1304c is formed from an insulator crown 1348c of the overmolded insulator 1348 and a core crown 1346c of the core 1346.

[0171] The insulator yoke 1348a of the overmolded insulator 1348 forms a support portion 1308 that axially projects away from the core yoke 1346a at an axial end of the second stator segment 1342b. The support portion 1308 can contact or abut the bus bar assembly 1236. Specifically, the support portion 1308 can contact a first axial surface 1223 ( Figure 59 ) of the overmolded body 1280 of the bus bar assembly 1236. Referring to Figure 66 and Figure 67 , the support portion 1308 includes a curved inner surface 1309a facing the insulator tooth 1348b and the insulator crown 1348c, a curved outer surface 1309b facing away from the insulator tooth 1348b, and a generally flat top surface 1309c that axially faces away from the core yoke 1346a.

[0172] The coil stator winding 1350 ( Figure 65 and Figure 68 ) is formed by winding an elongate wire 1351 around the stator segment teeth 1304b within the winding slots 1306 to form coils 1355. The elongate wire 1351 includes two respective ends or leads 1386 that extend away from the coils 1355 and are connected to two respective adjacent shanks 1282 of the bus bar assembly 1236. In this way, the conductors 1278 of the bus bar assembly 1236 electrically connect the stator winding 1350 to the PCBA 1239.

[0173] The support portion 1308 defines a pair of first wire notches 1302a in the flat top surface 1309c. Each first wire notch 1302a is formed adjacent to or near the corresponding winding slot 1306 and extends generally radially from the curved inner surface 1309a to the curved outer surface 1309b. Each first wire notch 1302a has a depth dimension measured axially of the second stator segment 1342b that starts from the flat top surface 1309c and terminates at the first notch bottom wall 1311. Each first wire notch 1302a is axially open in a direction away from the core yoke portion 1346a and is radially open in both an inward and outward direction relative to the stator assembly 1320. The leads 1386 of the stator winding 1350 are led out from the winding slots 1306 by passing through the first wire notches 1302a. The first wire notches 1302a receive the leads 1386 and enable the leads to pass between the bus bar assembly 1236 and the support portion 1308. That is, since the top surface 1309c of the support portion 1308 can be in direct contact with the overmolded body 1280 of the bus bar assembly 1236 ( Figure 65 ), the first wire notches 1302a provide space for the leads 1386 to pass between the support portion 1308 and the overmolded body 1280.

[0174] Referring to Figure 66 , Figure 67 , Figure 69 and Figure 70, the support portion 1308 defines a release notch or a second wire notch 1302b in the recessed curved inner surface 1309a. The second wire notch 1302b is formed to be proximate to or co-extensive with one of the first wire notches 1302a in the first wire notch and communicates with the adjacent first wire notch 1302a. The second wire notch 1302b extends axially from the top surface 1309c in the second stator segment 1342b until it terminates at the axial end face of the second notch bottom wall 1313 near the axial end face of the core yoke portion 1346a. The second wire notch 1302b is also defined by a second notch base wall 1317, which faces the radial direction of the stator assembly 1320 and extends axially from the second notch bottom wall 1313 to the first notch bottom wall 1311. The second wire notch 1302b is also defined by a second notch first side wall 1319a and a second notch second side wall 1319b, which face each other and generally face the circumferential direction of the assembled stator assembly 1320. The second notch first side wall 1319a and the second side wall 1319b extend from the second notch base wall 1317 to the curved inner surface 1309a respectively, and extend from the second notch bottom wall 1313 to the top surface 1309c. The second wire notch 1302b opens radially inward (i.e., towards the stator segment crown portion 1304c) and axially opens in the direction away from the core yoke portion 1346a.

[0175] The second wire notch 1302b provides a release space to accommodate one of the leads 1386 of the stator winding 1350. As Figure 68 and Figure 70 shown, the wire 1351 forming the stator winding 1350 winds around the stator segment tooth portion 1304b for multiple turns to form a coil 1355, which fills the winding slot 1306. One of the leads 1386 can be considered as a starting lead 1386a, from which the wire 1351 enters the winding slot 1306 and forms the first turn around the stator segment tooth portion 1304b. When subsequent additional turns are formed by the winding wire 1351, these turns overlap with the first turn and with each other, and generally cover a part of the starting lead 1386a. Thus, as Figure 70As shown, the starting lead 1386a can be captured or enclosed between the curved inner surface 1309a and several turns of the winding wire 1351. The second wire notch 1302b receives the starting lead 1386a such that the starting lead 1386a is recessed within the curved inner surface 1309a. Thus, the second wire notch 1302b provides a release space through which the starting lead 1386a passes through adjacent turns of the winding wire 1351. The starting lead 1386a then passes from the second wire notch 1302b to the first wire notch 1302, through which the starting lead 1386a exits the winding slot 1306 and is attached to an adjacent lug 1282 of the bus bar assembly 1236. The second wire notch 1302b also enables an increase in the wire size of the winding wire compared to a stator assembly that does not include the second wire notch. For example, the second wire notch 1302b enables the diameter of the wire 1351 to be increased in size to, for example, a diameter of 1.7 millimeters (mm).

[0176] Although in Figure 67 and Figure 69 the second wire notch 1302b is only shown on the right side of the support portion 1308, the second stator segment 1342b alternatively includes a second wire notch 1302b that communicates with the left-side first wire notch 1302a on the left side. In additional embodiments, the second stator segment 1342b can include two second wire notches 1302b, each of which communicates with a corresponding first wire notch 1302a. Further, although the first wire notch 1302a and the second wire notch 1302b are described herein with respect to the second stator segment 1342b, the same arrangement of the first wire notch 1302a and the second wire notch 1302b can also be formed in the support portion of the first stator segment 1342a.

[0177] Although the present disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more of the independent aspects of the disclosed subject matter.

[0178] The various features of the invention are set forth in the following claims.

Claims

1. An electric motor, the electric motor comprising: a rotor assembly, the rotor assembly including a rotor shaft; a stator assembly, the stator assembly including a plurality of stator segments arranged adjacent to each other in the circumferential direction of the stator assembly, at least one stator segment including: a core having a core yoke portion and a core tooth portion; an insulator at least partially covering the core and having an insulator yoke portion and an insulator tooth portion; a stator segment yoke portion formed by the core yoke portion and the insulator yoke portion; a stator segment tooth portion formed by the core tooth portion and the insulator tooth portion; and a stator winding extending around the stator segment tooth portion, the stator winding including a wire lead; and a bus bar assembly coupled to the stator assembly and configured to be electrically connected to the stator winding, the bus bar assembly including an injection molded body and a plurality of conductors; wherein the insulator yoke portion of the at least one stator segment includes a support portion axially protruding away from the core yoke portion of the at least one stator segment, the support portion defining an inner surface facing the insulator tooth portion, an outer surface facing away from the insulator tooth portion, and a top surface facing away from the core yoke portion; wherein the support portion defines a wire notch recessed into the inner surface and extending in the axial direction of the electric motor; and wherein the wire notch at least partially receives the wire lead.

2. The electric motor according to claim 1, wherein the wire notch is a second wire notch, and wherein the support portion further defines a first wire notch recessed into the top surface and extending in the radial direction of the electric motor from the inner surface to the outer surface.

3. The electric motor according to claim 2, wherein the first wire notch at least partially receives the wire lead.

4. The electric motor according to claim 2, wherein the wire lead passes between the support portion and the injection molded body of the bus bar assembly via the first wire notch.

5. The electric motor according to claim 2, wherein the first wire notch communicates with the second wire notch.

6. The electric motor according to claim 1, wherein the plurality of stator segments includes a first stator segment and a second stator segment adjacent to the first stator segment in the circumferential direction.

7. The electric motor according to claim 1, wherein the wire notch extends in the axial direction from the top surface of the support portion to a notch bottom wall located near the axial end face of the core yoke portion.

8. The electric motor according to claim 7, wherein: the core further includes a core crown portion located at a distal end of the core tooth portion; the insulator further includes an insulator crown portion located at a distal end of the insulator tooth portion; the at least one stator segment further includes a stator segment crown portion formed by the core crown portion and the insulator crown portion; and the wire notch is radially open toward the stator segment crown portion.

9. The electric motor according to claim 8, wherein the wire notch also axially opens away from the core yoke portion.

10. An electric motor, the electric motor comprising: a rotor assembly including a rotor shaft; and a stator assembly including a plurality of stator segments arranged adjacent to each other circumferentially of the stator assembly, at least one stator segment including: a core having a core yoke portion and core teeth; an insulator at least partially covering the core and having an insulator yoke portion and insulator teeth; a stator segment yoke formed by the core yoke portion and the insulator yoke portion; a stator segment tooth formed by the core teeth and the insulator teeth; and a stator winding extending around the stator segment teeth and including wire leads; wherein the insulator yoke portion of the at least one stator segment includes a support portion axially protruding away from the core yoke portion of the at least one stator segment, the support portion defining an inner surface facing the insulator teeth, an outer surface facing away from the insulator teeth, and a top surface facing away from the core yoke portion; wherein the support portion defines a first wire notch recessed into the top surface and extending in a radial direction of the electric motor from the inner surface to the outer surface; wherein the support portion further defines a second wire notch recessed into the inner surface and extending axially of the electric motor, the first wire notch communicating with the second wire notch; and wherein the first wire notch and the second wire notch each at least partially receive the wire lead.

11. The electric motor according to claim 10, wherein the second wire notch extends axially from the top surface of the support portion to a second notch bottom wall located near an axial end face of the core yoke portion.

12. The electric motor according to claim 11, wherein: the core further includes a core crown portion located at a distal end of the core teeth; the insulator further includes an insulator crown portion located at a distal end of the insulator teeth; the at least one stator segment further includes a stator segment crown portion formed by the core crown portion and the insulator crown portion; and the second wire notch opens radially toward the stator segment crown portion.

13. The electric motor according to claim 12, wherein the second wire notch also axially opens away from the core yoke portion.

14. The electric motor according to claim 12, wherein the second wire notch is further defined by: a second notch base wall defined by the support portion and radially facing the stator segment crown portion; and a first second-notch side wall and a second second-notch side wall each defined by the support portion and facing each other circumferentially.

15. The electric motor according to claim 14, wherein the first wire notch is defined by a first notch bottom wall that is recessed axially from the top surface of the support portion and away from the core yoke portion.

16. The electric motor according to claim 15, wherein the second notch base wall extends axially from the second notch bottom wall to the first notch bottom wall.

17. The electric motor according to claim 10, wherein the first wire notch opens axially away from the core yoke portion, opens inwardly in the radial direction, and opens outwardly in the radial direction.

18. A power tool, the power tool comprising: a housing; and an electric motor received in the housing, the electric motor comprising: a rotor assembly including a rotor shaft, a stator assembly including a plurality of stator segments arranged adjacent to each other circumferentially of the stator assembly, at least one stator segment including: a core having a core yoke portion and a core tooth portion, an insulator at least partially covering the core and having an insulator yoke portion and an insulator tooth portion, a stator segment yoke portion formed by the core yoke portion and the insulator yoke portion, a stator segment tooth portion formed by the core tooth portion and the insulator tooth portion, and a stator winding extending around the stator segment tooth portion, the stator winding including wire leads; wherein the electric motor further includes a bus bar assembly coupled to the stator assembly and configured to be electrically connected to respective stator windings, the bus bar assembly including an injection molded body and a plurality of conductors; wherein the insulator yoke portion of the at least one stator segment includes a support portion that axially protrudes away from the core yoke portion of the at least one stator segment, the support portion defining an inner surface facing the insulator tooth portion, an outer surface facing away from the insulator tooth portion, and a top surface facing away from the core yoke portion; wherein the support portion defines a wire notch that is recessed into the inner surface and extends axially of the electric motor; and wherein the wire notch at least partially receives the wire leads.

19. The power tool according to claim 18, wherein the wire notch extends axially from the top surface of the support portion to a notch bottom wall located near an axial end face of the core yoke portion, and wherein the wire notch opens in the radial direction and in the axial direction of the electric motor.

20. The power tool according to claim 19, wherein the stator winding includes a wire having a diameter of 1.7 millimeters.

21. An electric motor, the electric motor comprising: a rotor assembly including a rotor shaft; a stator assembly including: a core having a core yoke portion, a core tooth portion extending from the core yoke portion, and a core crown portion attached to the core tooth portion and positioned opposite the core yoke portion, An insulator that at least partially covers the core, the insulator having an insulator yoke portion that at least partially covers the core yoke portion, an insulator tooth portion that at least partially covers the core tooth portion, and an insulator crown portion that at least partially covers the core crown portion, and A stator winding that extends around the insulator tooth portion, the stator winding including a wire lead; and A bus bar assembly that is coupled to the stator assembly and is configured to be electrically connected to the stator winding, the bus bar assembly including an injection molded body and a plurality of conductors; Wherein the insulator yoke portion includes a support portion that axially projects away from the core yoke portion, the support portion defining an inner surface facing the insulator crown portion, an outer surface facing away from the insulator crown portion, and a top surface facing away from the core yoke portion; Wherein the support portion defines a wire notch that is recessed into the inner surface and extends in the axial direction of the electric motor; and Wherein the wire notch at least partially receives the wire lead.

22. The electric motor according to claim 21, wherein the wire notch is radially open towards the insulator crown portion.

23. The electric motor according to claim 22, wherein the wire notch is also axially open away from the core yoke portion.

24. The electric motor according to claim 23, wherein the wire notch is a second wire notch, and wherein the support portion further defines a first wire notch that is recessed into the top surface and extends in the radial direction of the electric motor from the inner surface to the outer surface.

25. The electric motor according to claim 24, wherein the first wire notch at least partially receives the wire lead.

26. The electric motor according to claim 24, wherein the wire lead passes between the support portion and the injection molded body of the bus bar assembly via the first wire notch.

27. The electric motor according to claim 24, wherein the first wire notch communicates with the second wire notch.

28. The electric motor according to claim 24, wherein the second wire notch extends in the axial direction from the top surface of the support portion to a second notch bottom wall that is located near the axial end face of the core yoke portion.

29. The electric motor according to claim 28, wherein the second wire notch is further defined by: A second notch base wall that is defined by the support portion and radially faces the insulator crown portion; and A second notch first side wall and a second notch second side wall, each of the second notch first side wall and the second notch second side wall being defined by the support portion and facing each other circumferentially.

30. The electric motor according to claim 29, wherein the first wire notch is defined by a first notch bottom wall that is recessed in the axial direction from the top surface of the support portion and faces away from the core yoke portion.

31. The electric motor according to claim 30, wherein the second notch base wall extends axially from the second notch bottom wall to the first notch bottom wall.

32. The electric motor according to claim 21, wherein the wire notch extends axially from the top surface of the support portion to a notch bottom wall that is near the axial end face of the core yoke portion, and wherein the wire notch is open in the radial direction and open in the axial direction of the electric motor.

33. An electric motor, the electric motor comprising: a rotor assembly including a rotor shaft; and a stator assembly including: a core having a core yoke portion, core teeth portions extending from the core yoke portion, and a core crown portion attached to the core teeth portions and positioned opposite to the core yoke portion, an insulator at least partially covering the core, the insulator having an insulator yoke portion at least partially covering the core yoke portion, insulator teeth portions at least partially covering the core teeth portions, and an insulator crown portion at least partially covering the core crown portion, and a stator winding extending around the insulator teeth portions, the stator winding including wire leads; wherein the insulator yoke portion includes a support portion that axially projects away from the core yoke portion, the support portion defining an inner surface facing the insulator crown portion, an outer surface facing away from the insulator crown portion, and a top surface facing away from the core yoke portion; wherein the support portion defines a first wire notch that is recessed into the top surface and extends in the radial direction of the electric motor from the inner surface to the outer surface; wherein the support portion further defines a second wire notch that is recessed into the inner surface and extends in the axial direction of the electric motor; and wherein each of the first wire notch and the second wire notch at least partially houses the wire lead.

34. The electric motor according to claim 33, wherein the second wire notch extends axially from the top surface of the support portion to a second notch bottom wall that is near the axial end face of the core yoke portion.

35. The electric motor according to claim 34, wherein the second wire notch is radially open toward the insulator crown portion.

36. The electric motor according to claim 35, wherein the second wire notch is also axially open away from the core yoke portion.

37. The electric motor according to claim 36, wherein the second wire notch is further defined by a second notch base wall defined by the support portion and radially facing the insulator crown portion.

38. The electric motor according to claim 37, wherein the first wire notch is defined by a first notch bottom wall that is recessed axially from the top surface of the support portion and away from the core yoke portion.

39. The electric motor according to claim 38, wherein the second notch base wall extends axially from the second notch bottom wall to the first notch bottom wall.

40. The electric motor according to claim 33, wherein the first wire notch opens axially away from the core yoke portion, opens radially inwardly, and opens radially outwardly.

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