Electric motor

Abstract

To provide a stator for an electric motor.SOLUTION: An electric motor may include a stator assembly including a plurality of stator segments arranged adjacently to one another in a circumferential direction of the stator assembly. At least one stator segment includes: 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 about the stator segment tooth portion and including a wire lead. The insulator yoke portion includes a standoff portion that defines a wire notch. The wire notch at least partially receives the wire lead.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims priority to U.S. Provisional Patent Application No. 63 / 513,042, filed July 11, 2023, the entire contents of which are incorporated herein by reference.

[0002] FIELD OF THEINVENTION The present disclosure relates to electric motors, and more particularly, to stators for electric motors. [Background technology]

[0003] A stator for an electric motor may be formed from a plurality of annular stator segments arranged in a cylindrical configuration. Summary of the Invention

[0004] In some aspects, the technology described herein provides an electric motor including a rotor assembly including a rotor shaft; a stator assembly including a plurality of stator segments disposed adjacent to one another 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 portion and an insulator tooth portion; a stator segment yoke portion formed by the core yoke portion and the insulator yoke portion; a stator winding extending around the stator segment tooth portion including wire leads; and a stator assembly including a stator winding extending around the stator segment tooth portion including wire leads. and a busbar assembly coupled to the stator windings and configured to electrically connect to the stator windings, the busbar assembly including a molding and a plurality of conductors, wherein an insulator yoke portion of at least one stator segment includes a stand-off portion that protrudes axially away from a core yoke portion of the at least one stator segment, the stand-off portion defining an inner surface facing toward 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, the stand-off portion defining a wire notch recessed in the inner surface and extending in the axial direction of the electric motor, the wire notch at least partially receiving a wire lead.

[0005] In some aspects, the techniques described herein provide an electric motor including a rotor assembly including a rotor shaft; and a stator assembly including a plurality of stator segments disposed adjacent to one another 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 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 including wire leads, the insulator yoke portion includes a standoff portion protruding axially away from a core yoke portion of at least one stator segment, the standoff portion defining an inner surface facing toward the insulator tooth portion, an outer surface facing away from the insulator tooth portion, and an upper surface facing away from the core yoke portion, the standoff portion defining a first wire notch recessed in the upper surface and extending in a radial direction of the electric motor from the inner surface to the outer surface, the standoff portion further defining a second wire notch recessed in the inner surface and extending in an axial direction of the electric motor, the first wire notch communicating with the second wire notch, the first wire notch and the second wire notch each at least partially receiving a wire lead.

[0006] In some aspects, the technology described herein provides a power tool including a housing, an electric motor received within the housing, a rotor assembly including a rotor shaft, a stator assembly including a plurality of stator segments disposed adjacent to one another 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 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 including wire leads. and an electric motor, the electric motor being coupled to the stator assembly and configured to electrically connect to each stator winding, the busbar assembly further including a molding and a plurality of conductors, an insulator yoke portion of at least one stator segment including a standoff portion protruding axially away from the core yoke portion of the at least one stator segment, the standoff portion defining an inner surface facing toward 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, the standoff portion defining a wire notch recessed into the inner surface and extending in the axial direction of the electric motor, the wire notch at least partially receiving a wire lead.

[0007] In some aspects, the technology described herein provides an 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 opposite the core yoke portion; an insulator at least partially covering the core, the insulator having the insulator yoke portion at least partially covering the core yoke portion, the insulator tooth portion at least partially covering the core tooth portion, and the insulator crown portion at least partially covering the core crown portion; and a stator winding extending around the insulator tooth portions, the stator winding including wire leads. and a busbar assembly coupled to a stator assembly and configured to electrically connect to a stator winding, the busbar assembly including a molding and a plurality of conductors, wherein the insulator yoke portion includes a standoff portion protruding axially away from the core yoke portion, the standoff portion defining an inner surface facing toward 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, the standoff portion defining a wire notch recessed in the inner surface and extending in the axial direction of the electric motor, the wire notch at least partially receiving a wire lead.

[0008] In some aspects, the technology described herein provides an 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 at least partially covering the core, the insulator having the insulator yoke portion at least partially covering the core yoke portion, the insulator tooth portion at least partially covering the core tooth portion, and the insulator crown portion at least partially covering the core crown portion; and a stator winding extending around the insulator tooth portions, the stator winding including wire leads. and an insulator yoke portion including a standoff portion protruding axially away from the core yoke portion, the standoff portion defining an inner surface facing toward 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, the standoff portion defining a first wire notch recessed in the top surface and extending in a radial direction of the electric motor from the inner surface to the outer surface, and the standoff portion further defining a second wire notch recessed in the inner surface and extending in an axial direction of the electric motor, the first wire notch and the second wire notch each at least partially receiving a wire lead.

[0009] Other features and aspects of the present disclosure will become apparent by consideration of the following detailed description and accompanying drawings. [Brief description of the drawings]

[0010] [Figure 1] 1 is a perspective view of a power tool according to one embodiment; [Diagram 2] FIG. 2 is a perspective view of an electric motor of the power tool of FIG. 1; [Diagram 3] FIG. 3 is an exploded perspective view of the electric motor of FIG. 2. [Figure 4] FIG. 3 is an exploded perspective view of the electric motor of FIG. 2. [Diagram 5]3 is a perspective view illustrating a stator assembly of the electric motor of FIG. 2. [Figure 6] FIG. 6 is a partially exploded perspective view illustrating the stator assembly of FIG. 5. [Figure 7] FIG. 6 is a partially exploded perspective view illustrating the stator assembly of FIG. 5 with a portion removed; [Figure 8] 6 is a perspective view illustrating a portion of the stator assembly of FIG. 5. [Figure 9] 6 is a perspective view illustrating a portion of the stator assembly of FIG. 5. [Figure 10] FIG. 3 is a perspective view illustrating a busbar assembly of the electric motor of FIG. 2. [Figure 11] FIG. 11 is an exploded perspective view illustrating the bus bar assembly of FIG. [Figure 12] 12 is a perspective cross-sectional view of the electric motor of FIG. 2 taken along line 12-12 of FIG. 2. [Figure 13] FIG. 13 is a perspective view of a stator assembly according to another embodiment. [Figure 14] FIG. 14 is an exploded perspective view of the stator assembly of FIG. 13. [Figure 15] FIG. 14 is a perspective view of a portion of the stator assembly of FIG. 13. [Figure 16] FIG. 14 is a perspective view of a portion of the stator assembly of FIG. 13. [Figure 17] FIG. 13 is a perspective view of a stator assembly according to another embodiment. [Figure 18] 18 is a partial exploded perspective view illustrating the stator assembly of FIG. 17. [Figure 19] FIG. 13 is a perspective view of a stator assembly according to another embodiment. [Figure 20] FIG. 13 is a perspective view of a stator assembly according to another embodiment. [Figure 21] FIG. 2 is a perspective view of an electric motor according to another embodiment. [Figure 22] 22 is a cross-sectional view of the electric motor of FIG. 21 taken along line 22-22 of FIG. 21. [Figure 23] FIG. 2 is a side view of an electric motor according to another embodiment. [Figure 24] FIG. 24 is a partial perspective view of a stator assembly of the electric motor of FIG. 23. [Diagram 25] FIG. 24 is a partial perspective view of a stator assembly of the electric motor of FIG. 23. [Figure 26] FIG. 25 is a partial perspective view of a portion of the stator assembly of FIG. 24 according to another embodiment. [Figure 27] 25 is a partial perspective view of a portion of the stator assembly of FIG. 24 according to another embodiment. [Figure 28] FIG. 25 is a partial perspective view of a portion of the stator assembly of FIG. 24 according to another embodiment. [Figure 29] FIG. 2 is a perspective view of an electric motor according to another embodiment. [Diagram 30] FIG. 30 is a top view of the electric motor of FIG. 29 with portions removed. [Diagram 31] FIG. 30 is a partial perspective view of the electric motor of FIG. 29. [Diagram 32] FIG. 30 is a perspective view of a molded insulator of the busbar assembly of the electric motor of FIG. 29. [Diagram 33] FIG. 2 is a perspective view of a portion of an electric motor according to another embodiment. [Diagram 34] FIG. 34 is a partially exploded perspective view of the electric motor of FIG. 33. [Diagram 35] FIG. 34 is a side view illustrating a busbar assembly of the electric motor of FIG. 33. [Diagram 36] FIG. 36 is a plan view of the bus bar assembly of FIG. [Figure 37] FIG. 36 is an exploded perspective view of the bus bar assembly of FIG. [Figure 38] FIG. 36 is an exploded plan view of the busbar assembly of FIG. 35 with portions removed. [Figure 39] FIG. 2 is a perspective view of a portion of an electric motor according to another embodiment. [Diagram 40] FIG. 40 is a partially exploded perspective view of the electric motor of FIG. 39. [Diagram 41] FIG. 40 is a side view illustrating a busbar assembly of the electric motor of FIG. 39. [Diagram 42] FIG. 42 is a plan view of the bus bar assembly of FIG. [Diagram 43] FIG. 42 is an exploded perspective view of the bus bar assembly of FIG. [Diagram 44] FIG. 42 is an exploded plan view of the busbar assembly of FIG. 41 with portions removed. [Diagram 45] FIG. 2 is a perspective view of a portion of an electric motor according to another embodiment. [Diagram 46] FIG. 46 is a partially exploded perspective view of the electric motor of FIG. 45. [Figure 47] FIG. 46 is a side view illustrating a busbar assembly of the electric motor of FIG. 45. [Figure 48] FIG. 48 is a plan view of the bus bar assembly of FIG. [Figure 49] FIG. 48 is an exploded perspective view of the bus bar assembly of FIG. [Figure 50] FIG. 48 is an exploded plan view of the busbar assembly of FIG. 47 with portions removed. [Figure 51] FIG. 2 is a perspective view of a portion of an electric motor according to another embodiment. [Figure 52] FIG. 52 is a partially exploded perspective view of the electric motor of FIG. 51. [Figure 53] FIG. 52 is a side view illustrating the busbar assembly of the electric motor of FIG. 51. [Figure 54] FIG. 54 is a plan view of the bus bar assembly of FIG. [Figure 55] FIG. 54 is an exploded perspective view of the bus bar assembly of FIG. [Figure 56] FIG. 54 is an exploded plan view of the busbar assembly of FIG. 53 with portions removed. [Figure 57] FIG. 2 is a perspective view of a portion of an electric motor according to another embodiment. [Figure 58] FIG. 58 is a partially exploded perspective view of the electric motor of FIG. 57. [Figure 59] FIG. 58 is a side view illustrating the busbar assembly of the electric motor of FIG. 57. [Figure 60] FIG. 60 is a plan view of the bus bar assembly of FIG. [Figure 61] FIG. 60 is an exploded perspective view of the bus bar assembly of FIG. [Figure 62] FIG. 60 is an exploded plan view of the busbar assembly of FIG. 59 with portions removed. [Figure 63] FIG. 58 is a perspective view illustrating a busbar assembly of the electric motor of FIG. 57 according to another embodiment. [Figure 64] FIG. 2 is a perspective view of a portion of an electric motor according to another embodiment. [Figure 65] FIG. 65 is a partial exploded perspective view of the electric motor of FIG. [Figure 66] FIG. 65 is a perspective view of a stator segment of the electric motor of FIG. [Figure 67] FIG. 67 is a top view of the stator segment of FIG. 66 with a portion removed. [Figure 67A] FIG. 65 is a partial perspective view of a stator segment of the electric motor of FIG. 64. [Figure 68] FIG. 67 is a partial perspective view of the stator segment of FIG. 66. [Figure 69] FIG. 67 is a partial perspective view of the stator segment of FIG. 66 with a portion removed. [Figure 70] 70 is a cross-sectional view of the stator segment of FIG. 66 taken along line 70-70 of FIG. 68.

[0011] Before any embodiment of the present disclosure is described in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or carried out in various ways. Also, 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 OF THE PREFERRED EMBODIMENTS

[0012] 1 and 2 illustrate a power tool 10, such as, for example, a drill, 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 a bottom end of the housing 12. The battery pack 16 includes a plurality of battery cells (not shown) that are electrically connected to provide a desired output (e.g., nominal voltage, current capacity, etc.) of the battery pack 16. The electric motor 14 receives power from the battery pack 16 when the battery pack 16 is coupled to the battery receptacle 18.

[0013] In some embodiments, the power tool 10 may include a power cord for electrically connecting the motor 14 to an AC power source. However, because cordless power tools can be used in locations where other sources of power are unavailable, the battery pack 16 is the preferred means for powering the power tool 10.

[0014] 2-4, the illustrated motor 14 is a brushless direct current ("BLDC") motor having a stator assembly 20 and a rotor assembly 22 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 forward end 32 of the motor 14. The stator assembly 20 includes a central cavity 34 that receives the rotor assembly 22 for rotation about the axis 24. The motor 14 also includes a bus bar assembly 36 and a printed circuit board assembly (PCBA) 38, each coupled to the stator assembly 20 at a second or aft end 40 opposite the forward end 32 of the motor 14.

[0015] 5-9, the stator assembly 20 is a segmented stator assembly 20 that, in the illustrated embodiment, includes six stator segments 42 disposed within a cylindrical housing 44. Each stator segment 42 includes a core 46, an overmolded insulation 48, and a stator winding 50. Adjacent stator segments 42 are interconnected to one another by notch and protrusion interlocks 52. Specifically, each stator segment 42 includes a longitudinally extending notch 54 provided in a first circumferential end face 56 and a longitudinally extending protrusion 58 protruding from a second circumferential end face 60. The notch 54 of one stator segment 42 receives the protrusion 58 of an adjacent stator segment 42 to align the two adjacent stator segments 42.

[0016] The cylindrical housing 44 surrounds the disposed stator segments 42 and secures the stator segments 42 together. Specifically, the cylindrical housing 44 includes a cylindrical wall 62 that defines an internal cavity 64, and the stator segments 42 are received within the internal cavity 64 such that the cylindrical wall 62 converges around the stator segments 42. In one example, the cylindrical housing 44 can be heated to expand an outer diameter of the cylindrical wall 62, and the cylindrical housing 44 can then be pressed against the stator segments 42. When the cylindrical housing 44 cools, the cylindrical wall 62 contracts around the stator segments 42 to secure the assembly. In the illustrated embodiment, the cylindrical housing 44 also includes mounting tabs 66 extending radially outward from the cylindrical wall 62, each mounting tab 66 defining a mounting opening 68 configured to receive a fastener (e.g., a screw) for securing the motor 14 to, for example, a gear case (not shown).

[0017] 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 hole 72 that receives a first fastener 74 or a second fastener 76 for securing the bus bar assembly 36 and PCBA 38 to the stator assembly 20 (FIGS. 3 and 4).

[0018] 10 and 11, the busbar assembly 36 includes three annular conductors 78 extending generally circumferentially around the motor 14 and an overmolded body 80 that securely supports the conductors 78. Each conductor 78 includes two tangs 82 provided at both ends of the conductor 78 and a terminal 84 extending in the axial direction of the motor 14. Each terminal 84 mechanically and electrically connects to the PCBA 38. Specifically, the PCBA 38 includes a number of openings 85 (FIGS. 3 and 12) that correspond to the locations of the terminals 84. During assembly, the terminals 84 are inserted into the openings 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 (FIG. 8) that connect to adjacent tangs 82 of the conductors 78. The leads 86 can be soldered or fused to the tangs 82. In this manner, the conductors 78 electrically connect the stator windings 50 to the PCBA 38. The PCBA 38 receives power from the battery pack 16 and selectively applies current to the windings 50 , thereby causing the rotor shaft 30 to rotate about the axis 24 .

[0019] The overmolded body 80 includes a central hub 88 that defines a central opening or bearing pocket 90 that receives a rotor bearing 92 (FIGS. 10-12). The rotor bearing 92 receives the rotor shaft 30 to rotatably support the rotor assembly 22. The overmolded body 80 further includes radial arms 94 that extend 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 that correspond to the six mounting portions 70 of the six stator segments 42. Each radial arm 94 defines a first opening 96 that aligns with a threaded hole 72 of a corresponding mounting portion 70.

[0020] 3 and 12, the busbar assembly 36 is secured to the mounting portion 70 of the stator assembly 20 by a first fastener 74 and a second fastener 76, and the PCBA 38 is secured to the stator assembly 20 by the second fastener 76. The PCBA 38 includes second openings 98 that extend through the PCBA 38 and correspond to the first openings 96 of every other radial arm 94 in the circumferential direction. Thus, the radial arms 94 include a first radial arm 94a and a second radial arm 94b. The first radial arm 94a is directly coupled to the mounting portion 70 by the first fastener 74. The second radial arm 94b is coupled to both the mounting portion 70 and the PCBA 38 by the second fastener 76. More specifically, the first fastener 74 is received through the first opening 96 of the first radial arm 94a and tightened into the threaded hole 72 to secure the first radial arm 94a to the mounting portion 70. The second fastener 76 is received through the second opening 98 of the PCBA 38 and the first opening 96 of the second radial arm 94b and tightened into the threaded hole to secure both the PCBA 38 and the second radial arm 94 to the mounting portion 70. Thus, the busbar assembly 36 is fixedly mounted to each mounting portion 70 of each stator segment 42 and supports the rotor bearings 92 to center the rotor assembly 22 relative to the stator assembly 20.

[0021] 3, 4, and 12, the PCBA 38 includes a printed circuit board (PCB) 95 and a heat sink 97 fixedly mounted to the PCB 95. The heat sink 97 includes a number of recesses 97a, and the overmolded body 80 includes a number of axially extending protrusions 80a that are received in corresponding recesses 97a to align the PCBA 38 with the bus bar assembly 36.

[0022] 13-16 illustrate a stator assembly 120 according to another embodiment of the present disclosure. The stator assembly 120 is similar to the stator assembly 20 described above and includes many of the same structures as the stator assembly 20. The stator assembly 120 is also operable with each of the rotor assemblies 22, busbar assemblies 36, and PCBA 38 described above. Features and elements of the stator assembly 120 that are similar to features and elements of the stator assembly 20 are assigned the same reference numerals "+100". It should be understood that features of the stator assembly 120 that are not explicitly described below have the same nature as features of the stator assembly 20.

[0023] 13 and 14, the stator assembly 120 is coupled to the busbar assembly 36 and the PCBA 38 via the first fasteners 74 and the second fasteners 76 in the same manner as described above in connection with the stator assembly 20. The stator assembly 120 also includes stator segments 142 arranged end-to-end. However, the stator assembly 120 does not include a cylindrical housing. Instead, the stator segments 142 are laser welded at the interlocking portions 152 of each notch and protrusion to secure the stator segments 142 together. Furthermore, the stator segments 142 are not uniform, but instead include first stator segments 142a and second stator segments 142b arranged in an alternating order (FIGS. 15 and 16). More specifically, each first stator segment 142a is connected to a second stator segment 142b at each circumferential end. The first stator segments 142a each include a radially outwardly projecting and axially longitudinally extending mounting rib 121. Each mounting rib 121 defines a mounting opening 123 that receives a fastener for mounting the stator assembly 120 to, for example, a gear case (not shown). The second stator segment 142b does not include a mounting rib, but does include an axially extending groove that receives a portion of the overmolded insulator 148.

[0024] 17 and 18 illustrate a stator assembly 220 according to another embodiment of the present disclosure. The stator assembly 220 is similar to the stator assemblies 20, 120 described above and includes many of the same structures. The stator assembly 220 is also operable with the rotor assembly 22 described above. Features and elements of the stator assembly 220 that are similar to features and elements of the stator assemblies 20 and 120 are assigned the same reference numerals "+200". It should be understood that features of the stator assembly 220 that are not explicitly described below have the same nature as features of the stator assembly 20.

[0025] The stator assembly 220 includes stator segments 242 that are laser welded at the interlocking portions 252 of each notch and protrusion to secure the stator segments 242 together. Each stator segment 242 includes an external groove 225 formed in a peripheral outer surface of the core 246 and extending longitudinally in an axial direction. The stator assembly 220 may be mounted inside the housing 12. In this regard, the housing 12 may be provided with longitudinal ribs (not shown) that protrude inwardly within the housing 12 and may be received in the grooves 225 to secure the stator assembly 220 against rotation relative to the housing 12. Additionally, the stator assembly 220 is operable with a PCBA 238 that includes peripheral notches 227 formed at spaced intervals around the periphery of the PCBA 238. Each notch 227 may receive two adjacent leads 286 of the stator winding 250. The leads 286 may be soldered directly to solder pads provided in the notches 227 to electrically connect the leads 286 directly to the PCBA 238. Because the leads 286 are secured directly to the PCBA 238, there is no need to provide a separate bus bar assembly. The PCBA 238 also includes second openings 298 that receive fasteners 229 that tighten to at least some of the mounting portions 270 to secure the PCBA 238 to the axial ends of the stator assembly 220.

[0026] 19 illustrates a stator assembly 320 according to another embodiment of the present disclosure. The stator assembly 320 is similar to the stator assembly 20 described above and includes many of the same structures. The stator assembly 320 is also operable with the rotor assembly 22 described above. Features and elements of the stator assembly 320 that are similar to features and elements of the stator assembly 20 are assigned the same reference numeral "+300." It should be understood that features of the stator assembly 320 that are not explicitly described below have the same nature as features of the stator assembly 20.

[0027] Similar to the segmented stator assembly 20 described above, the stator assembly 320 is a segmented stator assembly 320 that includes six stator segments 342 disposed within a cylindrical housing 344 in the illustrated embodiment. Unlike the stator assembly 20, however, the stator assembly 320 does not couple to a busbar assembly at its axial end. Rather, the stator assembly 320 further includes a terminal block assembly 353 molded directly onto an outer circumferential surface 356 of a cylindrical wall 362 of the cylindrical housing 344. The terminal block assembly 353 includes three conductors 360 that, in the illustrated embodiment, extend generally longitudinally along the outer circumferential surface 356. Each conductor 360 includes a winding connection portion 364 provided adjacent an axial end of the stator assembly 320 and a terminal 368 that extends away from the winding connection portion 364 in the axial direction of the stator assembly 320. The winding connection portion 364 mechanically and electrically connects to a pair of leads of the windings 350, and each terminal 368 electrically connects to a PCBA (not shown). In this manner, 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, thereby rotating the rotor shaft 30 about the axis 24. The conductors 360 may be supported on the outer circumferential surface 356 by a molding material (e.g., a resin) that electrically insulates the conductors 360 from the tubular housing 344 and the cores 346 of the stator segments 342.

[0028] 20 illustrates 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 many of the same structures. The stator assembly 420 is also operable with the rotor assembly 22 described above. Features and elements of the stator assembly 420 that are similar to features and elements of the stator assembly 120 are assigned the same reference numeral "+300". It should be understood that features of the stator assembly 420 that are not explicitly described below have the same nature as features of the stator assembly 120.

[0029] Similar to the segmented stator assembly 120 described above, the stator assembly 420 is a segmented stator assembly 420 that includes six stator segments 442 that are laser welded at the interlocking portions 452 of each notch and protrusion to secure the stator segments 442 together in the illustrated embodiment. However, unlike the stator assembly 120, the stator assembly 420 does not couple to a busbar assembly at its axial end. Rather, the stator assembly 420 further includes a terminal block assembly 453 molded directly onto an outer circumferential surface 456 of the core 446 of one of the stator segments 442. The terminal block assembly 453 includes three conductors 460 that extend generally longitudinally along the outer circumferential surface 456 in the illustrated embodiment. Each conductor 460 includes a winding connection portion 464 provided adjacent an axial end of the stator assembly 420 and a terminal 468 that extends away from the winding connection portion 464 in the axial direction of the stator assembly 420. The winding connection portion 464 mechanically and electrically connects to the pair of leads of the windings 450, and each terminal 468 electrically connects to a PCBA (not shown). In this manner, 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, thereby rotating the rotor shaft 30 about the axis 24. The conductors 460 may be supported on the outer circumferential surface 456 by a molding material (e.g., resin) that electrically insulates the conductors 460 from the core 446 of the stator segment 442. In some embodiments, the overmolded insulator 448 of the stator segment 442 may be formed with a terminal block portion 472 that supports the conductors 460.

[0030] 21 and 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 many of the same structures. The stator assembly 520 is also operable with the rotor assembly 22 described above. Features and elements of the stator assembly 520 that are similar to features and elements of the stator assembly 120 are assigned the same reference numeral "+400". It should be understood that features of the stator assembly 520 that are not explicitly described below have the same nature as features of the stator assembly 120.

[0031] Similar to the segmented stator assembly 120 described above, the stator assembly 520 is a segmented stator assembly 520 that includes six stator segments 542 that, in the illustrated embodiment, are laser welded at the interlocking portions 552 of each notch and protrusion to secure the stator segments 542 together. In an alternative embodiment (not shown), the stator segments 542 may alternatively be disposed within a cylindrical housing, such as the cylindrical housing 44 of the stator assembly 20 (FIG. 3) discussed above. 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 instead include first stator segments 542a and second stator segments 542b arranged in an alternating order. Each first stator segment 542a is connected to a second stator segment 542b at each circumferential end.

[0032] A 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 tang 582 provided 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 tang 582 and a terminal block portion 583 that extends axially away from the disk portion 581 at a periphery of the disk portion 581. The terminal block portion 583 supports the terminal 584. The disk portion 581 also includes a mounting tab 594 that engages a mounting portion 570 defined by the overmolded insulator 548 of the first stator segment 542a. The mounting tab 594 can be secured to the mounting portion 570 via, for example, a threaded fastener.

[0033] Each terminal 584 electrically connects (e.g., via a wire (not shown)) to a PCBA, which receives power from battery pack 16 ( FIG. 1 ) and selectively applies current to stator windings 550. Each winding 550 includes a pair of leads 586 that connect to adjacent tangs 582 of conductors 578. In this manner, conductors 578 electrically connect stator windings 550 to PCBA 538.

[0034] Disk portion 581 of overmolded body 580 defines a central opening or bearing pocket 590 that receives rotor bearing 92 (FIG. 3) that receives rotor shaft 30 of rotor assembly 22 (FIG. 3) to rotatably support rotor assembly 22. A bus bar assembly 536 is fixedly attached to each mounting portion 570 of each stator segment 542a and further supports rotor bearing 592 such that bus bar assembly 536 centers rotor assembly 22 relative to stator assembly 520.

[0035] 23-25 ​​illustrate 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 many of the same structures. The stator assembly 620 is also operable with the rotor assembly 22 described above. Features and elements of the stator assembly 620 that are similar to features and elements of the stator assembly 120 are assigned the same reference numerals "+500". It should be understood that features of the stator assembly 620 that are not explicitly described below have the same nature as features of the stator assembly 120.

[0036] Similar to the segmented stator assembly 120 described above, the stator assembly 620 is a segmented stator assembly 620 that, in the illustrated embodiment, includes six stator segments 642 that are laser welded together at notch and protrusion interlocks 652 to secure the stator segments 642 together. In an alternative embodiment (not shown), the stator segments 642 may alternatively be disposed within a cylindrical housing, such as the cylindrical housing 44 of the stator assembly 20 ( FIG. 3 ) discussed above. Each stator segment 642 includes a core 646, an overmolded insulator 648, and a stator winding 650.

[0037] The stator assembly 620 is operable with a PCBA 638 coupled to an axial end of the stator assembly 620. The PCBA 638 receives power from the battery pack 16 (FIG. 1) and selectively applies current to the stator windings 650. Each overmolded insulator 648 defines a pair of notches 685 at an axial end, and an L-shaped conductive terminal 678 is molded into the overmolded insulator 648 adjacent 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 a corresponding one of the notches 685 and electrically connected (e.g., by laser welding) to a corresponding first leg 687 of the terminal 678. The second legs 689 of the terminals 678 are mechanically and electrically coupled (e.g., by soldering) to the PCBA 638. In some embodiments, the solder connection between the PCBA 638 and the terminals 678 is sufficient to mechanically secure the PCBA 638 to the stator assembly 620.

[0038] 26, in another embodiment, a stator assembly 620 may alternatively include stator segments 642a including formed conductive terminals 678a each having a vertical tang 687a instead of a radially extending first leg as described above. Each vertical tang 687a is bent over and fused to a corresponding lead 686 of the stator winding 650. A second leg (not shown) of the terminal 678a is soldered to the PCBA 638 (FIG. 23) in a manner similar to that described above.

[0039] 27, in another embodiment, a stator assembly 620 may alternatively include stator segments 642b including formed conductive terminals 678b each defining a stuff slot 691. Leads 686 of a stator winding 650 are press fit into the stuff slots 691 to form an electrical connection. Second legs 689b of terminals 678b are soldered to a PCBA 638 (FIG. 23) in a manner similar to that described above.

[0040] 28, in another embodiment, a stator assembly 620 can alternatively include stator segments 642c each including formed conductive terminals 678c having pinch weld slots 693. Leads 686 of the stator windings 650 are press fit and welded into the pinch weld slots 693 to form an electrical connection. Second legs 689c of the terminals 678c are soldered to the PCBA 638 (FIG. 23) in a manner similar to that described above.

[0041] 29-32 illustrate a segmented stator assembly 720 according to another embodiment of the present disclosure. Stator assembly 720 is similar to stator assembly 520 described above and includes many of the same structures. Stator assembly 720 is also operable with rotor assembly 22 described above. Features and elements of stator assembly 720 that are similar to features and elements of stator assembly 520 are assigned the same reference numeral "+200." It should be understood that features of stator assembly 720 that are not explicitly described below have the same nature as features of stator assembly 520.

[0042] Similar to the segmented stator assembly 520 described above, the stator assembly 720 is a segmented stator assembly 720 that includes six stator segments 742 that, in the illustrated embodiment, are laser welded at the interlocking portions 752 of each notch and protrusion to secure the stator segments 742 together. In an alternative embodiment (not shown), the stator segments 742 may alternatively be disposed within a cylindrical housing, such as the cylindrical housing 44 of the stator assembly 20 (FIG. 3) discussed above. Each stator segment 742 includes a core 746, an overmolded insulator 748, and a stator winding 750. The stator segments 742 are not uniform, but instead include first stator segments 742a and second stator segments 742b arranged in an alternating order. Each first stator segment 742a is connected to a second stator segment 742b at each circumferential end.

[0043] 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 overmolded body 780 that fixedly supports the conductors 778. The overmolded body 780 is molded over the arranged conductors 778 such that a portion of each conductor 778 generally extends within the overmolded body 780.

[0044] 30 illustrates the segmented stator assembly 720 with the overmolded body 780 removed to expose the annular conductors 778. Each conductor 778 includes two pairs of tangs 782, each of which projects radially outward or radially and tangentially outward from the overmolded body 780. The two pairs of conductors 778 are provided on either circumferential side of the annular conductor 778. Each tang 782 connects to a lead 786 (FIG. 31) of an adjacent stator winding 750.

[0045] 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. A respective lead 786 of each winding 750 is bent into a corresponding one of the notches 785 and electrically connected (e.g., by laser welding) to the corresponding tang 782. Similarly, each tang 782 is bent toward the notch 785 (i.e., toward the axial direction) to bring the tang 782 into contact with the lead 786.

[0046] Each conductor 778 also includes a terminal 784 that projects radially outward, or at least radially and tangentially outward, from overmolded body 780. Each terminal 784 electrically connects (e.g., via wires (not shown)) to a PCBA, which receives power from battery pack 16 ( FIG. 1 ) and selectively applies current to stator windings 750. In this manner, conductors 578 electrically connect stator windings 550 to PCBA 538.

[0047] 29 and 32, the overmolded body 780 includes a generally disk-shaped disk portion 781 and a mounting tab 794 projecting radially outward from the disk portion 781. The mounting tab 794 engages a mounting portion 770 defined by the overmolded insulator 748 of the first stator segment 742a. ​​The mounting tab 794 may be secured to the mounting portion 770 via, for example, a threaded fastener.

[0048] The overmolded body 780 includes a central annular wall 755 that extends axially away from the disk portion 781 toward the rotor assembly 22 (FIG. 3). The annular wall 755 and the disk portion 781 together define a central opening or bearing pocket 790 that receives a rotor bearing 92 (FIG. 29). The rotor bearing 92 receives a rotor shaft 30 (FIG. 3) of the rotor assembly 22 to rotatably support the rotor assembly 22. A busbar assembly 736 is fixedly mounted to each mounting portion 770 of each stator segment 742a and further supports the rotor bearing 792 such that 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 openings 757 that surround the bearing pocket 790 (FIG. 32). The vent openings 757 allow cooling airflow generated by the fan 28 (FIG. 3) to pass through the busbar assembly 736.

[0049] 33-38 illustrate a portion of an electric motor 814 according to another embodiment of the present disclosure. Motor 814 includes a segmented stator assembly 820 that is similar to, and includes many of the same structures as, stator assembly 120 described above. Stator assembly 820 is also operable with rotor assembly 22 described above. Features and elements of stator assembly 820 that are similar to features and elements of stator assembly 120 are assigned the same reference numeral "+700." It should be understood that features of stator assembly 820 that are not explicitly described below have the same nature as features of stator assembly 120.

[0050] Similar to the segmented stator assembly 120 described above, the stator assembly 820 is a segmented stator assembly 820 that includes six stator segments 842 that, in the illustrated embodiment, are laser welded at the interlocking portions 852 of each notch and protrusion to secure the stator segments 842 together. In an alternative embodiment (not shown), the stator segments 842 may alternatively be disposed within a cylindrical housing, such as the cylindrical housing 44 of the stator assembly 20 (FIG. 3) discussed above. 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 instead include first stator segments 842a and second stator segments 842b arranged in an alternating order. Each first stator segment 842a is connected to a second stator segment 842b at each circumferential end.

[0051] The motor 814 includes a busbar assembly 836 that couples 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 tangs 882 provided at two opposing ends of the conductor 878 and a terminal 884 formed at one of the ends of the conductor 878 and located adjacent one of the two tangs 882. The overmolded body 880 includes a mounting tab 894 that engages a mounting portion 870 defined by the overmolded insulator 848 of the first stator segment 842a. The mounting tab 894 can be secured to the mounting portion 870 via, for example, a threaded fastener.

[0052] Each terminal 884 electrically connects (e.g., via a wire (not shown)) to a PCBA, which receives power from battery pack 16 (FIG. 1) and selectively applies current to stator windings 850. Each winding 850 includes a pair of leads 886 that connect to two adjacent tangs 882 of conductor 878. In this manner, conductor 878 electrically connects stator winding 850 to the PCBA.

[0053] Overmolded body 880 defines a central opening or bearing pocket 890 that receives rotor bearing 92 (FIG. 3) that receives rotor shaft 30 of rotor assembly 22 (FIG. 3) to rotatably support rotor assembly 22. A bus bar assembly 836 is fixedly attached to each mounting portion 870 of each stator segment 842a and further supports rotor bearing 92, such that bus bar assembly 836 centers rotor assembly 22 relative to stator assembly 820.

[0054] A PCBA 839, such as a rotor position sensor circuit board, is coupled to an overmolded body 880 of the bus bar assembly 836. The PCBA 839 is generally annular in shape and is received within a corresponding centrally located, annular-shaped recess 841 defined in the overmolded body 880 and secured thereto by threaded fasteners. The PCBA 839 covers at least a portion of the bearing pocket 890.

[0055] 35 and 36, the busbar assembly 836 includes a total of twelve tangs 882 equally spaced circumferentially around the overmolded body 880. In other embodiments (not shown), fewer or more tangs are contemplated and the number of tangs may be twice the number of stator windings, such that each tang connects to a corresponding lead of the stator winding. In the illustrated embodiment, the busbar assembly 836 also includes six terminals 884 provided in three pairs 884a-884c (i.e., three groups 884a-884c of two terminals 884). The three pairs 884a-884c are circumferentially spaced from one another around the overmolded body 880. In the illustrated embodiment, each group 884a-884c is spaced from the other groups 884a-884c by approximately 120 degrees measured around the central axis 824 of the motor 814.

[0056] 35, the overmolded body 880 includes a first axial surface 823 extending at a first axial end thereof and a second axial surface 825 extending at a second axial end thereof. The first axial surface 823 faces toward the stator assembly 820 and the second axial surface 825 faces away from the stator assembly 820. The tangs 882 each protrude from the first axial surface 823 and extend partially axially and partially radially. That is, each tang 882 generally extends toward the stator assembly 820 and also extends radially outward. Each tang 882 also includes a V-shaped notch 827 defined at its distal end between two adjacent prongs 829. Corresponding leads 886 ( FIG. 33 ) of adjacent stator windings 850 are received in notches 827 and are mechanically attached to tangs 882 between the prongs 829, for example by laser welding. As further shown in FIG. 35 , each of the tangs 882 is also generally located in the same axial region of the motor 814. In particular, the tips of each of the prongs 829 of each tang 882 together define a first plane 831 that extends perpendicular to the central axis 824.

[0057] Each terminal 884 projects from the second axial surface 825 of the overmolded body 880 and is generally L-shaped having an axially extending first leg 833 and a radially extending second leg 835. The second legs 835 of each terminal 884 are all generally located within the same axial region of the motor 814. In particular, the second legs 835 of each of the terminals 884 together define a second plane 837 that extends perpendicular to the central axis 824 and parallel to the first plane 831.

[0058] 39-44 illustrate a portion of an electric motor 914 according to another embodiment of the present disclosure. Motor 914 includes a segmented stator assembly 820 as described herein with reference to FIGS. 33-38 and is operable with rotor assembly 22 as described herein with reference to FIGS. 2-4 and 12.

[0059] The motor 914 includes a busbar assembly 936 that couples to an 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 tangs 982 provided at two opposing ends of the conductor 978 and a terminal 984 formed at one of the ends of the conductor 978 and located adjacent one of the two tangs 982. The overmolded body 980 includes a mounting tab 994 that engages a mounting portion 870 defined by the overmolded insulator 848 of the first stator segment 842a. The mounting tab 994 can be secured to the mounting portion 870 via, for example, a threaded fastener.

[0060] Each terminal 984 electrically connects (e.g., via a wire (not shown)) to a PCBA, which receives power from battery pack 16 (FIG. 1) and selectively applies current to stator windings 850. Leads 886 of windings 850 connect to two adjacent tangs 982 of conductor 978. In this manner, conductor 978 electrically connects stator windings 850 to the PCBA.

[0061] Overmolded body 980 defines a central opening or bearing pocket 990 that receives rotor bearing 92 (FIG. 3) that receives rotor shaft 30 of rotor assembly 22 (FIG. 3) to rotatably support rotor assembly 22. A bus bar assembly 936 is fixedly secured to each mounting portion 870 of each stator segment 842a and provides further support to rotor bearing 92, such that bus bar assembly 936 centers rotor assembly 22 relative to stator assembly 820.

[0062] A PCBA 939, such as a rotor position sensor circuit board, is coupled to an overmolded body 980 of the bus bar assembly 936. The PCBA 939 is generally annular in shape and is received within a corresponding centrally located, annular-shaped recess 941 defined in the overmolded body 980 and secured thereto by threaded fasteners. The PCBA 939 covers at least a portion of the bearing pocket 990.

[0063] As shown in FIG. 41 , the overmolded body 980 includes a first axial surface 923 extending at a first axial end thereof and a second axial surface 925 extending at a second axial end thereof. The first axial surface 923 faces toward 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 tangs 982 each project in a generally radial direction from the circumferential outer surface 943. Each tang 982 includes a hook portion 945 extending in a generally circumferential direction. A corresponding lead 886 ( FIG. 33 ) of an adjacent stator winding 850 is received by and contacts the hook portion 945 and is mechanically attached to the hook portion, 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 further shown in FIG. 41 , each of the tangs 982 also generally resides in the same axial region of the motor 814. In particular, each of the hook portions 945 of each tang 982 together define a first plane 931 that extends perpendicular to the central axis 924.

[0064] In the illustrated embodiment, the busbar assembly 936 includes six terminals 984 grouped on one side of the overmolded body 980. Each terminal 984 includes a leg portion 935 that projects from the second axial surface 925 of the overmolded body 980 and extends in a lateral outward direction perpendicular to the central axis 924. Each of the leg portions 935 extend generally parallel to one another. The longitudinal extent of each leg portion 935 together defines a second plane 937 that extends perpendicular to the central axis 924 and parallel to the first plane 931. In addition, the distal tips 947 of each leg portion 935 are laterally aligned with one another. In particular, the distal tips 947 terminate along a straight line L that extends perpendicular to the central axis 924 and perpendicular to the lateral outward direction. 42, the bus bar assembly 936 may be divided into four equal radial quadrants AD, each beginning at the central axis 924. The leg portions 935 of each terminal 984 are located in a single quadrant A.

[0065] Figures 45-50 illustrate all or a portion of an electric motor 1014 according to another embodiment of the present disclosure. The motor 1014 includes a segmented stator assembly 820 as described herein with reference to Figures 33-38 and is operable with a rotor assembly 22 as described herein with reference to Figures 2-4 and 12.

[0066] The motor 1014 includes a busbar assembly 1036 that couples to an axial end of the stator assembly 820. The busbar assembly 1036 includes three annular conductors 1078 (FIGS. 49-50) and an overmolded body 1080 that fixedly supports the conductors 1078. Each conductor 1078 includes four winding connection terminals or tangs 1082 provided at two opposing ends of the conductor 1078 and a power connection terminal 1084 projecting from the conductor 1078. The overmolded body 1080 includes three mounting arms 1094 that project radially from a central region of the body 1080 and are equally spaced about its circumference. The mounting arms 1094 engage the mounting portion 870 defined by the overmolded insulator 848 of the first stator segment 842a. The mounting arm 1094 can be secured to the mounting portion 870 via, for example, a threaded fastener.

[0067] Each terminal 1084 electrically connects (e.g., via a wire (not shown)) to a PCBA, which receives power from battery pack 16 (FIG. 1) and selectively applies current to stator windings 850. Leads 886 of windings 850 connect to two adjacent tangs 1082 of conductor 1078. In this manner, conductor 1078 electrically connects stator windings 850 to the PCBA.

[0068] The overmolded body 1080 defines a central opening or bearing pocket 1090 that receives the rotor bearing 92 (FIG. 3) which receives the rotor shaft 30 of the rotor assembly 22 (FIG. 3) to rotatably support the rotor assembly 22. A bus bar assembly 1036 is fixedly attached to each mounting portion 870 of each stator segment 842a and further supports the rotor bearing 92, such that the bus bar assembly 1036 centers the rotor assembly 22 relative to the stator assembly 820.

[0069] A PCBA 1039, such as a rotor position sensor circuit board, is coupled to the overmolded body 1080 of the bus bar assembly 1036. The PCBA 1039 is generally annular in shape and is received within a corresponding centrally located, annular-shaped recess 1041 defined in the overmolded body 1080 and secured thereto by threaded fasteners. The PCBA 1039 covers at least a portion of the bearing pocket 1090.

[0070] 47, the overmolded body 1080 includes a first axial surface 1023 extending at a first axial end thereof and a second axial surface 1025 extending at a second axial end thereof. The first axial surface 1023 faces toward 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 tangs 1082 each project in a generally radial direction from the circumferential outer surface 1043. Each tang 1082 includes a bifurcated tip 1045 at a distal end thereof and is generally planar in shape. Corresponding leads 886 (FIG. 45) of adjacent stator windings 850 are received by and contact the bifurcated tip 1045 and are mechanically attached to the bifurcated tip, for example, by laser welding. In other embodiments, the leads 886 can be attached to the bifurcated tip 1045 by other means, such as soldering, ultrasonic welding, crimping, and the like. As further shown in FIG. 47, each of the tangs 1082 is also generally located within the same axial region of the motor 1014. In particular, each tang 1082 lies within and defines a first plane 1031 that extends perpendicular to the central axis 1024. As shown in FIG. 47, the tangs 1082 are generally equally spaced apart around the circumference of the overmolded body 1080. Thus, angle A is measured center-to-center about the central axis 1024 between any two adjacent tangs 1082. In the illustrated embodiment, the busbar assembly 1036 includes twelve tangs 1082 and the angle A is approximately 30 degrees.

[0071] In the illustrated embodiment, the bus bar assembly 1036 includes three power connection terminals 1084 that protrude in the axial direction 1037 from the second axial surface 1025 of the overmolded body 1080. Each terminal 1084 is formed as a straight leg oriented perpendicular to the central axis 1024. All of the terminals 1084 extend generally parallel to each other and perpendicular to the first plane 1031.

[0072] The busbar assembly 1036 is configured to provide a parallel delta winding configuration for the motor 1014. Specifically, when the leads 886 of the windings 850 forming each coil are connected to the corresponding branch tips 1045 of their respective nearest tangs 1082, the windings 850 are arranged in a parallel delta winding configuration.

[0073] 51-56 illustrate a portion of an electric motor 1114 according to another embodiment of the present disclosure. The motor 1114 includes a segmented stator assembly 820 as described herein with reference to FIGS. 33-38 and is operable with a rotor assembly 22 as described herein with reference to FIGS. 2-4 and 12.

[0074] The motor 1114 includes a busbar assembly 1136 that couples to an axial end of the stator assembly 820. The busbar assembly 1136 includes six annular conductors 1178 (FIGS. 55 and 56) and an overmolded body 1180 that fixedly supports the conductors 1178. Each conductor 1178 includes two winding connection terminals or tangs 1182 provided at two opposing ends of the conductor 1178 and a power connection terminal 1184. The overmolded body 1180 includes three mounting arms 1194 that project radially from a central region of the body 1180 and are equally spaced about its circumference. The mounting arms 1194 engage a mounting portion 870 defined by the overmolded insulator 848 of the first stator segment 842a. The mounting arms 1194 can be fixed to the mounting portion 870 via, for example, threaded fasteners.

[0075] Each terminal 1184 electrically connects (e.g., via a wire (not shown)) to a PCBA, which receives power from the battery pack 16 (FIG. 1) and selectively applies current to the stator windings 850. Two leads 886 of each winding 850 forming each coil connect to two adjacent tangs 1182 of the conductor 1178. In this manner, the conductor 1178 electrically connects the stator windings 850 to the PCBA.

[0076] The overmolded body 1180 defines a central opening or bearing pocket 1190 that receives the rotor bearing 92 (FIG. 3) which receives the rotor shaft 30 of the rotor assembly 22 (FIG. 3) to rotatably support the rotor assembly 22. A bus bar assembly 1136 is fixedly attached to each mounting portion 870 of each stator segment 842a and further supports the rotor bearing 92, such that the bus bar assembly 1136 centers the rotor assembly 22 relative to the stator assembly 820.

[0077] A PCBA 1139, such as a rotor position sensor circuit board, is coupled to the overmolded body 1180 of the bus bar assembly 1136. The PCBA 1139 is generally annular in shape and is received within a corresponding centrally located, annular-shaped recess 1141 defined in the overmolded body 1180 and secured thereto by threaded fasteners. The PCBA 1139 covers at least a portion of the bearing pocket 1190.

[0078] 53, the overmolded body 1180 includes a first axial surface 1123 extending at a first axial end thereof and a second axial surface 1125 extending at a second axial end thereof. The first axial surface 1123 faces toward the stator assembly 820 and the second axial surface 1125 faces away from the stator assembly 820. The overmolded body 1180 also includes a circumferential outer surface 1143 extending between the first axial surface 1123 and the second axial surface 1125. The tangs 1182 each project in a generally radial direction from the circumferential outer surface 1143. Each tang 1182 includes a bifurcated tip 1145 at a distal end thereof and is generally planar in shape. Corresponding leads 886 (FIG. 51) of adjacent stator windings 850 are received by and contact the bifurcated tips 1145 and are mechanically attached thereto, for example by laser welding. In other embodiments, the leads 886 can be attached to the bifurcated tips 1145 by other means such as soldering, ultrasonic welding, crimping, and the like. As further shown in FIG. 53, each of the tangs 1182 also generally lies within a different axial region of the motor 1114. In particular, some of the tangs 1182 lie within and define a first plane 1131a, others of the tangs 1182 lie within and define a second plane 1131b, others of the tangs 1182 lie within and define a third plane 1131c, and still others of the tangs 1182 lie within and define a fourth plane 1131d. Each of the first, second, third and fourth planar surfaces 1131a-1131d extend parallel to one another and perpendicular to the central axis 1124 and are axially spaced apart from one another. As shown in FIG. 54, the tangs 1182 are generally equally spaced around the circumference of the overmolded body 1180. Thus, angle A is measured on the center about the central axis 1124 between any two adjacent tangs 1182. In the illustrated embodiment, the busbar assembly 1136 includes twelve tangs 1182 and angle A is approximately 30 degrees.

[0079] In the illustrated embodiment, the busbar assembly 1136 includes six terminals 1184 grouped on one side of the overmolded body 1180. The terminals 1184 include four first terminals 1184a that protrude in the axial direction 1137 from the second axial surface 1125 of the overmolded body 1180. Each terminal 1184a is formed as a straight leg oriented perpendicular to the central axis 1124. All of the first terminals 1184a extend generally parallel to each other and perpendicular to the first plane 1131a. The terminals 1184 also include two second terminals 1184b that protrude radially outward from the circumferential surface 1143 of the overmolded body 1180 in a direction perpendicular to the central axis 1124. Both of the second terminals 1184b reside in the first plane 1131a that extends perpendicular to the central axis 1124.

[0080] The busbar assembly 1136 is configured to provide a delta-wye winding configuration for the motor 1014. Specifically, when the leads 886 of the windings 850 forming each coil are connected to the corresponding branch tips 1145 of their respective nearest tangs 1182, the windings 850 are arranged in a delta-wye winding configuration.

[0081] 57-62 illustrate all or a portion of an electric motor 1214 according to another embodiment of the present disclosure. The motor 1214 includes a segmented stator assembly 820 as described herein with reference to FIGS. 33-38 and is operable with a rotor assembly 22 as described herein with reference to FIGS. 2-4 and 12.

[0082] The motor 1214 includes a busbar assembly 1236 that couples to an axial end of the stator assembly 820. The busbar assembly 1236 includes three annular conductors 1278 (FIGS. 61-62) and an overmolded body 1280 that fixedly supports the conductors 1278. Each conductor 1278 includes four winding connection terminals or tangs 1282 provided at two opposing ends of the conductor 1278 and a power connection terminal 1284 projecting from the conductor 1278. The overmolded body 1280 includes three mounting arms 1294 that project radially from a central region of the body 1280 and are equally spaced about its circumference. The mounting arms 1294 engage the mounting portion 870 defined by the overmolded insulator 848 of the first stator segment 842a. The mounting arm 1294 can be secured to the mounting portion 870 via, for example, a threaded fastener.

[0083] Each terminal 1284 electrically connects (e.g., via a wire (not shown)) to a PCBA, which receives power from battery pack 16 (FIG. 1) and selectively applies current to stator windings 850. Leads 886 of windings 850 connect to two adjacent tangs 1282 of conductor 1278. In this manner, conductor 1278 electrically connects stator windings 850 to the PCBA.

[0084] Overmold body 1280 defines a central opening or bearing pocket 1290 that receives rotor bearing 92 (FIG. 3). Rotor bearing 92 receives rotor shaft 30 of rotor assembly 22 (FIG. 3) to rotatably support rotor assembly 22. A bus bar assembly 1236 is fixedly attached to each mounting portion 870 of each stator segment 842a and further supports rotor bearing 92, such that bus bar assembly 1236 centers rotor assembly 22 relative to stator assembly 820.

[0085] A PCBA 1239, such as a rotor position sensor circuit board, is coupled to the overmolded body 1280 of the bus bar assembly 1236. The PCBA 1239 is generally annular in shape and is received within a corresponding centrally located, annular-shaped recess 1241 defined in the overmolded body 1280 and secured thereto by threaded fasteners. The PCBA 1239 covers at least a portion of the bearing pocket 1290.

[0086] 59 , the overmolded body 1280 includes a first axial surface 1223 extending at a first axial end thereof and a second axial surface 1225 extending at a second axial end thereof. The first axial surface 1223 faces toward 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 tangs 1282 each project in a generally radial direction from the circumferential outer surface 1243. Each tang 1282 includes a bifurcated tip 1245 at a distal end thereof and is generally planar in shape. Corresponding leads 886 (FIG. 45) of adjacent stator windings 850 are received by and contact the bifurcated tip 1245 and are mechanically attached to the bifurcated tip, for example, by laser welding. In other embodiments, the leads 886 can be attached to the bifurcated tip 1245 by other means, such as soldering, ultrasonic welding, crimping, and the like. As further shown in FIG. 47, each of the tangs 1282 is also generally located within the same axial region of the motor 1214. In particular, each tang 1282 lies within and defines a first plane 1231 that extends perpendicular to the central axis 1224. As shown in FIG. 60, the tangs 1282 are generally equally spaced around the circumference of the overmolded body 1280. Thus, angle A is measured center-to-center about the central axis 1224 between any two adjacent tangs 1282. In the illustrated embodiment, the busbar assembly 1236 includes twelve tangs 1282 and the angle A is approximately 30 degrees.

[0087] 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 portion 1235 that extends radially outwardly perpendicular to the central axis 1224. The longitudinal extent of each leg portion 1235 together defines a second plane 1237 that extends perpendicular to the central axis 1224 and parallel to the first plane 1231.

[0088] FIG. 63 illustrates a busbar assembly 1236 according to another embodiment. The busbar assembly 1236 of FIG. 63 is substantially similar to the busbar assembly 1236 of FIGS. 57-62, but differs with respect to the power connection terminals. In particular, the busbar assembly 1236 of FIG. 63 includes three modified conductors 1278a having three power connection terminals 1284a protruding in the axial direction 1238 from the second axial surface 1225 of the overmolded body 1280. Each terminal 1284a is formed as a straight leg oriented perpendicular to the central axis 1224. All of the terminals 1284 extend generally parallel to one another.

[0089] The busbar assembly 1236 is configured to provide a series-delta winding configuration for the motor 1214. Specifically, when the leads 886 of the windings 850 forming each coil are connected to the corresponding branch tips 1245 of their respective nearest tangs 1282, the windings 850 are arranged in a series-delta winding configuration.

[0090] 64-70 illustrate all or a portion of an electric motor 1314 according to another embodiment of the present disclosure. The motor 1314 includes a segmented stator assembly 1320 substantially similar to the segmented stator assembly 820 described herein in connection with FIGS. 33-38. The motor 1314 further includes or is operable with a rotor assembly 22 described herein in connection with FIGS. 2-4 and 12. Features and elements of the stator assembly 1320 similar to those of the stator assembly 820 are assigned the same reference numeral "+500". The following disclosure focuses on the differences between the stator assembly 1320 and the stator assembly 820. In particular, the following disclosure focuses on the arrangement of the first and second wire notches 1302a, 1302b formed in the overmolded insulator 1348 of each of the multiple stator segments 1342 of the stator assembly 1320. It should be understood that features of stator assembly 1320 not explicitly described below have the same characteristics as features of stator assembly 820. Additionally, although the arrangement of first and second wire notches 1302a, 1302b is described in relation to stator assembly 1320, the notch arrangement may also be incorporated into any of the embodiments of 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.

[0091] Motor 1314 further includes busbar assembly 1236 as described herein with respect to Figures 57-62. Busbar assembly 1236 couples to stator assembly 1320 in a manner similar to that described herein with respect to stator assembly 820. Alternatively, in other configurations (not shown) of electric motor 1314, stator assembly 1320 may instead couple 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).

[0092] The stator assembly 1320 is a segmented stator assembly and, in the illustrated embodiment, includes six stator segments 1342 that are laser welded together at interlocks 1352 in each notch and protrusion to secure the stator segments 1342 together. In an alternative embodiment (not shown), the stator segments 1342 are not laser welded together, but may instead be disposed within a cylindrical housing, such as the cylindrical housing 44 of the stator assembly 20 (FIG. 3) discussed above. In the illustrated embodiment, each stator segment 1342 includes a core 1346, an overmolded insulator 1348, and a coil or stator winding 1350. The stator segments 1342 are not uniform, but instead include first stator segments 1342a and second stator segments 1342b arranged in alternating order in the circumferential direction. Each first stator segment 1342a is connected at each circumferential end (ie, at the notch and protrusion interlocks 1352) to a second stator segment 1342b.

[0093] 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 busbar assembly 1236 to secure the busbar assembly 1236 to the stator assembly 1320. The mounting arm 1294 can be secured to the mounting portion 1370 via, for example, a threaded fastener.

[0094] 66 and 67 illustrate one of the second stator segments 1342b of the stator assembly 1320. Each second stator segment 1342b includes an annular stator segment yoke portion 1304a, a stator segment tooth portion 1304b projecting radially from a central region of the stator segment yoke portion 1304a, and a stator segment crown portion 1304c at an end of the stator segment tooth portion 1304b opposite the stator segment yoke portion 1304a. In the illustrated embodiment, the stator segment tooth portion 1304b projects radially inward from the stator segment yoke portion 1304a in a direction toward the central axis 1324 (FIG. 64) of the assembled electric motor 1314. Winding slots 1306 are defined between the stator segment yoke portion 1304a and the stator segment crown portion 1304c, and on each side and each axial end of the stator segment tooth portion 1304b. The winding slots 1306 accommodate a coiled stator winding 1350. The stator segment yoke portion 1304a, the stator segment tooth portion 1304b, and the stator segment crown portion 1304c are each formed from respective portions of the core 1346 and the overmolded insulator 1348. Specifically, the stator segment yoke portion 1304a is formed from the insulator yoke portion 1348a of the overmolded insulator 1348 and from the core yoke portion 1346a of the core 1346. The stator segment tooth portion 1304b is formed from the insulator tooth portion 1348b of the overmolded insulator 1348 and from the core tooth portion 1346b of the core 1346. The stator segment crown portion 1304c is formed from the insulator crown portion 1348c of the overmolded insulator 1348 and from the core crown portion 1346c of the core 1346.

[0095] The insulator yoke portion 1348a of the overmolded insulator 1348 forms a standoff portion 1308 that projects axially away from the core yoke portion 1346a at one axial end of the second stator segment 1342b. The standoff portion 1308 may contact or join with the busbar assembly 1236. Specifically, the standoff portion 1308 may contact the first axial surface 1223 ( FIG. 59 ) of the overmolded body 1280 of the busbar assembly 1236. Referring to FIGS. 66 and 67 , the standoff portion 1308 includes a curved inner surface 1309a facing toward the insulator tooth portion 1348b and the insulator crown portion 1348c, a curved outer surface 1309b facing away from the insulator tooth portion 1348b, and a generally flat top surface 1309c facing axially away from the core yoke portion 1346a.

[0096] The coiled stator winding 1350 (FIGS. 65 and 68) is formed by winding an elongated wire 1351 around the stator segment tooth portions 1304b in the winding slots 1306 to form a coil 1355. The elongated wire 1351 extends away from the coil 1355 and includes two respective end portions or leads 1386 that connect to two respective adjacent tangs 1282 of the bus bar assembly 1236. In this manner, the conductors 1278 of the bus bar assembly 1236 electrically connect the stator winding 1350 to the PCBA 1239.

[0097] The standoff portion 1308 defines a pair of first wire notches 1309c in the flat top surface 1302a. Each first wire notch 1302a is formed adjacent or adjacent to a 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 in the axial direction of the second stator segment 1342b beginning at the flat top surface 1309c and terminating at the bottom wall 1311 of the first notch. Each first wire notch 1302a opens axially in a direction away from the core yoke portion 1346a and opens radially in both inward and outward directions relative to the stator assembly 1320. The leads 1386 of the stator windings 1350 exit the winding slots 1306 by passing through the first wire notch 1302a. The first wire notch 1302a accommodates the leads 1386 and allows the leads to pass between the busbar assembly 1236 and the standoff portion 1308. That is, the first wire notch 1302a provides space for the leads 1386 to pass between the standoff portion 1308 and the overmolded body 1280 because the top surface 1309c of the standoff portion 1308 can be in direct contact with the overmolded body 1280 ( FIG. 65 ) of the busbar assembly 1236.

[0098] 66, 67, 69, and 70, the standoff portion 1308 defines a relief notch or second wire notch 1302b recessed into the curved inner surface 1309a. The second wire notch 1302b is formed adjacent to or coextensive with one of the first wire notches 1302a and communicates with the adjacent first wire notch 1302a. The second wire notch 1302b extends axially of the second stator segment 1342b from the top surface 1309c to a bottom wall 1313 of the second notch located near the axial end face of the core yoke portion 1346a. The second wire notch 1302b is further defined by a second notch base wall 1317 that faces in a radial direction of the stator assembly 1320 and extends in an axial direction 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 sidewall 1319a and a second notch second sidewall 1319b that are in facing relationship to each other and face in a generally circumferential direction of the assembled stator assembly 1320. The second notch first sidewall 1319a and second sidewall 1319b extend from the second notch base wall 1317 to the curved inner surface 1309a and from the second notch bottom wall 1313 to the top surface 1309c, respectively. The second wire notch 1302b opens radially inward, ie, toward the stator segment crown portion 1304c, and opens axially in a direction away from the core yoke portion 1346a.

[0099] The second wire notch 1302b provides a clearance space to accommodate one of the leads 1386 of the stator winding 1350. As shown in FIGS. 68 and 70, the wire 1351 forming the stator winding 1350 passes multiple times around the stator segment tooth portion 1304b to form a coil 1355 that fills the winding slot 1306. One of the leads 1386 may be considered the starting lead 1386a, from which the wire 1351 first enters the winding slot 1306 and makes a first pass around the stator segment tooth portion 1304b. Thereafter, as additional passes are made by the winding wire 1351, they overlap the first pass and each other, generally covering a portion of the starting lead 1386a. 70, the starting lead 1386a can be trapped or encircled between the curved inner surface 1309a and several passes of the winding wire 1351. The second wire notch 1302b receives the starting lead 1386a such that the starting lead 1386a is recessed into the curved inner surface 1309a. The second wire notch 1302b thus provides clearance space for the starting lead 1386a to pass through an adjacent pass of the winding wire 1351. The starting lead 1386a then passes from the second wire notch 1302b to the first wire notch 1302, whereby the starting lead 1386a exits the winding slot 1306 and is attached to an adjacent tang 1282 of the busbar assembly 1236. The second wire notch 1302b also allows for an increase in the wire size of the winding wires compared to a stator assembly that does not include the second wire notch, for example, the second wire notch 1302b allows for an increase in the diameter of the wire 1351, for example, to a diameter of 1.7 millimeters (mm).

[0100] Although the second wire notch 1302b is only shown on the right side of the standoff portion 1308 in FIGS. 67 and 69, the second stator segment 1342b can alternatively include a second wire notch 1302b on the left side in communication with the first wire notch 1302a on the left side. In additional embodiments, the second stator segment 1342b can include two second wire notches 1302b each in communication with a respective first wire notch 1302a. Additionally, although the first and second wire notches 1302a, 1302b are described herein for the second stator segment 1342b, the same arrangement of the first and second wire notches 1302a, 1302b can also be formed in the standoff portion of the first stator segment 1342a.

[0101] Although the present disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist that are within the scope and spirit of one or more independent aspects of the disclosure as described.

[0102] Various features of the invention are set forth in the following claims.

Claims

1. 1. An electric motor, comprising: a rotor assembly including a rotor shaft; A stator assembly including a plurality of stator segments disposed adjacent to one another in a circumferential direction of the stator assembly, at least one of the stator segments having: a core having a core yoke portion and a core teeth 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; a stator assembly including: a stator winding extending around the stator segment tooth portions, the stator winding including wire leads; and a busbar assembly coupled to the stator assembly and configured to electrically connect to the stator windings, the busbar assembly including a molding and a plurality of conductors; the insulator yoke portion of the at least one stator segment includes a standoff portion that protrudes axially away from the core yoke portion of the at least one stator segment, the standoff portion defining an inner surface facing toward 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; the standoff portion defines a wire notch recessed in the inner surface and extending in an axial direction of the electric motor; The wire notch at least partially receives the wire lead.

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

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

4. The electric motor of claim 2 , wherein the wire lead passes through the first wire notch and between the standoff portion and the molding of the busbar assembly.

5. The electric motor of claim 2 , wherein the first wire notch is in communication with the second wire notch.

6. The electric motor of claim 1 , wherein the plurality of stator segments includes a first stator segment and a second stator segment circumferentially adjacent the first stator segment.

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

8. the core further comprises a core crown portion at a distal end of the core tooth portion; the insulator further includes an insulator crown portion at a distal end of the insulator tine 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; The electric motor of claim 7 , wherein the wire notches open radially toward the stator segment crown portion.

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

10. 1. An electric motor, comprising: a rotor assembly including a rotor shaft; A stator assembly including a plurality of stator segments disposed adjacent to one another in a circumferential direction of the stator assembly, at least one of the stator segments having: a core having a core yoke portion and a core teeth 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; a stator winding extending around the stator segment tooth portions and including wire leads; the insulator yoke portion of the at least one stator segment includes a standoff portion that protrudes axially away from the core yoke portion of the at least one stator segment, the standoff portion defining an inner surface facing toward 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; the standoff 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; the standoff portion further defines a second wire notch recessed into the inner surface and extending in an axial direction of the electric motor, the first wire notch being in communication with the second wire notch; the first wire notch and the second wire notch each at least partially receive the wire lead.

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

12. the core further comprises a core crown portion at a distal end of the core tooth portion; the insulator further includes an insulator crown portion at a distal end of the insulator tine 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; The electric motor of claim 11 , wherein the second wire notch opens radially toward the stator segment crown portion.

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

14. The second wire notch comprises: a base wall of a second notch defined by the standoff portion and facing radially toward the stator segment crown portion; 13. The electric motor of claim 12, further defined by a second notch first sidewall and a second notch second sidewall each defined by the standoff portion and facing toward one another in a circumferential direction.

15. 15. The electric motor of claim 14, wherein the first wire notch is recessed in the axial direction from the top surface of the standoff portion and defined by a first notch bottom wall facing away from the core yoke portion.

16. 16. The electric motor of claim 15, wherein a base wall of the second notch extends in the axial direction from a bottom wall of the second notch to a bottom wall of the first notch.

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

18. A power tool, Housing and an electric motor received within the housing, a rotor assembly including a rotor shaft; A stator assembly including a plurality of stator segments disposed adjacent to one another in a circumferential direction of the stator assembly, at least one of the stator segments having: a core having a core yoke portion and a core teeth 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 assembly including a stator winding extending around the stator segment teeth, the stator winding including wire leads; the electric motor further comprising a busbar assembly coupled to the stator assembly and configured to electrically connect to each stator winding, the busbar assembly including a molding and a plurality of conductors; the insulator yoke portion of the at least one stator segment includes a standoff portion that protrudes axially away from the core yoke portion of the at least one stator segment, the standoff portion defining an inner surface facing toward 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; the standoff portion defines a wire notch recessed in the inner surface and extending in an axial direction of the electric motor; The wire notch at least partially receives the wire lead.

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

20. 20. The power tool of claim 19, wherein the stator windings comprise wire having a diameter of 1.7 millimeters.

21. 1. An electric motor, comprising: a rotor assembly including a rotor shaft; 1. A stator assembly comprising: 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 at least partially covering the core, the insulator having an insulator yoke portion at least partially covering the core yoke portion, an insulator tooth portion at least partially covering the core tooth portion, and an insulator crown portion at least partially covering the core crown portion; a stator winding extending around the insulator tooth portion, the stator winding including a wire lead; a busbar assembly coupled to the stator assembly and configured to electrically connect to the stator windings, the busbar assembly including a molding and a plurality of conductors; the insulator yoke portion includes a standoff portion that projects axially away from the core yoke portion, the standoff portion defining an inner surface facing toward 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; the standoff portion defines a wire notch recessed in the inner surface and extending in an axial direction of the electric motor; The wire notch at least partially receives the wire lead.

22. 22. The electric motor of claim 21, wherein the wire notch opens radially toward the insulator crown portion.

23. 23. The electric motor of claim 22, wherein the wire notch also opens axially away from the core yoke portion.

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

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

26. 25. The electric motor of claim 24, wherein the wire lead passes through the first wire notch, between the standoff portion and the molding of the busbar assembly.

27. 25. The electric motor of claim 24, wherein the first wire notch is in communication with the second wire notch.

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

29. The second wire notch comprises: a base wall of a second notch defined by the standoff portion and facing radially toward the insulator crown portion; 30. The electric motor of claim 28, further defined by a second notch first sidewall and a second notch second sidewall each defined by the standoff portion and facing toward one another in a circumferential direction.

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

31. 31. The electric motor of claim 30, wherein a base wall of the second notch extends in the axial direction from a bottom wall of the second notch to a bottom wall of the first notch.

32. 22. The electric motor of claim 21, wherein the wire notch extends in the axial direction from the top surface of the standoff portion to a notch bottom wall located near an axial end face of the core yoke portion, the wire notch being open in a radial direction of the electric motor and open in the axial direction.

33. 1. An electric motor, comprising: a rotor assembly including a rotor shaft; 1. A stator assembly comprising: 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 at least partially covering the core, the insulator having an insulator yoke portion at least partially covering the core yoke portion, an insulator tooth portion at least partially covering the core tooth portion, and an insulator crown portion at least partially covering the core crown portion; a stator assembly including a stator winding extending around the insulator tooth portion, the stator winding including a wire lead; the insulator yoke portion includes a standoff portion that projects axially away from the core yoke portion, the standoff portion defining an inner surface facing toward 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; the standoff 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; the standoff portion further defines a second wire notch recessed into the inner surface and extending in an axial direction of the electric motor; the first wire notch and the second wire notch each at least partially receive the wire lead.

34. 34. The electric motor of claim 33, wherein the second wire notch extends in the axial direction from the top surface of the standoff portion to a bottom wall of a second notch located near an axial end face of the core yoke portion.

35. 35. The electric motor of claim 34, wherein the second wire notch opens radially toward the insulator crown portion.

36. 36. The electric motor of claim 35, wherein the second wire notch also opens axially away from the core yoke portion.

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

38. 38. The electric motor of claim 37, wherein the first wire notch is recessed in the axial direction from the top surface of the standoff portion and defined by a first notch bottom wall facing away from the core yoke portion.

39. 39. The electric motor of claim 38, wherein a base wall of the second notch extends in the axial direction from a bottom wall of the second notch to a bottom wall of the first notch.

40. 34. The electric motor of claim 33, wherein the first wire notch opens away from the core yoke portion in the axial direction, opens inwardly in the radial direction, and opens outwardly in the radial direction.

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