Allyn R Boyce

7088024, Aug 8, 2006

Apr 22, 2005

11/113414

Michael Agnes - Bel Air MD, US
Allyn Boyce - Baldwin MD, US
Hung Du - Reisterstown MD, US
Earl Ortt - Bel Air MD, US
Brandon Verbrugge - Towson MD, US
Richard H. Walter - Baldwin MD, US
Ren T. Wang - Timonium MD, US
Jiaqi Zhang - Cockeysville MD, US

Black & Decker Inc. - Newark DE

H02K 21/26
H02K 21/38
H02K 5/24

31015412, 31015613, 310 43, 29596, 29597, 29598

A stator of an electric motor is formed by inserting pre-formed magnets on a cylinder having anchors and plastic is molded around the magnets and anchors to secure the magnets to a surface of the cylinder, forming a cylinder/magnet assembly. A pilot feature is formed in at least one endwall of the plastic molding when it is molded. An end plate is located with respect to the cylinder/magnet assembly by mating a corresponding pilot feature of the end plate with the pilot feature in the endwall of the plastic molding. In another aspect of the invention, magnets are inserted into magnet receiving pockets of a cylinder and plastic molded therearound with the magnet pockets holding the magnets in place during molding of the plastic. In another aspect of the invention, the north and south poles of a cylinder and magnet assembly have unequal distribution angles. In another aspect of the invention, the north and south poles of a cylinder and magnet assembly have unequal numbers of magnets.

7091642, Aug 15, 2006

Apr 22, 2005

11/113429

Michael Agnes - Bel Air MD, US
Allyn Boyce - Baldwin MD, US
Hung Du - Reisterstown MD, US
Earl Ortt - Bel Air MD, US
Brandon Verbrugge - Towson MD, US
Richard H. Walter - Baldwin MD, US
Ren T. Wang - Timonium MD, US

Black & Decker Inc. - Newark DE

H02K 21/26
H02K 21/38
H02K 5/24

31015412, 31015413, 310 43, 29596, 29597, 29598

A cylinder/magnet assembly for a field of an electric machine, such as a stator of a brush type motor or a rotor of a brushless motor, alternator or generator, is formed by stamping a blank to form anchors extending upwardly from a surface of the blank and stamping holes in the blank where first and second portions of the anchors meet an inner surface of the cylinder to facilitate rolling of the cylinder from the blank. After a cylinder is rolled from the blank, pre-formed magnets are placed around an inner surface of the cylinder and plastic molded around the magnets and anchors to secure the magnets to the cylinder. In an aspect of the invention, the holes act as magnetic chokes. In another aspect of the invention, the anchors are formed as flux spreaders. In another aspect of the invention, the north and south poles of a cylinder and magnet assembly have unequal distribution angles. In another aspect of the invention, the north and south poles of a cylinder and magnet assembly have unequal numbers of magnets.

20040113504, Jun 17, 2004

Aug 20, 2003

10/468643

Michael Agnes - Bel Air MD, US
Allyn Boyce - Baldwin MD, US
Hung Du - Reisterstown MD, US
Earl Ortt - Bel Air MD, US
Brandon Verbrugge - Towson MD, US
Richard Walter - Baldwin MD, US
Ren Wang - Timonium MD, US
Jiaqi Zhang - Cockeysville MD, US

H02K021/26
H02K021/38
H02K023/04

310/154080

A cylindrical magnet ring assembly having a cylinder magnet flux ring () formed with a plurality of inwardly projecting anchors (); a plurality of permanent magnets (), wherein the magnet can be formed with step portions () in the inner radial surface; a molded plastic member () being molded around the magnets and anchors to secure the magnets to a surface of the cylinder flux ring. There are several variations of the embodiments of the invention. Few embodiments are the following: in one aspect of the invention, magnets are inserted into magnet molded around an assembly ring () and the molded plastic secures the assembly ring to the flux ring; in another aspect, there are two assembly rings, a first assembly ring (is inserted into the one side of the cylinder flux ring then the second assembly ring is inserted into the other side of the cylinder flux ring and mated to the first assembly ring, after that the molded plastic secures the two assembly rings. The foregoing cylindrical magnet ring assembly is used in a stator of a motor which is used in a power tool.