Patent attributes
A BLDC motor assembly and method for manufacturing same is disclosed. The motor has a housing, a shaft supported for rotation within the housing, a stator disposed within the housing for generating an electro-magnetic field, a rotor operatively coupled to the shaft and disposed for powered rotation within the stator in response to the electro-magnetic field, at least one temperature sensitive electronic device (TSED) disposed within the housing and electrically connected to the stator for controlling or measuring an aspect of the electro-magnetic field, and a fuel resistant and electrically insulated polymeric material encapsulating the TSED so that the TSED is protected from adverse temperature and chemical agents without the need for a separate internal container or a pre-potting operating. The TSED, which may be carried on a printed circuit board within the housing, is thus overmolded with polymeric material so that the polymeric material fills, or substantially fills, a space within the housing. Not only is the cost and weight associated with a prior art dedicated container for the electronics eliminated, but this invention allows greater design freedom in the location or placement of the various electrical devices within the housing for better motor efficiency and/or protection.
