Electric motor case with folded-out mounting brackets and economical motor-fan packaging

Abstract

A cooling module 67 includes a motor assembly 42 having a motor case 24 having at least one open end and including mounting brackets 30 integral therewith. Each bracket has only a bottom portion 32 connected with the motor case. An armature assembly is disposed in the motor case and includes a rotatable shaft 46. A brush card assembly 56 is associated with the armature assembly, and an end cap 60 is disposed over the brush card assembly and partially covers the open end of the motor case and thereby defining a non end cap covered motor portion 63. A fan 64 is coupled to an end of the shaft and has a hub substantially covering one end of the motor assembly. A shroud 74 has a motor cover 76. Fastening structure 78 is associated with the shroud and engaged with the brackets thereby mounting the motor assembly to the shroud, with the motor cover substantially covering the end cap and the non end cap covered motor portion.

1 . A cooling module comprising: 
 a motor assembly comprising: 
 a motor case defining a stator of generally cylindrical shape having at least one open end, the motor case including a plurality of mounting brackets integral therewith at the open end, each mounting bracket having only a bottom portion connected with the motor case with side portions of each bracket being separated from the motor case by cut-out portions in the motor case, and  
 an armature assembly disposed in the motor case for rotation with respect to the motor case, the armature assembly including a shaft that rotates with the armature assembly,  
 a brush card assembly associated with the armature assembly, and  
 an end cap disposed over the brush card assembly and partially covering the open end of the motor case and thereby defining a non end cap covered motor portion,  
   a fan coupled to an end of the shaft, the fan having a hub substantially covering one end of the motor assembly,    a shroud having a motor cover, and    fastening structure associated with the shroud and engaged with the brackets thereby mounting the motor assembly to the shroud, with the motor cover substantially covering the end cap and the non end cap covered motor portion.    
   
   
       2 . The module of  claim 1 , wherein the motor case defines a central axis and each bracket is folded out so as to be generally transverse with respect to the central axis.  
   
   
       3 . The module of  claim 2 , wherein the motor assembly includes permanent magnet structure mounted to the motor case in an interior thereof.  
   
   
       4 . The module of  claim 3 , wherein the permanent magnet structure includes four permanent magnets, and at least three spaced brackets are provided, a radial position of at least two of the brackets with respect to the central axis being generally centered with respect to an associated magnet.  
   
   
       5 . The module of  claim 1 , wherein each bracket includes a surface defining a hole and wherein the fastening structure is a thread forming screw engaged with an associated hole.  
   
   
       6 . The module of  claim 1 , wherein the fastening structure is a rivet.  
   
   
       7 . The module of  claim 1 , wherein the end cap includes a bushing assembly that supports an end of the shaft for rotation.  
   
   
       8 . A method of mounting a motor assembly to a shroud, the method including: 
 providing a motor assembly having a motor case of generally cylindrical shape having at least one open end, an end cap partially covers the open end, the motor case defines a central axis, the motor case includes a plurality of mounting brackets integral therewith at the open end, each mounting bracket having only a bottom portion connected with the case with side portions of each bracket being separated from the motor case by cut-out portions in the motor case,    bending the mounting brackets about the bottom portion thereof with respect to the motor case so as to be generally transverse with respect to the central axis,    providing a shroud having a motor cover, and    mounting the motor case and thus the motor assembly to the shroud by engaging a fastener, associated with the motor cover, with each of the brackets such that the motor cover substantially covers the end cap and open end of the motor case.    
   
   
       9 . The method of  claim 8 , wherein each bracket includes a hole and the fastener is a thread-forming screw, the method includes engaging a thread-forming screw with an associated hole.  
   
   
       10 . The method of  claim 8 , wherein the motor assembly includes: 
 an armature assembly disposed in the motor case for rotation with respect to the motor case, the armature assembly including a shaft that rotates with the armature assembly,    a brush card assembly associated with the armature assembly, and    the end cap is disposed over the brush card assembly and defines a non end cap covered motor portion,    wherein the step of providing shroud and motor cover includes ensuring that the motor cover substantially covers the end cap and the non end cap covered motor portion.    
   
   
       11 . The method of  claim 10 , wherein the shaft has an end extending from a second end of the motor case opposite the open end thereof, the method further includes coupling a fan to the end of the shaft, the fan having a hub constructed and arranged to substantially cover the second end of the motor case.  
   
   
       12 . A stator for a permanent magnet DC motor, the stator comprising: 
 a motor case of generally cylindrical shape having at least one open end, the case including a plurality of mounting brackets integral therewith at the open end, each mounting bracket having only a bottom portion connected with the motor case with side portions of each bracket being separated from the motor case by cut-out portions in the motor case, each mounting bracket being folded-out about the bottom portion thereof with respect to the motor case for mounting the motor case to another object.    
   
   
       13 . The stator of  claim 12 , wherein the motor case defines a central axis and each bracket is folded out so as to be generally transverse with respect to the central axis.  
   
   
       14 . The stator of  claim 13 , further including permanent magnets mounted to an interior of the motor case, a radial position of certain brackets with respect to the central axis being generally centered with respect to an associated magnet  
   
   
       15 . The stator of  claim 12 , wherein four permanent magnets are provided and at least three spaced brackets are provided, at least two of the brackets define the certain brackets that are generally centered with respect to an associated magnet.  
   
   
       16 . The stator of  claim 12 , in combination with an armature assembly disposed in the motor case, the motor case including permanent magnet structure fixed with respect to an interior of the motor case and associated with the armature assembly.  
   
   
       17 . The combination of  claim 16 , in further combination with a shroud, the shroud including a motor cover, wherein fastening structure, associated with the motor cover, is engaged with the brackets mounting the motor case to the shroud.  
   
   
       18 . The combination of  claim 17 , wherein each bracket includes a surface defining a hole receiving fastening structure in the form of a thread-forming screw.  
   
   
       19 . The combination of  claim 17 , wherein the fastening structure is a rivet.  
   
   
       20 . The stator of  claim 12 , wherein each bracket includes fastener engagement structure constructed and arranged to engage fastening structure.