Patent ID: 7096566

Claim:
A method for forming a given size armature to increase the power of an electric motor using that given size armature, comprising: securing a lamination stack having slots therein on an armature shaft; securing a commutator on one end of the armature shaft; winding magnet wires in the slots in the lamination stack and securing ends of the magnet wires to the commutator; molding plastic to at least partially encase the magnet wires in the plastic to hold them in place in the slots without using coil stays; and winding the magnet wires in the slots includes winding them so that they also occupy portions of the slots that are occupied by coil stays in an armature where coil stays are used to hold the magnet wires in place in the slots and where the armature in which the coil stays are used has the same size as the given size armature.