Patent ID: 7567010

Claim:
A method of manufacturing a single pole for use in an electric motor stator comprising: forming a first and second tooth of a soft magnetic composite, each tooth comprising a winding support and a stator face, the stator face on the winding support; forming a first and second back iron, each back iron comprising an axial face adapted to interface to an adjacent tooth or a motor housing; forming a first and second coil, each coil having an open core; inserting the winding support on the first tooth in the open core of the first coil; inserting the winding support on the second tooth in the open core of the second coil; attaching the first back iron to the winding support of the first tooth to secure the first coil intermediate the first back iron and the stator face on the first tooth to form a first stator pole component; attaching the second back iron to the winding support of the second tooth to secure the second coil intermediate the second back iron and the stator face on the second tooth to form a second stator pole component; assembling a modular stator pole by stacking the first stator pole component on the second stator pole component having the axial face of the first back iron on the axial face on the second back iron wherein the first coil is held in spaced relation to the second coil.