Patent ID: 8628716

Claim:
A method of manufacturing a bonded metal assembly having a form and a powdered metal-filled plastic permanent magnet member, said powdered metal-filled plastic member having a cylindrical surface generally surrounding said form, said method comprising: using a mold having a cylindrical interior surface corresponding generally to the cylindrical surface of the powdered metal-filled plastic member; using a gate to the mold, said gate extending at least partially along a radius of the cylindrical interior surface of the mold; positioning the form in said mold; and injecting a powdered metal-filled plastic material made up of a powdered metal in a plastic through said gate to said mold and flowing the material in the mold in a manner that the powdered metal is generally uniformly distributed throughout the member thereby enhancing magnetic characteristic of the assembly including flowing the material generally unidirectionally substantially the full circumference around the form wherein a higher density of powdered metal in the plastic injected through said gate is offset by a lower density of powdered metal in the plastic that has flowed substantially the full circumference around the form.