Patent ID: 7036206

Claim:
A process for preparing an over molded motor stator structure comprising: constructing a bobbin assembly around which a coil is wound; constructing an intermediate stator assembly including assembling said bobbin assembly to a stator core comprising a plurality of stator laminations having an internal diameter and an external diameter; disposing said intermediate stator assembly into a mold fixture comprising a cover half and an ejector half that includes a first portion, a second portion, an internal cavity inserted into said second portion for receiving the intermediate stator assembly, an inner ejector core, within said first portion and a moveable plate; loading a bearing carrier into said ejector half fixture; closing said cover half over said ejector half of said thereby causing said moveable plate to travel within said mold; injecting a unitizing material into said mold fixture to partially encapsulate said intermediate stator assembly and form an over molded motor stator structure including a unitized stator assembly having a central bore and a molded main body; said moveable plate traveling within said ejector half so as to allow said unitizing material to only fill selected areas and achieve an over molded motor stator structure such that the internal diameter and the external diameter of said stator laminations is not covered in unitizing material after molding.