IP Library › Granted Patent US 8,291,574
Granted Patent B2
US 8,291,574 · App. 12/942,264 · Granted Oct 23, 2012

Method of making a BLDC motor assembly

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Quick Facts
Patent No.
US 8,291,574
App. No.
12/942,264
Granted
Oct 23, 2012
Kind
B2
Abstract

A BLDC electric motor assembly ( 24 ) includes a rotor ( 42 ) having a plurality of magnet segments ( 50 ) securely retained thereabout by an annular ring ( 68 ) which is shrunk in situ in an electromagnetic forming operation. The magnet segments ( 50 ) are formed with tongues ( 62, 64 ) on their upper and lower ends ( 56, 58 ). One tongue ( 64 ) seats in a retaining pocket ( 48 ) molded on the rotor shaft ( 40 ), whereas the other tongue ( 62 ) provides a ledge into which the ring ( 68 ) seats. After the magnet forming operation, wherein the ring ( 68 ) is shrunk, the outer surface of the ring ( 68 ) is flush with the outer surfaces ( 54 ) of the magnet segments ( 50 ).

Claims (15)

1. A method for attaching permanent magnet segments into an operative array on a rotor for a brushless direct current (BLDC) electric motor assembly of the type used in liquid fuel pumps, said method comprising the steps of:

providing a rotary shaft having a hub section with an outer surface;

providing a plurality of permanent magnet segments, each magnet segment having opposing ends;

supporting the magnet segments in an operative position on the outer surface of the hub section;

said step of supporting the magnet segments including arranging the magnet segments side-by-side in equal arcuate increments around the outer surface of the hub;

fabricating an annular ring from an electrically conductive material;

loosely encircling at least one end of the magnet segments with the ring;

and shrinking the ring by inducing therein a current flow using a high energy pulsed magnetic field to squeeze each magnet segment into pressing engagement against the outer surface of the hub and collectively hold the magnet segments in the operative position upon the rotary shaft.

2. The method of claim 1 wherein said step of fabricating an annular ring includes forming the ring from metal.

3. The method of claim 1 wherein said step of fabricating an annular ring includes forming the ring from aluminum or an alloy thereof.

4. The method of claim 1 wherein said step of providing a plurality of permanent magnet segments includes fabricating each magnet segment with a first tongue adjacent one end thereof for receiving the ring.

5. The method of claim 4 wherein said step of providing a rotary shaft includes forming a retaining pocket for receiving one end of each magnet segment.

6. The method of claim 5 wherein said step of providing a plurality of permanent magnet segments includes fabricating each magnet segment with a second tongue adjacent the other end thereof for seating in the retaining pocket.

7. The method of claim 1 wherein said step of providing a plurality of permanent magnet segments includes fabricating each magnetic segment with a convex, semi-cylindrical outer surface.

8. The method of claim 7 wherein said step of fabricating an annular ring includes forming an outer circumferential edge of the ring, and said step of rapidly shrinking the ring includes stopping the shrinkage when the outer circumferential edge of the ring is generally aligned flush with the outer surface of each magnet segment.

Assignments (29)
LIEN Recorded Dec 8, 2025
From: JEFFERIES FINANCE LLC
To: WILMINGTON SAVINGS FUND SOCIETY, FSB
Reel/Frame 073892/0154 →
LIEN Recorded Dec 3, 2025
From: JEFFERIES FINANCE LLC
To: WILMINGTON SAVINGS FUND SOCIETY, FSB
Reel/Frame 073819/0490 →
FIRST LIEN INTELLECTUAL PROPERTY SECURITY AGREEMENT Recorded Jun 18, 2025
From: AIRTEX INDUSTRIES, LLC; AIRTEX PRODUCTS, LP; APC INTERMEDIATE HOLDINGS, LLC; APC PARENT, LLC; ASC INDUSTRIES, INC.; AUTOLITE OPERATIONS LLC; AVM EXPORT, INC.; BPI ACQUISITION COMPANY, LLC; BPI EC, LLC; BPI HOLDINGS INTERNATIONAL, LLC; BRAKE PARTS INC CHINA LLC; BRAKE PARTS INC INDIA LLC; BRAKE PARTS INC LLC; CARDONE INDUSTRIES, INC.; CARRAND COMPANIES, INC.; CARTER CARBURETOR HOLDINGS, LLC; CARTER CARBURETOR, LLC; CARTER FUEL EXPORT, INC.; CARTER FUEL SYSTEMS, LLC; CHAMPION LABORATORIES, INC.; CWD HOLDING, LLC; CWD INTERMEDIATE HOLDINGS I, LLC; CWD INTERMEDIATE HOLDINGS II, LLC; CWD, LLC; DALTON CORPORATION; DALTON CORPORATION, KENDALLVILLE; MANUFACTURING FACILITY DALTON CORPORATION, ASHLAND; MANUFACTURING FACILITY DALTON CORPORATION, STRYKER MACHINING FACILITY CO.; DALTON CORPORATION, WARSAW MANUFACTURING FACILITY; EAGLE CASTING, LLC; EAGLE MACHINING, LLC; FIRST BRANDS GROUP INTERMEDIATE, LLC; FIRST BRANDS GROUP, LLC; FRAM GROUP IP LLC; FRAM GROUP OPERATIONS LLC; FRAMAUTO HOLDINGS, LLC; FUEL FILTER TECHNOLOGIES, INC.; GLOBAL REMAN VENTURES, LLC; HEATHERTON HOLDINGS, LLC; HOPKINS ACQUISITION, INC.; HOPKINS MANUFACTURING CORPORATION; HORIZON EURO FINANCE LLC; HORIZON GLOBAL AMERICAS INC.; HORIZON GLOBAL COMPANY LLC; HORIZON GLOBAL CORPORATION; HORIZON INTERNATIONAL HOLDINGS LLC; IBI INTERNATIONAL HOLDING COMPANY, INC.; INTERNATIONAL BRAKE INDUSTRIES, INC.; JASPER ACQUISITION CORP.; JASPER RUBBER PRODUCTS, INC.; KTRI HOLDINGS, INC.; KTRI OFFSHORE HOLDINGS, LLC; LONGMAN ENTERPRISES, INC.; PHNX ACQUISITION CORP.; PREMIER MARKETING GROUP, LLC; PYLON MANUFACTURING CORP.; PYLON SOUTH BEND, INC.; QUALIS AUTOMOTIVE, L.L.C.; QUALIS ENTERPRISES, LLC; QUALITOR ACQUISITION INC.; QUALITOR AUTOMOTIVE, LLC; QUALITOR SUBSIDIARY H, INC.; QUALITOR SUBSIDIARY S, INC.; QUALITOR, INC.; REMAN MANAGEMENT INTERNATIONAL LLC; SDC TX, LLC; SMART CHOICE, LLC; SPECIALTY PUMPS GROUP, INC.; STRONGARM, LLC; TAE BRAKES, LLC; TAE CHINA HOLDINGS, INC.; TMD INTERNATIONAL HOLDINGS LLC; TMD MEXICO LLC; TOLEDO MOLDING & DIE, LLC; TRANSPORTATION AFTERMARKET ENTERPRISE, LLC; TRICO HOLDING CORPORATION; TRICO PRODUCTS CORPORATION; TRICO TECHNOLOGIES CORPORATION; TRIDONEX USA LLC; UCI ACQUISITION HOLDINGS (NO. 4) LLC; UCI INTERNATIONAL HOLDINGS PARENT, INC.; UCI INTERNATIONAL HOLDINGS, INC.; UCI INTERNATIONAL, LLC; UCI PENNSYLVANIA, INC.; UCI-AIRTEX HOLDINGS, INC.; UNITED COMPONENTS, LLC; UNIVERSAL AUTO FILTER LLC; VIPER ACQUISITION I, INC.; VIPER ACQUISITION, INC.; WALBRO LLC; WALBRO MIDCO LLC; WEM US CO.
To: GLAS USA LLC
Reel/Frame 071674/0688 →
CORRECTIVE ASSIGNMENT TO CORRECT THE THE PATENT APPLICATION NUMBERS PREVIOUSLY RECORDED AT REEL: 053377 FRAME: 0596. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Recorded Dec 19, 2022
From: CREDIT SUISSE AG, CAYMAN ISLANDS BRANCH
To: JEFFERIES FINANCE LLC
Reel/Frame 062584/0429 →
CORRECTIVE ASSIGNMENT TO CORRECT THE INCORRECT PATENT REGISTRATION NUMBERS:8166953, 6673433, 6631292, 7392363, 7265473 8535456, 9709133 PREVIOUSLY RECORDED ON REEL 053377 FRAME 0499. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT OF SECURITY INTEREST. Recorded Apr 9, 2021
From: CREDIT SUISSE AG
To: JEFFERIES FINANCE LLC
Reel/Frame 058292/0469 →
ASSIGNMENT OF SECURITY INTEREST Recorded Jul 31, 2020
From: CREDIT SUISSE AG, CAYMAN ISLANDS BRANCH
To: JEFFERIES FINANCE LLC
Reel/Frame 053377/0499 →
ASSIGNMENT OF SECURITY INTEREST Recorded Jul 31, 2020
From: CREDIT SUISSE AG, CAYMAN ISLANDS BRANCH
To: JEFFERIES FINANCE LLC
Reel/Frame 053377/0596 →
RELEASE OF INTELLECTUAL PROPERTY SECURITY INTEREST Recorded May 25, 2020
From: ACQUIOM AGENCY SERVICES LLC
To: ASC INDUSTRIES, INC.; CARTER FUEL SYSTEMS, LLC; FRAM GROUP IP LLC; STRONGARM, LLC; TRICO PRODUCTS CORPORATION; TRICO GROUP, LLC; TRICO GROUP HOLDINGS, LLC
Reel/Frame 053313/0812 →
SECURITY INTEREST Recorded Apr 23, 2020
From: CARTER FUEL SYSTEMS, LLC
To: ACQUIOM AGENCY SERVICES LLC
Reel/Frame 052481/0512 →
ASSIGNMENT OF SECURITY INTEREST IN INTELLECTUAL PROPERTY RIGHTS Recorded Feb 27, 2019
From: GOLDMAN SACHS BANK USA, AS COLLATERAL AGENT
To: CREDIT SUISSE AG, CAYMAN ISLANDS BRANCH, AS COLLATERAL AGENT
Reel/Frame 048455/0762 →
SECOND LIEN INTELLECTUAL PROPERTY SECURITY AGREEMENT Recorded Feb 27, 2019
From: ASC INDUSTRIES, INC.; CARTER FUEL SYSTEMS, LLC; FRAM GROUP IP LLC; HEATHERTON HOLDINGS, LLC; STRONGARM, LLC; TRICO PRODUCTS CORPORATION
To: CREDIT SUISSE AG, CAYMAN ISLANDS BRANCH, AS COLLATERAL AGENT
Reel/Frame 048887/0495 →
TERMINATION OF SECURITY INTEREST IN PATENTS AT REEL/FRAME 038847/0322 Recorded Feb 6, 2018
From: HPS INVESTMENT PARTNERS, LLC
To: AVM INDUSTRIES, LLC; CARTER FUEL SYSTEMS LLC; TRICO PRODUCTS CORPORATION; PARTHENON METAL WORKS, LLC
Reel/Frame 045261/0321 →
TERMINATION OF SECURITY INTEREST IN PATENTS AT REEL/FRAME 33958/0771 Recorded Feb 6, 2018
From: JPMORGAN CHASE BANK, N.A.
To: TRICO PRODUCTS CORPORATION; AVM INDUSTRIES, LLC; CARTER FUEL SYSTEMS LLC
Reel/Frame 045261/0197 →
ABL INTELLECTUAL PROPERTY SECURITY AGREEMENT Recorded Feb 5, 2018
From: CARTER FUEL SYSTEMS; STRONGARM, LLC; TRICO PRODUCTS CORPORATION
To: GOLDMAN SACHS BANK USA
Reel/Frame 045252/0469 →
RELEASE OF SECURITY INTEREST Recorded Feb 5, 2018
From: HPS INVESTMENT PARTNERS, LLC
To: AVM INDUSTRIES, LLC; TRICO PRODUCTS CORPORATION; CARTER FUEL SYSTEMS, LLC; PARTHENON METAL WORKS, LLC
Reel/Frame 045252/0543 →
FIRST LIEN INTELLECTUAL PROPERTY SECURITY AGREEMENT Recorded Feb 5, 2018
From: CARTER FUEL SYSTEMS; STRONGARM, LLC; TRICO PRODUCTS CORPORATION
To: GOLDMAN SACHS BANK USA
Reel/Frame 045252/0800 →
RELEASE OF SECURITY INTEREST Recorded May 30, 2016
From: JEFFERIES FINANCE LLC
To: TRICO PRODUCTS CORPORATION; AVM INDUSTRIES, LLC; CARTER FUEL SYSTEMS, LLC
Reel/Frame 038847/0400 →
SECURITY INTEREST Recorded May 30, 2016
From: AVM INDUSTRIES, LLC; CARTER FUEL SYSTEMS, LLC; TRICO PRODUCTS CORPORATION; PARTHENON METAL WORKS, LLC
To: HPS INVESTMENT PARTNERS, LLC
Reel/Frame 038847/0322 →
RELEASE OF SECURITY INTEREST Recorded May 30, 2016
From: JEFFERIES FINANCE LLC
To: TRICO PRODUCTS CORPORATION; AVM INDUSTRIES, LLC; CARTER FUEL SYSTEMS, LLC
Reel/Frame 038847/0154 →
RELEASE OF SECURITY INTEREST Recorded Oct 13, 2014
From: JPMORGAN CHASE BANK, N.A.
To: CARTER FUEL SYSTEMS, LLC; AVM INDUSTRIES, LLC
Reel/Frame 033974/0133 →
SECURITY INTEREST Recorded Oct 10, 2014
From: TRICO PRODUCTS CORPORATION; AVM INDUSTRIES, LLC; CARTER FUEL SYSTEMS, LLC
To: JPMORGAN CHASE BANK, N.A., AS ADMINISTRATIVE AGENT
Reel/Frame 033958/0771 →
RELEASE OF SECURITY INTEREST IN PATENTS AND TRADEMARKS Recorded Oct 6, 2014
From: MWV PINNACLE CAPITAL FUND, L.P.
To: CARTER FUEL SYSTEMS, LLC
Reel/Frame 033897/0135 →
SECURITY INTEREST Recorded Oct 2, 2014
From: TRICO PRODUCTS CORPORATION; AVM INDUSTRIES, LLC; CARTER FUEL SYSTEMS, LLC
To: JEFFERIES FINANCE LLC, AS SECOND LIEN TERM LOAN ADMINISTRATIVE AGENT
Reel/Frame 033886/0719 →
SECURITY INTEREST Recorded Oct 2, 2014
From: TRICO PRODUCTS CORPORATION; AVM INDUSTRIES, LLC; CARTER FUEL SYSTEMS, LLC
To: JEFFERIES FINANCE LLC, AS FIRST LIEN TERM LOAN ADMINISTRATIVE AGENT
Reel/Frame 033886/0695 →
SECURITY AGREEMENT Recorded Oct 18, 2013
From: CARTER FUEL SYSTEMS, LLC
To: MWV PINNACLE CAPITAL FUND, L.P.
Reel/Frame 031436/0508 →
SECURITY AGREEMENT Recorded Oct 8, 2013
From: AVM INDUSTRIES, LLC; CARTER FUEL SYSTEMS, LLC
To: JP MORGAN CHASE BANK, N.A.
Reel/Frame 031393/0769 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 3, 2013
From: FEDERAL-MOGUL CORPORATION
To: CARTER FUEL SYSTEMS, LLC
Reel/Frame 031334/0429 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Sep 20, 2013
From: FEDERAL-MOGUL WORLD WIDE, INC.
To: FEDERAL-MOGUL CORPORATION
Reel/Frame 031246/0838 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 7, 2011
From: ACHOR, KYLE D.
To: FEDERAL-MOGUL WORLD WIDE, INC.
Reel/Frame 025910/0850 →