Patent ID: 7788790

Claim:
A method of forming a stator core comprising: providing a generally cylindrically-shaped stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof, the core slots extending between a first and a second end of the stator core; providing a stator winding having a plurality of phases, each phase comprised of at least one conductor having a plurality of slot segments housed in the core slots, the slot segments alternately connected at the first and second ends of the stator core by the plurality of end loop segments; providing a plurality of insulators; placing one insulator within each of the core slots; securing the insulators within the core slots by inserting tooling into the core slots such that the insulator is disposed between the tooling and at least one side of the core slots thereby pressing the insulator to the at least one side of the core slot; and inserting the slot segments into said core slots radially inboard of the tooling.