Continuous radially inserted stator winding

A stator for an electric machine, the stator comprising:

• an inner diameter and an outer diameter;
• first and second end faces;
• a plurality of stator teeth extending inward toward the inner diameter;
• a plurality of slots each formed between adjacent stator teeth of the plurality of stator teeth, the plurality of slots extending between the first and second end faces and at least partially open along the inner diameter;
• and
• a continuous winding passing successively through at least three slots of the plurality of slots, the continuous winding comprising a conductor having a rectangular cross-section defining at least a first exterior face of the conductor, the winding positioned in each of the at least three slots with the first exterior face facing the inner diameter.

A continuous stator winding comprising:

• a conductor having a rectangular cross-section defining first, second, third, and fourth exterior faces of the conductor, the first exterior face opposing the second exterior face, the third exterior face opposing the fourth exterior face;
• a plurality of linear segments formed in the conductor, each linear segment of the plurality of linear segments positioned parallel to the other linear segments of the plurality of linear segments;
• and
• a plurality of crowns formed in the conductor, each crown of the plurality of crowns comprising first and second straight segments joined by a bent segment and connecting successive linear segments of the plurality of linear segments such that, when the conductor is radially wound, the first exterior face of each of the plurality of linear segments faces inward.

A method of manufacturing a stator for an electric machine, the method comprising:

• providing a stator having:
• an inner diameter and an outer diameter,
• first and second end faces,
• a plurality of stator teeth extending inward toward the inner diameter, and
• a plurality of slots each formed between adjacent stator teeth of the plurality of stator teeth, the plurality of slots extending between the first and second end faces and at least partially open along the inner diameter;
• forming a continuous winding, wherein the forming comprises:
• providing a conductor having a rectangular cross-section, the rectangular cross-section defining first, second, third, and fourth exterior faces of the conductor, wherein the first exterior face opposes the second exterior face and the third exterior face opposes the fourth exterior face, and
• shaping the conductor to form a plurality of crowns and a plurality of linear segments, wherein pairs of successive linear segments of the plurality of linear segments are connected by a crown of the plurality of crowns;
• wrapping the continuous winding into a circular configuration;
• and
• radially inserting the continuous winding into corresponding slots of the plurality of slots such that, for each linear segment of the plurality of linear segments, the first exterior face faces the inner diameter of the stator.