Method of forming a stator core assembly

A method of forming a stator core assembly comprising:

• providing an inner core having a bore defined therethrough and a plurality of first connector structures defined generally axially thereof on an outer peripheral surface thereof;
• providing a plurality of tooth structures, each said tooth structure being formed from pre-stacked laminations;
• securing at least one tooth structure to each said first connector structure whereby each said tooth structure is secured to said inner core and projects radially outwardly therefrom, thereby defining radial and axial slots therebetween for receiving generator winding structures;
• disposing at least one winding structure in each said slot;
• fixedly securing an outer core to radially outer ends of said tooth structures, wherein the outer core is formed from pre-stacked laminations, said securing comprising mounting at least two tooth structures axially adjacent one another on the outer surface of the inner core along each said first connector structure;
• and
• disposing a stiffener between each said axially adjacent tooth structures, wherein said stiffener comprises a plurality of circumferentially spaced tooth portions, said tooth portions being interconnected with connecting portions.