Inductor windings forming apparatus and method of manufacturing inductors

An inductor formed according to a method comprising:

• forming a first portion and a second portion of a clamshell casing,
• wherein the first portion comprises a first set of electrically conductive segments, a first inner carrier, and a first outer carrier, wherein the first set of electrically conductive segments are held in a first pattern in the first portion by the first inner carrier and the first outer carrier, and
• wherein the second portion comprises a second set of electrically conductive segments, a second inner carrier, and a second outer carrier, wherein the second set of electrically conductive segments are held in a second pattern that is symmetric to the first pattern, using the second inner carrier and the second outer carrier;
• placing an inductor core on the first set of electrically conductive segments between the first inner carrier and the first outer carrier within the first portion;
• joining the first portion with the second portion of the clamshell casing such that the first set of electrically conductive segments in the first pattern are attached to the second set of electrically conductive segments in the second pattern that is symmetric to the first pattern;
• and
• removing the first outer carrier, the second outer carrier, the first inner carrier, and the second inner carrier from the joined first portion and the second portion of the clamshell casing to form continuous turns of inductor windings around the inductor core.

An inductor formed according to a method comprising:

• forming a first portion and a second portion of a clamshell casing,
• wherein the first portion comprises a first set of electrically conductive segments and a first carrier, wherein the first set of electrically conductive segments are held in a first pattern in the first portion by the first carrier, and
• wherein the second portion comprises a second set of electrically conductive segments in a second pattern;
• placing an inductor core on the first set of electrically conductive segments adjacent to the first carrier within the first portion;
• joining the first portion with the second portion of the clamshell casing such that the first set of electrically conductive segments are attached to the second set of electrically conductive segments;
• and
• removing the first carrier to form continuous turns of inductor windings around the inductor core.