Inductor apparatus optimized for low power loss in class-D audio amplifier applications and method for making the same

An inductor, comprising:

• a first ferrite core piece and a second ferrite core piece, each of which are fashioned in a substantially similar manner and shape, and wherein
• each of the first and second ferrite core pieces comprises
• a substantially planar mating surface,
• a center post, and
• a wire core assembly channel comprising an inner channel wall, outer channel wall, and channel floor, the inner channel wall comprising an outer surface of the center post, and wherein
• a first substantially planar mating surface of the first ferrite core piece is adapted to planarly mate with a second substantially planar mating surface of the second ferrite core piece;
• and
• a wire core assembly adapted to be substantially self-locating and self-centering about a first or second center post when located in a respective first or second wire core assembly channel, wherein
• such self-locating and self-centering occurs through operation of a spring-like characteristic built into the wire core assembly, and further wherein when the wire core assembly is located about the first or second center post, an outer surface of the wire core assembly is mated to a portion of the outer channel wall.

An inductor, comprising:

• a first ferrite core piece and a second ferrite core piece, each of which are fashioned in a substantially similar manner and shape, and wherein
• each of the first and second ferrite core pieces comprises
• a substantially planar mating surface,
• a center post, and
• a wire core assembly (WCA) channel, wherein the WCA channel surrounds the center post, and comprises
• a WCA channel inner wall that is also a center post radial outer wall;
• a WCA channel outer wall that comprises a substantially circular portion and two substantially linear portions, and wherein the substantially circular portion is centered between and in contact with the two substantially linear portions to form a substantially smooth wall surface, and wherein the substantially circular portion comprises a WCA channel outer wall radius;
• and
• a substantially planar WCA channel surface;
• and
• a WCA made of substantially flat wire, formed as a coil, the coil comprising
• a coiled portion,
• a first lead, and
• a second lead, and wherein
• the first and second leads extending from the coiled portion, and further wherein
• the wire core assembly formed as a spring and with such dimensions that when the first lead and second lead are pulled towards each other, the wire core assembly is adapted to be substantially self-locating and self-centering about a first or second center post when located in a respective first or second wire core assembly channel.