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

A method for assembling an inductor, the method comprising:

• (a) obtaining first and second ferrite core pieces, 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 centered between and in contact with two substantially linear portions to form a substantially continuous outer wall, and wherein
• the substantially circular portion comprises a WCA channel outer wall radius;
• and
• a substantially planar WCA channel surface;
• (b) obtaining a WCA,
• the WCA adapted to be compressible from a first outer radius to a second outer radius, and
• the WCA comprising a substantially cylindrical outer radial surface and a substantially cylindrical inner radial surface;
• (c) compressing the WCA from the first outer radius to the second outer radius, wherein the second outer radius is less than the WCA channel outer wall radius, and the first outer radius is greater than the WCA channel outer wall radius;
• and
• (d) inserting the compressed WCA into the substantially planar WCA channel about the center post of either the first or second ferrite core piece.