Other

Steve Schiffer

Grant A MacLennan

Hans Wennerstrom

Matt Cotner

Saul Gonzalez

The invention comprises a method of: providing an inductor core, placing a winding guide within an inch of the inductor core, positioning a first turn element with the winding guide, positioning a second turn element with the winding guide, and mechanically coupling the first turn element to the second turn element to form at least a part of a winding, the winding forming a wrapped shape about the inductor core. Optionally and preferably, turn elements are subsequently joined, mechanically coupled, and/or welded together to form sections of the winding.

Inductor winding guide apparatus and method of use thereof

The invention comprises an apparatus, comprising an inductor, the inductor comprising: an inductor core; a first winding section comprising a first cast shape and a second winding section comprising the first cast shape, the first winding section mechanically joined to the second winding section to form a winding, the winding forming a wound shape about the inductor core. Optionally and preferably, a third winding section, comprising a second cast shape, mechanically joins the first winding section to the second winding section and a mechanical connector and/or an aluminum weld join the first winding section to the third winding section.

Cast winding inductor apparatus and method of use thereof

The invention comprises an apparatus, comprising: a toroid shaped inductor and a cooling jacket including at least two sections joined to encase the toroid shaped inductor, where the cooling jacket has an inner toroid shaped surface separated by a coolant flow gap from the toroid shaped inductor. Optionally, the inductor comprises a cast winding, a cast heat sink element of the cast winding protruding from a longitudinal length of a turn of the winding, and/or a distributed gap pressed powder inductor core.

Cooled / cast inductor apparatus and method of use thereof

The invention comprises a method for manufacturing an inductor, comprising the steps of: casting a cast winding comprising an inner cavity; inserting a first inductor core subsection into the inner cavity; inserting a second inductor core subsection into the inner cavity; and mechanically coupling the first inductor core subsection to the second inductor core subsection to form an inductor core wound by the cast windings. The method of manufacturing optionally includes the steps of: forming at least a portion of the cast winding into an arced helical shape; forming the first inductor core subsection and the second inductor core subsection into elements of a torpid shaped inductor core; deforming the cast winding to physically allow the step of inserting the first inductor core subsection into the inner cavity; and/or deforming at least a portion of the cast winding into an arced helical coil shape after the step of inserting.

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Waddell, AZ, United States of America

Steve Schiffer