Abstract: The invention comprises an apparatus, comprising: an inductor, comprising: an inductor core and a winding comprising a wound shape around the inductor core, where the winding comprises a first cross-sectional area at a first longitudinal position along the winding and a second cross-sectional area at a second longitudinal position along the winding, the second cross-sectional area at least twenty percent larger than the first cross-sectional area. Optionally and preferably, the winding includes a first set of cast elements sharing a first geometric shape and a second set of cast elements sharing a second geometric shape, where the alternating members of the first set of cast elements and the second set of cast elements are welded together to form the winding.

Abstract: 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.

Abstract: The invention comprises a method for manufacturing an inductor, comprising the steps of: casting a first cast winding section; casting a second cast winding section; and mechanically coupling the first cast winding section to the second cast winding section to form a section of a winding about a core of the inductor. Optionally, a first end of a connector section is welded to the first cast winding section and a second end of the connector section is welded to the second cast winding section, where the first and second cast winding sections have a common cast shape.

Abstract: The invention comprises a method, including the steps of: providing an inductor core and longitudinally joining a first electrical turn section to a second electrical turn section to form at least part of an electrical turn of a winding about the inductor core and optionally including at least one of the steps of: (1) additive manufacturing, casting, stamping from metal stock, cutting material, and/or bending metal to form the first electrical turn section and/or (2) welding and/or mechanically joining the first electrical turn section to the second electrical turn section.

Abstract: The invention comprises a method for forming an inductor, comprising the steps of: providing an inductor core and fastening at least ten sections of a winding together to form a winding, the winding comprising a formed wound shape about the inductor core. Optionally and preferably the step of fastening repeats steps of joining a member of a first set of winding parts to an element of a second set of winding parts, where the two sets of winding parts have different cast or formed shapes.

Abstract: 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.

Abstract: The invention comprises an apparatus, comprising: an inductor, the inductor comprising: an electrical turn about an inductor core, the inductor core comprising a ring shape; the electrical turn comprising a first width at a first radial distance from a center of the inductor core and a second width at a second radial distance from the center, the second width at least ten percent larger than the first width. Optionally and preferably, the electrical turn comprises: a first cast element and a second cast element and a mechanical connection connecting the first cast element to the second cast element, such as an aluminum weld.

Abstract: 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.

Abstract: The invention comprises a multi-inductor mounting/cooling apparatus and method of use thereof comprising: an elongated tube having a first elongated section and a second elongated section separated by at least a first longitudinal split down a length of the elongated tube and at least three inductors affixed to a baseplate, the at least three inductors positioned within the elongated tube, the at least three inductors comprising a plurality of connectors extending radially outward through at least one aperture formed between the first elongated section and the second elongated section. Optionally and preferably a fan is positioned within and/or at an end of the elongated tube.

Abstract: The invention comprises a harmonic filter apparatus and method of use thereof, the harmonic filter including a delta circuit comprising: (1) a first leg connecting a first apex to a second apex of the delta circuit; a second leg connecting the second apex to a third apex of the delta circuit; and a third leg connecting the third apex to the first apex and (2) a first capacitor and a second capacitor wired in parallel within the first leg of the delta circuit. Optionally and preferably, each apex of the delta circuit is connected to individual phases of three phase power via respective inductor—coupled inductor pairs, where the harmonic filter magnetically isolates individual phases of the three phase power.

Abstract: The invention comprises a method for fastening an inductor, comprising an aperture therethrough, to a mounting surface with a set of at least two mechanical straps and a strap force of ten to one hundred pounds of force per strap, the step of fastening further comprising the step of: passing at least a first portion of each of a first and second mechanical strap of the set of mechanical straps through the aperture and on opposing sides of the aperture, the first portion comprising a non-conductive material, where the inductor winding is fabricated during installation and/or the inductor is a component of a harmonic filter magnetically isolating and filtering individual phases of three phase power.

Abstract: 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.

Abstract: The invention comprises an apparatus, comprising: an inductor comprising a cast winding and/or a cast heat sink element of the cast winding protruding from a longitudinal length of a turn of the winding wrapped around an inductor core, such as a distributed gap/pressed powder inductor core. Optionally, the inductor comprises a toroid shape, is cooled using a cooling jacket with a toroid shaped void therein, and/or is wrapped with an arced helical shaped cast winding, which is optionally deformable for insertion of the inductor core in sections.

Abstract: 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.