Patent ID: 9558881
Date: 2017-01-31
CPC Classifications: H01F

Claim:
1. A surface mount power inductor, comprising: a first shaped-core piece and a second shaped-core piece each fabricated from a magnetically soft powder material, the first shaped-core piece and the second shaped-core piece being separately and independently fabricated from one another; a preformed C-shaped conductive winding clip separately fabricated from either of the first shaped-core piece and the second shaped-core piece; wherein the winding clip includes a main winding section, first and second legs extending from opposing ends of the main winding section, and first and second terminal lead sections extending from the respective first and second legs; wherein the first shaped-core piece is asymmetrical and includes a bottom surface defined by opposing first and second side edges and opposing first and second end edges interconnecting the first and second side edges, wherein the first end edge is longer than the second end edge, the first and second side edges include a respective first and second recess, and the first shaped-core piece further including an upper surface and groove in the upper surface; wherein the preformed C-shaped conductive winding clip is coupled to the first shaped-core piece without bending any portion of the winding clip around the first shaped-core piece and the first and second terminal lead sections being received in the respective first and second recess; wherein the second shaped-core piece is coupled to the first shaped-core piece to complete the power inductor; and wherein the main winding section of the preformed C-shaped conductive winding clip extends between the first shaped-core piece and the second shaped-core piece.