Patent Publication Number: US-10325715-B2

Title: Low profile electromagnetic component

Description:
BACKGROUND OF THE INVENTION 
     The field of the invention relates generally to electromagnetic components such as inductors, and more particularly to miniaturized, surface mount power inductor components for circuit board applications. 
     Power inductors are used in power supply management applications and power management circuitry on circuit boards for powering a host of electronic devices, including but not necessarily limited to hand held electronic devices. Power inductors are designed to induce magnetic fields via current flowing through one or more conductive windings, and store energy via the generation of magnetic fields in magnetic cores associated with the windings. Power inductors also return the stored energy to the associated electrical circuit as the current through the winding and may, for example, provide regulated power from rapidly switching power supplies. 
     Recent trends to produce increasingly powerful, yet smaller electronic devices have led to numerous challenges to the electronics industry. Electronic devices such as smart phones, personal digital assistant (PDA) devices, entertainment devices, and portable computer devices, to name a few, are now widely owned and operated by a large, and growing, population of users. Such devices include an impressive, and rapidly expanding, array of features allowing such devices to interconnect with a plurality of communication networks, including but not limited to the Internet, as well as other electronic devices. Rapid information exchange using wireless communication platforms is possible using such devices, and such devices have become very convenient and popular to business and personal users alike. 
     For surface mount component manufacturers for circuit board applications required by such electronic devices, the challenge has been to provide increasingly miniaturized components so as to minimize the area occupied on a circuit board by the component (sometimes referred to as the component “footprint”) and also its height measured in a direction parallel to a plane of the circuit board (sometimes referred to as the component “profile”). By decreasing the footprint and profile, the size of the circuit board assemblies for electronic devices can be reduced and/or the component density on the circuit board(s) can be increased, which allows for reductions in size of the electronic device itself or increased capabilities of a device with comparable size. Miniaturizing electronic components in a cost effective manner has introduced a number of practical challenges to electronic component manufacturers in a highly competitive marketplace. Because of the high volume of components needed for electronic devices in great demand, cost reduction in fabricating components has been of great practical interest to electronic component manufacturers. 
     In order to meet increasing demand for electronic devices, especially hand held devices, each generation of electronic devices need to be not only smaller, but offer increased functional features and capabilities. As a result, the electronic devices must be increasingly powerful devices. For some types of components, such as magnetic components that provide energy storage and regulation capabilities, meeting increased power demands while continuing to reduce the size of components that are already quite small, has proven challenging. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Non-limiting and non-exhaustive embodiments are described with reference to the following Figures, wherein like reference numerals refer to like parts throughout the various drawings unless otherwise specified. 
         FIG. 1  is an exploded view of an exemplary electromagnetic surface mount, power inductor component shown in  FIG. 1 . 
         FIG. 2  is an elevational view of the conductive winding for surface mount, power inductor component shown in  FIG. 1 . 
         FIG. 3  is a perspective view of the conductive winding shown in  FIG. 2 . 
         FIG. 4  is a top plan view of a first core piece for the surface mount, power inductor component shown in  FIG. 1 . 
         FIG. 5  is a perspective view of the first core piece shown in  FIG. 4 . 
         FIG. 6  is an assembled view of the surface mount, power inductor component shown in  FIG. 1 . 
         FIG. 7  is a first alternative core piece and conductive winding structure for the inductor component shown in  FIG. 1 . 
         FIG. 8  is a second alternative core piece and conductive winding structure for the inductor component shown in  FIG. 1 . 
         FIG. 9  is a third alternative core piece and conductive winding structure for the inductor component shown in  FIG. 1 . 
         FIG. 10  is a fourth alternative core piece and conductive winding structure for the inductor component shown in  FIG. 1 . 
         FIG. 11  is a fifth alternative core piece and conductive winding structure for the inductor component shown in  FIG. 1 . 
         FIG. 12  is a sectional view of a known surface mount, power inductor component. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Exemplary embodiments of inventive electromagnetic component assemblies and constructions are described below for higher current and power applications having lower profiles while offering comparable performance to existing electromagnetic components having much larger profiles on a circuit board. Electromagnetic components and devices such as power inductors components may also be fabricated with reduced cost compared to other known miniaturized power inductor constructions. Manufacturing methodology and steps associated with the devices described are in part apparent and in part specifically described below but are believed to be well within the purview of those in the art without further explanation. 
       FIG. 12  illustrates a known construction in sectional view of an electromagnetic component  100 , and more specifically a power inductor component that performs acceptably in its magnetic and electrical characteristics in an electrical power system. In the example shown in  FIG. 12 , the inductor component  100  includes a first magnetic core piece  102  including a U-shaped groove  104  that receives a single turn, C-shaped conductive winding clip  106  and a second magnetic core piece  108  that is assembled with the first core piece  102 . By virtue of the shape of the first magnetic core piece  102  it is sometimes referred to by those in the art as a U-core, and by virtue of the shape of the second magnetic core piece  108  it is sometimes referred to by those in the art as an I-core. The I-core  108  may be gapped from the U-core  102  as shown, and in combination the core pieces  102  and  108  produce a low profile height H 1  that is realized at least in part because of the construction of the conductive winding clip  106 . 
     The conductive winding clip  106  includes as shown a planar center main winding section  110  that extends as a straight line across the core piece  102 , first and second legs  112 ,  114  and surface mount terminal sections  116 ,  118  depending from each respective leg  112 ,  114 . The legs  112 ,  114  extend perpendicularly to a plane of the planar main winding section  110 , and the surface mount terminal sections  116 ,  118  extend perpendicularly from the respective legs  112 ,  114 . As such, the planar main winding section  110  extends horizontally in the winding clip  106  and the surface mount terminal sections  116 ,  118  also extend horizontally parallel to the main winding section  110 . When the surface mount terminal sections  116 ,  118  are mounted to circuit traces  120 ,  122  on a circuit board  126 , the main winding section  110  and the surface mount terminal sections  116 ,  118  also extend parallel to the plane of the circuit board  126 . The legs  112 ,  114 , however, extend perpendicular to the plane of the circuit board  126  as well as the planar main winding section  110  and the surface mount terminal section  116 ,  118  of the winding clip  106 . The general orthogonal arrangement of the sections  110 ,  112 ,  114 ,  116  and  118  imparts a C-shaped appearance to the winding clip  106 . 
     The winding clip  106  may be fabricated from a freestanding, elongated strip of conductive material that is shaped into the C-shaped winding clip  106  as shown in the sectional view of  FIG. 12 . The elongated strip of conductive material has a thickness dimension t, a width dimension w that is much larger than the thickness dimension t, and a length dimension equal to the combined axial length of the sections  110 ,  112 ,  114 ,  116  and  118 . In the winding clip  106 , the thickness of the conductor in the center main winding section  110  is oriented to extend vertically or perpendicularly to the plane of the circuit board  126 . The proportions of the elongated strip of conductive material used to make the winding clip  106 , as well as the smaller proportions of the axial length of the legs  112 ,  114  relative to the axial length of the main winding section  110 , a low profile winding clip  106  facilitates the low profile height H 1  of the component  100  as well as facilitates an efficient power inductor capable of handling higher current with acceptable direct current resistance (DCR) performance and saturation current relative to other types of inductor components having alternative types of coil structures. 
     While the component  100  delivers an increased power capability in a smaller package size than previous electromagnetic components, still further reduction in the low profile height H 1  is desired for state of the art electronic devices, but while otherwise offering comparable performance to the inductor component  100 . More specifically, a reduction in the low profile height H 1  of the component  100  of about 50% is desired. While such 50% reduction in the low profile height H 1  may be accomplished following the design concept shown and described, it requires a much longer length of the elongated conductive strip used to make winding clip  106  in order to keep the saturation current of the component about the same. Specifically, if the low profile height H 1  is reduced by ½ the elongated strip to make the winding clip  106  must double in length to provide the same high current capability as before. However, doubling length of the conductor in the winding clip of the component undesirably increases DCR to about twice that of the component  100 . Doubling the length of the conductor in the winding clip  106  would also greatly expand the footprint of the component. Another solution is therefore needed. 
     Exemplary embodiments of electromagnetic component constructions are described herein below that facilitate a significant reduction in the low profile height H 1  of the component  100  by 50% without while maintaining the footprint of the component  100 , while maintaining the same saturation current of the winding clip  106 , and while offering comparable DCR in operation relative to the component  100 . This is accomplished at least in part with two or more series connected conductors in the coil winding structure, one of which has a reduced cross sectional area relative to the other such that DCR can be maintained. Lower profile magnetic core pieces are shaped to receive the two or more series connected conductors, such that the low profile height of the completed component can therefore be reduced without significantly increasing the length and width of the component (i.e., the component footprint) relative to the component  100 . 
       FIG. 1  is a top perspective view of a first exemplary embodiment of a surface mount, electromagnetic component  200  and  FIG. 6  is a completed view of the component  200  that advantageously achieves the benefits described above. As described below, the component  200  is configured as a power inductor component, although other types of electromagnetic components may benefit from the teachings described below, including but not limited to inductor components other than power inductors, and also including transformer components. 
     As shown in  FIGS. 1 and 6 , the component  200  generally includes a magnetic core  202  defined by a first core piece  204  and a second core piece  206 . A conductive coil winding  208  is contained in the first core piece  206  and is covered by the second magnetic core piece  206 . In combination, the core pieces  204 ,  206  and coil winding  208  impart on overall length L of the magnetic core  202  along a first dimension such as an x axis of a Cartesian coordinate system. Each core piece  204 ,  206  also has a width W measured along a second dimension perpendicular to the first axis such as a y axis of a Cartesian coordinate system, and a low profile height H 2  measured along a third dimension perpendicular to the first and second axis such as a z axis of a Cartesian coordinate system. In the example of  FIGS. 1 and 6 , the dimensions L and W are much greater than the dimension H 2 , such that when the component  200  is surface mounted on a circuit board  210  in the x, y plane the component  200  has a small height dimension H 2  along the z axis facilitating use of the circuit board  210  to provide a slim electronic device. Relative to the component  100 , ( FIG. 12 ) the dimensions L and W of the component  200  are about the same as the corresponding dimensions of the component  100 , while the height dimension H 2  of the component  100  is about ½ the height dimension H 1  of the component  100 . In the x, y plane the length L and width W of the core  202  formed by the combination of the core pieces  204 ,  206  allows the component to capably handle higher current, higher power applications commensurate with the component  100  but beyond the limits of more conventional electromagnetic component constructions having a comparable low profile height H 2 . 
     The coil winding  208  ( FIGS. 1-3 ) includes a center main winding section  220  and terminal sections  222 ,  224  on either side of the center main winding section  220 . The terminal sections  222 ,  224  are connected in series with the center main winding section  220 . The center section  220  is fabricated from a first freestanding, elongated strip of conductive material having a first height dimension H 3  and each of the terminal sections  222 ,  224  are fabricated from an elongated strip of conductive material having a second height dimension H 4  that is greater than the first height dimension H 3 . The conductor material of the center section  220  and terminal sections  222 ,  224  have approximately the same thickness t 1  in the example shown, although they may each have a different thickness in an another embodiment as desired. The increased height dimension H 4  of the terminal sections  222 ,  224  provides a larger cross sectional area of the conductor in the terminal sections  222 ,  224  and a smaller cross sectional area in the center section such that DCR is maintained at the desired level. The increased height dimension H 4  of the terminal sections  222 ,  224  further allows the terminal sections  224 ,  226  to reach the circuit board  210  in the completed component for surface mounting while the center main winding section  220  is elevated from the board  210  on the first magnetic core piece  204 . As seen in the example of  FIGS. 1 and 3 , a top edge of the conductor in the center main winding section  220  and a top edge of the terminal sections  222 ,  224  are coplanar, while the bottom edge of the conductor in the terminal sections  224 ,  224  are parallel to but spaced from the bottom edge of the center main winding section  220 . 
     Relative to the coil winding clip  106  in the component  100 , the center main winding section  220  of the coil winding  208  in the component  200  is relatively large in the height dimension as the thickness t 1  ( FIG. 2 ) of the conductor used to make the coil winding  208  is oriented to extend in a horizontal direction extending parallel to the circuit board  210 . In the component  100  ( FIG. 12 ), the thickness of the center main winding section  110  is oriented to extend vertically or perpendicular to the plane of the circuit board  126 . Alternatively stated, the length and width plane of the conductor in the main winding section  110  in the component  100  extends generally parallel to the plane of the circuit board  126 , whereas in the center main winding section  220  of the component  200 , the length and width planes of the conductor extends perpendicular to the plane of the circuit board  210 . The orientation of the conductor thickness t 1  in the component  200  contributes to the low profile height H 2  of the component  200 . 
     As best shown in  FIG. 2 , and unlike the main winding section  110  in the component  100 , the center main winding section  220  of the component  200  in the illustrated example includes a series of straight conductor sections  230 ,  232 ,  234 ,  236  and  238 . Each adjacent one of the straight conductor sections  230 ,  232 ,  234 ,  236  and  238  is connected by an angular bend  240 ,  242 ,  244  and  246 . In the example shown, the angular bends  240 ,  242 ,  244  and  246  are each right angle, 90° bends. The straight conductor sections  230 ,  238  are shown to be generally aligned and coplanar to one another to respectively extend a first axial distance from each terminal section  222 ,  224 . The straight conductor sections  232 ,  236  in the example shown extend in a spaced apart and parallel orientation to one another and perpendicularly to the straight conductor sections  230 ,  238  for a second axial distance larger than the first axial distance. The straight conductor section  234  extends between and generally perpendicular to the straight conductor sections  232 ,  236  and parallel to the straight conductor sections  230 ,  238 . The center main winding section  208  in this example is symmetrical and defines a serpentine winding path between the terminal sections  222 ,  224  that are each provided as straight and flat conductor plates. 
     The shape and geometry of the center section  220  and the conductor plates  222 ,  224  provides for an economical manufacture and ease of assembly with the first core piece  204  as further described below. The shape and geometry of the center section  220  may vary, however, in alternative embodiments as desired. That is, the angular bends need not be 90° and curved conductor sections, as opposed to straight conductor sections, may be utilized in alternative embodiments. The conductive winding  208  including the center main winding section  220  and the terminal sections  222 ,  224  may be pre-formed as a separate stage of manufacture and provided for assembly with the magnetic core pieces  204  and  206 . 
     As shown in  FIGS. 1, 4 and 5 , the first magnetic core piece  204  includes a bottom wall or surface  250 , a top wall or surface  252  opposing the bottom wall or surface  250 , a first set of opposing lateral walls or surfaces  254  and  256 , and a second set of walls or surface  258  and  260 . The walls  254 ,  256  and  258 ,  260  are orthogonally arranged such that the core piece  204  is generally rectangular in its outer appearance. The top surface  252  in the example shown is defined by longitudinally extending rectangular posts  262 ,  264  that are spaced apart and extend generally parallel to one another for a distance less than the distance between the lateral side walls  254 ,  256 . In between the rectangular posts  262 ,  264  is a third rectangular post  266  that extends parallel to the posts  262 ,  264  for a distance less than the distance between the side walls  254 ,  256 . The post  266  is longitudinally staggered or offset from the posts  262 ,  264  such that a recess is provided between an end  270  of the post  226  and the side wall  254 , and a recess is likewise provided between respective ends  272 ,  274  of the posts  262 ,  264  and the side wall  256 . 
     The staggered posts  262 ,  264 ,  266  define a groove  280  ( FIG. 4 ) extending therebetween and in the recesses at each end of the posts  262 ,  264 ,  266  described above. The groove  280  accordingly includes segments  282 ,  284 ,  286 ,  288  and  290  that dimensionally and geometrically receive the conductor sections of the center main winding section  220  described above as the component  200  is assembled. The core piece  204  may be pre-formed at a separate stage of manufacture and may be provided for assembly with the coil winding  208 . 
     As shown in  FIGS. 1 and 6 , when the coil winding  208  is assembled to the first core piece  204 , the conductor section  230  is exposed in the groove segment  286  on the lateral side wall  254 , the terminal sections  222 ,  224  run alongside the opposed lateral side walls  258 ,  260  of the core piece  204  for the entire length between the walls  254 ,  256 . Alternative geometry and proportions of the terminal sections  222 ,  224  may be utilized in another embodiment. Also, in alternative embodiments a conductor section of the center main winding section  220  need not be exposed on an exterior side of the core piece  204 . 
     The assembly of the component  200  is completed by coupling the second magnetic core piece  206  to the core piece  204  after the center main winding section  220  is received in the groove  280  of the core piece  204  with the terminal sections  222 ,  224  extending exterior to the core piece  204  as shown and described. In the illustrated example, the core piece  206  is a rectangular, flat plate that does not include any grooves, slots or openings and is therefore economically manufactured with a minimal low profile height. The core piece  206 , however, could assume an alternative shape in another embodiment. The core piece  206  may be fabricated at a separate stage of manufacture and provided for assembly with the first coil piece  204  and the coil winding  108 . 
     The core pieces  204 ,  206  may be defined and shaped utilizing soft magnetic particle materials and known techniques such as molding of granular magnetic particles to produce the desired shape. Soft magnetic powder particles used to fabricate the core pieces  204 ,  206  may include Ferrite particles, Iron (Fe) particles, Sendust (Fe—Si—Al) particles, MPP (Ni—Mo—Fe) particles, HighFlux (Ni—Fe) particles, Megaflux (Fe—Si Alloy) particles, iron-based amorphous powder particles, cobalt-based amorphous powder particles, and other suitable materials known in the art. Combinations of such magnetic powder particle materials may also be utilized if desired. The magnetic powder particles may be obtained using known methods and techniques. The magnetic powder particles may be coated with an insulating material such that the core pieces  204 ,  206  possess-so called distributed gap properties. The core pieces  204 ,  206  may also be physically gapped from one another in a known manner. 
     In the completed component, the terminal sections  222 ,  224  may be surface mounted to circuit traces  292 ,  294  on the circuit board  210  using known soldering techniques. The low profile height H 2  is about ½ of the low profile height H 1  of the component  100  while providing about the same footprint on the board  100  and with similar saturation current and DCR performance characteristics. 
       FIG. 7  shows a construction of an electromagnetic component  300  that is similar in aspects to the component  200  described above. In the component  300 , the core piece  204  is formed with an additional post  302  that is staggered from the posts  262 ,  264  with the post  266 . The center main winding section  220  of the coil winding  208  further includes additional bends  304  and  306  and additional conductor sections  308 ,  310  extending from the conductor section  230 . As such, the serpentine path of the center main winding section  220  in the component  300  is larger than in the component  200 . The component  300  is accordingly operable with a higher inductance value than the component  200 . Additional conductor segments and bends may be provided in the center main winding section  220  to produce components with still further performance variations to meet a variety of different needs in different power systems, or at different locations in an electrical power system. The core piece  204  in the component  300  is larger than in the component  200  and the component  300  accordingly has a larger footprint on a circuit board, but when completed with an appropriately dimensioned core piece  206  it may have about the same low profile height H 2  of the component  200 . Additional conductor segments and bends may be provided in the center main winding section  220  to produce components with still further performance variations to meet a variety of different needs in different power systems, or at different locations in an electrical power system. The length of the serpentine path in the center main section  220  is generally scalable to provide more or less inductance as desired. 
       FIG. 8  shows another construction of an electromagnetic component  310  that is another adaptation of the component  200 . In the component  310 , the post  262  is omitted in the core piece  204  such that the core piece  204  only includes the posts  264  and  266  that are offset as described above. The conductor sections  230  and  232  and the bends  240 ,  242  are also omitted in the center main winding section  220  of the coil winding  208 . As such, the serpentine path of the center main winding section  220  in the component  310  is smaller than in the component  200 . The component  300  is accordingly operable with a lower inductance value than the component  200 . The core piece  204  in the component  300  is smaller than in the component  200  and the component  300  accordingly has a smaller footprint on a circuit board, but when completed with an appropriately dimensioned core piece  206  it may have about the same low profile height H 2  of the component  200 . 
       FIG. 9  shows another construction of an electromagnetic component  320  that is an adaptation of the component  200 . In the component  320 , the post  266  is omitted in the core piece  204  and only the posts  262 ,  264  are provided but with no offset as shown. The conductor sections  230  and  232  and the bends  240 ,  242  are also omitted in the center main winding section  220  of the coil winding  208 . As such, the serpentine path of the center main winding section  220  in the component  320  is smaller than in the component  200 . The component  300  is accordingly operable with a lower inductance value than the component  200 . The core piece  204  in the component  300  is smaller than in the component  200  and the component  300  accordingly has a smaller footprint on a circuit board, but when completed with an appropriately dimensioned core piece  206  it may have about the same low profile height H 2  of the component  200 . 
       FIG. 10  shows another construction of an electromagnetic component  330  that is an adaptation of the component  320 . In the component  330 , a third post  332  is provided with the posts  262 ,  264  but with no offset as shown. The conductor sections  230  and  232  and the bends  240 ,  242  are included in the center main winding section  220  of the coil winding  208 . As such, the serpentine path of the center main winding section  230  in the component  330  is larger than in the component  320 . The component  330  is accordingly operable with a lower inductance than the component  200 . The core piece  204  in the component  330  is about the same size as in the component  200  and the component  300  accordingly has about the same footprint on a circuit board. When the component  330  is completed with an appropriately dimensioned core piece  206  it may have about the same low profile height H 2  of the component  200 . Additional conductor segments and bends may be provided in the center main winding section  220  to produce components with still further performance variations to meet a variety of different needs in different power systems, or at different locations in an electrical power system. The length of the serpentine path in the center main section  220  is generally scalable to provide more or less inductance as desired. 
     Also in the component  330 , additional sections  334 ,  336  are included in the terminal sections  222 ,  224  that wrap around the corners of the core piece  204  and extend inwardly toward the conductor section  234  of the center main winding section, but do not connect to the conductor section  234 . In this arrangement of the component, the ends of the terminal sections (i.e., the ends of the sections  334 ,  336 ) extend on the same side of the core piece as opposed to different sides as in the preceding embodiments. 
       FIG. 11  shows another construction of an electromagnetic component  340  that is an adaptation of the component  330 . The center main winding section includes fewer conductor segments and bends than in the component  330 , and the terminal section  336  is now located on an opposite side of the core piece  204  than the terminal section  232 . Also, additional posts  342 ,  344  are provided on the sides of the core piece  204  such that the sections  222 ,  236  are not exposed on the respective sides of the core piece  204 . Groove segments are defined between the side posts  342 ,  344  and the respective posts  332 ,  264  that receive the sections  222 ,  236 . Only the tends of the terminal sections (i.e., the ends of the sections  334 ,  336 ) extend exterior to the core piece  204 . When the component  340  is completed with an appropriately dimensioned core piece  206  it may have about the same low profile height H 2  of the component  200 . 
     The benefits and advantages of inventive concepts described are now believed to have been amply illustrated in relation to the exemplary embodiments disclosed. 
     An embodiment of a low profile electromagnetic component assembly for a circuit board has been disclosed including a first shaped magnetic core piece having a bottom surface for seating upon the circuit board, a top surface opposing the bottom surface, and a groove defined on the top surface. The component assembly also includes a conductive coil winding having first and second terminal sections and a center main winding section extending between the first and second terminal sections. The center main winding section is a freestanding elongated strip of conductor having a thickness oriented to extend parallel to a plane of the circuit board. The conductor includes a first end, a second end, and an axial length between the first and second ends that includes at least one bend. The conductor in the center main winding section has a first low profile height dimension and is received in the groove. The first and second terminal sections each have a second low profile height dimension, with the second low profile height direction being larger than the first low profile height dimension. A second shaped magnetic core piece overlies the first magnetic core piece and the center main winding section. 
     Optionally, the first shaped magnetic core piece may further include a first lateral side and a second lateral side opposing the first lateral side, and a portion of the center main winding section may be exposed on the first lateral side. The first lateral side may include at least one recess, and the exposed portion of the center section may extend in the at least one recess. The first magnetic core piece may also include a third lateral side and a fourth lateral side opposing the third lateral side between the top and bottom surfaces, and the first and second terminal sections may extend along the third and fourth lateral sides. The first and second terminal sections may extend along an entirety of the third and fourth lateral sides. 
     As another option, at least a portion of the first and second terminal sections may extend along one of the first and second lateral sides. The first terminal section may extend on the first lateral side and the second terminal section may extend on the second lateral side. 
     The center main winding section may include a series of conductor sections defining a symmetrical shape. The conductor of the center main winding section may define at least a portion of a serpentine path including at least two bends between the first and second ends. The conductor of the center main winding section may also define a serpentine path including at least four bends between the first and second ends. 
     The center main winding section may include a plurality of straight conductor sections interconnected by the at least one bend. The at least one bend may be a 90° bend. The at least one bend may include a plurality of 90° bends. 
     The first shaped magnetic core piece may include a first post and a second post on the top surface, and the groove may be at least partly defined between the first post and the second post. The first shaped magnetic core piece may also include a third post on the top surface, the third post being staggered from the first post and second post, and the groove being a serpentine groove extending at least partly between the first, second and third posts. 
     The first magnetic core piece may include at least one additional side post on the top surface, and a groove extending between the at least one additional side post and at least one of the first post and the second post. 
     The first shaped magnetic core piece may have a length dimension and a width dimension on the bottom surface, and the height dimension of the first shaped magnetic core piece may be less that the length dimension and the width dimension. The second shaped magnetic core piece may be a flat piece. The second shaped magnetic core piece may have a low profile height dimension that is less than a low profile height dimension of the first shaped magnetic core piece. The component may be a power inductor component. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.