Patent ID: 8400245

Claim:
A magnetic component assembly comprising: a first magnetic core piece; a first pre-formed winding clip separately fabricated from the first magnetic core piece, the first pre-formed winding clip including terminal lead sections configured for surface mounting of the assembly, the first pre-formed clip assembled to said first magnetic core piece without shaping any portion of the winding clip about the first magnetic core piece a second magnetic core piece fitted with the first magnetic core piece and the assembled pre-formed winding clip; wherein the first pre-formed winding clip comprises a flat conductor formed substantially in a C-shape having a planar main winding section extending in a first plane, opposing first and second legs extending substantially perpendicular to the first plane, and first and second terminal lead sections respectively extending from each of the first and second legs, the first and second terminal lead sections extending in a plane spaced from but parallel to the first plane and the first and second terminal lead sections extending inwardly toward one another; a third magnetic core piece interposed between the first and second magnetic core piece; and a second preformed clip fitted with the second magnetic core piece and the third magnetic core piece; wherein the third magnetic core piece includes a first clip channel and a second clip channel; wherein the third magnetic piece includes a first side and a second side opposing the first side; and wherein the first clip channel extends on the first side and the second clip channel extends on the second side.