US Patent 7218197 Power inductor with reduced DC current saturation

A power inductor comprises a first magnetic core material having first and second ends. An inner cavity is arranged in the first magnetic core material and extends from the first end to the second end. A crossover conductor structure includes a first lead frame that passes through the inner cavity and that has a first terminal and a second terminal, a second lead frame passes through the inner cavity and has a first terminal and a second terminal. The first and second terminals of the first lead frame are located at first opposite diagonal corners of the inner cavity and the first and second terminals of the second lead frame are at second opposite diagonal corners of the cavity. An insulating material is located between the first and second lead frames.