Sumitomo Electric Industries, Limited

Sumitomo Wiring Systems, Limited

Autonetworks Technologies, Limited

Shintaro Nanbara

Kazushi Kusawake

Takashi Takada

Yusaku Maeda

Kouhei Yoshikawa

Seiji Shitama

Kouji Nishi

Provided is a composite material molded article including soft magnetic powder and resin containing the soft magnetic powder in a dispersed state. The composite material molded article is provided with a roughened region having an arithmetic average roughness Ra of 3.0 μm or more on at least a portion of its surfaces.

Composite material molded article, reactor, comprising a roughened surface

A reactor includes a coil, an annular magnetic core that forms a closed magnetic circuit when the coil is excited, a plurality of divided reactors arranged in parallel, and a holding member that holds the plurality of divided reactors in a state in which the divided reactors are arranged in parallel at a predetermined spacing. Each of the divided reactors includes a coil unit that is formed of a wound wire and constitutes a part of the coil and a core unit that passes through the coil unit from one end of the coil unit to the other end and constitutes a part of the magnetic core. The core unit has an inner core portion inserted through the coil unit, and outer core portions that protrude from both ends of the coil unit and extend in a direction that intersects the inner core portion.

Reactor

Provided is a coil molded article including: a coil having a winding portion; and an integration resin portion that coats at least an inner peripheral face of the winding portion, wherein the coil molded article further includes a gap portion that is integrated into the inner peripheral face and divides an internal space of the winding portion into two portions in an axial direction of the winding portion. Further provided is a reactor including: the above-described coil molded article; and a magnetic core including an inner core portion that is arranged inside the winding portion included in the coil molded article, and an outer core portion that is arranged outside the winding portion.

Coil molded article and reactor

A reactor includes a coil, a magnetic core having an inner core portion inside a winding portion, and an inner interposed member insulating the winding portion from the inner core portion. The inner interposed member includes a thin portion with a small thickness formed by a recess, and a thick portion with a thickness larger than that of the thin portion. The inner core portion includes a core-side projecting portion with a shape conforming to a shape of the inner peripheral face of the thin portion. The thickness of the thin portion is 0.2 mm or more and 1.0 mm or less, and the thickness of the thick portion is 1.1 mm or more and 2.5 mm or less. Clearances are in part of a portion between the inner core portion and the inner interposed member and of a portion between the inner interposed member and the winding portion.

A reactor includes a coil, a magnetic core having an inner core portion arranged inside a winding portion, and an inner interposed member insulating the winding portion from the inner core portion. The inner interposed member includes a thin portion with a small thickness, and a thick portion with a thickness larger than that of the thin portion. The inner core portion includes, on an outer peripheral face facing the inner interposed member, a core-side projecting portion with a shape conforming to a shape of the inner peripheral face of the thin portion. The thickness of the thin portion is 0.2 mm or more and 1.0 mm or less, and the thickness of the thick portion is 1.1 mm or more and 2.5 mm or less. There is a clearance in at least part of a portion between the inner interposed member and the winding portion.

A reactor including: a coil including a pair of winding portions that are arranged side by side; a magnetic core including inner core portions that are provided inside the winding portions, and an outer core portion that is exposed to the outside from the winding portions; and a casing that houses a combined member that includes the coil and the magnetic core combined with each other. The casing includes: a bottom plate on which the combined member is placed; and a side wall that stands on the bottom plate, and the side wall is provided with a cutout for the core, through which at least a portion of the outer core portion is exposed to the outside of the casing.

Provided is a reactor that includes: a coil; a magnetic core with an inner core portion arranged inside the coil; and an inwardly interposed member insulating the inner core portion from the coil. The inwardly interposed member has a thin portion defined by a recessed inner-circumferential surface, and a thick portion that is thicker than the thin portion. The inner core portion has a core-side projection portion facing the inwardly interposed member that has a shape conforming to the inner-circumferential surface shape of the thin portion. The thin portion has a thickness of 0.2 mm to 1.0 mm inclusive, and the thick portion has a thickness of 1.1 mm to 2.5 mm inclusive. A clearance is provided at least at a portion between the inner core portion and the inwardly interposed member, and the inwardly interposed member and the wound portion are in contact with each other.

A reactor includes a coil; a magnetic core with an inner core portion arranged inside the coil; and an inwardly interposed member insulating the coil from the inner core portion. The inwardly interposed member has a thin portion defined by a recess of an inner-circumferential surface, and a thick portion that is thicker than the thin portion. The inner core portion has, on an outer circumferential surface facing the inwardly interposed member, a core-side projection portion has a shape conforming to the inner-circumferential surface shape of the thin portion. The thin portion has a thickness of 0.2 mm to 1.0 mm inclusive, and the thick portion has a thickness of 1.1 mm to 2.5 mm inclusive. The inner core portion and the inwardly interposed member are in intimate contact with each other, and the inwardly interposed member and the wound portion are in intimate contact with each other.

A reactor including: a coil that includes a winding portion; a magnetic core that includes an inner core portion that is located inside the winding portion and an outer core portion that is located outside the winding portion; an inner interposed member that is interposed between an inner surface of the winding portion and the inner core portion; and an end surface interposed member that is interposed between an end surface of the winding portion and the outer core portion. The inner interposed member is provided with first positioning portions that engage with the end surface interposed member and are located so as to respectively face a first pair of surfaces of the outer core portion to position the outer core portion, the first pair of surfaces being composed of a pair of surfaces that face each other.

Provided is a composite material molded article including soft magnetic powder and resin containing the soft magnetic powder in a dispersed state. The composite material molded article includes a parting line corresponding to a parting surface of a mold for molding the composite material molded article, and an inner core portion to be arranged inside a coil. A peripheral surface includes surfaces along a circumferential direction of a magnetic flux excited in the inner core portion by the coil, and the parting line is formed to split a peripheral direction of the peripheral surface.

Composite material molded article and reactor

Provided is soft magnetic powder constituted by an Fe alloy containing Si, in which soft magnetic particles of the soft magnetic powder include a SiOlayer formed on a surface of the particles, and a surface layer formed directly on the SiOlayer. The surface layer includes a first material that constitutes a matrix and a second material that is dispersed in the matrix. The first material is silicone or phosphate, and the second material is silicone or phosphate and is different from the first material.

Soft magnetic powder, magnetic core, method for manufacturing soft magnetic powder, and method for manufacturing magnetic core

Provided is a reactor that can be manufactured without holding an assembly when the assembly is fixed to a mounting plate via a bonding layer. The reactor includes a coil, a magnetic core, an interposed insulating member, a metal mounting plate, and a bonding layer. The interposed insulating member is provided with an inwardly interposed portion, a first interposed end face portion, and a second interposed end face portion. The interposed insulating member is obtained by combining a plurality of divided pieces that includes a divided piece having the first interposed end face portion, and a divided piece having the second interposed end face portion. The divided pieces are respectively provided with engaging portions that engage with each other, and the first interposed end face portion and the second interposed end face portion are each provided with a leg piece that separates the coil from the mounting plate.

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Mie, Japan

Shintaro Nanbara