Abstract: Provided are a composite material having direct current superposition characteristics, low iron loss, and high strength, a magnetic core for a magnetic component and a reactor, the magnetic core and the reactor including the composite material, a converter including the reactor, and a power conversion device including the converter. A composite material includes a soft magnetic powder, a filler, and a resin portion enclosing the soft magnetic powder and the filler dispersed therein, wherein the filler has rubber and an outer circumferential layer that covers a surface of the rubber and that contains an organic substance, and the resin portion contains a thermoplastic resin.

Abstract: 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 ?m or more on at least a portion of its surfaces.

Abstract: The invention is directed to a method of manufacturing a green compact. The method includes a filling step of filling a compacting space with an insulated coated soft magnetic powder. The compacting space is defined by a die. The die has a through hole with which a part of the outer circumferential surface of the green compact is molded. The die also has a core rod with which another part of the outer circumferential surface of the green compact is molded, and a first punch disposed so as to cover one of opening portions of the through hole, the core rod being inserted and disposed in a space of the through hole. The method also includes a pressurizing step using the first punch and a second punch disposed so as to face the first punch. The method also includes a removing step.

Abstract: Provided are a composite material having low iron loss, high saturation magnetization, and high strength, and a magnetic component and a reactor that include the composite material. A composite material contains a soft magnetic powder and a resin having the soft magnetic powder dispersed therein, the soft magnetic powder including a coarse powder having an average particle size D1 of not less than 50 ?m nor more than 500 ?m and a fine powder having an average particle size D2 of not less than 0.1 ?m but less than 30 wherein the soft magnetic powder is contained in an amount of not less than 60 vol % nor more than 80 vol % with respect to the composite material as a whole.

Abstract: A reactor includes: a combined body formed by combining a coil, with a magnetic core; and a case for accommodating the combined body. The wire-wound portion has a case-opposing face that is at least a portion of an outer peripheral face of the wire-wound portion, and opposes an inner wall face of the case, and when it is assumed that a bottom face side of the case is a lower side, and a side opposite to the lower side is an upper side, the wire-wound portion is formed so that one of an end portion of the case-opposing face on the lower side and an end portion of the case-opposing face on the upper side is closer to the center of the wire-wound portion than the other one of the end portion of the case-opposing face on the lower or the upper side.

Abstract: A composite material molded article that includes soft magnetic powder; and resin containing the soft magnetic powder in a dispersed state, wherein when the composite material molded article is divided into nine portions in total such that, out of surfaces of the composite material molded article, an interlinkage surface that intersects a magnetic flux excited in the composite material molded article is equally divided into three portions in a vertical direction and three portions in a horizontal direction, in these portions, a density decrease ratio Dd of a density of a portion having a minimum density Dmin to a density of a portion having a maximum density Dmax, namely {(Dmax?Dmin)/Dmax}×100, is 1.2% or less.

Abstract: A reactor including: a coil that includes a winding portion that is constituted by a plurality of turns formed by spirally winding a winding wire; a magnetic core that includes a portion that is located in the winding portion; a casing that houses a combined body that includes the coil and the magnetic core; and a filling material that contains resin and fills the casing, wherein the winding portion includes an exposed portion that protrudes from an opening edge of the casing, the filling material includes an embedding portion in which a portion of the combined body is embedded and that has a surface located below or at the same level as the opening edge of the casing, and turn interposed portions that are interposed between the turns in the exposed portion, and surfaces of the turn interposed portions are located above a surface of the embedding portion.

Abstract: Provided is soft magnetic powder constituted by an Fe alloy containing Si, in which soft magnetic particles of the soft magnetic powder include a SiO2 layer formed on a surface of the particles, and a surface layer formed directly on the SiO2 layer. 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.

Abstract: 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.

Abstract: A low-loss compact and a method for producing the compact are provided. A method for producing a compact by using coated soft magnetic powder that includes coated soft magnetic particles constituted by soft magnetic particles and insulating coatings coating outer peripheries of the soft magnetic particles includes a raw material preparation step and an irradiation step. In the raw material preparation step, a raw compact is prepared by press-forming coated soft magnetic powder. In the irradiation step, part of a surface of the raw compact is irradiated with a laser. Irradiating a part of a surface of a raw compact with laser increases the number of disrupted portions of conductive portions where constituent materials of the soft magnetic particles at the surface of the raw compact have become conductive to each other, and the loss of the compact can be decreased.

Abstract: Provided are a composite material having direct current superposition characteristics, low iron loss, and high strength, a magnetic core for a magnetic component and a reactor, the magnetic core and the reactor including the composite material, a converter including the reactor, and a power conversion device including the converter. A composite material includes a soft magnetic powder, a filler, and a resin portion enclosing the soft magnetic powder and the filler dispersed therein, wherein the filler has rubber and an outer circumferential layer that covers a surface of the rubber and that contains an organic substance, and the resin portion contains a thermoplastic resin.

Abstract: Provided are a composite material having low iron loss, high saturation magnetization, and high strength, and a magnetic component and a reactor that include the composite material. A composite material contains a soft magnetic powder and a resin having the soft magnetic powder dispersed therein, the soft magnetic powder including a coarse powder having an average particle size D1 of not less than 50 ?m nor more than 500 ?m and a fine powder having an average particle size D2 of not less than 0.1 ?m but less than 30 wherein the soft magnetic powder is contained in an amount of not less than 60 vol % nor more than 80 vol % with respect to the composite material as a whole.

Abstract: Provided are a green compact from which a low-loss core can be formed, a method of manufacturing the green compact, and a core for a reactor using the green compact. Parts of outer circumferential surfaces of green compacts 41 and 42 are molded with an inner peripheral surface of a through hole 10hA of a die 10A, and the other parts are molded with an outer circumferential surface of a core rod 13A that is inserted and disposed in the through hole 10hA. A raw-material powder P, which is a coated soft magnetic powder, is fed into compacting spaces 31 and 32 and pressurized by using a lower punch 12 (first punch) and an upper punch 11 (second punch). Then, the green compacts 41 and 42 are removed from the compacting spaces 31 and 32 by moving the die 10A with respect to the green compacts 41 and 42 without moving the core rod 13A with respect to the green compacts 41 and 42.

Abstract: The present invention relates to a method for molding a powder mold product according to which a powder mold product of uniform quality can be molded with excellent productivity. The present invention includes the steps of: preparing raw material powder 3 (a preparing step); interposing a mold assembly-use lubricant between an outer circumferential face 12s of a first punch (a lower punch 12) and an inner circumferential face 10s of a die 10, the lower punch 12 and the die 10 in this state being relatively shifted to apply the mold assembly-use lubricant to the inner circumferential face 10s of the die 10 (an applying step); and packing the raw material powder 3 into a cavity, a powder mold product 100 being molded by the raw material powder 3 being pressed (a molding step).

Abstract: A compact 10 is obtained by compression-molding coated soft magnetic particles covered with insulating coatings, and is a modified frustum body having, as a main body, a frustum portion 113 sandwiched between plate-shaped portions 111 and 112 arranged in opposing relation. A vertical cross-section of the compact 10 is made up of a trapezoidal surface 113s, a long-side rectangular surface 111s joining to a long side of the trapezoidal surface 113s, and a short-side rectangular surface 112s joining to a short side of the trapezoidal surface 113s.

Abstract: A low-loss compact and a method for producing the compact are provided. A method for producing a compact by using coated soft magnetic powder that includes coated soft magnetic particles constituted by soft magnetic particles and insulating coatings coating outer peripheries of the soft magnetic particles includes a raw material preparation step and an irradiation step. In the raw material preparation step, a raw compact is prepared by press-forming coated soft magnetic powder. In the irradiation step, part of a surface of the raw compact is irradiated with a laser. Irradiating a part of a surface of a raw compact with laser increases the number of disrupted portions of conductive portions where constituent materials of the soft magnetic particles at the surface of the raw compact have become conductive to each other, and the loss of the compact can be decreased.

Abstract: When an outer core that is to be mounted on a reactor is seen in plan, the outer core is a compact that has a plan-view shape in which a side of the outer core that is opposite to a facing side of the outer core, which faces the inner cores, has a smaller dimension in a width direction, which is parallel to a facing surface, than the facing side of the outer core. A method of manufacturing such an outer core includes a preparing step and a compacting step. In the preparing step, coated soft magnetic powder including multiple coated soft magnetic particles formed by coating soft magnetic particles with insulating coated films is prepared as raw-material powder of the outer core.

Abstract: The present invention relates to a method for molding a powder mold product according to which a powder mold product of uniform quality can be molded with excellent productivity. The present invention includes the steps of: preparing raw material powder 3 (a preparing step); interposing a mold assembly-use lubricant between an outer circumferential face 12s of a first punch (a lower punch 12) and an inner circumferential face 10s of a die 10, the lower punch 12 and the die 10 in this state being relatively shifted to apply the mold assembly-use lubricant to the inner circumferential face 10s of the die 10 (an applying step); and packing the raw material powder 3 into a cavity, a powder mold product 100 being molded by the raw material powder 3 being pressed (a molding step).

Abstract: A compact 10 is obtained by compression-molding coated soft magnetic particles covered with insulating coatings, and is a modified frustum body having, as a main body, a frustum portion 113 sandwiched between plate-shaped portions 111 and 112 arranged in opposing relation. A vertical cross-section of the compact 10 is made up of a trapezoidal surface 113s, a long-side rectangular surface 111s joining to a long side of the trapezoidal surface 113s, and a short-side rectangular surface 112s joining to a short side of the trapezoidal surface 113s.

Abstract: A low-loss compact and a method for producing the compact are provided. A method for producing a compact by using coated soft magnetic powder that includes coated soft magnetic particles constituted by soft magnetic particles and insulating coatings coating outer peripheries of the soft magnetic particles includes a raw material preparation step and an irradiation step. In the raw material preparation step, a raw compact is prepared by press-forming coated soft magnetic powder. In the irradiation step, part of a surface of the raw compact is irradiated with a laser. Irradiating a part of a surface of a raw compact with laser increases the number of disrupted portions of conductive portions where constituent materials of the soft magnetic particles at the surface of the raw compact have become conductive to each other, and the loss of the compact can be decreased.