Abstract: The invention offers a method for producing a soft magnetic material. The method effectively produces a soft magnetic material having soft magnetic metallic particles each coated with a plurality of insulating layers. A soft magnetic material to be used as the material for a dust core is produced through the following steps: a step of preparing a material powder having composite magnetic particles produced by forming an insulating film containing hydrated water on each of the surfaces of soft magnetic metallic particles, a step of preparing a resin material containing silicone that cures through a hydrolysis-polycondensation reaction, and a step of mixing the material powder and the resin material in a heated atmosphere at 80° C. to 150° C. to form a silicone film on the surface of the insulating film.

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: 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: A split stator for an electric motor includes a core having a tooth portion, a coil formed around the tooth portion, insulation spacers arranged between a surface of the tooth portion and an inner periphery of the coil, and holding the inner periphery of the coil with a space kept from the surface of the tooth portion, and a resin filler material having high thermal conductivity and filling the space. The resin filler material is configured to allow heat release from the inner periphery of coil to the core.

Abstract: The invention offers a method for producing a soft magnetic material. The method effectively produces a soft magnetic material having soft magnetic metallic particles each coated with a plurality of insulating layers. A soft magnetic material to be used as the material for a dust core is produced through the following steps: a step of preparing a material powder having composite magnetic particles produced by forming an insulating film containing hydrated water on each of the surfaces of soft magnetic metallic particles, a step of preparing a resin material containing silicone that cures through a hydrolysis-polycondensation reaction, and a step of mixing the material powder and the resin material in a heated atmosphere at 80° C. to 150° C. to form a silicone film on the surface of the insulating film.

Abstract: A split stator for an electric motor includes a core having a tooth portion, a coil formed around the tooth portion, insulation spacers arranged between a surface of the tooth portion and an inner periphery of the coil, and holding the inner periphery of the coil with a space kept from the surface of the tooth portion, and a resin filler material having high thermal conductivity and filling the space. The resin filler material is configured to allow heat release from the inner periphery of coil to the core.

Abstract: A soft magnetic material includes a plurality of composite magnetic particles (30) each including an iron-based particle (10) containing iron and an insulating coating film (20) surrounding a surface of the iron-based particle (10). The insulating coating film contains an organic group derived from an organic acid having at least one substance selected from the group consisting of titanium, aluminum, silicon, calcium, magnesium, vanadium, chromium, strontium, and zirconium. The at least one substance in the insulating coating film (20) is bonded to iron in the iron-based particles (10) through the organic group derived from the organic acid in the insulating coating film (20). Furthermore, a method for producing a soft magnetic material includes the steps of preparing the iron-based particles (10) containing iron and forming the insulating coating film (20) surrounding a surface of each of the iron-based particles (10).

Abstract: To provide a core component for making it possible to enhance the space factor of a conductor wire in a storage section, a motor component including the core component, and a forming method of the motor component, the motor component includes a core component 10 shaped like a letter T in transverse cross section and a coil made of a conductor wire 200 wound on a tooth 11 of the core component 10. The core component 10 includes the tooth 11, an outer peripheral piece 12 placed on one end side of the tooth 11, and an inner peripheral piece 13 placed on an opposite end side of the tooth, and a space surrounded by the outer peripheral surface of the tooth 11, an opposed face 12a of the outer peripheral piece 12 to the inner peripheral piece, and an opposed face 13a of the inner peripheral piece 13 to the outer peripheral piece is a coil storage section 14.