JP2017063113A - Composite material mold, and reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a composite material mold which enables the construction of a reactor of a low loss.SOLUTION: A composite material mold 10 including soft magnetic powder including a plurality of soft magnetic particles, and a resin with the soft magnetic powder dispersed therein comprises: a parting line 15 corresponding to a division plane of a mold for molding the composite material mold 10; an inside core part 11 disposed inside a coil; and a laser irradiation trace 18 formed in a surface of the inside core part 11. Supposing that in the surface of the inside core part 11, a face along a circumferential direction, the axis of which is made by a magnetic flux magnetically excited by the coil in the inside core part 11 is a circumferential face, the parting line 15 is formed so as to divide the axial direction of the magnetic flux, and the laser irradiation trace 18 is formed so as to divide the circumferential direction of the circumferential face therein.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a composite material molded body suitable for a constituent member of a magnetic component such as a reactor, and a reactor including the composite material molded body. In particular, the present invention relates to a composite material molded body capable of constructing a low-loss reactor.

  Magnetic parts are used as parts of various products such as automobiles, electrical equipment, and industrial machines. Specific examples of the magnetic component include a reactor, a choke coil, a transformer, and a motor. The magnetic component includes a coil formed by winding a winding and a magnetic core on which the coil is disposed. As at least a part of the magnetic core, for example, in the reactor shown in Patent Document 1, a powder compact formed by pressure-molding the coated soft magnetic powder is used. In the reactor shown in Patent Document 2, the magnetic powder and resin are used. The composite material (composite material molded object) containing is used.

  The reactor of patent document 1 is equipped with a pair of columnar inner core part arrange | positioned inside a pair of coil element (winding part). This inner core part is comprised by the core piece and gap material which are comprised with the compacting body by which the laser was irradiated to at least one part of the surface. The compacted compact is manufactured by irradiating a laser beam onto a molded compact that has been molded by filling a mold with coated soft magnetic powder comprising a plurality of coated soft magnetic particles whose outer periphery is coated with an insulating coating. Done. At the time of die cutting of the material molded body, the circumferential surface along the circumferential direction in the mold drawing direction of the mold and the inner surface of the mold along the circumferential direction in the mold drawing direction of the surface of the material molded body are in sliding contact. By this sliding contact, the insulating coating of the coated soft magnetic particles is damaged, and the soft magnetic particles are exposed and spread, so that a film-like conductive portion where the soft magnetic particles are connected to each other is spread over the entire circumference of the material molded body. It may be formed over. When the circumferential surface of the molded body of the material formed with the conductive portion is a surface along the circumferential direction with the magnetic flux as the axis, eddy currents flow on the circumferential surface along the circumferential direction of the magnetic flux, increasing eddy current loss. To do. In the reactor of Patent Document 1, in order to suppress an increase in the eddy current loss, a compacted body in which the conductive portion of the circumferential surface of the material molded body is irradiated with a laser to divide the conductive portion is used as a core piece. The eddy current is cut off at the part of the cut to reduce the loss.

  The reactor of Patent Document 2 is formed integrally with a pair of coil arrangement portions (inner core portions) inserted into each of a pair of coil elements (winding portions) and one end side of both coil arrangement portions, and is an end face of the coil. A core piece having an exposed portion (outer core portion) disposed outside the coil so as to cover at least a part of the coil. This core piece is comprised with a composite material (composite material molded object). The composite material is manufactured by filling a mold with a mixture of magnetic powder and resin and solidifying (curing) the resin. As the metal mold, a metal mold is used in which the die cutting direction of the core piece is the direction along the longitudinal direction of the coil placement portion, that is, the direction parallel to the magnetic flux excited by the coil.

JP 2012-199513 A JP 2014-239120 A

  It is desired to further reduce the loss of a reactor including a core composed of a composite material molded body.

  The present invention has been made in view of the above circumstances, and one of its purposes is to provide a composite material molded body capable of constructing a low-loss reactor.

  The other objective of this invention provides a reactor provided with the said composite material molded object.

  The composite material molded body according to one aspect of the present invention includes a soft magnetic powder having a plurality of soft magnetic particles and a resin encapsulating the soft magnetic powder in a dispersed state. This composite material molded body has a parting line corresponding to the dividing surface of the mold for molding the composite material molded body, an inner core portion disposed inside the coil, and a laser irradiation formed on the surface of the inner core portion. With scars. Of the surface of the inner core portion, a surface along the circumferential direction with the magnetic flux excited in the inner core portion by the coil as an axis is defined as a circumferential surface. At this time, the parting line is formed so as to divide the axial direction of the magnetic flux, and the laser irradiation trace is formed on the circumferential surface so as to divide the circumferential direction of the circumferential surface.

  The reactor which concerns on 1 aspect of this invention is equipped with the coil formed by winding a coil | winding, and the magnetic core in which a coil is arrange | positioned. At least a part of the magnetic core includes the composite material molded body according to one embodiment of the present invention.

  The composite material molded body can construct a low-loss reactor.

  The reactor has a low loss.

The composite material molded object which concerns on Embodiment 1 is shown, the left figure is the schematic perspective view seen from the outer end surface side, and the right figure is the schematic perspective view seen from the linkage surface side. The reactor which concerns on Embodiment 1 is shown, the upper figure is a schematic perspective view, and the lower figure is a disassembled perspective view.

<< Description of Embodiments of the Present Invention >>
The inventors of the present invention have investigated the factors that hinder the reduction of loss in a conventional composite material molded body manufactured using a mold in which the die cutting direction of the core piece is along the longitudinal direction (magnetic flux) of the inner core portion. As a result, the following knowledge was obtained.
(I) In the sliding contact region with the inner surface of the mold at the time of die-cutting in the composite material molded body, a film-like conduction portion is formed in which the soft magnetic particles spread and the magnetic particles are conducted with each other.
In general, since the resin content of a composite material molded body is higher than that of a powder molded body formed by pressure-molding soft magnetic powder, the soft magnetic particles expand due to sliding contact with the inner surface of the mold during die cutting. It was difficult to extend, and it was thought that it was difficult to form a film-like conduction part in which soft magnetic particles such as a green compact were conducted. However, even in the composite material molded body, a conductive portion is formed.
(Ii) Since the die-cutting direction of the conventional composite material molded body is a direction parallel to the magnetic flux excited by the coil, conduction portions are formed on all surfaces parallel to the magnetic flux of the composite material molded body, Eddy current flows along the circumferential direction centering on the magnetic flux.
(Iii) The formation of the conductive portion does not affect the loss increase and is not substantially negligible, but greatly affects the loss increase, that is, causes a large eddy current loss.
(Iv) The conducting part is formed even in the case of soft magnetic powder comprising Fe-based alloy particles that are harder and harder to spread than pure iron.
Based on these findings, the inventors of the present invention have intensively studied to divide the conducting portion, thereby completing the present invention. First, embodiments of the present invention will be listed and described.

  (1) A composite material molded body according to an aspect of the present invention includes a soft magnetic powder having a plurality of soft magnetic particles and a resin encapsulating the soft magnetic powder in a dispersed state. This composite material molded body has a parting line corresponding to the dividing surface of the mold for molding the composite material molded body, an inner core portion disposed inside the coil, and a laser irradiation formed on the surface of the inner core portion. With scars. Of the surface of the inner core portion, a surface along the circumferential direction with the magnetic flux excited in the inner core portion by the coil as an axis is defined as a circumferential surface. At this time, the parting line is formed so as to divide the axial direction of the magnetic flux, and the laser irradiation trace is formed on the circumferential surface so as to divide the circumferential direction of the circumferential surface.

  According to said structure, a low loss reactor can be constructed | assembled. Reduces eddy current loss because eddy currents flowing along the circumferential direction of the circumferential surface are difficult to flow due to laser irradiation marks formed on the circumferential interface so as to divide the circumferential direction of the circumferential surface of the inner core part Because it can.

  The composite material molded body is manufactured by irradiating a laser to a conduction portion formed on the surface of the molded body material taken out from the mold. The mold drawing direction at the time of molding the composite material molded body is parallel to the axial direction of the magnetic flux of the inner core portion. This is because the parting line is formed so as to divide the magnetic flux axial direction. At this time, the entire circumferential surface of the inner core portion is a sliding contact area with the inner surface of the mold. Therefore, before the laser irradiation, a film-like conduction part in which the soft magnetic particles spread and the soft magnetic particles are conducted may be formed on the entire circumference of the inner core part. The laser irradiation trace is considered to be formed as follows by irradiating the surface (the conductive portion) with a laser so as to divide the circumferential direction of the circumferential surface of the inner core portion. The conduction portion is rapidly heated and melted by laser irradiation, and is divided by agglomeration due to the surface tension of the molten metal. By subsequent cooling, the molten metal is solidified in a divided state. By dividing the conductive portion, a region having a high electrical resistance is formed between the divided portions. Therefore, the laser irradiation trace is difficult to flow eddy current flowing along the circumferential direction of the circumferential surface, and can be blocked.

  (2) As one form of the composite material molded body, the laser irradiation trace may include an oxide film containing a main component element of soft magnetic particles.

  Since the laser irradiation trace is formed by irradiating the conducting portion with laser, it can have an oxide film containing the main component element of the soft magnetic particles by melting and solidifying the conducting portion by laser irradiation. By providing this oxide film, the composite material molded body can further block eddy currents and suppress rust of soft magnetic particles.

  (3) As one form of the said composite material molded object, it is mentioned that the arithmetic mean roughness Ra of a laser irradiation trace is larger than the periphery of the laser irradiation trace in a surrounding surface.

  According to said structure, it is easy to improve adhesiveness (bondability) with resin which covers the surface of a composite material molded object. This is because the surface roughness of the laser irradiation trace is larger than that of its peripheral portion, so that the contact area of the resin with the laser irradiation trace can be increased. When a composite material molded body is used as the magnetic core of the reactor, a resin mold portion may be formed on the surface of the composite material molded body in order to improve insulation between the coil.

  (4) As one form of the said composite material molded object, it is mentioned that the width | variety of a laser irradiation trace is 1/4 or less of the circumference of a surrounding surface more than the average particle diameter of soft-magnetic powder.

  If the width of the laser irradiation mark is set to be equal to or larger than the average particle diameter of the soft magnetic powder, eddy current loss can be easily reduced effectively. If the width of the laser irradiation trace is set to 1/4 or less of the circumference of the circumferential surface, the effect of reducing the eddy current loss can be sufficiently obtained, and the width of the laser irradiation trace is not excessively large. Formation is not complicated.

  (5) As one form of the said composite material molded object, providing a pair of inner core part located in parallel and the outer core part which is arrange | positioned on the outer side of a coil and connects both these inner core parts is mentioned. . In this case, the circumferential surface on which the laser irradiation trace is formed is orthogonal to the parallel direction of the pair of inner core portions.

  According to said structure, an eddy current cannot flow easily and a low-loss reactor can be constructed | assembled.

  (6) As one form of the said composite material molded object, it is mentioned that a soft magnetic powder contains the soft magnetic particle | grains of the Fe base alloy which contains 1.0 mass% or more and 8.0 mass% or less of Si.

  An Fe-based alloy containing 1.0% by mass or more of Si has a high electrical resistivity and can easily reduce eddy current loss. In addition, since it is harder than pure iron, it is difficult to introduce strain in the manufacturing process, and it is easy to reduce hysteresis loss. Therefore, iron loss can be further reduced. An Fe-based alloy containing 8.0% by mass or less of Si does not have an excessive amount of Si, and it is easy to achieve both low loss and high saturation magnetization.

  (7) As one form of the said composite material molded object, it is mentioned that content with respect to the whole composite material molded object of a soft-magnetic powder is 30 volume% or more and 80 volume% or less.

  If the content is 30% by volume or more, the ratio of the magnetic component is sufficiently high. Therefore, when a reactor is constructed using this composite material molded body, it is easy to increase the saturation magnetization. Since the resin content decreases as the content increases, it is easy to form a conductive portion in which the particles are electrically connected in the sliding contact region. However, by providing the laser irradiation trace, eddy current loss can be reduced even when the conductive portion is easily formed. If the said content is 80 volume% or less, since the ratio of a magnetic component is not too high, the insulation between soft-magnetic particles can be improved and eddy current loss can be reduced.

  (8) As one form of the said composite material molded object, it is mentioned that the average particle diameter of soft-magnetic powder is 5 micrometers or more and 300 micrometers or less.

  If the average particle size of the soft magnetic powder is 5 μm or more, it is difficult to agglomerate, and it is easy to reduce the eddy current loss because the resin is easily interposed between the powder particles. If the average particle diameter of the soft magnetic powder is 300 μm or less, the eddy current loss of the powder particle itself can be reduced because it is not excessively large, and consequently the eddy current loss of the composite material compact can be reduced. Moreover, it is easy to increase the saturation magnetization of the composite material molded body by increasing the filling rate.

  (9) The reactor which concerns on 1 aspect of this invention is equipped with the coil formed by winding a coil | winding, and the magnetic core by which a coil is arrange | positioned. At least a part of the magnetic core includes the composite material molded body according to any one of the above (1) to (8).

  According to said structure, since the said composite material molded object which can reduce an eddy current loss effectively is provided, it is a low loss.

<< Details of Embodiment of the Present Invention >>
Details of embodiments of the present invention will be described below with reference to the drawings.

Embodiment 1
[Composite material compact]
A composite material molded body 10 according to Embodiment 1 will be described mainly with reference to FIG. The composite material molded body 10 is obtained by solidifying (curing) a resin of an unsolidified mixture containing soft magnetic powder and resin, and typically constitutes at least a part of a magnetic core provided in a reactor. As will be described in detail later, the reactor includes, for example, a coil 2 and a magnetic core 3 shown in FIG. Here, the coil 2 is formed by connecting a pair of winding portions 2a and 2b obtained by spirally winding the winding 2w in parallel with each other. The magnetic core 3 is formed in an annular shape by combining two core members 30 having the same shape. Both the core members 30 are composed of the composite material molded body 10. The composite material molded body 10 is produced by filling a resin material in a fluid state from a gate into a mold cavity having a specific direction as a die cutting direction and solidifying a resin. The main feature of the composite material molded body 10 is that it is formed at the circumferential interface so as to divide the circumferential surface along the circumferential direction around the magnetic flux of the inner core portion 11 disposed inside the coil 2. The laser irradiation mark 18 is provided. Details will be described below. Here, the reactor 1 is constructed by assembling the core member 30 to the coil 2, and the installation target side when the reactor 1 is installed on the installation target such as the cooling base will be described below, and the opposite side of the installation target will be described as the top. The same reference numerals in the figure indicate the same names.

[overall structure]
The composite material molded body 10 includes a pair of inner core portions 11 and an outer core portion 12 that connects the inner core portions 11 on one end side of the pair of inner core portions 11. The shape seen from above the composite material molded body 10 is substantially U-shaped. The pair of inner core portions 11 are respectively disposed in the pair of winding portions 2a and 2b when the core member 30 having the composite material molded body 10 is assembled to the coil 2 (FIG. 2). Similarly, the outer core portion 12 protrudes from the end surface of the coil 2 when the core member 30 having the composite material molded body 10 is assembled to the coil 2 (FIG. 2). The upper surfaces 11U and 12u of the inner core portion 11 and the outer core portion 12 are substantially flush. On the other hand, the lower surface 12d of the outer core portion 12 protrudes from the lower surface 11D of the inner core portion 11 so that the outer core is substantially flush with the lower surface of the coil 2 when the composite material molded body 10 is combined with the coil 2. The size of the portion 12 is adjusted. A parting line 15 is formed in the composite material molded body 10 so as to divide the axial direction of the magnetic flux, and each of the pair of inner core portions 11 has a laser irradiation mark 18 orthogonal to a plane including the parting line 15. Is formed.

(Inner core part)
The shape of each inner core portion 11 is preferably a shape that matches the shape of the coil 2 (the internal space of the coil 2). Here, it is a rectangular parallelepiped shape, and its corners are rounded along the inner peripheral surfaces of the winding portions 2a and 2b (FIG. 2). Of the surface of the inner core portion 11, the circumferential surface along the circumferential direction around the magnetic flux (the surface along the circumferential direction of the winding portions 2a, 2b) is orthogonal to the surface including the parting line 15. It is a parallel plane parallel to the magnetic flux of the inner core portion 11. That is, the circumferential surface of the inner core portion 11 is a surface other than the end surface 11E that intersects (or intersects perpendicularly with) the magnetic flux of the inner core portion 11 in the surface. Here, the surrounding surface of each inner core part 11 is comprised by four curved surfaces which connect the planes which adjoin four planes, 11U, 11D, 11L, and 11R of upper, lower, left and right surfaces 11R. The left and right are defined as the parallel direction of the pair of inner core portions 11 when the pair of inner core portions 11 are viewed from the outer core portion 12 side. The end surface 11E of the inner core portion 11 is parallel to the surface including the parting line 15 and is formed continuously with the circumferential surface. A direction parallel to the magnetic flux (circumferential surface) in the inner core portion 11, that is, a direction orthogonal to the end surface 11E is a die cutting direction. As will be described in detail later, since the parting line 15 corresponds to the dividing surface of the mold, the direction orthogonal to the surface including the parting line 15 is the die cutting direction when the composite material molded body 10 is molded. .

  A laser irradiation mark 18 (described later) is formed on the circumferential surface of each inner core portion 11 so as to divide the circumferential direction. The region excluding the laser irradiation marks 18 on the circumferential surfaces of both inner core portions 11 is a sliding contact region that is parallel to the die-cutting direction and that is in sliding contact with the inner surface of the mold. This is a low electrical resistance region in which a film-like conducting part that conducts each other is formed. The end surface 11E of the inner core portion 11 is a non-sliding contact region that is pressed against the inner surface of the mold during molding, but does not slide in contact with the inner surface of the mold during die cutting, and the conductive portion is not substantially formed. It is a resistance region. Therefore, an eddy current that flows along the circumferential direction centered on the magnetic flux hardly flows on the end surface 11E of the inner core portion 11, and eddy current loss can be reduced.

<Laser irradiation trace>
The laser irradiation mark 18 is difficult to flow eddy current flowing in the circumferential direction of the circumferential surface, and thus cuts off. In FIG. 1 (FIG. 2), the laser irradiation mark 18 is shown by cross hatching. The laser irradiation trace 18 is a region having a high electrical resistance formed between the conducting portions, without being substantially formed by dividing the conducting portion. This is because an oxide film, which will be described later, and a surface with an insulating coating (when the soft magnetic particles have an insulating coating) are exposed. Therefore, by providing the laser irradiation trace 18, eddy current loss can be reduced as compared with a composite material molded body in which all of the circumferential surface is constituted by a sliding contact region. It is considered that the laser irradiation mark 18 is formed as follows by irradiating a conduction portion with a laser described later. The conduction portion is rapidly heated and melted by laser irradiation, and is divided by agglomeration due to the surface tension of the molten metal. By subsequent cooling, the molten metal is solidified in a divided state. By dividing the conductive portion, a region having a high electrical resistance is formed between the divided portions.

  The formation location of the laser irradiation trace 18 on the circumferential surface may be any of the upper, lower, left, and right surfaces 11U, 11D, 11L, and 11R, and four curved surfaces. The formation length of the laser irradiation mark 18 (the length in the direction parallel to the magnetic flux) may be a length extending from one end to the other end of the circumferential surface. If it does so, an eddy current can be made difficult to flow over the full length of the inner core part 11 in the direction parallel to the magnetic flux, and an eddy current loss can be reduced. Here, the laser irradiation mark 18 is formed on the outer side surface of the pair of inner core portions 11 of each composite material molded body 10, and the laser irradiation mark 18 is formed from one end to the other end of the side surface. It is a length. That is, the laser irradiation mark 18 is formed in a portion extending from one end to the other end of the left surface 11L in the left inner core portion 11 and a portion extending from one end to the other end of the right surface 11R in the right inner core portion 11. . By forming the laser irradiation mark 18 as the outer side surface in each inner core part 11, it is easier to irradiate the laser than the inner side surface in each inner core part 11, so that the laser irradiation mark 18 can be easily formed. It is.

  The width of the laser irradiation mark 18 (the length in the direction perpendicular to the magnetic flux) is preferably equal to or greater than the average particle diameter of the soft magnetic powder. By doing so, it is easy to effectively obtain an effect of reducing eddy current loss. The width of the laser irradiation mark 18 is preferably ¼ or less of the circumferential length of the circumferential surface. If it does so, the reduction effect of an eddy current loss will fully be acquired, and also the width | variety of a laser irradiation trace will not be too large, and formation of a laser irradiation trace will not become complicated. More specifically, the width of the laser irradiation mark 18 is particularly preferably 0.1 mm or more and 20 mm or less.

  The arithmetic average roughness Ra of the laser irradiation mark 18 is often larger than the periphery thereof. Examples of the periphery of the laser irradiation mark 18 include a sliding contact area adjacent to the laser irradiation mark 18. For example, the ratio of the arithmetic average roughness Ra in the non-sliding contact region (for example, the end surface 11E), the sliding contact region (for example, the upper surfaces 11U and 12u), and the laser irradiation mark 18 is as follows. = 1: 8-15: 16-30 or so. Since the arithmetic average roughness Ra of the laser irradiation mark 18 is rougher than the periphery thereof, it is easy to improve the adhesion (bondability) with a resin (for example, a resin mold portion described later) covering the surface of the composite material molded body 10. This is because it is easy to increase the contact area of the resin with respect to the laser irradiation mark 18.

The laser irradiation mark 18 includes an oxide film containing a main component element of soft magnetic particles. The laser irradiation mark 18 is formed by irradiating the conduction portion with a laser as described above. When this conductive portion is irradiated with a laser, the conductive portion is melted by the energy, so that the conductive portion is divided and an oxide film containing the main component element of the soft magnetic particles is formed. This oxide film contains iron, for example, when soft magnetic particles are made of iron or an iron alloy. Examples of the composition include one or more selected from FeO, α-Fe ₂ O ₃ , γ-Fe ₂ O ₃ , and Fe ₃ O ₄ . The composition of the oxide film can be detected by, for example, X-ray diffraction (XRD). For example, the oxide film has a portion having a thickness of 0.1 μm or more, and is 0.5 μm or more, 1.0 μm or more, 3.0 μm or more, further 5.0 μm or more, 7.0 μm or more, particularly 10.0 μm. There are places with the above thickness. The thickness of the oxide film depends on the energy density U (described later) of the laser that forms the laser irradiation trace 18 and tends to increase as the energy density U increases. The thickness of the oxide film can be measured by, for example, cross-sectional observation with a scanning electron microscope (SEM).

(Outer core part)
The outer core portion 12 has a substantially trapezoidal column shape. The outer core portion 12 includes upper and lower surfaces 12u and 12d parallel to the magnetic flux, an outer end surface 12o that connects the upper and lower surfaces 12u and 12d (parallel to the end surface 11E of the inner core portion 11), and an outer end surface 12o. And an opposite inner end face 12i. The inner end face 12 i is formed continuously between the inner core parts 11 and the inner side faces of the inner core parts 11. Here, the inner end surface 12 i is also formed continuously on the lower surface 11 d of each inner core portion 11. The entire circumference of the boundary between the outer core portion 12 and the inner core portion 11 (the envelope edge of both inner core portions 11 including the peripheral edge of the inner end surface 12i of the outer core portion 12) is divided so as to divide the axial direction of the magnetic flux. A parting line 15 is formed over the entire area. The upper and lower surfaces 12u and 12d of the outer core portion 12 are slidable contact areas that are in sliding contact with the inner surface of the mold, like the upper and lower surfaces 11U and 11D of the inner core portion 11, and the outer end surface 12o and the inner end surface 12i of the outer core portion 12. Is a non-sliding contact region that is not slidably contacted with the inner surface of the mold, like the end surface 11E of the inner core portion 11.

(Parting line)
The parting line 15 corresponds to the dividing surface of the mold. The parting line 15 is substantially made of a resin, and is formed to protrude outward from the surface of the composite material molded body 10. The parting line 15 has a transverse cross-sectional shape that has the widest width on the base side of the parting line 15 and gradually becomes narrower toward the tip side. The protruding height and base width of the parting line 15 depend on the shape of the dividing surface of the mold and the molding conditions. For example, the protruding height of the parting line 15 is 0.05 mm or more and 10 mm or less. The width of the base of the line 15 is 0.05 mm or more and 1 mm or less. In FIG. 1 (FIG. 2), the parting line 15 is emphasized and protruded for convenience of explanation.

  The parting line 15 is formed at a part where the axial direction of the magnetic flux is divided (a part where the surface including the parting line 15 is perpendicular to the magnetic flux), depending on the shape of the composite material molded body 10 to be molded. There is no particular limitation as long as it can be punched in a parallel direction. Here, the part where the parting line 15 is formed is a boundary between the outer core part 12 and the inner core part 11. That is, the parting line 15 is formed in a frame shape and exists on a single plane. For example, a stepped part that is partly formed in a stepped shape or a curved part that is formed in a curved shape is an outer core part. 12 may be formed on the upper surface 12u or the lower surface 12d.

  The composite material molded body 10 may include at least one of a resin remelting mark and a fracture mark formed on at least a part of the parting line 15 (both not shown). The remelt mark can be formed by a heat treatment described later. The fracture mark can be formed by, for example, breaking the parting line 15 with a deburring brush.

  The form of the remelt mark is (1) When the protrusion height is lower than that of the parting line 15 but protrudes outward from the surface of the composite material molded body 10 (2) The periphery of the parting line 15 And (3) the case where it is recessed more than its periphery. Although the width | variety of a remelting mark depends on the formation method and conditions, the width of the parting line 15, etc., 0.1 mm or more and 20 mm or less are mentioned, for example. The surface roughness of the remelting marks depends on the formation method and form of the remelting marks. For example, when the shape of the remelting mark formed by the laser protrudes from the surface, the arithmetic average in the non-sliding contact area (for example, the end surface 11E), the sliding contact area (for example, the upper surface 11U, 12u), and the remelting mark The ratio of the roughness Ra is about non-sliding contact area: sliding contact area: remelting mark = 1: 8-15: 16-30.

  On the other hand, the shape of the fracture mark is often substantially flush with the periphery of the parting line 15. The surface roughness of the fracture mark is rougher than that around the parting line 15. For example, the ratio of the arithmetic average roughness Ra in the non-sliding contact region (for example, the end surface 11E), the sliding contact region (for example, the upper surface 11U, 12u, etc.), and the fracture mark is, for example, non-sliding contact region: sliding contact region: rupture It is mentioned that the marks are about 1: 8 to 15:16 to 35.

  By providing remelting marks and fracture marks, it is easy to improve adhesion (bondability) with a resin (for example, a resin mold part to be described later) that covers the surface of the composite material molded body 10 as with the laser irradiation marks 18. In particular, when a remelting mark is provided, rust of the soft magnetic powder can be suppressed. Even if the soft magnetic powder is exposed in the parting line 15, the resin can be flowed by the heat treatment at the time of forming the remelt mark, and the exposed soft magnetic powder can be embedded in the resin. Because.

[Constituent materials]
(Soft magnetic powder)
Examples of the material of the soft magnetic powder include soft magnetic materials such as iron group metals, Fe-based alloys containing Fe as a main component, ferrite, and amorphous metals. The material of the soft magnetic powder is preferably an iron group metal or an Fe group alloy in terms of eddy current loss and saturation magnetization. Examples of the iron group metal include Fe, Co, and Ni. In particular, Fe may be pure iron (including inevitable impurities). Since Fe has a high saturation magnetization, the saturation magnetization of the composite material can be increased as the Fe content is increased. The Fe-based alloy contains at least one element selected from Si, Ni, Al, Co, and Cr as additive elements in a total amount of 1.0% by mass to 20.0% by mass, with the balance being Fe and inevitable And having a composition consisting of mechanical impurities. Examples of Fe-based alloys include Fe-Si alloys, Fe-Ni alloys, Fe-Al alloys, Fe-Co alloys, Fe-Cr alloys, and Fe-Si-Al alloys (Sendust). It is done. In particular, Fe-based alloys containing Si, such as Fe-Si based alloys and Fe-Si-Al based alloys, have high electrical resistivity, can easily reduce eddy current loss, and have low hysteresis loss, and are composite material molded bodies. 10 low iron loss can be achieved. For example, in the case of an Fe—Si based alloy, the Si content is 1.0% by mass or more and 8.0% by mass or less, and preferably 3.0% by mass or more and 7.0% by mass or less. The soft magnetic powder may be a mixture of multiple types of powders of different materials. For example, a mixture of both types of powders of Fe and an Fe-based alloy can be used.

  The average particle size of the soft magnetic powder is preferably 5 μm or more and 300 μm or less, particularly preferably 10 μm or more and 100 μm or less. If the average particle size of the soft magnetic powder is 5 μm or more, it is difficult to agglomerate, and it is easy to reduce the eddy current loss because the resin is easily interposed between the soft magnetic particles. If the average particle diameter of the soft magnetic powder is 300 μm or less, the eddy current loss of the powder itself can be reduced because the powder is not excessively large, and consequently the eddy current loss of the composite material molded body 10 can be reduced. In addition, it is easy to increase the saturation magnetization of the composite material molded body 10 by increasing the filling factor.

  The soft magnetic powder may be a mixture of a plurality of types of powders having different particle sizes. When a soft magnetic powder obtained by mixing a fine powder and a coarse powder is used as the material of the composite material molded body 10, it is easy to obtain the reactor 1 having a high saturation magnetic flux density and a low loss. When using a soft magnetic powder in which fine powder and coarse powder are mixed, it is preferable to use different materials so that one is Fe and the other is Fe-based alloy. Thus, if the materials of the two powders are different, both the characteristics of Fe (high saturation magnetization) and the characteristics of Fe-based alloys (high electrical resistance and easy to reduce eddy current loss) can be combined and saturated. Good balance between magnetization improvement effect and iron loss. When different materials are used for both powders, either the coarse powder or the fine powder may be Fe (Fe-based alloy), but the fine powder is preferably Fe. That is, it is preferable that the coarse-grained powder is an Fe-based alloy. By doing so, the iron loss is lower than when the fine powder is an Fe-based alloy and the coarse powder is Fe.

  The soft magnetic powder may have an insulating coating on the surface (outer periphery) of the soft magnetic particles in order to improve the insulation. The soft magnetic powder may be subjected to a surface treatment (for example, a silane coupling treatment) for enhancing the compatibility with the resin and the dispersibility of the resin.

  The content of the soft magnetic powder in the composite material molded body 10 is preferably 30% by volume or more and 80% by volume or less when the composite material molded body 10 is 100% by volume. Since the ratio of the magnetic component is sufficiently high because the soft magnetic powder is 30% by volume or more, when the reactor 1 is constructed using this composite material molded body 10, the saturation magnetization is easily increased. Since the resin content is relatively small as the content increases, it is easy to form a conduction portion in which the soft magnetic particles are conducted in the sliding contact region. However, since the composite material molded body 10 has the laser irradiation marks 18, eddy current loss can be reduced even if the content of the soft magnetic powder is large. When the soft magnetic powder is 80% by volume or less, since the ratio of the magnetic component is not excessively high, the insulation between the soft magnetic particles can be enhanced, and eddy current loss can be reduced. Further, the fluidity of the mixture of the soft magnetic powder and the resin is excellent, and the productivity of the composite material molded body 10 is excellent. The content of the soft magnetic powder is 50% by volume or more, further 55% by volume or more, particularly 60% by volume or more. The content of the soft magnetic powder is 75% by volume or less, particularly 70% by volume or less.

(resin)
Examples of the resin include thermosetting resins such as epoxy resin, phenol resin, silicone resin, and urethane resin, polyphenylene sulfide (PPS) resin, polyamide resin (for example, nylon 6, nylon 66, nylon 9T), and liquid crystal polymer (LCP). ), Thermoplastic resins such as polyimide resins and fluororesins. In addition, a room temperature curable resin, a BMC (Bulk molding compound) in which calcium carbonate or glass fiber is mixed with an unsaturated polyester, a millable silicone rubber, a millable urethane rubber, or the like can also be used.

(Other)
In addition to the soft magnetic powder and the resin, the composite material molded body 10 may contain a powder (filler) made of a nonmagnetic material such as ceramics such as alumina or silica. The filler contributes to improvement of heat dissipation and suppression (uniform dispersion) of uneven distribution of the soft magnetic powder. Further, if the filler is fine and is interposed between soft magnetic particles, it is possible to suppress a decrease in the ratio of the soft magnetic powder due to the inclusion of the filler. The content of the filler is preferably 0.2% by mass or more and 20% by mass or less, more preferably 0.3% by mass or more and 15% by mass or less, particularly 0.5% by mass or more, when the composite material is 100% by mass. 10 mass% or less is preferable.

[Effects of composite material compact]
According to the composite material molded body 10 described above, the entire range of the circumferential surface of the inner core portion 11 in the axial direction is formed by the laser irradiation marks 18 formed from one end to the other end on the outer side surface of each inner core portion 11. Thus, eddy current flowing along the circumferential direction of the circumferential surface can be made difficult to flow. Therefore, eddy current loss can be reduced and a low-loss reactor can be constructed.

[Method of manufacturing composite material molded body]
The composite material molded body 10 can be manufactured by a method for manufacturing a composite material molded body including the following raw material manufacturing process and laser irradiation process. The manufacturing method of the composite material molded body can further include a remelting mark forming step and a breakage mark forming step performed at an appropriate time as necessary after the material preparation step.

[Material production process]
In the raw material production step, a molded body material of the composite material molded body 10 is obtained by filling an unsolidified (fluid state) mixture containing soft magnetic powder and resin from the gate into the mold cavity to solidify the resin. Is made. The molded body material corresponds to the composite material molded body 10 not irradiated with laser. Here, a pair of inner core part 11 and outer core part 12 are provided. Although not shown in the drawings, the mold used for this production is divided at the boundary between the outer core portion 12 of the composite material molded body 10 and the pair of inner core portions 11, and the mold drawing direction is a pair with the outer core portion 12. A mold in which the inner core portion 11 is aligned is used. Injection molding, hot press molding, and MIM (Metal Injection Molding) can be used as a method for producing a molded body material using a mold.

[Laser irradiation process]
In the laser irradiation step, a laser irradiation mark 18 is formed by irradiating the circumferential surface with laser so as to divide the circumferential direction of the circumferential surface along the circumferential direction with the magnetic flux as an axis among the surface of the inner core portion 11.

  The kind of laser should just be a laser which can divide | segment a conduction | electrical_connection part. Specific examples include a solid laser in which the laser medium is solid. For example, a laser selected from a YAG laser, a YVO4 laser, and a fiber laser is preferable. By doing so, the said conduction | electrical_connection part can be parted. Each of these lasers includes known lasers in which various materials are doped in the medium of each laser. That is, the YAG laser may be doped with Nd, Er, or the like in the medium, the YVO4 laser may be doped with Nd or the like in the medium, and the fiber laser is a fiber that is the medium. The core is doped with a rare earth element or the like, for example, doping with Yb or the like.

  The wavelength of the laser is more preferably within the wavelength absorption region of the soft magnetic particles (conduction part). By doing so, it becomes easy to divide a conduction part, and it can control removing other than the conduction part concerned. Specifically, the wavelength is preferably about 532 nm to 1064 nm.

The energy density U (W / mm ² ) of the laser is expressed by U = P / S, where P (W) is the average output of the laser and S (mm ² ) is the irradiation area of the laser. preferably satisfies the ^{2W / mm 2 ≦ U ≦ 450W} / mm 2. By setting the energy density U to 2 W / mm ² or more, the resin of the parting line 15 can be sufficiently remelted. On the other hand, when the energy density U is 450 W / mm ² or less, the contact between the soft magnetic particles due to excessive melting can be sufficiently suppressed. The energy density U (W / mm ² ) of the laser is particularly preferably ² W / mm ² ≦ U ≦ 35 W / mm ² .

  The ratio of the irradiation interval to the laser beam diameter is preferably small. The beam diameter refers to the diameter of the laser on the conducting part. The irradiation interval refers to the distance that the laser beam moves in the scanning direction during the irradiation time of one pulse of laser. If the ratio of the irradiation interval to the laser beam diameter is small, when the conducting portion is scanned with the laser, the unprocessed area where the laser is not irradiated can be reduced, and the conducting portion can be easily divided. Specifically, the ratio is preferably 0.35 or less, and particularly preferably 0.30 or less.

  A smaller ratio of the scanning interval to the laser beam diameter is also preferable. The scanning interval refers to a distance when moving a line scanned by a laser to an adjacent line. That is, if the ratio of the scanning interval to the laser beam diameter is small, the region not irradiated with the laser can be reduced as described above, and the conducting portion can be easily divided.

  The number of laser overlaps is preferably a plurality of times. The number of overlaps refers to the number of times the same area is processed (scanned) with a laser. The greater the number of laser overlaps, the better. If it does so, the conduction | electrical_connection part can be divided reliably. Specifically, the number of times of overlapping is 5 times or more, and particularly preferably 10 times or more.

[Remelt mark formation process]
In the remelting mark forming step, heat treatment is performed on at least part of the parting line 15 to form a remelting mark. As the heat treatment for forming the remelting marks, there are a contact type in which a heating medium is brought into direct contact and an indirect type in which the heating medium is not brought into contact.

  Examples of the contact method include ultrasonic heating, hot plate heating, and impulse welder. The ultrasonic heating is a method in which ultrasonic vibration generated by an ultrasonic generator and an ultrasonic transducer is transmitted to the surface of the parting line 15 by a horn (heating medium) and heated by frictional heat generated. Hot plate heating is a method of heating by bringing a heated metal plate (heating medium) into contact with the parting line 15. The impulse welder is a method in which a pressurized heater wire (heating medium) is installed in the parting line 15 and the parting line 15 is heated with heat generated by flowing an instantaneous large current through the heater wire.

  On the other hand, examples of the indirect method include light heating. Examples of the light heating include laser heating and infrared heating using temperature radiation. The laser heating may be performed under the same conditions as those for forming the laser irradiation mark 18 (energy density U or the like).

[Break mark forming step]
In the fracture trace forming step, as described above, the fracture trace is formed by breaking at least a part of the parting line 15 with the deburring brush. A commercially available deburring brush can be used.

[Reactor]
The composite material molded body 10 described above can be suitably used for at least a part of the magnetic core 3 of the reactor 1 shown in FIG. As described at the beginning of the first embodiment, the reactor 1 includes the coil 2 including the pair of winding portions 2a and 2b and the magnetic core 3 including the two core members 30 having the same shape. Both core members 30 are composed of the composite material molded body 10 described above.

[coil]
The pair of winding portions 2a and 2b are formed by spirally winding one continuous winding 2w having no joint portion, and are connected via a connecting portion 2r. As the winding 2w, a coated wire having an insulating coating made of an insulating material on the outer periphery of a conductor such as a flat wire or a round wire made of a conductive material such as copper, aluminum, or an alloy thereof can be suitably used. In this example, the conductor is made of a flat rectangular wire made of copper, and the insulating covering is made of a coated rectangular wire made of enamel (typically polyamideimide). Each winding part 2a, 2b is comprised by the edgewise coil which made this covering rectangular wire the edgewise winding. The winding portions 2a and 2b are arranged in parallel (side by side) so that the respective axial directions are parallel to each other. The shape of the winding parts 2a and 2b is a hollow cylindrical body (square cylinder) having the same number of turns. The end surface shape of the winding parts 2a and 2b is a shape obtained by rounding the corners of the rectangular frame. The connecting portion 2r is formed by bending a part of the winding in a U shape on one end side (the right side in FIG. 2) of the coil 2. The upper surface of the connecting portion 2r is substantially flush with the upper surface of the turn forming portion of the coil 2. Both end portions 2e of the winding 2w of the winding portions 2a and 2b are extended from the turn forming portion. Both end portions 2e are connected to a terminal member (not shown), and an external device (not shown) such as a power source for supplying power to the coil 2 is connected through the terminal member.

[Magnetic core]
The pair of inner core portions 11 of each core member 30 are disposed inside the pair of winding portions 2 a and 2 b when assembled to the coil 2. Similarly, the outer core portion 12 of each core member 30 is disposed so as to protrude from the coil 2 when the core member 30 is assembled to the coil 2. The annular magnetic core 3 is formed by connecting the end surfaces 11E (linkage surfaces) of the inner core portion 11 of the one and the other core members 30 within the winding portions 2a and 2b. When the coil 2 is excited by the connection of the core members 30, a closed magnetic path is formed, and the magnetic flux is parallel to the longitudinal direction of the inner core portion 11 and orthogonal to the interlinkage plane. The core members 30 may be connected without interposing a gap material between the interlinkage surfaces of the inner core portion 11, or may be connected with a gap material interposed. An adhesive can be used to connect the core members 30 to each other. A gap (air gap) may be provided between the core members 30. Examples of the material of the gap material include materials having lower magnetic permeability than the core member 30. For example, a nonmagnetic material such as alumina or unsaturated polyester, a nonmagnetic material such as PPS resin, and a magnetic material (iron powder or the like) are used. And a mixture containing the same.

[Others]
(Resin mold part)
The magnetic core 3 may further include a resin mold portion that covers the surface of the core member 30. Since the core member 30 includes the laser irradiation marks 18, the adhesion (bondability) of the resin mold portion to the core member 30 can be improved. Furthermore, if the parting line 15 of the core member 30 has a remelt mark or a break mark, the adhesion can be improved. The covering region of the resin mold part can be, for example, the entire surface of the core member 30. The constituent material of the resin mold part is, for example, the same thermoplastic resin (for example, PPS resin) as the resin of the composite material molded body 10 described above or a thermosetting resin, or the following thermoplastic resin or thermosetting resin. Is mentioned. Examples of the thermoplastic resin include polytetrafluoroethylene (PTFE) resin, polybutylene terephthalate (PBT) resin, acrylonitrile / butadiene / styrene (ABS) resin, and the thermosetting resin includes unsaturated polyester resin. Is mentioned. This constituent resin may contain a ceramic filler such as alumina or silica. If it does so, it will become a resin mold part excellent in heat conductivity, and the heat dissipation of the reactor 1 will be improved.

[Reactor effects]
According to the reactor 1 described above, since the core member includes the composite material molded body having the laser irradiation trace 18 parallel to the magnetic flux on the surface parallel to the magnetic flux, the eddy current can hardly flow through the laser irradiation trace 18, so that the loss is low. It is.

《Test example》
A sample of a composite material molded body including a soft magnetic powder and a resin encapsulating the soft magnetic powder in a dispersed state was prepared, and the magnetic characteristics of the sample were evaluated.

[Sample No. 1-1]
Sample No. As a composite material molded body of 1-1, a composite material molded body 10 shown in FIG. 1 was manufactured through a raw material preparation process, a material manufacturing process, and a laser irradiation process.

[Raw material preparation process]
In the raw material preparation step, a mixture of soft magnetic powder and resin was prepared. As the soft magnetic powder, an Fe—Si alloy powder having an average particle diameter of 80 μm, containing 6.5% by mass of Si, and having the balance of Fe and inevitable impurities was used. On the other hand, a PPS resin was used as the resin. The soft magnetic powder and the resin were mixed, and the resin was kneaded with the soft magnetic powder in a molten state to prepare a mixture. The content of the soft magnetic powder in the mixture was 70% by volume.

[Material production process]
In the material production process, a U-shaped molded material comprising a pair of inner core portion 11 and outer core portion 12 was produced by injection molding. In the production of the molded body material, a mold having a split surface at the boundary between the outer core portion 12 and the pair of inner core portions 11, that is, the direction in which the outer core portion 12 and the pair of inner core portions 11 are arranged is the die cutting direction. The above mold was used, and the above mixture was filled in the mold and cooled and solidified. The dividing surface of the mold was to be the boundary between the outer core portion 12 and the inner core portion 11. In this molded body material, a parting line 15 is formed at the boundary between the outer core portion 12 and the inner core portion 11.

[Laser irradiation process]
In the laser irradiation step, a laser irradiation mark 18 was formed by irradiating laser from one end to the other end of the outer side surface of the left and right inner core portions 11 of the molded body material taken out from the mold. The laser irradiation conditions were a processing width of 3 mm (1/60 of the circumference of the circumferential surface) and a laser energy density U of 5.5 W / mm ² . Sample No. The composite material molded body 1-1 includes a laser irradiation mark 18 formed from one end of the left surface 11 </ b> L of the left inner core portion 11 to the other end, and one end of the right surface 11 </ b> R of the right inner core portion 11. And a laser irradiation mark 18 formed over the end. Laser irradiation traces 18 are not formed on the right surface 11R of the left inner core portion 11 and the left surface 11L of the right inner core portion 11. Sample No. The arithmetic average roughness Ra of the non-sliding contact region (end surface 11E), the sliding contact region (upper surface 11U), and the laser irradiation mark in the composite material molded body of 1-1 was measured using a commercially available surface roughness measuring device. JIS B 0601 (2013). The ratio of the arithmetic average roughness Ra was approximately non-sliding contact area: sliding contact area: laser irradiation mark = 1: 10: 21.

[Sample No. 1-101]
Sample No. 1-101 except that the laser irradiation process is not performed. It was produced in the same manner as 1-1. That is, sample no. The composite material molded body of 1-101 is still in a state of being taken out from the mold, and the laser irradiation trace 18 is not formed.

[Magnetic properties]
A copper wire was wound around an annular test piece obtained by combining two composite material molded bodies of each sample, and a measurement member having a primary winding coil: 300 turns and a secondary winding coil: 20 turns was produced. About each measurement member, the iron loss W4 / 20k (W) in excitation magnetic flux density Bm: 4kG (= 0.4T) and measurement frequency: 20kHz was measured using the AC-BH curve tracer. The results are shown in Table 1.

  As shown in Table 1, sample no. 1-1 has an iron loss of 8.9 W. The iron loss of 1-101 was 9.8 W. In this way, sample no. 1-1 is Sample No. Compared to 1-101, the iron loss was low. Such a result was obtained in Sample No. The composite material molded body of 1-1 was sample No. This is probably because the eddy current loss was effectively reduced compared to 1-101.

  Sample No. The composite material molded body of 1-1 was irradiated with a laser so as to divide the circumferential direction of the circumferential surface of the inner core portion after taking out the molded body material from the mold having the mold drawing direction parallel to the magnetic flux. As a result, it was possible to form a laser irradiation mark 18 having a high electrical resistance in which the conduction portion was divided. Therefore, the eddy current flowing along the circumferential direction of the circumferential surface can be made difficult to flow over the entire length of the inner core portion. On the other hand, sample No. Since the composite material molded body of 1-101 does not have a high electrical resistance portion such as a laser irradiation trace on the circumferential surface and a conductive portion having a low electrical resistance is formed over the entire circumferential surface, The eddy current flowing along the circumferential direction centered on the magnetic flux on the side surface of the core portion could not be suppressed.

  The present invention is not limited to these exemplifications, but is defined by the scope of the claims, and is intended to include all modifications within the scope and meaning equivalent to the scope of the claims. For example, the shape of the core member can be appropriately selected depending on the combination of a plurality of core members of the magnetic core. A combination of a plurality of core members may be in a form called an LL (JJ) type core in which one inner core part is integrated with an outer core part in addition to the above-described U-U core. it can. Moreover, it can be set as a reactor provided with the coil which has only one winding part, and the magnetic core called EE type | mold core, EI type | mold core, etc.

  The composite material molded body of the present invention can be suitably used for magnetic cores of various magnetic parts (reactors, choke coils, transformers, motors, etc.) and materials thereof. The reactor of the present invention includes various converters such as an in-vehicle converter (typically a DC-DC converter) and an air conditioner converter mounted on a vehicle such as a hybrid vehicle, a plug-in hybrid vehicle, an electric vehicle, and a fuel cell vehicle. It can be suitably used as a component part of a power conversion device.

DESCRIPTION OF SYMBOLS 10 Composite material molded body 11 Inner core part 11U Upper surface 11D Lower surface 11L Left surface 11R Right surface 11E End surface 12 Outer core part 12u Upper surface 12d Lower surface 12o Outer end surface 12i Inner end surface 15 Parting line 18 Laser irradiation trace 1 Reactor 2 Coil 2a, 2b Winding Part 2r connecting part 2w winding 2e end 3 magnetic core 30 core member

Claims (9)

A composite material molded body comprising a soft magnetic powder having a plurality of soft magnetic particles and a resin encapsulating the soft magnetic powder in a dispersed state,
A parting line corresponding to a split surface of a mold for molding the composite material molded body;
An inner core disposed inside the coil;
With laser irradiation traces formed on the surface of the inner core part,
Of the surface of the inner core part, when the surface along the circumferential direction around the magnetic flux excited in the inner core part by the coil as a circumferential surface,
The parting line is formed to sever the axial direction of the magnetic flux,
The said laser irradiation trace is a composite material molded object formed in the said surrounding surface so that the circumferential direction of the said surrounding surface may be parted.   The composite material molded body according to claim 1, wherein the laser irradiation trace has an oxide film containing a main component element of the soft magnetic particles.   The composite material molded body according to claim 1 or 2, wherein an arithmetic average roughness Ra of the laser irradiation trace is larger than a periphery of the laser irradiation trace on the circumferential surface.   The composite material molded body according to any one of claims 1 to 3, wherein a width of the laser irradiation mark is equal to or greater than an average particle diameter of the soft magnetic powder and equal to or less than ¼ of a circumference of the circumferential surface. A pair of said inner core parts located in parallel;
An outer core portion arranged on the outside of the coil and connecting both inner core portions;
The composite material molded body according to any one of claims 1 to 4, wherein the circumferential surface on which the laser irradiation trace is formed is orthogonal to a parallel direction of the pair of inner core portions.   The composite material molded body according to any one of claims 1 to 5, wherein the soft magnetic powder includes Fe-based alloy soft magnetic particles containing Si by 1.0 mass% or more and 8.0 mass% or less.   The composite material molded body according to any one of claims 1 to 6, wherein a content of the soft magnetic powder with respect to the entire composite material molded body is 30% by volume or more and 80% by volume or less.   The composite material molded body according to any one of claims 1 to 7, wherein an average particle diameter of the soft magnetic powder is 5 µm or more and 300 µm or less. A reactor comprising a coil formed by winding a winding and a magnetic core on which the coil is disposed,
At least one part of the said magnetic core is a reactor provided with the composite material molded object of any one of Claims 1-8.

Images