# US 11,908,604 B2 · Composite material molded article, reactor, comprising a roughened surface > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,908,604 B2 - Document ID: US11908604B2 - Status: Granted - Kind: B2 - Application number: 15/781,567 - Filed: 2016-12-12 - Published: 2019-08-22 - Granted: 2024-02-20 - Earliest claimed: 2015-12-24 - Assignees: Autonetworks Technologies, Ltd.; Sumitomo Wiring Systems, Ltd.; Sumitomo Electric Industries, Ltd. - Applicants: AutoNetworks Technologies, Ltd.; Sumitomo Wiring Systems, Ltd.; Sumitomo Electric Industries, Ltd. - Inventors: Shintaro Nanbara; Takashi Takada; Kazushi Kusawake - Web page: https://patentgrep.com/patent/US11908604B2 ## CPC - H01F 1/26: by macromolecular organic substances - H01F 27/255: made from particles (H01F27/26 takes precedence) - C08K 3/34: Silicon-containing compounds - H01F 1/20: in the form of particles, e.g. powder (H01F1/147 takes precedence) - H01F 3/08: made from powder (powder coatings on sheets H01F3/02; on strips or ribbons H01F3/04; on wires H01F3/06) - H01F 3/10: Composite arrangements of magnetic circuits - H01F 27/263: {Fastening parts of the core together} - H01F 27/2823: {Wires (H01F27/2866 takes precedence)} - H01F 37/00: Fixed inductances not covered by group H01F17/00 - H01F 41/0246: {Manufacturing of magnetic circuits by moulding or by pressing powder (magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36)} - H01F 41/063: with insulation - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES - C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09) ## 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 μm or more on at least a portion of its surfaces. ## Claims ### Claim 1 A composite material molded article comprising: a soft magnetic powder; and a resin containing the soft magnetic powder in a dispersed state; and an interlinkage surface, the interlinkage surface is a surface that intersects a magnetic flux excited in the composite material molded article among surfaces of the composite material molded article; and wherein a roughened region has an arithmetic average roughness Ra of 4.4 μm or more and has such surface properties defined by innumerable needle-shaped projections projecting outward from a surface of the roughened region, and wherein the innumerable needle-shaped projections are only formed on the interlinkage surface. ### Claim 2 (depends on 1) The composite material molded article according to claim 1, wherein the soft magnetic powder contains soft magnetic particles made of an Fe-based alloy that contains Si in an amount of 1.0 mass % or more and 8.0 mass % or less. ### Claim 3 (depends on 1) The composite material molded article according to claim 1, wherein the soft magnetic powder is contained in the composite material molded article in an amount of 30 vol % or more and 80 vol % or less with respect to the entirety of the composite material molded article. ### Claim 4 (depends on 1) The composite material molded article according to claim 1, wherein the soft magnetic powder has an average particle diameter of 5 μm or more and 300 μm or less. ### Claim 5 (depends on 1) A reactor comprising: a coil obtained by winding a winding wire; and a magnetic core around which the coil is arranged, wherein at least a portion of the magnetic core includes the composite material molded article according to claim 1. ### Claim 6 A composite material molded article comprising: a pair of inner core portions each having: a soft magnetic powder; a resin containing the soft magnetic powder in a dispersed state; and an interlinkage surface, the interlinkage surface being a surface that intersects a magnetic flux excited in the composite material molded article among surfaces of the composite material molded article; and a roughened region having an arithmetic average roughness Ra of 4.4 μm or more and has such surface properties defined by innumerable needle-shaped projections projecting outward from a surface of the roughened region, and wherein the innumerable needle-shaped projections are only formed on the interlinkage surface; wherein each of the interlinkage surfaces are joined to each other by an adhesive. ### Claim 7 A composite material molded article comprising: soft magnetic powder; and resin containing the soft magnetic powder in a dispersed state, and a peripheral surface includes surfaces along a circumferential direction of a magnetic flux excited in the composite material molded article among surfaces of the composite material molded article, and the roughened region is formed only on the peripheral surface. ### Claim 8 (depends on 7) The composite material molded article according to claim 7, wherein the soft magnetic powder contains soft magnetic particles made of an Fe-based alloy that contains Si in an amount of 1.0 mass % or more and 8.0 mass % or less. ### Claim 9 (depends on 7) The composite material molded article according to claim 7, wherein the soft magnetic powder is contained in the composite material molded article in an amount of 30 vol % or more and 80 vol % or less with respect to the entirety of the composite material molded article. ### Claim 10 (depends on 7) The composite material molded article according to claim 7, wherein the soft magnetic powder has an average particle diameter of 5 μm or more and 300 μm or less.