JP2008121952A - Electric heater, air conditioner for vehicle, and method of manufacturing electric heater - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an electric heater facilitating lamination work of a heat exchange member, a current carrying heat generating member and an electrode member. <P>SOLUTION: A plate 22b constituting a heat exchange fin 22 is provided with a collar part 22c, and a claw part 24a provided at an electrode plate 24 is locked to the collar part 22c and integrated. The integrated heat exchange fin 22 and electrode plate 24, and the current carrying heat generating member are sequentially laminated. Since the electric motor can be constituted only by laminating substantially two kinds of components in sequence, lamination work can be facilitated. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to an electric heater that generates heat when supplied with electric power, a vehicle air conditioner using the electric heater, and an electric heater manufacturing method.

Conventionally, Patent Document 1 discloses an electric heater configured by sequentially laminating a plurality of heat dissipating fins, an energizing heat generating member, and an electrode plate for energizing the energizing heat generating member. Furthermore, in the electric heater of this patent document 1, each said component is laminated | stacked, and it fixes by inserting | pinching with a flame | frame via the spring member from the both ends side of the lamination direction.
US Pat. No. 5,562,844

  By the way, in the electric heater of patent document 1, when laminating | stacking the heat radiating fin which is a heat exchange member, the energization heat generating member, and the electrode plate which is an electrode member, it is necessary to laminate | stack three types of components one by one. The work is complicated and the manufacturing cost is increased.

  In view of the above points, the first object of the present invention is to facilitate laminating work in an electric heater configured by sequentially laminating a heat exchange member, an energizing heat generating member and an electrode member.

  The second object of the present invention is to provide a method of manufacturing an electric heater that is advantageous in reducing the manufacturing cost.

  In order to achieve the above object, in the present invention, an energization heating member (23) that generates heat by energization, a heat exchange member (22) that promotes heat dissipation of the energization heating member (23), an energization heating member (23), and An electric heater configured by sequentially laminating an electrode member (24) that is in contact with the heat exchange member (22) and energizes the energization heating member (23), and the heat exchange member (22) has a heat radiation area. It has a fin (22a) to be increased and a plate (22b) fixed to both ends in the stacking direction of the fin (22a). The plate (22b) includes a longitudinal direction and a stacking direction of the heat exchange member (22). A hook part (22c) extending in the width direction perpendicular to the electrode part is provided, and the electrode member (24) is provided with a claw part (24a) locked to the hook part (22c). 24) and the heat exchange member (22) It is a first feature of being laminated in reduction state.

  According to this, the nail | claw part (24a) provided in the electrode member (24) is latched by the collar part (22c) provided in the plate (22b), and an electrode member (24) and a heat exchange member (22). ) Are integrated (sub-assembled) in a stacked state, so that an electric heater can be constructed by simply stacking two types of components in sequence. Therefore, the stacking operation can be facilitated with respect to the electric heater of Patent Document 1, and the manufacturing cost can be reduced.

  The integration in the present invention does not mean that the electrode member (24a) and the plate (22b) are configured as one member in a relatively completely fixed state, but can be removed. It also means that it is configured as one member in a temporarily fixed state.

  In the electric heater having the first feature described above, a chamfered portion (22e) whose width direction dimension is gradually reduced may be provided on at least one of the longitudinal ends of the plate (22b). According to this, the assembly | attachment property at the time of moving (sliding) an electrode member (24) or a heat exchange member (22) to a longitudinal direction and latching a nail | claw part (24a) to a collar part (22c) can be improved.

  In the electric heater having the first feature described above, the flange portion (22c) is provided with a cut-and-raised portion (22d) cut and raised toward the opposite side of the contact surface with the electrode member (24). May be. According to this, when the electrode member (24) and the heat exchange member (22) are locked, the claw portion (24a) can be positioned by the cut-and-raised portion (22d), and the claw portion (24a) (22c) can be prevented from coming off.

  In the electric heater having the first feature described above, specifically, the energization heat generating member (23) may be configured to include a PTC element (23a).

  Moreover, in this invention, let the vehicle air conditioner provided with the electric heater of the above-mentioned 1st characteristic be the 2nd characteristic. According to this, the manufacturing cost reduction as the whole vehicle air conditioner can also be aimed at by the manufacturing cost reduction effect of the electric heater (20).

  Further, in the present invention, the energization heat generating member (23) that generates heat by energization, the heat exchange member (22) that promotes heat radiation of the energization heat generation member (23), the energization heat generation member (23), and the heat exchange member (22). Is a method of manufacturing an electric heater which is formed by sequentially laminating an electrode member (24) for energizing an energizing heat generating member (23) in contact with the heat generating member (23). (22a) and plates (22b) fixed to both ends in the stacking direction of the fins (22a), and further perpendicular to the longitudinal direction and stacking direction of the heat exchange member (22) on the plate (22b) A member provided with a flange portion (22c) extending in the width direction is prepared, and a claw portion (24a) provided on the electrode member (24) is engaged with the flange portion (22c), so that the electrode member (24 ) And heat exchange member (22) A integration step of reduction, heat-generating member (23), and, for that and a laminating step of laminating an integrated electrode member (24) and the heat exchange member (22) and the third feature.

  According to this, since the electrode member (24) and the heat exchange member (22) can be stacked in an integrated (sub-assembled) state, the electric heater is substantially stacked by sequentially stacking two types of components. Can be configured. Therefore, it is advantageous for reducing the manufacturing cost as compared with the case of sequentially stacking three types of parts.

  In addition, the code | symbol in the bracket | parenthesis of each means described in this column and the claim shows the correspondence with the specific means as described in embodiment mentioned later.

  1-7 demonstrates one Embodiment of this invention. FIG. 1 shows an electric heater 20 according to the present invention applied to a vehicle air conditioner. FIG. 1 is a schematic sectional view of an indoor air conditioning unit 1 of the vehicle air conditioner.

  The vehicle air conditioner is mounted on a vehicle (for example, a hybrid vehicle or a diesel engine vehicle) in which the engine cooling water temperature does not easily rise when the engine is started or a vehicle with a cold district specification. The electric heater 20 of the present invention is used as an auxiliary heater for heating the blown air.

  First, the indoor air conditioning unit 1 is disposed inside the instrument panel (instrument panel) at the forefront of the vehicle interior and has a resin case 2 that constitutes an outer shell. An air passage through which air flows toward the vehicle interior is formed inside the case 2, and an inside / outside air switching box 3 is disposed at the most upstream part of the air flow.

  The inside / outside air switching box 3 includes an inside air introduction port 4, an outside air introduction port 5, and an inside / outside air switching door 6. The inside air introduction port 4 is an introduction port for introducing inside air (vehicle compartment air) into the case 2, and the outside air introduction port 5 is an introduction port for introducing outside air (vehicle compartment outside air) into the case 2. The inside / outside air switching door 6 is disposed inside the inside / outside air switching box 5 so as to be rotatable, and is inside / outside air switching means driven by a servo motor (not shown).

  Specifically, depending on the rotational position of the inside / outside air switching door 6, an inside air mode for introducing inside air from the inside air introduction port 4, an outside air mode for introducing outside air from the outside air introduction port 5, and an inside air / Switch to outside air mode. FIG. 1 shows a state of the inside air mode, and the inside air is introduced into the case 2 as indicated by an arrow A.

  On the downstream side of the air flow in the inside / outside air switching box 5, an electric blower 7 that blows air toward the passenger compartment is disposed. The blower 7 rotates a known centrifugal multiblade fan 7a by an electric motor 7b to blow air in the direction of arrow B. On the downstream side of the air flow of the blower 7, an evaporator 8 that is a cooling heat exchanger for cooling the blown air is disposed.

  The evaporator 8 is one of elements constituting a refrigeration cycle (not shown), and as is well known, absorbs heat from the blown air blown by the blower 7 when the low-pressure refrigerant flowing into the evaporator 8 evaporates. To cool the blown air. On the downstream side of the evaporator 8, a heater core 9 for heating the air (cold air) after passing through the evaporator 8 is arranged.

  The heater core 9 is a heating heat exchanger that reheats the air (cold air) that has passed through the evaporator 8 using the engine coolant as a heat source (the engine coolant circuit is not shown). Further, a bypass passage 10 through which air (cold air) after passing through the evaporator 8 bypasses the heater core 9 and passes through the heater core 9 inside the case 2 is formed.

  In the vehicle air conditioner of the present embodiment, the electric heater 20 is disposed on the downstream side of the heater core 9. When the heater core 9 cannot sufficiently heat the air after passing through the evaporator 8 during the heating operation of the vehicle air conditioner, the electric heater 20 generates heat by being supplied with electric power from a control device (not shown), and after passing through the heater core 9. It is an auxiliary heater that heats the air. Details of the electric heater 20 will be described later.

  As specific control of the electric heater 20 by the control device, for example, the temperature of the engine coolant passing through the heater core 9 is detected, and when the engine coolant temperature is below a predetermined temperature, the heater core 9 evaporates. It may be determined that the air after passing through the vessel 8 is in a state where the air cannot be sufficiently heated, and the electric heater 20 may be supplied with electric power.

  An air mix door 11 is disposed between the evaporator 8 and the heater core 9. The air mix door 11 is rotatably disposed in the case 2 and is driven by a servo motor (not shown) so that its rotational position (opening) can be adjusted continuously.

  Therefore, depending on the opening degree of the air mix door 11, the amount of air passing through the heater core 9 and the electric heater 20 (the amount of hot air indicated by arrow C) and the amount of air passing through the bypass passage 10 (the amount of cold air indicated by arrow D) are as follows. The proportion is adjusted. The hot air (arrow C) and the cold air (arrow D) are mixed downstream of the heater core 9, the electric heater 20, and the bypass passage 10 and blown into the vehicle interior. Air temperature is adjusted.

  In the most downstream part of the air passage of the case 2, a defroster opening 12 for blowing conditioned air toward the front window glass of the vehicle, a face opening 13 for blowing conditioned air toward the face of the occupant, and A total of three types of openings, a foot opening 14 for blowing air-conditioned air toward the passenger's feet, are provided.

  A defroster door 15, a face door 16 and a foot door 17 are rotatably arranged in the upstream portions of these openings 12 to 14, and these doors 15 to 17 are connected to a common servo via a link mechanism (not shown). Opening and closing operation is performed by a motor (not shown). FIG. 1 shows a state of the foot / defroster mode in which the defroster door 15 and the foot door 17 are simultaneously opened.

  Next, the details of the electric heater 20 will be described with reference to FIGS. FIG. 2 is an overall perspective view showing a schematic configuration of the electric heater 20 of the present embodiment, and FIG. 3 is a schematic exploded view of the electric heater 20. Note that the up / down / left / right and front / back arrows in FIG. 2 and the up / down / left / right arrows in FIG.

  2 and 3, the vertical direction is the stacking direction of the energizing heat generating member 23, the heat exchange fins 22, and the electrode plate 24, which will be described later, the horizontal direction is the longitudinal direction, and the front-rear direction is the width direction. Further, the electric heater 20 of the present embodiment is a so-called PTC heater configured to include a PTC element 23a described later.

  The electric heater 20 is energized in contact with the energization heat generating member 23 that generates heat by energization, the heat exchange fin 22 that is a heat exchange member that promotes heat dissipation of the energization heat generation member 23, and the energization heat generation member 23 and the heat exchange fin 22. A heat radiating portion 25 is formed by sequentially laminating an electrode plate 24 that is an electrode member for energizing the heat generating member 23.

  Then, in order that these stacked component parts 22, 23, and 24 are in good contact, the stacking direction (in FIGS. (Up and down direction) is applied, and the frame 21 is sandwiched from both ends in the stacking direction. Furthermore, housings 26a and 26b are fitted from both ends of the longitudinal direction (left and right direction in FIGS. 2 and 3) of each component 22, 23 and 24.

  Details of the energization heat generating member 23 will be described with reference to FIG. FIG. 4 is an overall view of the energization heat generating member 23 viewed from the stacking direction. The energizing heat generating member 23 is configured by fitting a plurality of PTC elements 23a in a resin frame 23b formed of a heat-resistant resin material (for example, polyamide-based synthetic fiber or polybutadiene terephthalate).

  The PTC element 23a rapidly increases in temperature when energized. When the temperature reaches a predetermined temperature (Curie point), the electrical resistance value rapidly increases to limit the current and to have a self-temperature control function that suppresses heat generation. It is a thermistor.

  Details of the heat exchange fins 22 will be described with reference to FIG. FIG. 5A is an overall view of the heat exchange fins 22 as viewed from the stacking direction, and FIG. 5B is a side view of the heat exchange fins 22 as viewed from the width direction. FIG.5 (c) is the side view of FIG.5 (b) which looked at the heat exchange fin 22 from the longitudinal direction.

  The heat exchange fins 22 are corrugated fins 22a that form a thin aluminum plate into a wave shape to increase the heat radiation area, and keep the fins 22a in a fixed shape, and also have a contact area with the PTC element 23a and the electrode plate 24. The aluminum plates 22b and 22b ′ for securing are configured by brazing and joining. Of the plates 22b and 22b ', the side in contact with the electrode plate 24 is the plate 22b, and the side in contact with the energization heating member 23 is the plate 22b'.

  The plate 22 in contact with the electrode plate 24 is provided with flange portions 22c extending in the width direction with respect to the corrugated fins 22a on both sides in the width direction, and the flange portions 22c on both sides are opposite to the contact surface with the electrode plate 24. A total of four cut-and-raised portions 22d that are cut and raised toward each other are provided. Further, a chamfered portion 22e having a width direction dimension gradually reduced is provided at the longitudinal end portion of the plate 22b.

  Details of the electrode plate 24 will be described with reference to FIG. FIG. 6A is an overall view of the electrode plate 24 viewed from the stacking direction. FIG. 6B is a side view of FIG. 6A in which the electrode plate 24 is viewed from the width direction. FIG.6 (c) is the side view of FIG.6 (b) which looked at the electrode plate 24 from the longitudinal direction.

  As shown in FIG. 6, the electrode plate 24 is formed by pressing a flat metal (aluminum, brass, copper, etc.) having good electrical conductivity by pressing, and a portion corresponding to the cut-and-raised portion 22 d of the plate 22 b. A claw portion 24a having a substantially U-shaped cross section bent toward the plate 22b is provided. Moreover, the terminal part 24b which connects the electric wire 28 is provided in the longitudinal direction edge part on the same side as the chamfering part 22e of the plate 22b.

  The housings 26a and 26b are resin housings molded from the same resin material as the resin frame 23b. The housing 26b only holds the heat dissipating part 25 on the one end side (the right end side in FIG. 2). In the housing 26a on the left end side in FIG. 2, each terminal portion 24b provided in the electrode plate 24 penetrates, and an electric wire 28 is connected to each terminal portion 24b outside the housing 26b. . The housing 26c functions as a lid that protects each terminal portion 24b.

  Next, a method for manufacturing the electric heater 20 having the above-described configuration will be described. First, the heat exchange fin 22 and the electrode plate 24 are prepared. As described above, the heat exchange fins 22 can be easily formed by brazing the corrugated fins 22a and the aluminum plates 22b and 22b '. The electrode plate 24 can also be easily formed by press molding and bending.

  Then, the electrode plate 24 and the heat exchange fins 22 are integrated (sub-assembled) as shown in FIG. FIG. 7A is an overall view of the state in which the electrode plate 24 and the heat exchange fins 22 are integrated, and FIG. 7B is a side view of FIG.

  Specifically, while the electrode plate 24 and the plate 22b of the heat exchange fin 22 are in contact with each other, the electrode plate 24 is slid relative to the longitudinal arrow E direction, and the heat exchange fin 22 is slid relative to the longitudinal arrow F direction. .

  Thereby, the claw part 24a of the electrode plate 24 is locked to the flange part 22c of the plate 22b. Further, when the electrode plate 24 and the heat exchange fin 22 are slid, the claw portion 22a is positioned by the cut-and-raised portion 22d of the plate 22b and can be prevented from coming out in the longitudinal direction. The exchange fins 22 are appropriately integrated.

  Furthermore, since the plate 22b of the present embodiment is provided with the chamfered portion 22e, it is possible to improve the assembling property when the electrode plate 24 and the heat exchange fin 22 are moved (slid) in the longitudinal direction.

  As shown in FIG. 3, the integrated electrode plate 24 and the heat exchange fin 22 are sequentially laminated together with the above-described energizing heat generating member 23, and further, the leaf spring 27, the frame 21, and the housings 26a and 26b. The electric heater 20 is manufactured by attaching the housing 26c after fixing and connecting the electric wire 28.

  Next, the operation of the electric heater 20 will be described. As described above, when the vehicle air conditioner performs the heating operation, the electric heater 20 is supplied with electric power from the control device and generates heat when the heater core 9 cannot sufficiently heat the air after passing through the evaporator 8. As a result, the air blown into the passenger compartment can be heated, so that the vehicle air conditioner of the present embodiment can perform an immediate heating operation.

  In the electric heater 20 of the present embodiment, the claw portion 24a provided on the electrode plate 24 is locked to the flange portion 22c provided on the plate 22b, and the electrode plate 24 and the heat exchange fin 22 are integrated. Since they are stacked, an electric heater can be constructed by simply stacking two types of components in sequence. Therefore, the stacking operation can be facilitated with respect to the electric heater of Patent Document 1, and the manufacturing cost can be reduced.

  Further, due to the effect of reducing the manufacturing cost of the electric heater 20, it is possible to reduce the manufacturing cost of the entire vehicle air conditioner.

(Other embodiments)
The present invention is not limited to the above-described embodiment, and can be variously modified as follows.

  (1) In the above-described embodiment, an example in which two (total four) claw portions 24a are provided on both sides in the width direction of the electrode plate 24 is described. However, the number of the claw portions 24a is not limited thereto. . The number may be appropriately changed as long as the electrode plate 24 and the heat exchange fin 22 can be appropriately integrated.

  (2) In the above-described embodiment, an example in which four cut-and-raised portions 22d of the collar portion 22c are provided in a portion corresponding to the claw portion 24a has been described. However, the positioning function of the electrode plate 24 also for the cut-and-raised portion 22d. Alternatively, the position and quantity may be changed as appropriate so that the omission prevention function can be exhibited.

  (3) In the above-described embodiment, the example in which the collar portion 22c is formed in the entire longitudinal range on both sides in the width direction of the plate 22b has been described. However, the collar portion 22c is provided only in a portion corresponding to the claw portion 24a. Also good. Furthermore, in this case, the chamfered portions 22e may be formed on each flange portion 22c.

  (4) In the above-described embodiment, the electric heater 20 is disposed on the downstream side of the heater core 9, but a foot duct (not shown) that is disposed on the downstream side of the foot opening 14 and guides conditioned air to the feet of the occupant. You may arrange in. Further, the electric heater 20 of the present invention may be incorporated in a part of the heat exchange core portion of the heater core 9.

  (5) Application of the electric heater 20 of the present invention is not limited to a vehicle air conditioner, and can be applied to various uses.

It is sectional drawing of the indoor air conditioning unit of the vehicle air conditioner of one Embodiment. It is a whole perspective view showing a schematic structure of an electric heater of one embodiment. It is an exploded view of the electric heater of one Embodiment. It is a general view of the energization heat generating member of the electric heater of one embodiment. (A) is a general view of the heat exchange fin of the electric heater of one Embodiment, (b) is a side view of (a), (c) is a side view of (b). (A) is the whole electrode plate of the electric heater of one embodiment, (b) is a side view of (a), (c) is a side view of (b). (A) is the whole figure of the state which integrated the electrode plate and heat exchange fin of one Embodiment, (b) is a side view of (a).

Explanation of symbols

20 ... Electric heater, 22 ... Heat exchange fin, 22a ... Fin, 22b ... Plate,
22c ... collar part, 22d ... cut and raised part, 22e ... chamfered part, 23 ... energization heating member,
23a ... PTC element, 24 ... Electrode plate, 24a ... Claw part.

Claims (6)

An energization heating member (23) that generates heat when energized;
A heat exchange member (22) that promotes heat dissipation of the energization heating member (23);
An electric heater configured by sequentially laminating an electrode member (24) that contacts the energization heat generating member (23) and the heat exchange member (22) and energizes the energization heat generation member (23),
The heat exchange member (22) includes fins (22a) that increase a heat radiation area, and plates (22b) fixed to both ends in the stacking direction of the fins (22a),
The plate (22b) is provided with a flange (22c) extending in the longitudinal direction of the heat exchange member (22) and the width direction perpendicular to the stacking direction,
The electrode member (24) is provided with a claw portion (24a) locked to the flange portion (22c),
The electric heater, wherein the electrode member (24) and the heat exchange member (22) are laminated in an integrated state. 2. The electric heater according to claim 1, wherein a chamfered portion (22 e) in which the dimension in the width direction is gradually reduced is provided on at least one of the longitudinal ends of the plate (22 b). . The said collar part (22c) is provided with the cut-and-raised part (22d) cut and raised toward the opposite side to the contact surface with the said electrode member (24). The electric heater according to 1. The electric heater according to any one of claims 1 to 3, wherein the energization heat generating member (23) includes a PTC element (23a). A vehicle air conditioner comprising the electric heater (20) according to any one of claims 1 to 4. An energization heating member (23) that generates heat when energized;
A heat exchange member (22) that promotes heat dissipation of the energization heating member (23);
The method of manufacturing an electric heater is configured by sequentially laminating an electrode member (24) that contacts the energization heat generating member (23) and the heat exchange member (22) and energizes the energization heat generation member (23). And
The heat exchange member (22) includes a fin (22a) that increases a heat radiation area, and plates (22b) that are fixed to both ends in the stacking direction of the fin (22a), and the plate (22b) ), Provided with a flange (22c) extending in the longitudinal direction of the heat exchange member (22) and the width direction perpendicular to the stacking direction,
The claw part (24a) provided in the electrode member (24) is locked to the flange part (22c), and the electrode member (24) and the heat exchange member (22) are integrated. Process,
A method for producing an electric heater, comprising: a step of laminating the energization heat generating member (23) and the integrated electrode member (24) and the heat exchange member (22).

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