JP6640700B2 - Electric heater - Google Patents

Description

The present invention relates to electric heating data utilizing heat generated when performing the energization to the PTC element.

  An electric heater using a PTC (Positive Temperature Coefficient) element is used, for example, as an auxiliary heating heater for a vehicle. The electric heater includes an electrode plate for supplying electricity to the PTC element, a radiating fin for radiating heat transmitted from the PTC element, and a pair of PTC elements, a pair of electrodes disposed on both sides in the stacking direction of the laminated body of the electrode plate and the radiating fin. A frame, a pressing spring for pressing the pair of frames from both sides in the stacking direction, and the like are provided. In an electric heater, in order to effectively conduct electricity from the electrode plate to the PTC element and effectively conduct heat from the PTC element to the radiating fins, a plurality of PTC elements arranged in a horizontal direction are as even as possible on the electrode plate and the radiating fin. A device has been devised to make contact.

  For example, in the electric heater disclosed in Patent Document 1, a pair of frames is formed with a bent portion for pressing each of the PTC elements arranged in the lateral direction. Then, a portion of the laminate where each PTC element is arranged is pressed by each bent portion, so that each PTC element comes into close contact with the electrode plate and the radiation fin.

  Further, for example, in a car air conditioner power consumption heater disclosed in Patent Document 2, a warped elastic contact portion is provided at a position on an electrode plate facing a portion where a plurality of PTC elements are arranged in a lateral direction. When the laminated body is pressed by the pressing spring, the portion where each PTC element is arranged is pressed by the elastic contact portion, so that each PTC element comes into close contact with the electrode plate and the radiation fin.

JP 2009-152172 A Chinese Patent CN10173324

  However, there is still room for improvement in Patent Documents 1 and 2 in order to further improve the performance of the heater. In other words, as a result of the inventors' research and development, in order to more effectively conduct electricity from the electrode plate to the PTC element and conduct heat from the PTC element to the radiation fin more effectively, all the PTC elements, the electrode plate and the radiation fin must be connected. It has been found that it is effective to form a state in which is pressed with the same force as possible.

  In Patent Literature 1, by bending a frame using a pressing spring, each bent portion of the frame presses a portion of the laminate in which each PTC element is arranged. Therefore, the force with which each PTC element is pressed by the electrode plate and the radiation fin differs depending on how the frame bends. As a result, the magnitude of the pressing force acting on each PTC element is affected by the magnitude of a manufacturing error, deformation and the like of the frame. Therefore, in the cited document 1, there is a possibility that the force of each PTC element pressed against the electrode plate and the radiation fin may vary.

  In Patent Literature 2, the amount of elastic deformation of each elastic contact portion of the electrode plate differs according to the difference in the thickness in the stacking direction of the location of each PTC element in the laminate. Therefore, the force with which the PTC element is pressed by the electrode plate and the radiation fin differs for each elastic contact portion, and the PTC element that is opposed to the elastically deformed elastic contact portion is pressed with a larger force. Therefore, also in the cited document 2, there is a possibility that the force of each PTC element pressed against the electrode plate and the radiation fin may vary.

The present invention has been made in view of these problems, it has been obtained in an attempt to provide an electric heater motor which can improve the heater performance.

According to a first aspect of the present invention, a plurality of PTC elements (2) that generate heat when energized and are arranged side by side in the horizontal direction (W) include:
A plurality of electrode plates (3) laminated on both sides of the PTC element in a laminating direction (H) orthogonal to the lateral direction and configured to supply current to the PTC element;
A plurality of radiating fins (4) stacked on both sides of the PTC element in the stacking direction to radiate heat transmitted from the PTC element;
One or more resin plates (5, 5A, 5B) stacked in the stacking direction of the electrode plates or the radiation fins and insulating between the electrode plates having different polarities;
A pressing spring (7) for pressing a laminate (10, 10A, 10B) of the PTC element, the electrode plate, the radiation fins, and the resin plate from both sides in the lamination direction;
When the resin plate, a convex portion forming member having the convex part (5 1) (11), and said electrode plate or the heat radiating fins, and the projections contact member in contact with the convex portion (12),
The projections are respectively provided in a plurality of projection ranges (R) on the surface ( 501) of the projection forming member in the stacking direction, in which the plurality of PTC elements are arranged in the stacking direction. And
It said convex portion of all of said projection range has a deformed portion which is plastically deformed (51 1) by the protrusions contact member is in electrical heater (1).
According to a second aspect of the present invention, a plurality of PTC elements (2) that generate heat when energized and are arranged side by side in the horizontal direction (W) include:
A plurality of electrode plates (3) laminated on both sides of the PTC element in a laminating direction (H) orthogonal to the lateral direction and configured to supply current to the PTC element;
A plurality of radiating fins (4) stacked on both sides of the PTC element in the stacking direction to radiate heat transmitted from the PTC element;
One or more resin plates (5, 5A, 5B) stacked in the stacking direction of the electrode plates or the radiation fins and insulating between the electrode plates having different polarities;
A pressing spring (7) for pressing a laminate (10, 10A, 10B) of the PTC element, the electrode plate, the radiation fins, and the resin plate from both sides in the lamination direction;
When the electrode plate or the radiation fin is a projection forming member (11) having a projection (31, 41), and the resin plate is a projection contact member (12) contacting the projection,
The protrusions are respectively provided in a plurality of projection ranges (R) where the plurality of PTC elements are arranged in the stacking direction on the surfaces (301, 401) of the protrusion forming member in the stacking direction. Has been
The electric heater (1), wherein the convex contact member has a deformed portion (512) plastically deformed by the convex in all the projection ranges.
According to a third aspect of the present invention, there are provided a plurality of PTC elements (2) which generate heat when energized and are arranged side by side in the horizontal direction (W);
A plurality of electrode plates (3) laminated on both sides of the PTC element in a laminating direction (H) orthogonal to the lateral direction and configured to supply current to the PTC element;
A plurality of radiating fins (4) stacked on both sides of the PTC element in the stacking direction to radiate heat transmitted from the PTC element;
One or more resin plates (5, 5A, 5B) stacked in the stacking direction of the electrode plates or the radiation fins and insulating between the electrode plates having different polarities;
A pressing spring (7) for pressing a laminate (10, 10A, 10B) of the PTC element, the electrode plate, the radiation fins, and the resin plate from both sides in the lamination direction;
When the electrode plate is a projection forming member (11) having a projection (31), and the radiation fin is a projection contact member (12) that contacts the projection,
The protrusions are provided in a plurality of projection ranges (R) on the surface (301) of the protrusion forming member in the stacking direction, in which the plurality of PTC elements are respectively arranged in the stacking direction. Yes,
The electric heater (1), wherein the convex contact member has a deformed portion plastically deformed by the convex in all the projection ranges.

According to a fourth aspect of the present invention, a plurality of PTC elements (2) that generate heat when energized and are arranged side by side in the horizontal direction (W);
A plurality of electrode plates (3) laminated on both sides of the PTC element in the laminating direction (D) orthogonal to the lateral direction, and for supplying electricity to the PTC element;
A plurality of radiating fins (4) stacked on both sides of the PTC element in the stacking direction to radiate heat transmitted from the PTC element;
One or more resin plates (5, 5A, 5B) stacked in the stacking direction of the electrode plates or the radiation fins and insulating between the electrode plates having different polarities;
A pair of frames (6A, 6B) laminated on both ends in the laminating direction of the laminate (10, 10A, 10B) of the PTC element, the electrode plate, the radiation fins, and the resin plate;
A pressure spring (7) for pressing the laminate from both sides in the lamination direction via the pair of frames;
Said frame, a convex portion forming member (11) having a convex portion (61), or One prior Symbol electrode plate, the out noise either the said heat dissipating fins and the resin plates, in contact with the protrusion When the convex contact member (12) is used,
The protrusions are respectively provided in a plurality of projection ranges (R) on the surface ( 601) of the protrusion forming member in the stacking direction, in which the plurality of PTC elements are arranged in the stacking direction. And
The electric heater (1), wherein the convex contact member has a deformed portion ( 512) plastically deformed by the convex in all the projection ranges.
According to a fifth aspect of the present invention, a plurality of PTC elements (2) that generate heat when energized and are arranged side by side in the horizontal direction (W) include:
A plurality of electrode plates (3) laminated on both sides of the PTC element in the laminating direction (D) orthogonal to the lateral direction, and for supplying electricity to the PTC element;
A plurality of radiating fins (4) stacked on both sides of the PTC element in the stacking direction to radiate heat transmitted from the PTC element;
One or more resin plates (5, 5A, 5B) stacked in the stacking direction of the electrode plates or the radiation fins and insulating between the electrode plates having different polarities;
A pair of frames (6A, 6B) laminated on both ends in the laminating direction of the laminate (10, 10A, 10B) of the PTC element, the electrode plate, the radiation fins, and the resin plate;
A pressure spring (7) for pressing the laminate from both sides in the lamination direction via the pair of frames;
Any one of the electrode plate, the radiation fins, and the resin plate may be a protrusion forming member (11) having a protrusion (31, 41, 51), and the frame may be a protrusion that contacts the protrusion. When the part contact member (12) is used,
The protrusions are located within a plurality of projection ranges (R) on the surface (301, 401, 501) of the protrusion forming member in the stacking direction, in which the plurality of PTC elements are respectively projected in the stacking direction. Each is provided,
The electric heater (1) has a deformed portion (511) in which the projections in all the projection ranges are plastically deformed by the projection contact members.

According to a reference aspect of the present invention, a plurality of PTC elements (2) that generate heat when energized and are arranged in a horizontal direction (W);
A plurality of electrode plates (3) laminated on both sides of the PTC element in the laminating direction (D) orthogonal to the lateral direction, and for supplying electricity to the PTC element;
A plurality of radiating fins (4) stacked on both sides of the PTC element in the stacking direction to radiate heat transmitted from the PTC element;
One or more resin plates (5, 5A, 5B) stacked in the stacking direction of the electrode plates or the radiation fins and insulating between the electrode plates having different polarities;
Manufacturing an electric heater comprising: a pressing spring (7) for pressing a laminate (10, 10A, 10B) of the PTC element, the electrode plate, the radiation fins, and the resin plate from both sides in the laminating direction. In the method
The electrode plate, wherein any one of the electrode plate, the radiation fins, and the resin plate is a protrusion forming member (11) having a protrusion (31, 41, 51), and excluding the protrusion forming member. When any one of the radiation fins and the resin plate is a projection contact member (12) that comes into contact with the projection,
The projecting portion is located within a plurality of projection ranges (R) on the surface (301, 401, 501) of the projecting portion forming member in the stacking direction in which the plurality of PTC elements are respectively arranged in the stacking direction. Provided respectively,
By the pressing spring, when pressing the laminated body from both sides in the laminating direction, at least one of the convex portion and the convex portion contact member in all of the projection range is plastically deformed, and all the A method for manufacturing an electric heater (1), wherein a deformed portion (511, 512) is formed on at least one of the projection and the projection contact member in a projection range.

In the electric heaters of the first to third aspects, each of the PTC elements is formed by forming a deformed portion by plastic deformation on at least one of the electrode plate, the radiation fin, and the resin plate, which are in contact with each other. All the PTC elements are designed to make the force pressed by the electrode plate and the radiation fins as uniform as possible. Specifically, any one of the electrode plate, the radiation fins, and the resin plate is a protrusion forming member having a protrusion, and the other is a protrusion contact member that contacts the protrusion. The protrusions are provided in a plurality of projection ranges on the surface of the protrusion forming member in the stacking direction, in which the arrangement positions of the plurality of PTC elements are projected in the stacking direction. At least one of the protrusion contact members has a deformed portion due to plastic deformation.

  Then, within the projection range of all the PTC elements, the projections and the projection contact members are in contact, and at least one of the projections and the projection contact members has a deformed portion that is plastically deformed. The deformed portion is formed as a trace or a mark in which the convex portion is crushed so that the height is reduced by plastic deformation, or as a trace or a mark in which the surface of the convex portion contact member is depressed. Further, since the deformed portion is formed by plastic deformation, unlike the one formed by elastic deformation, there is almost no phenomenon that the pressing force generated in each convex portion varies depending on the magnitude of deformation.

Thus, in the electric heaters of the first to third aspects, the plastic deformation of at least one of the convex portion and the convex portion contact member is used to provide each of the PTC element, the electrode plate, the radiation fin, and the resin plate. Even if the thicknesses in the stacking direction at the respective lateral positions where the PTC elements are arranged are different from each other due to the produced dimensional errors and deformation in the manufacturing, all the PTC elements, the electrode plates and the radiation fins are as equal as possible. A state of being pressed and contacted by the force can be formed. The “thickness in the stacking direction” here refers to the total thickness of the PTC element, the electrode plate, the radiation fin, and the resin plate in the single stacking direction in the projection range of each PTC element.

This makes it possible to more effectively conduct electricity from the electrode plate to all the PTC elements and conduct heat from all the PTC elements to the radiation fins. Therefore, according to the electric heaters of the first to third aspects, the heater performance can be further improved.

In the electric heaters according to the fourth and fifth aspects, a frame is included in the protrusion forming member and the protrusion contact member. Other configurations are the same as those of the electric heaters of the first to third aspects. Therefore, according to the electric heaters of the fourth and fifth aspects, as in the case of the electric heaters of the first to third aspects, the heater performance can be further improved.

  In the method of manufacturing the electric heater, when the laminate is pressed from both sides in the stacking direction by the pressing spring, at least one of the protrusions and the protrusion contact members in all the projection ranges is formed by plastic deformation. Form a deformed part. Thus, according to the method for manufacturing an electric heater, an electric heater capable of further improving the heater performance can be easily manufactured.

  Note that the reference numerals in parentheses of each component shown in one embodiment of the present invention indicate the correspondence with the reference numerals in the drawings in the embodiment, but each component is not limited to the content of the embodiment.

FIG. 1 is an explanatory diagram illustrating an electric heater according to a first embodiment. FIG. 2 is an explanatory diagram showing an enlarged part of the electric heater according to the first embodiment. FIG. 2 is a cross-sectional view showing the electric heater according to the first embodiment in a state of being cut in the stacking direction. FIG. 2 is an explanatory view showing the electric heater in an exploded state according to the first embodiment. FIG. 2 is an explanatory view showing a main part of the electric heater according to the first embodiment in an exploded state. FIG. 4 is an explanatory view showing a main part of another electric heater in an exploded state according to the first embodiment. FIG. 4 is an explanatory view schematically showing a convex part forming member and a convex part contact member before each convex part is plastically deformed according to the first embodiment. FIG. 3 is an explanatory view schematically showing a projection forming member and a projection contact member after each projection is plastically deformed according to the first embodiment. Explanatory drawing which shows typically a pair of member before each elastic deformation part elastically deforms concerning a comparative form. Explanatory drawing which shows typically a pair of member after each elastic deformation part elastically deforms concerning a comparative form. FIG. 5 is an explanatory view showing a main part of the electric heater according to the second embodiment in an exploded state. Sectional drawing which shows the state which cut | disconnected the electric heater concerning Embodiment 2 in the lamination direction. FIG. 9 is an explanatory diagram showing a main part of another electric heater in an exploded state according to the second embodiment. Explanatory drawing which shows typically the convex part forming member and convex part contact member before convex part contact member plastically deforms concerning Embodiment 2. FIG. Explanatory drawing which shows typically the convex part formation member and convex part contact member after convex part contact member which carried out plastic deformation concerning Embodiment 2. FIG. FIG. 9 is an explanatory view showing a main part of an electric heater according to a third embodiment in an exploded state. FIG. 9 is a cross-sectional view illustrating the electric heater according to the third embodiment in a state where the electric heater is cut in a stacking direction. FIG. 9 is an explanatory view showing a main part of an electric heater according to a fourth embodiment in an exploded state. FIG. 13 is a cross-sectional view illustrating the electric heater according to the fourth embodiment in a state where the electric heater is cut in the stacking direction. FIG. 10 is an explanatory view showing a main part of another electric heater in an exploded state according to the fourth embodiment. FIG. 9 is an explanatory diagram showing an electric heater according to a fifth embodiment. FIG. 9 is an explanatory diagram showing a part of an electric heater according to a fifth embodiment in an enlarged manner. FIG. 13 is a cross-sectional view showing the electric heater according to the fifth embodiment in a state of being cut in the stacking direction. FIG. 9 is an explanatory view showing a main part of an electric heater according to a fifth embodiment in an exploded state. FIG. 13 is an explanatory diagram showing a main part of another electric heater in an exploded state according to the fifth embodiment. FIG. 14 is an explanatory view showing a main part of an electric heater according to a sixth embodiment in an exploded state. FIG. 13 is a cross-sectional view illustrating the electric heater according to the sixth embodiment in a state where the electric heater is cut in a stacking direction.

A preferred embodiment of the above-described electric heater will be described with reference to the drawings.
The electric heater 1 of this embodiment includes a plurality of PTC elements 2, a plurality of electrode plates 3, a plurality of radiating fins 4, a resin plate 5, and a pressing spring 7, as shown in FIGS. The PTC elements 2 generate heat when energized, and are arranged in a plurality in the horizontal direction W. The electrode plates 3 are laminated on both sides of the PTC element 2 in the laminating direction H orthogonal to the lateral direction W, and serve to supply electricity to the PTC element 2. The radiating fins 4 are stacked on both sides of the PTC element 2 in the stacking direction H, and radiate heat transmitted from the PTC element 2.

  The resin plate 5 is laminated in the laminating direction H of the electrode plate 3 or the radiation fin 4 and is for insulating between the electrode plates 3 having different polarities. The pressing spring 7 presses the laminated body 10 of the PTC element 2, the electrode plate 3, the radiation fins 4, and the resin plate 5 from both sides in the laminating direction H.

  In the electric heater 1, the resin plate 5 is used as the protrusion forming member 11, and the electrode plate 3 is used as the protrusion contact member 12 that contacts the protrusion 51. As shown in FIG. 3 and FIG. 5, an arrangement portion of the PTC element 2 in the lateral direction W and the depth direction D on the surface 501 in the stacking direction H of the resin plate 5 as the protrusion forming member 11 is projected in the stacking direction H. In each projection range R, a convex portion 51 protruding from the surface 501 is provided. The convex portion 51 in each projection range R has a deformed portion 511 that is plastically deformed in contact with the electrode plate 3 as the convex portion contact member 12.

Hereinafter, the electric heater 1 of the present embodiment will be described in detail.
The electric heater 1 is provided in a vehicle separately from an air conditioner such as an air conditioner, and is used to assist heating by the air conditioner or instead of heating by the air conditioner. The electric heater 1 can be used, in particular, to compensate for a decrease in the heat source of the vehicle due to higher efficiency of the engine, and is used for a vehicle having no heat source, such as an EV (electric vehicle) and an FCV (fuel cell vehicle). You can also.

  In the present embodiment, the lateral direction W refers to a direction in which the electrode plate 3, the radiation fins 4, the resin plate 5, and the like are formed in an elongated shape. The laminating direction H is a direction orthogonal to the lateral direction W and is a direction in which the PTC element 2, the electrode plate 3, the radiation fins 4, the resin plate 5, and the like are laminated. Further, a direction orthogonal to the lateral direction W and the laminating direction H is referred to as a depth direction D, and the depth direction D is a direction in which a fluid such as air-conditioning air passes through the electric heater 1.

  The PTC element 2 is configured using a semiconductor or the like, and has a PTC (positive temperature coefficient) characteristic in which heat is generated by energization and electric resistance increases as the temperature rises. When the PTC element 2 generates heat above a predetermined temperature, the PTC element 2 is maintained at a substantially constant temperature due to an increase in electric resistance. The PTC element 2 is formed in a plate shape, and generates heat when a voltage is applied between a pair of surfaces having the largest areas.

  As shown in FIG. 3, the PTC element 2 is held by a plate-shaped positioning plate 21 made of resin. A plurality of arrangement holes 211 in which the PTC elements 2 are arranged are formed in the positioning plate 21 at predetermined intervals in the lateral direction W. The plurality of arrangement holes 211 are formed to penetrate the positioning plate 21 in the stacking direction H. The four PTC elements 2 of this embodiment are arranged in each of the arrangement holes 211 of the positioning plate 21 in a state where four are arranged in the lateral direction W at a predetermined interval. For example, four to six PTC elements 2 can be arranged on the positioning plate 21. The thickness of the positioning plate 21 in the laminating direction H at the portion where the PTC element 2 is arranged is preferably smaller than that of the PTC element 2 so that the electrode plate 3 or the radiation fin 4 can easily contact the PTC element 2. . The positioning plate 21 is provided with a projection 212 for positioning the electrode plate 3 or the radiation fin 4 laminated on the positioning plate 21 in the depth direction D. By adjusting the height of the projection 212, the positioning of the electrode plate 3 and the radiation fin 4 with respect to the positioning plate 21 can be performed simultaneously. The projections 212 of the present embodiment are formed continuously on both edges in the depth direction D of the positioning plate.

  As shown in FIG. 5, the electrode plate 3 applies a voltage for energizing the PTC element 2. One of the pair of electrode plates 3 stacked on both sides of the PTC element 2 in the stacking direction H is connected to a positive power source, and the other is connected to a negative power source (ground). In the figure, the electrode plate 3 connected to the positive power supply is indicated by (+), and the electrode plate 3 connected to the negative power supply is indicated by (-). The electrode plate 3 of this embodiment is made of a material obtained by tin-plating a brass plate as a metal having excellent conductivity. As other materials, the electrode plate 3 can be made of a copper material made of copper or a copper alloy, an aluminum material made of aluminum or an aluminum alloy, or the like. Each of the electrode plates 3 is drawn out of the lateral direction W from one end in the lateral direction W to apply a voltage.

  As shown in FIGS. 2 and 5, the radiating fins 4 conduct and conduct heat to and from the PTC element 2 and transfer heat to and from a fluid such as heating air. One of a pair of radiating fins 4 stacked on both sides of the PTC element 2 in the stacking direction H is connected to a positive power supply via the electrode plate 3, and the other is connected to a negative power supply via the electrode plate 3. You. The heat radiation fins 4 are composed of a pair of flat plates 42 in contact with the PTC element 2, the electrode plate 3, and the like, and a corrugated plate 43 joined between the pair of flat plates 42. The pair of flat plates 42 are arranged on both sides in the stacking direction H of the radiation fins 4. The fluid heated by the electric heater 1 passes through the through gap 431 formed between the pair of flat plates 42 by the corrugated plate 43, and is heated by the radiation fins 4. The radiation fins 4 of the present embodiment are made of an aluminum material made of aluminum or an aluminum alloy, or a copper-based material made of copper or a copper alloy as a metal having excellent conductivity and heat conductivity.

  As shown in FIGS. 3 and 5, the resin plate 5 is used to insulate between the electrode plates 3 having different polarities and the radiation fins 4 connected to a positive power supply or a negative power supply. The resin plate 5 of this embodiment is made of 66 nylon as a thermoplastic resin. In addition, the resin plate 5 can be made of nylon resin, PBT (polybutylene terephthalate resin), PPS (polyphenylene sulfide resin), or the like. The resin plate 5 is provided with a projection 52 for positioning the electrode plate 3 (or the radiation fin 4) laminated on the resin plate 5 in the depth direction D. By adjusting the height of the projection 52, the positioning of the electrode plate 3 and the radiation fin 4 with respect to the resin plate 5 can be performed simultaneously. The projections 52 of the present embodiment are formed continuously on both edges in the depth direction D of the resin plate 5.

  As shown in FIGS. 1 to 3, a pair of frames 6 </ b> A and 6 </ b> B are laminated on both ends of the laminate 10 of the PTC element 2, the electrode plate 3, the radiation fins 4 and the resin plate 5 in the laminating direction H. The pair of frames 6A and 6B are used for receiving the pressing force (load) by the pressing spring 7 to bring the PTC element 2, the electrode plate 3, the radiation fins 4 and the resin plate 5 in the laminate 10 into close contact with each other. By using the pair of frames 6A and 6B, the rigidity of the electric heater 1 can be increased, and the pressing force applied from the pressing spring 7 to the laminate 10 can be applied to the plurality of PTC elements 2 equally. It will be easier.

  The frames 6A and 6B are made of metal and are formed in a cylindrical shape having a hollow hole 62 penetrating in the lateral direction W. The frames 6A and 6B can be formed by bending a flat plate into a tubular shape having a slit between the bent ends. A part of the pressing spring 7 is inserted into the hollow hole 62 of each of the frames 6A and 6B. The frames 6A and 6B of the present embodiment are made of SUS430. In addition, the frames 6A and 6B can be made of a SUS (stainless) material such as SUS304, or a steel material such as SECC (electrogalvanized steel sheet).

  The pressing springs 7 are arranged on both sides in the lateral direction W of the laminated body 10, and press the laminated body 10 from both sides in the laminating direction H via a pair of frames 6 </ b> A and 6 </ b> B on both sides in the lateral direction W. The pressing spring 7 extends in the stacking direction H and is formed to be bent from both sides of the spring center portion 71 that is arranged to face an end portion of the stacked body 10 in the lateral direction W. And a pair of holding portions 72 for holding the holding member. The pair of holding portions 72 are inserted into the hollow holes 62 of the frames 6A and 6B, and hold the stacked body 10 via the frames 6A and 6B. Since the interval between the pair of holding portions 72 is widened by the laminate 10 and the pair of frames 6A and 6B, the stacking state of the stack 10 from the pair of holding portions 72 to the stack 10 and the pair of frames 6A and 6B. The pressing force for maintaining the pressure acts.

  As shown in FIGS. 1 and 4, a resin cover 81 that engages with both ends of the pair of frames 6 </ b> A and 6 </ b> B in the horizontal direction W is provided at both ends in the horizontal direction W of the laminate 10. . In addition, a connector 82 for connecting the plurality of electrode plates 3 to a positive power source and a negative power source of a vehicle battery is provided on the cover 81 located on the side from which the electrode plates 3 are drawn out.

  As shown in FIGS. 3 to 5, in the laminate 10 of the electric heater 1 of the present embodiment, a plurality of PTC elements 2 are arranged in four stages, and the electrode plates 3 are disposed on both sides of the PTC element 2 in the lamination direction H. And radiating fins 4. The electrode plate 3 and the radiation fins 4 are alternately connected to a positive power supply and a negative power supply. The resin plate 5 is located at an end of the stacked body 10 in the stacking direction H. Each electrode plate 3 in the laminate 10 can separately receive the supply of the voltage from the positive power supply and the negative power supply. The electric heater 1 performs a partial heating operation of energizing a plurality of PTC elements 2 at a specific stacking position by switching whether or not to energize each electrode plate 3 in the stack 10, A full heating operation for energizing the PTC element 2 is possible.

  As shown in FIGS. 3 and 5, the arrangement portions of the PTC elements 2 in the lateral direction W and the depth direction D in the laminate 10 of the present embodiment match when viewed along the lamination direction H. Then, the projection range R of each PTC element 2 is uniquely determined. For example, when the number of stages in which the plurality of PTC elements 2 are stacked increases, there may be a case where the arrangement positions of the plurality of PTC elements 2 in the lateral direction W and the depth direction D in each stacked body 10 do not match. In this case, when the stacked body 10 is viewed along the stacking direction H, the projections 51 may be formed at positions where the projection ranges R of the plurality of PTC elements 2 in the stacked body 10 overlap with each other. it can.

  Further, as shown in FIG. 6, a case is also conceivable in which a part of the PTC element 2 is eliminated for power adjustment and a portion where the PTC element 2 is eliminated is filled with a positioning plate 21. In this case, in a portion where the PTC element 2 is not provided, the positioning plate 21 is pressed by the pressing spring 7 so that each projection range R in the entire laminate 10 is pressed evenly.

  As shown in FIG. 5, each electrode plate 3 in the electric heater 1 having the laminated body 10 is alternately connected to a plus power supply, a minus power supply, a plus power supply, a minus power supply, and a plus power supply in order from one side in the stacking direction H. Is done. The resin plate 5 is disposed between the electrode plate 3 and the frame 6B, which are located at the extreme end in the stacking direction H of the stacked body 10 and at one end in the stacking direction H. The resin plate 5 is located at the other end in the stacking direction H via the electrode plate 3 and the radiation fin 4 located at one end in the stacking direction H, and the frames 6A, 6B and the pressing spring 7. The electrode plate 3 and the radiation fin 4 are not electrically connected. The resin plate 5 is used to supply current to the plurality of PTC elements 2 located at one end in the stacking direction H and the plurality of PTC elements 2 located at the other end in the stacking direction H independently of each other. Used to insulate them.

  The protrusion 51 of this embodiment is provided on a surface 501 of the resin plate 5 facing the electrode plate 3. The protruding portions 51 are provided in four projection ranges R where the positions of the four PTC elements 2 on the resin plate 5 are projected in the stacking direction H. One projection 51 is provided at the center of each projection range R. Note that a plurality of projections 51 may be provided in each projection range R. The projections 51 do not necessarily need to be provided at the center of each projection range R, and a plurality of projections 51 may be provided at portions around the center of each projection range R.

  The hardness of the resin plate 5 as the protrusion forming member 11 of the present embodiment is lower than the hardness of the electrode plate 3 as the protrusion contact member 12. As shown in FIGS. 7 and 8, when the resin plate 5 and the electrode plate 3 come into contact with each other and a pressing force by the pressing spring 7 acts between them, each convex portion of the resin plate 5 is The tip of 51 is plastically deformed and crushed so that the height protruding from the surface 501 is reduced. At this time, most of the material located at the tip of each convex portion 51 flows around each convex portion 51 from between each convex portion 51 and the electrode plate 3. In this way, a trace or trace of plastic deformation is left as a deformed portion 511 on each convex portion 51.

  Here, FIG. 7 schematically shows a state before each protrusion 51 is plastically deformed, and FIG. 8 schematically shows a state after each protrusion 51 is plastically deformed. Each drawing is a diagram schematically showing a state in which a deformed portion 511 is formed on each convex portion 51 for explanation, and the convex portion 51 is exaggerated.

  Each convex portion 51 in the electric heater 1 may be formed in any shape as long as the deformed portion 511 is formed at the tip. The shape of the convex portion 51 before the deformation portion 511 is formed may be, for example, a cone, a pyramid such as a triangular pyramid or a quadrilateral, a curved protrusion such as a hemisphere, or the like in order to easily form the deformation portion 511. can do. Further, the shape of the convex portion 51 before the deformation portion 511 is formed may be a column or a prism having a flat or curved tip, a cone or a column having a plurality of tips, or the like. The shape of the convex portion 51 before the deformation portion 511 is formed is the same as that of the second embodiment described later, even when the convex portion 51 is plastically deformed so that the surface of the convex portion contact member 12 is depressed. The shape can be the same as described above.

  The plastic deformation of the convex portion 51 is performed by applying a load to the convex portion 51 beyond the elastic limit of elastic deformation. The size of the convex portion 51 can be made small in order to facilitate plastic deformation. The size of the convex portion 51 can be, for example, in the range of 0.5 to 5 mm as the maximum outer shape when the convex portion 51 of the resin plate 5 is viewed in plan. The height of the convex portion 51 on which the deformed portion 511 is formed can be, for example, 0.05 to 1 mm.

  The protrusion 51 may be provided on a surface 501 of the resin plate 5 facing the frame 6B. Also in this case, since the hardness of the resin plate 5 is lower than the hardness of the frame 6B, a deformed portion 511 crushed by plastic deformation is formed at the tip of each convex portion 51 in the resin plate 5 by the frame 6B. Is done.

  In addition, the protrusions 51 can be provided on both surfaces 501 of the resin plate 5. In this case, the one-side convex portion 51 has a deformed portion 511 caused by plastic deformation in contact with the electrode plate 3, and the other-side convex portion 51 deformed by plastic deformation in contact with the frame 6 </ b> B. A portion 511 may be provided.

Next, a method for manufacturing the electric heater 1 of the present embodiment will be described.
First, the PTC element 2, the electrode plate 3, the radiation fins 4, the resin plate 5, the frames 6A and 6B, and the pressing spring 7 are each processed by a known method. When the resin plate 5 is molded, a plurality of convex portions 51 are formed on the surface 501 of the resin plate 5. The plurality of convex portions 51 are formed so as to protrude from the front surface 501 in the respective projection ranges R in which the arrangement portions of the plurality of PTC elements 2 are projected in the stacking direction H on the front surface 501 of the resin plate 5 in the stacking direction H. I do.

  Next, each of the PTC elements 2 is arranged in each of the arrangement holes 211 of the positioning plate 21, and the positioning plate 21, the plurality of electrode plates 3, the plurality of radiating fins 4, and the resin plate 5 are stacked to form the laminate 10. . At this time, each protrusion 51 of the resin plate 5 is arranged within the projection range R of each PTC element 2 on the surface 501 of the resin plate 5 in the stacking direction H. Further, frames 6A and 6B are laminated on both ends of the laminate 10 in the laminating direction H.

  Next, using a jig or the like, the pressing spring 7 is elastically deformed so as to widen the space between the pair of holding portions 72 of the two pressing springs 7. The pressing springs 7 are arranged on both sides of the laminate 10 in the lateral direction W, and the holding portions 72 of the pressing springs 7 are inserted into the hollow holes 62 of the frames 6A and 6B. Then, when the state where the pressing spring 7 is elastically deformed is released, the interval between the pair of holding portions 72 becomes narrow. Thereby, the laminated body 10 is pressed by the pair of holding portions 72 of the pressing spring 7 via the pair of frames 6A and 6B.

  When the laminate 10 receives the pressing force of the pressing spring 7, each protrusion 51 of the resin plate 5 comes into contact with the surface 301 of the electrode plate 3, the hardness of each protrusion 51 is lower than the hardness of the electrode plate 3, and Since the strength of each projection 51 is low, the tip of each projection 51 is plastically deformed so as to be crushed. Then, a deformed portion 511 whose front end is crushed is formed on the convex portions 51 in all the projection ranges R. Then, the cover 81 and the connector 82 are attached, and the electric heater 1 is manufactured.

Next, the operation and effect of the electric heater 1 of the present embodiment will be described.
When the laminate 10 is pressed by the pair of pressing springs 7, the electrode plate 3 comes into contact with each convex portion 51 of the resin plate 5. At this time, the thickness of each part of the laminate 10 in the lateral direction W in the lamination direction H is such that the PTC element 2, the electrode plate 3, the radiating fins 4, the resin plate 5, and the production members formed in the respective components of the frames 6A and 6B. Variations are caused by the above dimensional errors and deformations. When the laminated body 10 receives the pressing force of the pressing spring 7, each convex portion 51 of the resin plate 5 having a lower strength than the electrode plate 3 is plastically deformed and crushed. At this time, in the projection range R of each PTC element 2 on the surface 501 of the resin plate 5, the amount of plastic deformation of each projection 51 differs due to the difference in the thickness of the laminated body 10 in each projection range R.

  7 and 8, in the projection range R of the plurality of PTC elements 2, the plurality of protrusions 51 of the protrusion forming member 11 contact the protrusion contact member 12, and the plurality of protrusions 51 are plastically deformed. Indicates a state in which The projections 51 in each projection range R have different amounts of plastic deformation due to the variation in the thickness of the multilayer body 10 in the stacking direction H. Specifically, as compared with the amount of plastic deformation of the projections 51a arranged in the projection range R where the thickness of the laminate 10 in the stacking direction H is small, the projections R are arranged in the projection range R where the thickness of the laminate 10 in the stacking direction H is large. The amount of plastic deformation of the projected portion 51b increases. The protrusion amount (height) of the latter protrusion 51b from the surface 501 is lower than the protrusion amount (height) of the former protrusion 51a from the surface 501. The difference in the amount of protrusion between the protrusions 51a and 51b can be understood by observing the deformed portion 511 formed at the tip of the protrusions 51a and 51b.

  As described above, the plastic deformation of the plurality of protrusions 51 in the resin plate 5 reduces the difference in the thickness of the stacked body 10 in the stacking direction H in the projection range R of each PTC element 2, and 10 so that the thickness in the laminating direction H of each part in the horizontal direction W in FIG. When each convex portion 51 is plastically deformed, the deformation or the like occurring in each of the constituent members 2, 3, 4, 5, 6A, and 6B may be corrected.

  Within the projection range R of all the PTC elements 2, each projection 51 of the resin plate 5 is in contact with the electrode plate 3, and all the projections 51 have a deformed portion 511 that is plastically deformed. The deformed portion 511 is formed as a trace or mark in which the convex portion 51 is crushed by plastic deformation so that the height is reduced. Since the deformed portion 511 is formed by plastic deformation, unlike the one formed by elastic deformation, the phenomenon that the reaction force generated in each convex portion 51 differs depending on the magnitude of the deformation hardly occurs. As a result, within the projection range R of each PTC element 2, the force with which each PTC element 2 is pressed against the electrode plate 3 and the radiation fins 4 becomes as uniform as possible.

  Thus, in the electric heater 1 of the present embodiment, the following effects can be obtained by utilizing the plastic deformation of all the protrusions 51 of the resin plate 5. That is, due to manufacturing dimensional errors, deformations, and the like generated in each of the PTC element 2, the electrode plate 3, the heat radiation fins 4, and the resin plate 5, the stacking direction H at each position in the horizontal direction W where the PTC element 2 is arranged. Even if the thicknesses of the PTC elements 2 are different from each other, it is possible to form a state in which all the PTC elements 2 and the electrode plates 3 and the radiation fins 4 are pressed and contacted with the same force as much as possible. Thereby, the conduction from the electrode plate 3 to all the PTC elements 2 and the heat conduction from all the PTC elements 2 to the radiation fins 4 can be performed more effectively. Therefore, according to the electric heater 1 of the present embodiment, the heater performance can be further improved.

  FIGS. 9 and 10 show, as a comparative example, a state in which a plurality of elastically deformable portions 51X are elastically deformed when a member 11X on which an elastically deformable portion 51X is formed is used instead of the convex portion forming member 11. Show. A contact member that comes into contact with the elastic deformation portion 51X of the member 11X is indicated by reference numeral 12X. The amount of elastic deformation of the elastically deformable portions 51X in each projection range R is different due to variations in the thickness of the stacked body 10 in the stacking direction H. Specifically, compared to the amount of elastic deformation of the elastic deformation portion 51Xa arranged in the projection range R where the thickness of the laminate 10 is small, the elastic deformation portion 51Xb arranged in the projection range R where the thickness of the laminate 10 is large. The amount of elastic deformation increases.

  At this time, the reaction force generated in each of the elastic deformation portions 51Xa and 51Xb differs depending on the magnitude of the deformation amount, and the elastic deformation portion 51Xb having a large elastic deformation amount has a larger reaction force than the elastic deformation portion 51Xa having a small elastic deformation amount. Is added. Thereby, within the projection range R of each PTC element 2, the force with which each PTC element 2 is pressed by the electrode plate 3 and the radiation fin 4 becomes non-uniform. As a result, the contact state of each PTC element 2 with the electrode plate 3 and the radiation fins 4 varies, and the conduction from the electrode plate 3 to each PTC element 2 and the heat conduction from each PTC element 2 to the radiation fins 4 vary. Will occur.

Further, when neither the plastically deformed convex portion 51 nor the elastically deformable portion 51X is formed on the resin plate 5 or the like, it is affected by the dimensional variation occurring in each of the components 2, 3, 4, 5, 6A, and 6B. In the projection range R of the PTC element 2, the force for the PTC element 2 to come into contact with the electrode plate 3 and the radiation fin 4 may hardly act.
Therefore, in order to enhance the heater performance of the electric heater 1, it can be said that it is effective to have the plastically deformed convex portions 51.

The electrode plate 3 and the radiation fins 4 only need to ensure conductivity and heat conductivity with the PTC element 2, and any of them may be arranged at a position that directly contacts the PTC element 2.
The electric heater 1 includes a plurality of PTC elements 2 arranged in one, two, three, or five or more layers in which electrode plates 3 and radiation fins 4 are arranged on both sides in the laminating direction H, respectively. The laminate 10 having the PTC element 2 may be pressed by the pressing spring 7.

(Embodiment 2)
In this embodiment, as shown in FIGS. 11 and 12, the protrusion forming member 11 is the electrode plate 3 on which the protrusion 31 is formed, and the protrusion contact member 12 that contacts the protrusion 31 is the resin plate 5. It shows about.
The protruding portions 31 are respectively provided within the projection ranges R of the plurality of PTC elements 2 on the surface 301 of the electrode plate 3 in the stacking direction H. The protrusion 31 is provided on a surface 301 of the electrode plate 3 facing the resin plate 5. The convex portion 31 is provided integrally with the electrode plate 3 by deforming a part of the electrode plate 3 and using a material of the same quality as the electrode plate 3. The protrusion 31 may be a metal material separately provided on the surface 301 of the electrode plate 3.

  The electrode plate 3 is made of a copper material, and the resin plate 5 is made of a resin material. Since the hardness of the electrode plate 3 is higher than the hardness of the resin plate 5, the resin plate 5 is plastically deformed by the convex portions 31 of the electrode plate 3, and the surface 501 of the resin plate 5 is recessed by the convex portions 31. An elastic deformation portion 512 is formed. The deformed portion 512 is formed as a trace or mark of the surface 501 of the resin plate 5 dented by plastic deformation.

  The electrode plate 3 on which the convex portions 31 of the present embodiment are formed is opposed to the resin plate 5. The convex portion 31 can be provided on any of the electrode plates 3 in the electric heater 1. Although the structure is different from that of the electric heater 1 of the present embodiment, the convex portion 31 can be provided on the surface 301 of the electrode plate 3 facing the frame 6A.

  Further, as shown in FIG. 13, the projection contact member 12 may be a radiation fin 4, and the projection 31 may be provided on a surface 301 of the electrode plate 3 facing the radiation fin 4. In this case, since the hardness of the electrode plate 3 is higher than the hardness of the radiation fin 4, the surface 401 of the flat plate 42 of the radiation fin 4 is plastically deformed by the projection 31 of the electrode plate 3, A deformed portion that is recessed by the convex portion 41 is formed on the surface 401 of the substrate.

  As shown in FIGS. 14 and 15, when the laminate 10 of the present embodiment is pressed by the pressing spring 7, each convex portion 31 of the electrode plate 3 comes into contact with the resin plate 5 and each part of the resin plate 5 The convex portion 31 is plastically deformed and dented. At this time, most of the material of the portion of the resin plate 5 with which the respective protrusions 31 come into contact flows around the respective protrusions 31 from between the respective protrusions 31 and the resin plate 5.

  Here, FIG. 14 schematically shows a state before the plastic deformation of the resin plate 5, and FIG. 15 schematically shows a state after the plastic deformation of the resin plate 5. Each drawing is a diagram schematically showing a state in which the deformed portion 512 is formed on the resin plate 5 for explanation, and the convex portion 31 and the deformed portion 512 are exaggeratedly shown.

  Then, the protrusions arranged in the projection range R where the thickness of the laminate 10 is large as compared with the amount of plastic deformation of the portion of the resin plate 5 that comes into contact with the protrusions 31a arranged in the projection range R where the thickness of the laminate 10 is small. The amount of plastic deformation of the portion of the resin plate 5 that comes into contact with the portion 31b increases. The amount of depression from the surface 301 of the portion of the resin plate 5 that is recessed by the latter convex portion 31b is compared with the amount of depression (the depth) of the portion of the resin plate 5 that is concave by the former convex portion 31a. (Depth) becomes deeper. The difference in the amount of depression of each part of the resin plate 5 can be understood by observing the deformed portion 512 formed on the surface 501 of the resin plate 5.

  Also in the electric heater 1 of the present embodiment, each projection range R of the radiation fin 4 is plastically deformed by all the projections 31, so that the PTC element 2, the electrode plate 3, the radiation fin 4, and the resin plate 5 are respectively provided. Even when the thickness in the laminating direction H at each position in the lateral direction W where the PTC element 2 is arranged is different from each other due to the produced dimensional error, deformation or the like in the production, all the PTC elements 2 and the electrode plates 3 and the resin It is possible to form a state where the plate 5 is pressed and contacted with the same force as much as possible. Thereby, the conduction from the electrode plate 3 to all the PTC elements 2 and the heat conduction from all the PTC elements 2 to the radiation fins 4 can be performed more effectively. Therefore, the electric heater 1 of the present embodiment can further improve the heater performance.

  Other configurations of the electric heater 1 of the present embodiment are the same as those of the first embodiment. Also in the present embodiment, the electric heater 1 can be manufactured in the same manner as in the first embodiment. The components and the like denoted by the same reference numerals as those in the first embodiment are the same as the components and the like in the first embodiment. Also in this embodiment, the same operation and effect as in the first embodiment can be obtained.

(Embodiment 3)
In the present embodiment, as shown in FIGS. 16 and 17, the protrusion forming member 11 is the radiation fin 4 having the protrusion 41 formed thereon, and the protrusion contact member 12 that contacts the protrusion 41 is the electrode plate 3. It shows about.
The protrusions 41 are provided in the projection range R of the plurality of PTC elements 2 on the surface 401 of the radiation fin 4 in the stacking direction H. The convex portion 41 is provided on a surface 401 of the heat radiation fin 4 that faces the electrode plate 3. The convex portion 41 is formed integrally with the heat radiation fin 4 by deforming a part of the flat plate 42 of the heat radiation fin 4 and using the same material as the heat radiation fin 4. The protrusion 41 may be a metal material separately provided on the surface 401 of the flat plate 42 of the radiation fin 4.

  The radiation fins 4 are made of an aluminum material, and the electrode plate 3 is made of a copper material. Since the hardness of the radiation fin 4 is lower than the hardness of the electrode plate 3, the convex portion 41 of the flat plate 42 of the radiation fin 4 is plastically deformed by the electrode plate 3. 3 forms a deformed portion 411 crushed. The deformed portion 411 is formed as a trace or a trace of the tip of the convex portion 41 of the radiation fin 4 crushed by plastic deformation.

  The radiation fins 4 having the projections 41 of the present embodiment are closest to the frame 6B. The convex portion 41 can be provided on any of the radiation fins 4 in the electric heater 1. For example, the convex portion 41 is different from the configuration of the electric heater 1 of the present embodiment, but can be provided on the surface 401 of the heat radiation fin 4 facing the frame 6A.

  Other configurations of the electric heater 1 of the present embodiment are the same as those of the first embodiment. Also in the present embodiment, the electric heater 1 can be manufactured in the same manner as in the first embodiment. The components and the like denoted by the same reference numerals as those in the first embodiment are the same as the components and the like in the first embodiment. Also in this embodiment, the same operation and effect as in the first embodiment can be obtained.

(Embodiment 4)
In the present embodiment, as shown in FIGS. 18 and 19, the protrusion forming member 11 is a frame 6B on which the protrusion 61 is formed, and the protrusion contact member 12 that contacts the protrusion 61 is the resin plate 5. It shows about.
The protruding portions 61 are provided in the projection range R of the plurality of PTC elements 2 on the surface 601 in the stacking direction H of the frame 6B. The protrusion 61 is provided on a surface 601 of the frame 6B facing the resin plate 5. The convex portion 61 is provided integrally with the frame 6B by deforming a part of the frame 6B with the same material as the frame 6B. The protrusion 61 may be a metal material separately provided on the surface 601 of the frame 6B.

  The frame 6B is made of a metal material such as stainless steel, and the resin plate 5 is made of a resin material. Since the hardness of the frame 6B is higher than the hardness of the resin plate 5, the resin plate 5 is plastically deformed by the convex portion 61 of the frame 6B, and the surface 501 of the resin plate 5 is deformed by the convex portion 61. A portion 512 is formed. The deformed portion 512 is formed as a trace or mark of the surface 501 of the resin plate 5 dented by plastic deformation.

  In the present embodiment, the frame 6B is the protrusion forming member 11 on which the protrusion 61 is formed. Alternatively, the frame 6A may be the protrusion forming member 11 on which the protrusion 61 is formed. In this case, as shown in FIG. 20, the protrusion contact member 12 is a heat radiation fin 4, and the protrusion 61 is provided on a surface 601 of the frame 6A facing the heat radiation fin 4. In this case, since the hardness of the frame 6A is higher than the hardness of the radiating fin 4, the flat plate 42 of the radiating fin 4 is plastically deformed by the convex portion 61 of the frame 6A, and the surface 401 of the flat plate 42 of the radiating fin 4 A concave deformed portion is formed by the frame 6A.

  Although different from the structure of the electric heater 1 of the present embodiment, the projection contact member 12 is used as the electrode plate 3, and the projections 61 of the frames 6A, 6B are formed on the surface of the electrode plate 3 facing the frames 6A, 6B. 301 can also be contacted. In this case, since the hardness of the frames 6A and 6B is higher than the hardness of the electrode plate 3, the surface 301 of the electrode plate 3 is plastically deformed by the projections 61 of the frames 6A and 6B, and the surface 301 of the electrode plate 3 The convex 61 forms a concave deformed portion.

  Other configurations of the electric heater 1 of the present embodiment are the same as those of the first embodiment. Also in the present embodiment, the electric heater 1 can be manufactured in the same manner as in the first embodiment. The components and the like denoted by the same reference numerals as those in the first embodiment are the same as the components and the like in the first embodiment. Also in this embodiment, the same operation and effect as in the first embodiment can be obtained.

(Embodiment 5)
This embodiment shows an electric heater 1Z having a different structure from the electric heater 1 of the first to fourth embodiments.
As shown in FIGS. 21 to 24, in the electric heater 1 </ b> Z of the present embodiment, a first stacked body 10 </ b> A including a plurality of PTC elements 2, a plurality of electrode plates 3, a plurality of radiation fins 4, and resin plates 5 </ b> A and 5 </ b> B. And the second stacked body 10 </ b> B are arranged in two layers in the stacking direction H. The electrode plates 3 in each of the stacked bodies 10A and 10B can separately receive the supply of the voltage from the plus power supply and the minus power supply. The electric heater 1 </ b> Z can perform a half-heating operation of heating by the first laminate 10 </ b> A or the second laminate 10 </ b> B and a full heating operation of heating by both laminates 10 </ b> A and 10 </ b> B. In FIG. 24, the electrode plate 3 connected to the positive power supply is indicated by (+), and the electrode plate 3 connected to the negative power supply is indicated by (-).

  The protrusion forming member 11 of the present embodiment is a resin plate 5 </ b> A on which the protrusion 51 is formed, and the protrusion contact member 12 is the electrode plate 3. The convex portion 51 of the present embodiment is provided on a surface 501 of the resin plate 5A disposed between the first laminate 10A and the second laminate 10B, which is opposed to the electrode plate 3 of the first laminate 10A. Have been. The protrusions 51 are provided in four projection ranges R in which the positions of the four PTC elements 2 are projected in the stacking direction H on the resin plate 5A.

  Also in the present embodiment, as in the first embodiment, since the hardness of the resin plate 5A is lower than the hardness of the electrode plate 3, the tip of each convex portion 51 in the resin plate 5A is plastically deformed and crushed. Further, as shown in FIG. 25, the convex portion 51 can be provided on a surface 501 of the resin plate 5A facing the heat radiation fins 4 of the second laminate 10B. Also in this case, since the hardness of the resin plate 5A is lower than the hardness of the radiating fins 4, the tips of the convex portions 51 in the resin plate 5A are plastically deformed and crushed. In addition, the convex portion 51 is provided on the surface 501 of the resin plate 5B disposed between the second laminate 10B and the frame 6B, which faces the electrode plate 3 of the second laminate 10B, or on the resin plate 5B. It can also be provided on the surface 501 facing the frame 6B.

  The arrangement positions of the PTC elements 2 in the lateral direction W and the depth direction D in the two laminates 10A and 10B of the present embodiment match when viewed along the laminate direction H. Then, the projection range R of each PTC element 2 is uniquely determined. On the other hand, the arrangement positions of the plurality of PTC elements 2 in the lateral direction W and the depth direction D in each of the laminates 10A and 10B do not necessarily have to match. In this case, when a plurality of stacked bodies 10A and 10B are viewed along the stacking direction H, the projections 51 are formed at positions where the projection ranges R of the PTC elements 2 in each of the stacked bodies 10A and 10B overlap each other. Can be formed.

  As shown in FIG. 24, each electrode plate 3 in the electric heater 1 </ b> Z having the two-stage laminates 10 </ b> A and 10 </ b> B alternately includes a plus power supply, a minus power supply, a plus power supply, and a minus power supply in order from one side in the lamination direction H. Connected to. The resin plates 5A and 5B are arranged between the first laminate 10A and the second laminate 10B and between the second laminate 10B and the frame 6B. The resin plate 5A disposed between the first laminated body 10A and the second laminated body 10B is composed of the electrode plate 3 and the radiation fins 4 of the first laminated body 10A, which are connected to a negative power supply, and the second laminated body 10A. Between the electrode plate 3 and the radiation fin 4 connected to the positive power supply of the laminated body 10B. The resin plate 5B disposed between the second laminated body 10B and the frame 6B is connected to the electrode plate 3 and the radiation fin 4 of the second laminated body 10B which are connected to a minus power source, the frames 6A and 6B, and the pressing plate. The conduction between the electrode plate 3 and the radiation fins 4 of the first laminate 10A, which are connected to the positive power supply, via the spring 7 is prevented.

  Other configurations of the electric heater 1 </ b> Z of the present embodiment are the same as those of the first embodiment. Also in this embodiment, the electric heater 1Z can be manufactured in the same manner as in the first embodiment. The components and the like denoted by the same reference numerals as those in the first embodiment are the same as the components and the like in the first embodiment. Also in this embodiment, the same operation and effect as in the first embodiment can be obtained.

(Embodiment 6)
This embodiment is a modification of the electric heater 1Z of the fifth embodiment, as shown in FIGS. 26 and 27, in which the projection forming member 11 is a radiation fin 4 on which the projection 41 is formed. The case where the convex contact member 12 which contacts the resin plate 5A is a resin plate 5A will be described.
The protrusions 41 are provided in the projection range R of the plurality of PTC elements 2 on the surface 401 of the radiation fin 4 in the stacking direction H. The convex portion 41 is provided on a surface 401 of the radiation fin 4 that faces the resin plate 5A. The convex portion 41 is formed integrally with the heat radiation fin 4 by deforming a part of the flat plate 42 of the heat radiation fin 4 and using the same material as the heat radiation fin 4. The protrusion 41 may be a metal material separately provided on the surface 401 of the flat plate 42 of the radiation fin 4.

  The radiation fins 4 are made of an aluminum material, and the resin plate 5A is made of a resin material. Since the hardness of the radiation fin 4 is higher than the hardness of the resin plate 5A, the resin plate 5A is plastically deformed by the projection 41 of the flat plate 42 of the radiation fin 4, and the surface 501 of the resin plate 5A has a projection. 41 forms a concave deformed portion 512. The deformed portion 512 is formed as a trace or mark of the surface 501 of the resin plate 5A by plastic deformation.

  The radiation fins 4 having the projections 41 of the present embodiment are used for the second laminate 10B. The convex portion 41 can be provided on any of the radiation fins 4 in the electric heater 1Z. The convex portion 41 can be provided, for example, on a surface 401 of the heat radiation fin 4 that faces the frame 6A.

  Other configurations of the electric heater 1 </ b> Z of the present embodiment are the same as those of the fifth embodiment. Also in this embodiment, the electric heater 1Z can be manufactured in the same manner as in the first embodiment. The components and the like denoted by the same reference numerals as those in the first embodiment are the same as the components and the like in the first embodiment. Also in this embodiment, the same operation and effect as in the first embodiment can be obtained.

(Other)
As described above, the protrusion forming member 11 that forms the protrusions 31, 41, 51, 61 may be any of the electrode plate 3, the radiation fins 4, the resin plates 5, 5A, 5B, or the frames 6A, 6B. it can. In addition, the protrusion contact member 12 that contacts the protrusions 31, 41, 51, and 61 may be any of the electrode plate 3, the radiation fins 4, the resin plates 5, 5A, 5B, or the frames 6A, 6B. Which of the protrusions 31, 41, 51, 61 and the protrusion contact member 12 undergoes plastic deformation is determined by the hardness of both, and the lower the hardness, the more the plastic deformation occurs. Therefore, when the hardnesses of the two become equal, the convex portions 31, 41, 51, and 61 may be plastically deformed so as to be crushed, and the convex portion contact member 12 may be plastically deformed so as to be dented. Further, even if the hardness of the projections 31, 41, 51, 61 is higher than the hardness of the projection contact member 12, depending on the shape of the projections 31, 41, 51, 61, it is necessary for the plastic deformation of the projection contact member 12. The convex portions 31, 41, 51, 61 may be plastically deformed with a load lower than the proper load.

  Among the electrode plate 3, the radiation fins 4, the resin plates 5, 5A, 5B and the frames 6A, 6B, the resin plates 5, 5A, 5B have the lowest hardness. Therefore, by using the resin plates 5, 5 </ b> A, and 5 </ b> B as the protrusion forming member 11 or the protrusion contact member 12, the protrusion 51 or the protrusion contact member 12 can be easily plastically deformed by the pressing force of the pressing spring 7. Become. In addition, since the resin plates 5, 5A, and 5B are molded by an injection molding method or the like, it is easy to integrally form the convex portions 51. When the projections 31, 41, 61 are formed on the electrode plate 3, the flat plate 42 of the radiation fins 4, and the frames 6A, 6B, a part of the material is deformed when the respective members are formed by press working. , The convex portions 31, 41, 61 can be formed integrally.

  It is preferable that the surface 301 of the electrode plate 3 in the stacking direction H and the surface 401 of the radiation fin 4 in the stacking direction H are in close contact with each other in order to secure conductivity or heat conductivity. Therefore, the case where the protrusion forming member 11 is the electrode plate 3 and the protrusion contact member 12 is the radiation fin 4, or the case where the protrusion formation member 11 is the radiation fin 4 and the protrusion contact member 12 is the electrode plate 3 The height of the projections 31 and 41 is reduced, and at least one of the projections 31 and 41 and the projection contact member 12 is plastically deformed while the surface 301 of the electrode plate 3 in the stacking direction H and the radiation fins are formed. It is also necessary to devise a method of forming a state in which the surface 401 of the layer 4 in the lamination direction H is in close contact with the surface 401.

  On the other hand, the resin plates 5, 5A, 5B and the frames 6A, 6B are not required to have conductivity and heat conductivity. Therefore, by forming at least one of the protrusion forming member 11 and the protrusion contact member 12 from the resin plates 5, 5A, 5B or the frames 6A, 6B, the surface in the stacking direction H does not necessarily have to be in close contact, and the protrusions are not required. The formation height, size, and the like of the projections 31, 41, 51, 61 of the formation member 11 can be easily set. However, the fluid such as air-conditioning air is basically heated by heat conduction from the radiation fins 4. The gap formed between the protrusions 31, 41, 51, 61 of the protrusion formation member 11 and the protrusion contact member 12 may be a gap through which the fluid passes without heating. Therefore, the height of the projections 31, 41, 51, 61 is reduced, and the surface of the projection forming member 11 in the stacking direction H excluding the portions where the projections 31, 41, 51, 61 are formed; It is preferable that a gap is not formed as much as possible between the contact member 12 and the surface in the stacking direction H.

  The present invention is not limited to each embodiment, and it is possible to configure further different embodiments without departing from the gist of the invention.

DESCRIPTION OF SYMBOLS 1 Electric heater 10, 10A, 10B laminated body 11 Convex part forming member 12 Convex part contact member 2 PTC element 3 Electrode plate 4 Radiation fin 5, 5A, 5B Resin plate 6A, 6B Frame 7 Press spring

Claims (6)

A plurality of PTC elements (2) that generate heat when energized and are arranged side by side in the horizontal direction (W);
A plurality of electrode plates (3) laminated on both sides of the PTC element in a laminating direction (H) orthogonal to the lateral direction and configured to supply current to the PTC element;
A plurality of radiating fins (4) stacked on both sides of the PTC element in the stacking direction to radiate heat transmitted from the PTC element;
One or more resin plates (5, 5A, 5B) stacked in the stacking direction of the electrode plates or the radiation fins and insulating between the electrode plates having different polarities;
A pressing spring (7) for pressing a laminate (10, 10A, 10B) of the PTC element, the electrode plate, the radiation fins, and the resin plate from both sides in the lamination direction;
When the resin plate, a convex portion forming member having the convex part (5 1) (11), and said electrode plate or the heat radiating fins, and the projections contact member in contact with the convex portion (12),
The projections are respectively provided in a plurality of projection ranges (R) on the surface ( 501) of the projection forming member in the stacking direction, in which the plurality of PTC elements are arranged in the stacking direction. And
It said convex portion of all of said projection range has a deformed portion which is plastically deformed (51 1) by the protrusions contact member, an electric heater (1). A plurality of PTC elements (2) that generate heat when energized and are arranged side by side in the horizontal direction (W);
A plurality of electrode plates (3) laminated on both sides of the PTC element in a laminating direction (H) orthogonal to the lateral direction and configured to supply current to the PTC element;
A plurality of radiating fins (4) stacked on both sides of the PTC element in the stacking direction to radiate heat transmitted from the PTC element;
One or more resin plates (5, 5A, 5B) stacked in the stacking direction of the electrode plates or the radiation fins and insulating between the electrode plates having different polarities;
A pressing spring (7) for pressing a laminate (10, 10A, 10B) of the PTC element, the electrode plate, the radiation fins, and the resin plate from both sides in the lamination direction;
When the electrode plate or the radiation fin is a projection forming member (11) having a projection (31, 41 ) , and the resin plate is a projection contact member (12) that contacts the projection. ,
The projections are respectively provided within a plurality of projection ranges (R) on the surface (301, 401 ) of the projection forming member in the stacking direction in which the plurality of PTC elements are arranged in the stacking direction. Is provided,
The electric heater (1), wherein the protrusion contact member has a deformed portion ( 512) plastically deformed by the protrusions in all the projection ranges. A plurality of PTC elements (2) that generate heat when energized and are arranged side by side in the horizontal direction (W);
A plurality of electrode plates (3) laminated on both sides of the PTC element in a laminating direction (H) orthogonal to the lateral direction and configured to supply current to the PTC element;
A plurality of radiating fins (4) stacked on both sides of the PTC element in the stacking direction to radiate heat transmitted from the PTC element;
One or more resin plates (5, 5A, 5B) stacked in the stacking direction of the electrode plates or the radiation fins and insulating between the electrode plates having different polarities;
A pressing spring (7) for pressing a laminate (10, 10A, 10B) of the PTC element, the electrode plate, the radiation fins, and the resin plate from both sides in the lamination direction;
When the electrode plate is a projection forming member (11) having a projection (31 ) , and the radiation fin is a projection contact member (12) that comes into contact with the projection,
The protrusions are respectively provided in a plurality of projection ranges (R) on the surface (301 ) of the protrusion forming member in the stacking direction, in which the plurality of PTC elements are arranged in the stacking direction. And
The electric heater (1), wherein the protrusion contact member has a deformed portion that is plastically deformed by the protrusions in all the projection ranges. A plurality of PTC elements (2) that generate heat when energized and are arranged side by side in the horizontal direction (W);
A plurality of electrode plates (3) laminated on both sides of the PTC element in the laminating direction (D) orthogonal to the lateral direction, and for supplying electricity to the PTC element;
A plurality of radiating fins (4) stacked on both sides of the PTC element in the stacking direction to radiate heat transmitted from the PTC element;
One or more resin plates (5, 5A, 5B) stacked in the stacking direction of the electrode plates or the radiation fins and insulating between the electrode plates having different polarities;
A pair of frames (6A, 6B) laminated on both ends in the laminating direction of the laminate (10, 10A, 10B) of the PTC element, the electrode plate, the radiation fins, and the resin plate;
A pressure spring (7) for pressing the laminate from both sides in the lamination direction via the pair of frames;
Said frame, a convex portion forming member (11) having a convex portion (61), or One prior Symbol electrode plate, the out noise either the said heat dissipating fins and the resin plates, in contact with the protrusion When the convex contact member (12) is used,
The protrusions are respectively provided in a plurality of projection ranges (R) on the surface ( 601) of the protrusion forming member in the stacking direction, in which the plurality of PTC elements are arranged in the stacking direction. And
The electric heater (1), wherein the protrusion contact member has a deformed portion ( 512) plastically deformed by the protrusions in all the projection ranges. A plurality of PTC elements (2) that generate heat when energized and are arranged side by side in the horizontal direction (W);
A plurality of electrode plates (3) laminated on both sides of the PTC element in the laminating direction (D) orthogonal to the lateral direction, and for supplying electricity to the PTC element;
A plurality of radiating fins (4) stacked on both sides of the PTC element in the stacking direction to radiate heat transmitted from the PTC element;
One or more resin plates (5, 5A, 5B) stacked in the stacking direction of the electrode plates or the radiation fins and insulating between the electrode plates having different polarities;
A pair of frames (6A, 6B) laminated on both ends in the laminating direction of the laminate (10, 10A, 10B) of the PTC element, the electrode plate, the radiation fins, and the resin plate;
A pressure spring (7) for pressing the laminate from both sides in the lamination direction via the pair of frames;
One of the electrode plate, the radiation fins, and the resin plate is a protrusion forming member (11) having a protrusion (31, 41, 51 ) , and the frame is brought into contact with the protrusion. When the convex contact member (12) is used,
The projecting portion is located within a plurality of projection ranges (R) on the surface (301, 401, 501 ) of the projecting portion forming member in the stacking direction in which the plurality of PTC elements are arranged in the stacking direction. Is provided in each,
It said convex portion of all of said projection range has a deformed portion which is plastically deformed (51 1) by the protrusions contact member, an electric heater (1). The electric heater according to any one of claims 1 to 5 , wherein the convex portion is provided integrally with the convex portion forming member using a material of the same quality as the convex portion forming member.

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