CN110140422B

CN110140422B - Electric heater and method for manufacturing the same

Info

Publication number: CN110140422B
Application number: CN201780074473.8A
Authority: CN
Inventors: 大矢康裕; 小林优希; 新西祥次
Original assignee: Denso Duolimu Co ltd
Current assignee: Denso Duolimu Co ltd
Priority date: 2016-12-02
Filing date: 2017-11-30
Publication date: 2022-05-13
Anticipated expiration: 2037-11-30
Also published as: JP2018092787A; CN110140422A; WO2018101407A1; JP6640700B2; DE112017006124T5

Abstract

An electric heater (1) having: a plurality of PTC elements (2) that generate heat when energized; a plurality of electrode plates (3) for energizing the PTC element (2); a plurality of heat radiating fins (4) for radiating heat transferred from the PTC element (2); a resin plate (5) for insulating the electrode plates (3) having different polarities from each other; and a compression spring (7) for pressing the laminated body (10) from both sides in the laminating direction (H). In the surface of the resin plate (5) in the stacking direction (H), projections (51) protruding from the surface are provided in each projection range (R) obtained by projecting the arrangement position of the PTC element (2) in the stacking direction (H). The convex portion (51) in each projection range (R) has a deformation portion which is in contact with the electrode plate (3) and is formed by plastic deformation.

Description

Electric heater and method for manufacturing the same

Cross Reference to Related Applications

The present application is based on Japanese patent application No. 2016-.

Technical Field

The present invention relates to an electric heater using heat generated when a PTC element is energized, and a method for manufacturing the same.

Background

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 has the following components and the like: an electrode plate for energizing the PTC element; a heat sink for dissipating heat transferred from the PTC element; a pair of frames disposed on both sides in the stacking direction of the stacked body of the PTC element, the electrode plate, and the heat sink; and a pressing spring for pressing the pair of frames from both sides in the stacking direction. In an electric heater, in order to efficiently conduct electricity from an electrode plate to PTC elements and heat from the PTC elements to heat dissipation fins, a plurality of PTC elements arranged in a lateral direction are brought into contact with the electrode plate and the heat dissipation fins as uniformly as possible.

For example, in the electric heater of patent document 1, bent portions for pressing the respective PTC elements arranged in the lateral direction are formed on a pair of frames. The portion of the laminate where each PTC element is disposed is pressed by each bent portion, so that each PTC element is brought into close contact with the electrode plate and the heat sink.

In the vehicle air conditioning electric heater disclosed in patent document 2, for example, a warped elastic contact portion is provided at a position of the electrode plate that faces a portion where the plurality of PTC elements are arranged in the lateral direction. When the stacked 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 is brought into close contact with the electrode plate and the heat sink.

Documents of the prior art

Patent document

Patent document 1: japanese laid-open patent publication No. 2009-152172

Patent document 2: chinese patent No. CN101730324

Disclosure of Invention

In order to further improve the performance of the heater, there is room for improvement in

patent documents

1 and 2. That is, as a result of the research and development by the inventors, in order to more effectively conduct the current from the electrode plate to the PTC element and the heat conduction from the PTC element to the heat dissipation fin, it is effective to form all the PTC elements in a state of being pressed and contacted with the electrode plate and the heat dissipation fin with as much force as possible.

In patent document 1, the frame is bent by using a pressing spring, and the bent portions of the frame press the locations where the PTC elements are arranged in the stacked body. Therefore, the force with which the PTC elements are pressed by the electrode plate and the heat sink differs depending on the manner of deflection of the frame. As a result, the magnitude of the pressing force acting on each PTC element is affected by the magnitude of errors, deformation, and the like in manufacturing the frame. Therefore, in patent document 1, there is a possibility that the force with which each PTC element is pressed by the electrode plate and the heat sink varies.

In patent document 2, the amount of elastic deformation of each elastic contact portion in the electrode plate differs depending on the difference in thickness in the stacking direction of the arrangement portion of each PTC element in the stacked body. Therefore, the force with which the PTC element is pressed by the electrode plate and the heat sink differs for each elastic contact portion, and the PTC element facing the elastic contact portion that is elastically deformed more strongly is pressed with a greater force. Therefore, in patent document 2, there is a possibility that the force with which each PTC element is pressed by the electrode plate and the heat sink varies.

The invention provides an electric heater capable of improving heater performance and a manufacturing method thereof.

An electric heater according to an embodiment of the present invention includes:

a plurality of PTC elements that generate heat when energized and are arranged in a horizontal direction;

a plurality of electrode plates laminated on both sides of the PTC element in a lamination direction orthogonal to the transverse direction, for energizing the PTC element;

a plurality of heat radiating fins laminated on both sides of the PTC element in the laminating direction, for radiating heat transferred from the PTC element;

one or more resin plates laminated in the lamination direction of the electrode plates or the heat sink for insulating the electrode plates having different polarities from each other; and

a compression spring that presses a stacked body of the PTC element, the electrode plate, the heat sink, and the resin plate from both sides in the stacking direction,

when any one of the electrode plate, the heat sink, and the resin plate is a projection forming member having a projection, and any one of the electrode plate, the heat sink, and the resin plate other than the projection forming member is a projection contact member that contacts the projection,

wherein the protrusions are provided on the surface of the protrusion-forming member in the stacking direction, and are respectively disposed within a plurality of projection ranges obtained by projecting the positions of the plurality of PTC elements in the stacking direction,

at least one of the convex portion and the convex portion contact member in all of the projection ranges has a deformed portion formed by plastic deformation.

An electric heater according to another aspect of the present invention includes:

one or more resin plates laminated in the lamination direction of the electrode plates or the heat sink for insulating the electrode plates having different polarities from each other;

a pair of frames laminated on both ends of a laminated body of the PTC element, the electrode plate, the heat sink, and the resin plate in the laminating direction; and

a pressing spring that presses the stacked body from both sides in the stacking direction with the pair of frames interposed therebetween,

when any one of the electrode plate, the heat sink, the resin plate, and the frame is a projection forming member having a projection, and any one of the electrode plate, the heat sink, the resin plate, and the frame other than the projection forming member is a projection contact member which contacts the projection,

A method of manufacturing an electric heater according to an aspect of the present invention is a method of manufacturing an electric heater including:

in the manufacturing method of the electric heater,

when the stacked body is pressed from both sides in the stacking direction by the pressing spring, at least one of the convex portions and the convex portion contact members in all the projection ranges is plastically deformed, and a deformed portion is formed in at least one of the convex portions and the convex portion contact members in all the projection ranges.

Effects of the invention

The electric heater according to the above-described one aspect is contrived in that the deformation portion formed by plastic deformation is formed in at least one of the members of the electrode plate, the heat sink, and the resin plate, which are in contact with each other, whereby the force with which each PTC element is pressed by the electrode plate and the heat sink is made as uniform as possible in all the PTC elements. Specifically, one of the electrode plate, the heat sink, and the resin plate is a projection forming member having a projection, and the other one is a projection contact member that contacts the projection. The protrusions are provided in a plurality of projection ranges obtained by projecting the positions of the plurality of PTC elements in the stacking direction on the surface of the protrusion-forming member in the stacking direction, and at least one of the protrusions and the protrusion-contacting member in each projection range has a deformation portion formed by plastic deformation.

In addition, the convex portions and the convex portion contact members contact each other in the projection range of all the PTC elements, and at least one of all the convex portions and the convex portion contact members has a plastically deformed portion. The deformed portion is formed by plastic deformation into a trajectory or trace in which the convex portion is crushed so as to decrease in height, a trajectory or trace in which the surface of the convex portion contact member is depressed, or the like. Further, since the deformation portion is formed by plastic deformation, the pressing force generated at each convex portion hardly varies depending on the magnitude of the deformation amount, unlike the case of forming the deformation portion by elastic deformation.

In this way, in the electric heater according to the one aspect, even when the thickness in the stacking direction at each position in the lateral direction where the PTC elements are arranged differs from each other due to dimensional errors, deformation, and the like in manufacturing that occur in the PTC elements, the electrode plates, the heat sink, and the resin plate, by utilizing plastic deformation of at least one of the protrusion and the protrusion contact member, it is possible to form a state in which all the PTC elements, the electrode plates, and the heat sink are pressed and contacted with the same force as possible. The "thickness in the stacking direction" referred to herein is a thickness obtained by adding the thicknesses in the stacking direction of the PTC elements, the electrode plates, the heat dissipation fins, and the resin plates individually to the projection range of each PTC element.

This allows more efficient conduction of electricity from the electrode plates to all the PTC elements and heat conduction from all the PTC elements to the heat sink. Therefore, according to the electric heater of the one aspect, the heater performance can be further improved.

In the electric heater according to the another aspect, the projection forming member and the projection contact member include a frame. The other structure is the same as that of the electric heater of the one mode. Therefore, according to the electric heater of the other aspect, the heater performance can be further improved as in the electric heater of the one aspect.

In the method of manufacturing an electric heater, when the stacked body is pressed from both sides in the stacking direction by the pressing spring, the deformed portion formed by plastic deformation is formed in at least one of the convex portion and the convex portion contact member in all the projection ranges. Thus, according to the method of manufacturing an electric heater, the electric heater capable of further improving the heater performance can be easily manufactured.

Note that, in the drawings of the embodiments, the parenthesized reference numerals of the respective constituent elements shown in one embodiment of the present invention indicate the correspondence with the reference numerals of the embodiments, but the respective constituent elements are not limited to the contents of the embodiments.

Drawings

The objects, features, advantages and the like of the present invention will be more apparent from the following detailed description with reference to the accompanying drawings. The drawings of the present invention are as follows.

Fig. 1 is an explanatory view showing an electric heater according to embodiment 1.

Fig. 2 is an explanatory diagram of embodiment 1 showing a part of an electric heater in an enlarged manner.

Fig. 3 is a cross-sectional view showing the electric heater according to embodiment 1 in a state of being cut in the stacking direction.

Fig. 4 is an explanatory diagram showing an electric heater in an exploded state according to embodiment 1.

Fig. 5 is an explanatory diagram of embodiment 1, showing a main part of the electric heater in an exploded state.

Fig. 6 is an explanatory diagram of embodiment 1, showing a main part of another electric heater in an exploded state.

Fig. 7 is an explanatory view schematically showing a projection forming member and a projection contact member before plastic deformation of each projection according to embodiment 1.

Fig. 8 is an explanatory view schematically showing a projection forming member and a projection contact member after each projection is plastically deformed according to embodiment 1.

Fig. 9 is an explanatory view schematically showing a pair of members before each elastic deformation portion is elastically deformed according to the comparative method.

Fig. 10 is an explanatory view schematically showing a pair of members in the comparative method after each elastic deformation portion is elastically deformed.

Fig. 11 is an explanatory diagram of embodiment 2, showing a main part of an electric heater in an exploded state.

Fig. 12 is a cross-sectional view showing the electric heater according to embodiment 2 in a state of being cut in the stacking direction.

Fig. 13 is an explanatory diagram of embodiment 2, showing a main part of another electric heater in an exploded state.

Fig. 14 is an explanatory view schematically showing the convex portion forming member and the convex portion contacting member before the convex portion contacting member is plastically deformed according to embodiment 2.

Fig. 15 is an explanatory view schematically showing a projection forming member and a projection contact member in accordance with embodiment 2 after plastic deformation of the projection contact member.

Fig. 16 is an explanatory diagram of embodiment 3, in which the main part of the electric heater is shown in an exploded state.

Fig. 17 is a cross-sectional view showing an electric heater according to embodiment 3 in a state of being cut in a stacking direction.

Fig. 18 is an explanatory diagram of embodiment 4, in which the main part of the electric heater is shown in an exploded state.

Fig. 19 is a cross-sectional view showing an electric heater according to embodiment 4 in a state of being cut in a stacking direction.

Fig. 20 is a sectional view showing a main part of another electric heater according to embodiment 4 in an exploded state.

Fig. 21 is an explanatory view showing an electric heater according to embodiment 5.

Fig. 22 is an explanatory diagram showing a part of an electric heater according to embodiment 5 in an enlarged manner.

Fig. 23 is a cross-sectional view showing an electric heater according to embodiment 5 in a state of being cut in a stacking direction.

Fig. 24 is an explanatory diagram of embodiment 5, in which the main part of the electric heater is shown in an exploded state.

Fig. 25 is an explanatory diagram of embodiment 5, showing a main part of another electric heater in an exploded state.

Fig. 26 is an explanatory diagram of embodiment 6, in which the main part of the electric heater is shown in an exploded state.

Fig. 27 is a cross-sectional view showing an electric heater according to embodiment 6 in a state of being cut in a stacking direction.

Detailed Description

Preferred embodiments of the electric heater described above will be described with reference to the drawings.

As shown in fig. 1, 2, and 4, the electric heater 1 of the present embodiment includes a plurality of PTC elements 2, a plurality of electrode plates 3, a plurality of heat radiation fins 4, a resin plate 5, and a pressure spring 7. The PTC elements 2 are members that generate heat when energized, and are arranged in the lateral direction W. The electrode plates 3 are stacked on both sides of the PTC element 2 in the stacking direction H orthogonal to the lateral direction W, and are used to energize the PTC element 2. The heat radiation fins 4 are laminated on both sides of the PTC element 2 in the lamination direction H, and radiate heat transferred from the PTC element 2.

The resin plate 5 is laminated in the lamination direction H of the electrode plates 3 or the heat dissipation fins 4, and insulates the electrode plates 3 having different polarities from each other. The compression springs 7 are used to press the stacked body 10 of the PTC elements 2, the electrode plates 3, the heat dissipation fins 4, and the resin plates 5 from both sides in the stacking direction H.

In the electric heater 1, the resin plate 5 is a projection forming member 11, and the electrode plate 3 is a projection contact member 12 that contacts the projection 51. As shown in fig. 3 and 5, the convex portions 51 protruding from the surface 501 are provided in each projection range R obtained by projecting the arrangement portions of the PTC elements 2 in the lateral direction W and the depth direction D in the lamination direction H on the surface 501 of the resin plate 5 serving as the convex portion forming member 11 in the lamination direction H. The convex portion 51 in each projection range R has a deformation portion 511 which is brought into contact with the electrode plate 3 as the convex portion contact member 12 and is plastically deformed.

Next, 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 of the air conditioner or to replace heating of the air conditioner. The electric heater 1 can be used for compensating for a decrease in the heat source of the vehicle due to an increase in the efficiency of the engine, and can also be used for a vehicle having no heat source, such as an EV (electric vehicle) or an FCV (fuel cell vehicle).

In this embodiment, the lateral direction W is a direction in which the electrode plate 3, the heat sink 4, the resin plate 5, and the like are formed to have a long shape. The stacking direction H is a direction in which the electrode plates 3 of the PTC elements 2, the heat dissipation fins 4, the resin plates 5, and the like are stacked, which is perpendicular to the lateral direction W. A direction perpendicular to the lateral direction W and the stacking 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 for air conditioning or the electric heater 1 passes.

The PTC element 2 is formed using a semiconductor or the like, generates heat when energized, and has PTC (positive temperature coefficient) characteristics in which the resistance increases with an increase in temperature. When the PTC element 2 generates heat to a predetermined temperature or higher, the temperature is maintained at a substantially constant temperature by an increase in 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 area.

As shown in fig. 3, the PTC element 2 is held by a plate-shaped positioning plate 21 made of resin. A plurality of placement holes 211 for placing the PTC elements 2 are formed in the positioning plate 21 at predetermined intervals in the lateral direction W. The plurality of positioning holes 211 are formed to penetrate through the positioning plate 21 in the stacking direction H. The PTC elements 2 of the present embodiment are arranged in the arrangement holes 211 of the positioning plate 21 in a state where 4 PTC elements are arranged in the lateral direction W at predetermined intervals. The PTC elements 2 can be arranged on the positioning plate 21 in 4 to 6 rows, for example. It is preferable that the thickness of the positioning plate 21 in the stacking direction H of the portion where the PTC element 2 is arranged is thinner than the PTC element 2 so that the electrode plate 3 or the heat sink 4 is easily brought into contact with the PTC element 2. The positioning plate 21 is provided with a protrusion 212, and the protrusion 212 is used to position the electrode plate 3 or the heat sink 4 stacked on the positioning plate 21 in the depth direction D. The projections 212 can simultaneously position the electrode plate 3 and the heat sink 4 with respect to the positioning plate 21 by adjusting the heights thereof. The projections 212 of the present embodiment are formed continuously at both edges of the positioning plate in the depth direction D.

As shown in fig. 5, the electrode plate 3 is a member to which a voltage for energizing the PTC element 2 is applied. 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 supply, and the other is connected to a negative power supply (ground). In the figure, the electrode plate 3 connected to the positive power supply is denoted by (+) and the electrode plate 3 connected to the negative power supply is denoted by (-) in the figure. The electrode plate 3 of the present embodiment is made of a material obtained by plating a brass plate, which is a metal having good electrical conductivity, with tin. As another material, 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 electrode plate 3 is drawn outward in the lateral direction W from one end portion in the lateral direction W so as to apply a voltage.

As shown in fig. 2 and 5, the heat sink 4 conducts electricity and heat with the PTC element 2 and conducts heat with a fluid such as heating air. One of a pair of heat dissipation sheets 4 stacked on both sides of the PTC element 2 in the stacking direction H is connected to a positive power supply via an electrode plate 3, and the other is connected to a negative power supply via the electrode plate 3. The heat sink 4 includes a pair of flat plates 42 that are in contact with the PCT 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 disposed on both sides of the heat dissipation fins 4 in the stacking direction H. 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 heat radiating fins 4. The heat sink 4 of the present embodiment is made of an aluminum material made of aluminum or an aluminum alloy or a copper-based material made of copper or a copper alloy, which is a metal having excellent electrical and thermal conductivity.

As shown in fig. 3 and 5, the resin plate 5 is used to insulate the electrode plate 3 and the heat sink 4, which are connected to the positive power supply or the negative power supply and have different polarities. The resin plate 5 of the present embodiment is made of 66 nylon as a thermoplastic resin. In addition, the resin plate 5 may be made of nylon-based resin, PBT (polybutylene terephthalate resin), PPS (polyphenylene sulfide resin), or the like. The resin plate 5 is provided with a projection 52, and the projection 52 is used for positioning in the depth direction D with the electrode plate 3 (or the heat sink 4) laminated on the resin plate 5. The projections 52 can be simultaneously positioned with respect to the electrode plate 3 and the heat sink 4 of the resin plate 5 by adjusting the height thereof. The projections 52 of the present embodiment are formed continuously at both edges of the resin plate 5 in the depth direction D.

As shown in fig. 1 to 3, a pair of

frames

6A and 6B are stacked on both ends of the stacked body 10 of the PTC element 2, the electrode plate 3, the heat sink 4, and the resin plate 5 in the stacking direction H. The pair of

frames

6A and 6B are used to receive the pressing force (load) of the pressing spring 7, and to closely adhere the PTC element 2, the electrode plate 3, the heat sink 4, and the resin plate 5 in the stacked body 10 to each other. By using the pair of

frames

6A, 6B, the rigidity of the electric heater 1 can be improved, and the pressing force applied to the stacked body 10 by the pressing spring 7 can be easily applied uniformly to the plurality of PTC elements 2.

The

frames

6A, 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 may be formed in a cylindrical shape in which a flat plate is bent and a gap is formed between the bent ends. A part of the pressing spring 7 is inserted into the hollow hole 62 of the

frames

6A, 6B. The

frames

6A and 6B of this embodiment are made of SUS 430. In addition, the

frames

6A and 6B may be made of SUS (stainless steel) material such as SUS304, or steel material such as SECC (galvanized steel sheet).

The pressing springs 7 are disposed on both sides of the laminated body 10 in the lateral direction W, and press the laminated body 10 from both sides in the laminating direction H through the pair of

frames

6A, 6B on both sides in the lateral direction W. The pressure spring 7 has: a spring center 71 extending in the stacking direction H and disposed opposite to an end of the stacked body 10 in the lateral direction W; the pair of holding portions 72 are formed by bending from both sides of the spring center portion 71, and hold the stacked body 10 therebetween. 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 between the

frames

6A and 6B. The gap between the pair of sandwiching portions 72 is widened by the stacked body 10 and the pair of

frames

6A, 6B, and a pressing force for maintaining the stacked state of the stacked body 10 is applied from the pair of sandwiching portions 72 to the stacked body 10 and the pair of

frames

6A, 6B.

As shown in fig. 1 and 4, resin shields 81 that engage with both ends in the transverse direction W of the pair of

frames

6A and 6B are provided at both ends in the transverse direction W of the stacked body 10. A connector 82 for connecting the plurality of electrode plates 3 to a positive power supply and a negative power supply of a battery of a vehicle is provided to the shield 81 located on the side from which the electrode plates 3 are drawn out.

As shown in fig. 3 to 5, in the laminated body 10 of the electric heater 1 of the present embodiment, the plurality of PTC elements 2 are arranged in four layers, and the electrode plates 3 and the heat radiating fins 4 are arranged on both sides of the PTC elements 2 in the laminating direction H. The electrode plate 3 and the heat sink 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 laminate 10 in the lamination direction H. Each electrode plate 3 in the stacked body 10 can independently receive voltage supply from a positive power supply and a negative power supply. The electric heater 1 can perform a local heating operation in which electricity is supplied to a plurality of PTC elements 2 at a specific stacking position and a total heating operation in which electricity is supplied to all the PTC elements 2 in the stacked body 10 by switching the presence or absence of the electricity supplied to each electrode plate 3 in the stacked body 10.

As shown in fig. 3 and 5, the positions of the PTC elements 2 in the lateral direction W and the depth direction D in the stacked body 10 of the present embodiment are uniform when viewed along the stacking direction H. The projection range R of each PTC element 2 is uniquely determined. For example, when the number of layers in which the plurality of PTC elements 2 are stacked is increased, it is also assumed that 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 are not uniform. In this case, when the stacked body 10 is viewed in the stacking direction H, the convex portions 51 can be formed at the positions where the projection ranges R of the plurality of PTC elements 2 overlap each other in the stacked body 10.

As shown in fig. 6, it is also conceivable that a portion of the PTC element 2 is removed for power adjustment, and the portion where the PTC element 2 is removed is buried in the positioning plate 21. In this case, at the positions where the PTC elements 2 are not present, the positioning plate 21 is pressed by the pressing springs 7, so that the respective projection ranges R in the entire laminated body 10 are uniformly pressed.

As shown in fig. 5, each electrode plate 3 of the electric heater 1 having the laminated body 10 is alternately connected with a positive power supply, a negative power supply, and a positive power supply in order from one side in the laminating direction H. The resin plate 5 is disposed between the electrode plate 3 and the frame 6B located at the outermost 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 configured such that the electrode plate 3 and the heat sink 4 positioned at one end in the stacking direction H are not electrically connected to the electrode plate 3 and the heat sink 4 positioned at the other end in the stacking direction H via the

frames

6A and 6B and the compression springs 7. The resin plate 5 is used to insulate the plurality of PTC elements 2 located at one end in the stacking direction H from the plurality of PTC elements 2 located at the other end in the stacking direction H when the two are independently energized.

The convex portion 51 of the present embodiment is provided on the surface 501 of the resin plate 5 facing the electrode plate 3. The convex portions 51 are provided in the resin plate 5 within 4 projection ranges R obtained by projecting the arrangement positions of the 4 PTC elements 2 in the stacking direction H. One projection 51 is provided at the center of each projection range R. Further, a plurality of convex portions 51 may be provided in each projection range R. The projection 51 does not necessarily need to be provided at the center of each projection range R, and a plurality of projections may be provided at positions around the center of each projection range R.

The hardness of the resin plate 5 as the projection forming member 11 of the present embodiment is lower than the hardness of the electrode plate 3 as the projection contact member 12. As shown in fig. 7 and 8, when the resin plate 5 and the electrode plate 3 are in contact with each other and the pressing force of the pressing spring 7 acts therebetween, the distal end portions of the respective projections 51 of the resin plate 5 are plastically deformed by the electrode plate 3 so as to decrease the height of the projections from the surface 501, and are crushed. At this time, a large amount of the material located at the tip end of each projection 51 flows around each projection 51 from between each projection 51 and the electrode plate 3. In this way, traces or traces of plastic deformation remain in the convex portions 51 as the deformation portions 511.

Here, fig. 7 schematically shows a state before each convex portion 51 is plastically deformed, and fig. 8 schematically shows a state after each convex portion 51 is plastically deformed. The drawings schematically show the state where the deformation portion 511 is formed in each convex portion 51 for the sake of explanation, and exaggeratedly show the convex portion 51.

Each projection 51 of the electric heater 1 may have any shape as long as the deformation portion 511 is formed at the distal end portion. The shape of the convex portion 51 before the deformation portion 511 is formed can be, for example, a conical shape, a square cone such as a triangular pyramid or a rectangular pyramid, or a protrusion having a curved surface such as a hemispherical shape, so that the deformation portion 511 can be easily formed. The shape of the convex portion 51 before the deformation portion 511 is formed may be a cylindrical shape or a prismatic shape having a flat or curved end portion, a tapered shape or a columnar shape having a plurality of end portions, or the like. The shape of the convex portion 51 before the deformation portion 511 is formed can be the same as that when the convex portion 51 is plastically deformed so that the surface of the convex portion contact member 12 is depressed as in embodiment 2 and the like described later.

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

The convex portion 51 may be provided on the surface 501 of the resin plate 5 facing the frame 6B. In this case, since the resin plate 5 has a lower hardness than the frame 6B, the frame 6B has a deformed portion 511 which is crushed by plastic deformation at the tip end of each convex portion 51 of the resin plate 5.

The convex portion 51 may be provided on both surfaces 501 of the resin plate 5. In this case, one convex portion 51 may have a deformation portion 511 formed by plastic deformation by contact with the electrode plate 31, and the other convex portion 51 may have a deformation portion 511 formed by plastic deformation by contact with the frame 6B.

Next, a method of manufacturing the electric heater 1 of the present embodiment will be described.

First, the PTC element 2, the electrode plate 3, the heat sink 4, the resin plate 5, the

frames

6A and 6B, and the compression spring 7 are each processed by a known method. When the resin plate 5 is molded, a plurality of projections 51 are formed on the surface 501 of the resin plate 5. The plurality of protrusions 51 are formed in the surface 501 of the resin plate 5 in the stacking direction H so as to protrude from the surface 501, and are formed in the respective projection ranges R obtained by projecting the arrangement positions of the plurality of PTC elements 2 in the stacking direction H.

Then, the PTC elements 2 are placed in the placement holes 211 of the positioning plate 21, and the positioning plate 21, the electrode plates 3, the heat sinks 4, and the resin plate 5 are laminated to form the laminated body 10. At this time, each convex portion 51 of the resin plate 5 is disposed within the projection range R of each PTC element 2 on the surface 501 of the resin plate 5 in the stacking direction H. The

frames

6A and 6B are laminated at both ends of the laminated body 10 in the laminating direction H.

Then, the pressing springs 7 are elastically deformed using a jig or the like so that the interval between the pair of clamping portions 72 of the two pressing springs 7 is enlarged. The compression springs 7 are disposed on both sides of the stacked body 10 in the lateral direction W, and the sandwiching portions 72 of the compression springs 7 are inserted into the hollow holes 62 of the

frames

6A and 6B. When the state in which the pressing spring 7 is elastically deformed is released, the interval between the pair of sandwiching portions 72 is narrowed. Thereby, the stacked body 10 is pressed by the pair of sandwiching portions 72 of the pressing spring 7 through the pair of

frames

6A, 6B.

When the laminated body 10 receives the pressing force of the pressing spring 7, the projections 51 of the resin plate 5 contact the surface 301 of the electrode plate 3, the hardness of the projections 51 is lower than that of the electrode plate 3, and the strength of the projections 51 is low, so that the tip end portions of the projections 51 are plastically deformed so as to be crushed. The convex portion 51 in all the projection ranges R is formed with a deformed portion 511 whose tip portion is crushed. Then, the cover 81 and the connector 82 are attached to manufacture the electric heater 1.

Next, the operation and effect of the electric heater 1 of the present embodiment will be described.

When the stacked body 10 is pressed by the pair of pressing springs 7, the electrode plate 3 contacts the respective convex portions 51 of the resin plate 5. At this time, the thickness of each portion of the stacked body 10 in the transverse direction W varies in the stacking direction H due to the influence of dimensional errors, deformation, and the like in manufacturing that occur in the PTC elements 2, the electrode plates 3, the heat dissipation fins 4, the resin plates 5, and the

frames

6A and 6B. When the stacked body 10 receives the pressing force of the pressing spring 7, the respective convex portions 51 of the resin plates 5 having a lower strength than the electrode plates 3 are 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 by which each convex portion 51 is plastically deformed differs depending on the difference in thickness of the laminated body 10 in the projection range R.

Fig. 7 and 8 show a state in which the plurality of convex portions 51 of the convex portion forming member 11 are in contact with the convex portion contact member 12 and the plurality of convex portions 51 are plastically deformed in the projection range R of the plurality of PTC elements 2. The convex portions 51 in each projection range R receive variations in thickness in the lamination direction H of the laminate 10, and differ in the amount of plastic deformation. Specifically, the amount of plastic deformation of the convex portions 51b arranged in the projection range R where the thickness in the stacking direction H of the stacked body 10 is large is larger than the amount of plastic deformation of the convex portions 51a arranged in the projection range R where the thickness in the stacking direction H of the stacked body 10 is small. The protruding amount (height) of the latter protruding portion 51b from the surface 501 is smaller than the protruding amount (height) of the former protruding portion 51a from the surface 501. By observing the deformation portions 511 formed at the distal end portions of the

convex portions

51a, 51b, the difference in the amount of protrusion between the

convex portions

51a, 51b can be seen.

As described above, by performing plastic deformation of the plurality of convex portions 51 of the resin plate 5, the difference in thickness in the stacking direction H of the stacked body 10 in the projection range R of each PTC element 2 is reduced, and the thickness in the stacking direction H of each portion varying in the lateral direction W of the stacked body 10 becomes uniform. When each of the convex portions 51 is plastically deformed, the deformation or the like generated in each of the

components

2, 3, 4, 5, 6A, and 6B may be corrected.

In the projection range R of all the PTC elements 2, the projections 51 of the resin plate 5 are in contact with the electrode plate 3, and all the projections 51 have the deformed portions 511 formed by plastic deformation. The deformation portion 511 is formed by plastic deformation into a trace or trace where the convex portion 51 is crushed to decrease in height. Since the deformation portion 511 is formed by plastic deformation, unlike the case of being formed by elastic deformation, the reaction force generated in each of the convex portions 51 hardly differs depending on the magnitude of the deformation amount. As a result, the force with which the PTC elements 2 are pressed by the electrode plates 3 and the heat dissipation fins 4 is made as uniform as possible within the projection range R of each PTC element 2.

In this way, in the electric heater 1 of the present embodiment, the following effects can be obtained by utilizing the plastic deformation of all the convex portions 51 of the resin plate 5. That is, even when the thicknesses in the stacking direction H at the respective positions in the lateral direction W where the PTC elements 2 are arranged are different from each other due to dimensional errors, deformation, and the like in manufacturing that occur in each of the PTC elements 2, the electrode plates 3, the heat dissipation fins 4, and the resin plates 5, all of the PTC elements 2, the electrode plates 3, and the heat dissipation fins 4 can be pressed and brought into contact with each other with as much force as possible. This enables the passage of current from the electrode plate 3 to all the PTC elements 2 and the transfer of heat from all the PTC elements 2 to the heat dissipation fins 4 to be performed efficiently. Therefore, according to the electric heater 1 of the present embodiment, the heater performance can be further improved.

Fig. 9 and 10 show a comparative state in which a plurality of elastic deformation portions 51X are elastically deformed when a member 11X formed with the elastic deformation portions 51X is used instead of the projection forming member 11. A contact member that comes into contact with the elastically deformable portion 51X of the member 11X is denoted by reference numeral 12X. The elastic deformation portions 51X in the respective projection ranges R are different in the amount of elastic deformation in response to the variation in thickness of the laminate 10 in the lamination direction H. Specifically, the elastic deformation amount of the elastic deformation portion 51Xb disposed in the projection range R where the thickness of the laminated body 10 is large is larger than the elastic deformation amount of the elastic deformation portion 51Xa disposed in the projection range R where the thickness of the laminated body 10 is small.

At this time, the reaction force generated in the elastic deformation portions 51Xa and 51Xb differs depending on the magnitude of the deformation amount, and a reaction force larger than that of the elastic deformation portion 51X having a smaller elastic deformation amount is applied to the elastic deformation portion 51Xb having a larger elastic deformation amount. As a result, the force with which the PTC elements 2 are pressed by the electrode plates 3 and the heat dissipation fins 4 is not uniform in the projection range R of the PTC elements 2. As a result, the contact state between each PTC element 2 and the electrode plate 3 and the heat dissipation fins 4 varies, and the current flow from the electrode plate 3 to each PTC element 2 and the heat transfer from each PTC element 2 to the heat dissipation fins 4 vary.

When the convex portions 51 and the elastic deformation portions 51X that are plastically deformed are not formed in the resin plate 5 or the like, there are cases where a force for bringing the PTC element 2 into contact with the electrode plate 3 and the heat sink 4 hardly acts in the projection range R of the PTC element 2 due to dimensional variations that occur in the respective

constituent members

2, 3, 4, 5, 6A, and 6B.

Therefore, in order to improve the heater performance of the electric heater 1, it can be said that it is effective to have the convex portion 51 plastically deformed.

The electrode plate 3 and the heat sink 4 may be disposed at positions directly contacting the PTC element 2, as long as they ensure electrical conductivity and thermal conductivity with the PTC element 2.

In the electric heater 1, a laminated body 10 including a plurality of PTC elements 2 in a laminated state of one layer, two layers, three layers, or five or more layers, in which the electrode plates 3 and the heat dissipation fins 4 are arranged on both sides of the plurality of PTC elements 2 in the laminating direction H, may be pressed by a pressing spring 7.

(embodiment mode 2)

As shown in fig. 11 and 12, this embodiment shows a case where the projection forming member 11 is the electrode plate 3 on which the projections 31 are formed, and the projection contact member 12 that contacts the projections 31 is the resin plate 5.

The protrusions 31 are provided on the surface 301 of the electrode plate 3 in the stacking direction H and within the projection range R of the plurality of PTC elements 2. The projection 31 is provided on the surface 301 of the electrode plate 3 facing the resin plate 5. The projection 31 is formed integrally with the electrode plate 3 by deforming a part of the electrode plate 3, using a material that is the same as that of the electrode plate 3. The projection 31 may be a metal member 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. By making the hardness of electrode plate 3 higher than the hardness of resin plate 5, resin plate 5 is plastically deformed by convex portion 31 of electrode plate 3, and deformed portion 512 recessed by convex portion 31 is formed on surface 501 of resin plate 5. The deformation portion 512 is formed by plastic deformation into a trace or trace of the depression of the surface 501 of the resin plate 5.

The electrode plate 3 having the projections 31 formed thereon of the present embodiment faces the resin plate 5. The projection 31 can also be provided to any electrode plate 3 of the electric heater 1. Further, although the structure is different from the electric heater 1 of the present embodiment, the convex portion 31 may be provided on the surface of the electrode plate 3 facing the frame 6A.

As shown in fig. 13, the projection contact member 12 may be a heat sink 4, and the projection 31 may be provided on a surface 301 of the electrode plate 3 facing the heat sink 4. In this case, by making the hardness of the electrode plate 3 higher than that of the heat sink 4, the surface 401 of the flat plate 42 of the heat sink 4 is plastically deformed by the convex portions 31 of the electrode plate 3, and a deformed portion recessed by the convex portions 41 is formed on the surface 401 of the flat plate 42 of the heat sink 4.

As shown in fig. 14 and 15, when the laminated body 10 of the present embodiment is pressed by the pressing spring 7, the respective convex portions 31 of the electrode plate 3 contact the resin plate 5, and the respective portions of the resin plate 5 are depressed by the plastic deformation of the respective convex portions 31. At this time, a large amount of the material in the portion of the resin plate 5 where the convex portions 31 contact flows from between the convex portions 31 and the resin plate 5 to the periphery of the convex portions 31.

Here, fig. 14 schematically shows a state before the resin plate 5 is plastically deformed, and fig. 15 schematically shows a state after the resin plate 5 is plastically deformed. Each drawing schematically shows a state where the deformed portion 512 is formed in the resin plate 5 for the sake of explanation, and exaggeratedly shows the convex portion 31 and the deformed portion 512.

The amount of plastic deformation of the resin plate 5 in the projection range R where the thickness of the laminate 10 is large is larger than the amount of plastic deformation of the resin plate 5 in the projection range R where the thickness of the laminate 10 is small, in the region of the resin plate 5 in contact with the convex portion 31b in the projection range R where the thickness of the laminate 10 is large. The portion of the resin plate 5 recessed by the projection 31b of the latter is deeper with respect to the amount of sinking (depth) of the surface 301 than the portion of the resin plate 5 recessed by the projection 31a of the former. By observing the deformed portion 512 formed on the surface 501 of the resin plate 5, the difference in the amount of sinking of each portion of the resin plate 5 can be understood.

In the electric heater 1 of the present embodiment, by plastically deforming the projection ranges R of the heat sink 4 by all the convex portions 31, even when the thicknesses in the stacking direction H at the positions in the lateral direction W where the PTC elements 2 are arranged are different from each other due to dimensional errors, deformation, and the like in manufacturing that occur in the PTC elements 2, the electrode plates 3, the heat sink 4, and the resin plate 5, all the PTC elements 2, the electrode plates 3, and the resin plate 5 can be pressed and brought into contact with each other with the same force as much as possible. This enables more efficient conduction of electricity from the electrode plates 3 to all the PTC elements 2 and heat transfer from all the PTC elements 2 to the heat dissipation fins 4. Therefore, according to the electric heater 1 of the present embodiment, the heater performance can be further improved.

In the electric heater 1 of this embodiment, the other configurations are the same as those in embodiment 1. In this embodiment, the electric heater 1 can be manufactured in the same manner as in embodiment 1. The constituent elements and the like denoted by the same reference numerals as those in embodiment 1 are the same as those in embodiment 1. In this embodiment, the same operational effects as those of embodiment 1 can be obtained.

(embodiment mode 3)

As shown in fig. 16 and 17, this embodiment shows a case where the projection forming member 11 is the heat sink 4 on which the projections 41 are formed, and the projection contact member 12 that contacts the projections 41 is the electrode plate 3.

The convex portions 41 are provided on the surface 401 of the heat sink 4 in the stacking direction H and within the projection range R of the plurality of PTC elements 2. The projection 41 is provided on the surface 401 of the heat sink 4 facing the electrode plate 3. The convex portion 41 is formed integrally with the heat sink 4 by deforming a part of the flat plate 42 of the heat sink 4, and is made of a material homogeneous to the heat sink 4. The projection 41 may be a metal member separately provided on the surface 401 of the flat plate 42 of the heat sink 4.

The heat sink 4 is made of an aluminum material, and the electrode plate 3 is made of a copper material. By making the hardness of the heat sink 4 lower than the hardness of the electrode plate 3, the convex portions 41 of the flat plate 42 of the heat sink 4 are plastically deformed by the electrode plate 3, and the deformed portions 411 crushed by the electrode plate 3 are formed at the distal end portions of the convex portions 41. The deformation portion 411 is formed as a trace or a trace of the crush of the tip end portion of the convex portion 41 of the heat sink 4 by plastic deformation.

The heat sink 4 having the convex portion 41 formed therein according to the present embodiment is the heat sink closest to the frame 6B. The protrusion 41 can also be provided to any heat sink 4 in the electric heater 1. For example, the convex portion 41 may be provided on the surface of the heat sink 4 facing the frame 6A, although the structure is different from that of the electric heater 1 of the present embodiment.

In the electric heater 1 of this embodiment, the other configurations are the same as those in embodiment 1. In this embodiment, the electric heater 1 can be manufactured as in embodiment 1. The constituent elements and the like denoted by the same reference numerals as those in embodiment 1 are the same as those in embodiment 1. In this embodiment, the same operational effects as those of embodiment 1 can be obtained.

(embodiment mode 4)

As shown in fig. 18 and 19, this embodiment shows a case where the projection forming member 11 is a frame 6B on which the projection 61 is formed, and the projection contact member 12 that contacts the projection 61 is a resin plate 5.

The protrusions 61 are provided on the surface 601 of the frame 6B in the stacking direction H and within the projection range R of the plurality of PTC elements 2. The projection 61 is provided on a surface 601 of the frame 6B facing the resin plate 5. The projection 61 is provided integrally with the frame 6B by deforming a part of the frame 6B with a material that is the same as the frame 6B. The convex portion 61 may be a metal member 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. By making the hardness of the frame 6B higher than the hardness of the resin plate 5, the resin plate 5 is plastically deformed by the convex portions 61 of the frame 6B, and the deformed portions 512 recessed by the convex portions 61 are formed on the surface 501 of the resin plate 5. The deformation portion 512 is formed by plastic deformation into a trace or trace of the depression of the surface 501 of the resin plate 5.

In this embodiment, the frame 6B is shown as the convex portion forming member 11 on which the convex portion 61 is formed. Alternatively, the frame 6A may be a projection forming member 11 in which the projection 61 is formed. In this case, as shown in fig. 20, the convex contact member 12 is provided as the heat sink 4, and the convex portion 61 is provided on the surface 601 of the frame 6A facing the heat sink 4. In this case, by making the hardness of the frame 6A higher than the hardness of the fin 4, the flat plate 42 of the fin 4 is plastically deformed by the convex portions 61 of the frame 6A, and a deformed portion recessed by the convex portions 61 of the frame 6A is formed on the surface 401 of the flat plate 42 of the fin 4.

Further, although the structure is different from the electric heater 1 of the present embodiment, the convex portion contact member 12 may be the electrode plate 3, and the convex portion 61 of the

frames

6A and 6B may be brought into contact with the surface of the electrode plate 3 facing the

frames

6A and 6B. In this case, by making the hardness of the

frames

6A and 6B higher than the hardness of the electrode plate 3, the surface of the electrode plate 3 is plastically deformed by the convex portions 61 of the

frames

6A and 6B, and a deformed portion recessed by the convex portions 61 is formed on the surface of the electrode plate 3.

(embodiment 5)

This embodiment shows an electric heater 1Z having a structure different from that of the electric heater 1 of embodiments 1 to 4.

As shown in fig. 21 to 24, in the electric heater 1Z of the present embodiment, a 1 st laminated body 10A and a 2 nd laminated body 10B, which are formed by a plurality of PTC elements 2, a plurality of electrode plates 3, a plurality of heat dissipation fins 4, and

resin plates

5A and 5B, are arranged so as to be overlapped in two layers in the lamination direction H. The electrode plates 3 in the

respective laminates

10A and 10B can receive supply of voltages from the positive power supply and the negative power supply independently. The electric heater 1Z can realize a half heating operation for heating the 1 st stacked body 10A or the 2 nd stacked body 10B and a full heating operation for heating both the

stacked bodies

10A and 10B. In fig. 24, the electrode plate 3 connected to the positive power supply is denoted by (+) and the electrode plate 3 connected to the negative power supply is denoted by (-) respectively.

The projection forming member 11 of the present embodiment is the resin plate 5A on which the projections 51 are formed, and the projection contact member 12 is the electrode plate 3. The convex portion 51 of the present embodiment is provided on the surface 501 of the resin plate 5A disposed between the 1 st stacked body 10A and the 2 nd stacked body 10B, which faces the electrode plate 3 of the 1 st stacked body 10A. The convex portions 51 are provided in the projection ranges R of 4 positions obtained by projecting the arrangement positions of the 4 PTC elements 2 in the stacking direction H on the resin plate 5A.

In this embodiment, as in the case of embodiment 1, by making the hardness of the resin plate 5A lower than the hardness of the electrode plate 3, the tip end portions of the respective convex portions 51 in the resin plate 5A are plastically deformed and crushed. As shown in fig. 25, the convex portion 51 may be provided on a surface 501 of the resin plate 5A facing the heat dissipation fins 4 of the 2 nd stacked body 10B. In this case, the resin plate 5A has a hardness lower than that of the heat sink 4, and the distal end portions of the respective projections 51 in the resin plate 5A are plastically deformed and crushed. The projection 51 may be provided on a surface of the resin plate 5B disposed between the 2 nd stacked body 10B and the frame 6B, the surface facing the electrode plate 3 of the 2 nd stacked body 10B, or a surface of the resin plate 5B facing the frame 6B.

The positions of the PTC elements 2 in the lateral direction W and the depth direction D in the two

stacked bodies

10A, 10B of the present embodiment are the same when viewed along the stacking direction H. The projection range R of each PTC element 2 is uniquely determined. On the other hand, the positions of the plurality of PTC elements 2 in the lateral direction W and the depth direction D in each laminate 10A, 10B are not necessarily uniform. In this case, when the multilayer stacked

bodies

10A, 10B are viewed in the stacking direction H, the convex portions 51 can be formed at the portions of the respective

stacked bodies

10A, 10B where the projection ranges R of the PTC elements 2 overlap each other.

As shown in fig. 24, each electrode plate 3 of the electric heater 1Z having the

laminated bodies

10A, 10B of two layers is alternately connected to a positive power supply, a negative power supply, a positive power supply, and a negative power supply in order from one side in the laminating direction H. The

resin plates

5A, 5B are disposed between the 1 st stacked body 10A and the 2 nd stacked body 10B and between the 2 nd stacked body 10B and the frame 6B. The resin plate 5A disposed between the 1 st stacked body 10A and the 2 nd stacked body 10B insulates between the electrode plate 3 and the heat sink 4 connected to the negative power supply of the 1 st stacked body 10A and the electrode plate 3 and the heat sink 4 connected to the positive power supply of the 2 nd stacked body 10B. The resin plate 5B disposed between the 2 nd stacked body 10B and the frame 6B is configured to electrically isolate the electrode plate 3 and the heat sink 4 connected to the negative power supply of the 2 nd stacked body 10B and the electrode plate 3 and the heat sink 4 connected to the positive power supply of the 1 st stacked body 10A via the

frames

6A and 6B and the compression spring 7.

In the electric heater 1Z of this embodiment, the other configurations are the same as those in embodiment 1. In this embodiment, the electric heater 1Z can be manufactured as in embodiment 1. The constituent elements and the like denoted by the same reference numerals as those in embodiment 1 are the same as those in embodiment 1. In this embodiment, the same operational effects as those of embodiment 1 can be obtained.

(embodiment mode 6)

This embodiment is a modification of the electric heater 1Z of embodiment 5 as shown in fig. 26 and 27, and shows a case where the projection forming member 11 is the heat sink 4 on which the projections 41 are formed, and the projection contact member 12 that contacts the projections 41 is the resin plate 5A.

The convex portions 41 are provided on the surface 401 of the heat sink 4 in the stacking direction H and within the projection range R of the plurality of PTC elements 2. The convex portion 41 is provided on the surface 401 of the heat sink 4 facing the resin plate 5A. The convex portion 41 is formed integrally with the heat sink 4 by deforming a part of the flat plate 42 of the heat sink 4, using a material which is the same as that of the heat sink 4. The projection 41 may be a metal member separately provided on the surface 401 of the flat plate 42 of the heat sink 4.

The heat sink 4 is made of an aluminum material, and the resin plate 5A is made of a resin material. By making the hardness of the heat sink 4 higher than the hardness of the resin plate 5A, the resin plate 5A is plastically deformed by the convex portions 41 of the flat plate 42 of the heat sink 4, and the deformed portion 512 recessed by the convex portions 41 is formed on the surface 501 of the resin plate 5A. The deformation portion 512 is formed by plastic deformation into a trace or trace of the depression of the surface 501 of the resin plate 5A.

The heat sink 4 having the convex portion 41 formed therein according to the present embodiment is used for the 2 nd stacked body 10B. The convex portion 41 can also be provided to any heat sink 4 in the electric heater 1Z. The convex portion 41 can be provided on the surface of the heat sink 4 facing the frame 6A, for example.

In the electric heater 1Z of this embodiment, the other configurations are the same as those in embodiment 5. In this embodiment, the electric heater 1Z can be manufactured as in embodiment 1. The constituent elements and the like denoted by the same reference numerals as those in embodiment 1 are the same as those in embodiment 1. In this embodiment, the same operational effects as those of embodiment 1 can be obtained.

(others)

As described above, the projection forming member 11 forming the

projections

31, 41, 51, 61 may be any one of the electrode plate 3, the heat sink 4, the

resin plates

5, 5A, 5B, or the

frames

6A, 6B. The projection contact member 12 that contacts the

projections

31, 41, 51, 61 may be any one of the electrode plate 3, the heat sink 4, the

resin plates

5, 5A, 5B, or the

frames

6A, 6B. As to which of the

convex portions

31, 41, 51, 61 and the convex portion contact member 12 is plastically deformed, the lower one is plastically deformed depending on the hardness of the both. Therefore, when the hardness of both is the same, there are cases where the

convex portions

31, 41, 51, 61 are plastically deformed so as to be crushed, and the convex portion contact member 12 is plastically deformed so as to be depressed. Even if the hardness of the

convex portions

31, 41, 51, 61 is higher than the hardness of the convex portion contact member 12, the

convex portions

31, 41, 51, 61 may be plastically deformed by a load lower than the load required for the plastic deformation of the convex portion contact member 12 depending on the shape of the

convex portions

31, 41, 51, 61.

Among the electrode plate 3, the heat sink 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 convex portion forming member 11 or the convex portion contact member 12 as the

resin plates

5, 5A, 5B, the convex portion 51 or the convex portion contact member 12 is easily plastically deformed by the pressing force of the pressing spring 7. Since the

resin plates

5, 5A, 5B are molded by injection molding or the like, the convex portions 51 are easily formed integrally. When the

projections

31, 41, 61 are formed on the plate 42 of the electrode plate 3 and the heat sink 4 and the

frames

6A, 6B, the

projections

31, 41, 61 can be integrally formed by deforming a part of the material when each member is formed by press working.

Preferably, the surface of the electrode plate 3 in the stacking direction H and the surface of the heat sink 4 in the stacking direction H are closely adhered to each other so as to ensure electrical conductivity or thermal conductivity. Therefore, when the projection forming member 11 is the electrode plate 3 and the projection contact member 12 is the heat sink 4, or when the projection forming member 11 is the heat sink 4 and the projection contact member 12 is the electrode plate 3, it is necessary to perform an operation of lowering the formation height of the

projections

31 and 41, plastically deforming at least one of the

projections

31 and 41 and the projection contact member 12, and bringing the surface of the electrode plate 3 in the stacking direction H and the surface of the heat sink 4 in the stacking direction H into close contact with each other.

On the other hand, the

resin plates

5, 5A, 5B and the

frames

6A, 6B do not require electrical conductivity and thermal conductivity. Therefore, by providing at least one of the convex portion forming member 11 and the convex portion contact member 12 as the

resin plates

5, 5A, 5B or the

frames

6A, 6B, it is not necessary to closely adhere the surfaces in the stacking direction H, and the formation height, size, and the like of the

convex portions

31, 41, 51, 61 of the convex portion forming member 11 can be easily set. However, the fluid such as air for air conditioning is basically heated by heat conduction from the fins 4. The gaps formed between the

convex portions

31, 41, 51, 61 of the convex portion forming member 11 and the convex portion contact member 12 may be gaps through which the fluid passes without being heated. Therefore, it is preferable to reduce the height of the

projections

31, 41, 51, 61 so that a gap is not formed between the surface of the projection forming member 11 in the stacking direction H except for the portions where the

projections

31, 41, 51, 61 are formed and the surface of the projection contact member 12 in the stacking direction H.

The present invention is not limited to the embodiments, and various embodiments may be configured without departing from the scope of the present invention. The present invention includes various modifications, modifications within a range of equivalence, and the like.

Claims

1. An electric heater, comprising:

a plurality of electrode plates laminated on both sides of the PTC element in a lamination direction orthogonal to the transverse direction, for applying current to the PTC element;

when the resin plate is a projection forming member having a projection and the electrode plate or the heat sink is a projection contact member which is in contact with the projection,

wherein the convex portions are provided on the surface of the convex portion forming member in the stacking direction, respectively, and are provided within a plurality of projection ranges obtained by projecting the arrangement positions of the plurality of PTC elements in the stacking direction, respectively,

the convex portions in all of the projection ranges have deformation portions that plastically deform beyond an elastic limit due to a load from the convex portion contact member.

2. An electric heater, comprising:

when the electrode plate or the heat sink is provided as a projection forming member having a projection, and the resin plate is provided as a projection contact member contacting the projection,

wherein the convex portions are provided on the surface of the convex portion forming member in the stacking direction, respectively, and are within a plurality of projection ranges obtained by projecting the arrangement positions of the plurality of PTC elements in the stacking direction, respectively,

the convex contact member has a deformation portion that is plastically deformed beyond an elastic limit by a load from the convex in all the projection ranges.

3. An electric heater, comprising:

when the electrode plate is provided with a projection forming member having a projection and the heat sink is provided with a projection contact member contacting the projection,

4. An electric heater, comprising:

a pressing spring that presses the stacked body from both sides in the stacking direction via the pair of frames,

when the frame is a projection forming member having a projection, and any one of the electrode plate, the heat sink, and the resin plate is a projection contact member which contacts the projection,

5. An electric heater, comprising:

when any one of the electrode plate, the heat sink, and the resin plate is a projection forming member having a projection, and the frame is a projection contact member that contacts the projection,

6. The electric heater according to any one of claims 1 to 5,

the convex portion is integrally provided with the convex portion forming member by using a material homogeneous to the convex portion forming member.