JP2006228713A - Ceramic heater, heat exchange unit, toilet seat with warm-water washing, and manufacturing method of ceramic heater - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a ceramic heater, a heat exchange unit, a toilet seat with warm-water washing, and a manufacturing method of the ceramic heater which are capable of achieving high heating efficiency with a compact structure, as well as of reducing the manufacturing cost. <P>SOLUTION: A ceramic heater (5) has such a shape that a heater member (11) made of ceramic is rolled into a double-cylinder shape and both ends of its circumferential direction are overlapped each other, and thus, a through hole (17) for allowing the passage of washing water is formed in the axial direction; wherein the heater member (11) is formed, in such a way that a heating element (21) is mounted in a meandering manner on the surface of a ceramic substrate (19) made of alumina, and the ceramic heater (5) is formed by rolling and sintering the heater member (11); thus, such slits formed in conventional ones are removed from the ceramic heater (5), and a plurality of the heating elements (21) are arranged substantially evenly in the circumferential direction of the ceramic heater (5). <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a ceramic heater, a heat exchange unit, a hot water cleaning toilet seat, and a method for manufacturing a ceramic heater used in, for example, a hot water cleaning toilet seat, an electric water heater, a 24-hour bath, a soldering iron, oil heating, an oxygen sensor, and the like.

  Conventionally, a heat exchange unit having a resin container (heat exchanger) is used, for example, in a warm water washing toilet seat, and this heat exchange unit is used to warm washing water contained in the heat exchanger. In addition, a long pipe-shaped ceramic heater is attached.

When manufacturing this ceramic heater, for example, as shown in FIG. 15, first, a heat generation pattern 1003 made of a refractory metal such as tungsten is printed on a ceramic green sheet 1001, and a ceramic paste is used thereon. Another ceramic green sheet 1005 is bonded to manufacture a heater sheet 1007. Thereafter, the heater sheet 1007 is cut to cut out a single heater sheet 1007. Next, a wound body 1011 is formed by winding and bonding a heater sheet 1007 around the surface of the fired cylindrical ceramic core member 1009 using ceramic paste (alumina paste) or the like. Thereafter, the wound body 1011 is integrally fired to complete the ceramic heater 1013 (see Patent Documents 1 and 2).
JP 9-7741 A (FIG. 1, page 2) Japanese Patent Laid-Open No. 9-7742 (FIG. 1, page 2)

  However, in the above-described technique, there is a gap (slit) formed when the heater sheet 1007 is wound around the core member 1009 and fired. That is, for example, as shown in FIG. 16, in the fired ceramic heater 1013, there is a slit 1017 between the heater members 1015 (the heater sheet 1007 is fired).

  Therefore, since there is no heating element 1019 (with the heat generation pattern 1003 baked) in the slit 1017, the cleaning water flowing in the vicinity thereof cannot be heated, and the heating efficiency of the cleaning water or the like is poor. There was a problem.

  As a countermeasure, when increasing the area heated by the heating element, it is conceivable to increase the outer diameter of the ceramic heater or increase the axial dimension. In this case, however, the ceramic heater is large. It is not preferable.

That is, it is not preferable because the material and the manufacturing cost increase with the increase in size, and the warm water washing toilet seat and the like in which the ceramic heater is used increase in size.
The present invention has been made in view of such problems, and an object of the present invention is to provide a ceramic heater, a heat exchange unit, a hot water cleaning toilet seat, and a method for manufacturing a ceramic heater that are compact and have high heating efficiency and can reduce manufacturing costs It is to provide.

  (1) The invention of claim 1 is a ceramic heater characterized in that a heater member in which a heating element is formed on a ceramic substrate is wound at least one turn and the heater members are overlapped with each other. .

  Since the present invention has a configuration in which the heater member is wound and overlapped, there is no slit formed on the core member as in the prior art. Accordingly, since the heating element can be arranged on the entire circumference of the ceramic heater, a fluid such as washing water can be heated on the entire circumference of the ceramic heater, and the heating efficiency is high. Further, since the heating efficiency is high, there is an advantage that the ceramic heater can be reduced in size and the manufacturing cost can be reduced.

Since the present invention relates to the structure of the fired ceramic heater, the heating element, the ceramic base and the heater member are fired.
(2) The invention of claim 2 is summarized in that the ceramic heater is a cylindrical body.

The present invention exemplifies the configuration of a ceramic heater.
(3) The invention of claim 3 is characterized in that the end portions of the heater member in the circumferential direction (for example, in the circumferential direction) are directly or indirectly overlapped in the thickness direction of the heater member. The summary is the ceramic heater according to Item 1 or 2.

  The present invention exemplifies the configuration of a ceramic heater. For example, when the heater member is wound once, the end portions are directly overlapped, and when it is wound twice or more, the end portions are indirectly overlapped via the heater member at a portion other than the end portion.

  (4) The invention according to claim 4 is characterized in that, in the heater member, the heat generating portion where the heating element is formed is at least partially overlapped in the thickness direction of the heater member. The main point is a ceramic heater.

  In the present invention, since the heat generating portions are at least partially overlapped, there is no slit between the end portions of the heater member as in the prior art. Therefore, since a heat generating body can be arrange | positioned to the perimeter of a ceramic heater, washing water etc. can be heated in the perimeter of a ceramic heater.

  (5) The invention of claim 5 is characterized in that the non-heat generating portion in which the heating element is not formed in the heater member is at least partially overlapped in the thickness direction of the heater member. 4 is a summary of the ceramic heater described in 4.

In the present invention, since the non-heat generating portion is wound into a cylindrical body, the strength of the ceramic heater can be increased by using the cylindrical body as a structure.
(6) The invention according to claim 6 is the ceramic heater according to any one of claims 1 to 5, wherein the heating element is at least partially overlapped in the thickness direction of the heater member. To do.

  (7) The invention according to claim 7 is characterized in that a chamfered portion chamfered along the circumferential direction is provided at an outermost circumferential end portion of circumferential ends of the heater member. The summary is the ceramic heater according to any one of Items 1 to 6.

  In the present invention, the outermost end (winding end portion) of the wound heater member is chamfered along the circumferential direction. As a result, the end of the heater member is smooth so that there is no step (or the step is reduced). Therefore, for example, it becomes easy to attach the ceramic heater to the heat exchanger using a sealing member such as a rubber hose, and the sealing performance is high. Further, instead of a specially shaped hose corresponding to the step, for example, a hose having a perfect circular cross section can be used, which is advantageous in terms of cost.

  (8) The ceramic heater according to any one of claims 1 to 7, wherein the heater member has a configuration in which the heater member is wound in multiple layers and the heating elements are stacked. The gist.

  In the present invention, since the heater members are wound in multiple layers to form a multiple laminated structure, the heating elements can be arranged in a laminated manner. That is, since more heat can be generated than a single one, it is not only compact but also has a high heating capacity.

  (9) The invention according to claim 9 is characterized in that the ceramic heater has a cylindrical shape, and the inner heating amount and the outer heating amount in the thickness direction are different from each other at the center in the thickness direction. The summary is the ceramic heater according to any one of Items 1 to 8.

  In the present invention, the amount of heat generation is made different between the outer peripheral side and the inner peripheral side of the ceramic heater, for example, by wrapping multiple heater members with biased heating element arrangements. Therefore, for example, when the heat generation amount on the inner side is increased by the shape of the heating element disposed on the inner side or the like, it is effective when the fluid flowing in the cylindrical shape is preferentially heated. Further, for example, when the heat generation amount on the outside is increased, it is effective in the case where the fluid flowing outside the cylinder is intensively heated.

  (10) The ceramic heater according to any one of claims 1 to 9, wherein the ceramic heater has a cylindrical shape, and an arrangement interval of the heating elements is different in a circumferential direction thereof. The main point is the heater.

  For example, when the end portions of the heater member are overlapped, the thickness of the ceramic heater is increased at the overlapped portion. However, in the present invention, the arrangement intervals of the heating elements (in the circumferential direction) are changed, for example, overlapped. By increasing the heat generation amount of the portion, the heating state (in the circumferential direction) of the ceramic heater can be made uniform.

  (11) The invention according to claim 11 is the ceramic heater according to claim 10, characterized in that the arrangement interval of the heating elements is denser as the thickness of the ceramic heater is larger.

  As the thickness of the ceramic heater is larger, the heat capacity is larger. However, in the present invention, the larger the thickness of the ceramic heater is, the closer the heating element is arranged, so that the heating state in the circumferential direction of the ceramic heater can be made uniform. .

  (12) The ceramic heater according to any one of claims 1 to 11, wherein the ceramic heater has a cylindrical shape, and a cross-sectional area of the heating element is different in a circumferential direction thereof. Is the gist.

  For example, when the end portions of the heater member are overlapped, the thickness of the ceramic heater is increased at the overlapped portion. However, in the present invention, the cross-sectional area of the heating element (in the circumferential direction) is changed, for example, the overlap By increasing the heat generation amount of the portion, the heating state (in the circumferential direction) of the ceramic heater can be made uniform.

  (13) The invention according to claim 13 is characterized in that the cross-sectional area of the heating element is smaller as the thickness of the ceramic heater is larger.

  The larger the thickness of the ceramic heater, the larger the heat capacity. In the present invention, the larger the thickness of the ceramic heater, the smaller the cross-sectional area of the heating element, so that the heating state in the circumferential direction of the ceramic heater can be made uniform. .

  (14) The invention of claim 14 is the ceramic heater according to any one of claims 1 to 13, characterized in that the number of windings of the heater member is different in the axial direction of the ceramic heater. To do.

  In the present invention, the number of turns of the heater member can be changed at each position in the axial direction of the ceramic heater. Thereby, since the outer diameter of a ceramic heater can be changed in a desired position, there exists an advantage that the freedom degree at the time of designing an outer diameter shape is high.

  (15) The invention of claim 15 is characterized in that the number of turns of the heater member at the end in the axial direction is smaller than the number of turns of the heater member at a position other than the end. The main point is the ceramic heater.

  In the present invention, since the number of windings of the heater member at the end of the ceramic heater in the axial direction is small, a step (in the axial direction) can be provided between the central part having a large number of windings. Thus, for example, when the hose is fitted into the end portion of the ceramic heater, the step portion serves as a stop step, and therefore, the operation of connecting the hose is easy.

  (16) The invention of claim 16 is characterized in that the ceramic heater according to any one of claims 1 to 15 is attached to a heat exchanger into which a fluid heated by the ceramic heater flows in and out. The gist of the replacement unit.

The present invention exemplifies a heat exchange unit including the ceramic heater described above.
(17) The invention of claim 17 includes a flow path from the through hole penetrating the ceramic heater in the axial direction to the space on the outer peripheral surface side of the ceramic heater as the flow path of the fluid in the heat exchange unit. The gist of the heat exchange unit according to claim 16.

  The present invention shows a fluid flow path in a heat exchange unit. In the present invention, the fluid is sandwiched between the space on the inner peripheral surface side of the ceramic heater (that is, the through hole) and the space on the outer peripheral side of the ceramic heater (that is, the outer peripheral surface of the ceramic heater and the inner peripheral surface of the heat exchanger). ), The fluid can be efficiently heated.

(18) The gist of the invention of claim 18 is a warm water washing toilet seat comprising the heat exchange unit according to claim 16 or 17.
The present invention exemplifies a warm water washing toilet seat provided with the heat exchange unit described above.

  (19) According to the nineteenth aspect of the present invention, a preheated heater sheet in which a heat generation pattern is formed on a ceramic base sheet is wound around a processing core member to form a wound body, and the processing core member is formed from the wound body. A gist of the method for producing a ceramic heater is characterized in that after the removal, the wound body is fired to produce a ceramic heater.

  In the present invention, the ceramic core member and the heater sheet wound around it (heater member) are not integrally fired, but the processing core member is taken out from the wound body around which the heater sheet is wound. Since the ceramic heater is manufactured by firing only the wound body, the disadvantages caused by using the conventional core member can be eliminated.

  That is, according to the method of the present invention, it is possible to eliminate the slits that are unavoidable in the conventional ceramic heater, and therefore it is possible to dispose the heating element all around the ceramic heater. Therefore, the heating efficiency can be increased without increasing the size of the heater.

Further, since the heating efficiency can be increased without increasing the size of the ceramic heater, there is an effect that the heat exchange unit and the like can also be reduced in size.
Furthermore, since a conventional core member is not required, there is an advantage that the manufacturing cost can be reduced.

The heater sheet is a sheet-like member in which an unfired heat generation pattern is formed on the surface of an unfired ceramic base sheet, for example. As the core member, a fired or temporarily fired ceramic member can be employed. (The same applies hereinafter)
(20) The invention of claim 20 is to form a wound body by winding a preheated heater sheet in which a heat generation pattern is formed on a ceramic base sheet around a processing core member made of a material that disappears during firing, The gist of the manufacturing method of the ceramic heater is characterized in that the wound body is fired and the core member for processing is lost during the firing to produce the ceramic heater.

  In the present invention, a processing core member made of a material that disappears upon firing, such as lost wax, is used as the processing core member. Therefore, there is an advantage that an operation of removing the processing core member after firing is unnecessary.

  (21) The invention according to claim 21 is to form a wound body by winding one or more turns of a preheated heater sheet having a heat generation pattern formed on a ceramic substrate sheet around a cylindrical or solid core member. A gist of a method for producing a ceramic heater is characterized in that a ceramic heater is produced by firing a body.

  Since the slit of the conventional ceramic heater can be eliminated by the method of the present invention, the heating element can be arranged over the entire circumference of the ceramic heater. Therefore, the heating efficiency can be increased without increasing the size of the heater.

Further, since the heating efficiency can be increased without increasing the size of the ceramic heater, there is an effect that the heat exchange unit and the like can also be reduced in size.
(22) According to the invention of claim 22, a heater sheet before firing in which a heating pattern is formed on a ceramic base sheet is wound one or more times to form a solid wound body, and the wound body is fired to form a ceramic. A gist of a method for producing a ceramic heater, characterized by producing a heater.

  Since the slit of the conventional ceramic heater can be eliminated by the method of the present invention, the heating element can be arranged over the entire circumference of the ceramic heater. Therefore, the heating efficiency can be increased without increasing the size of the heater.

Further, since the heating efficiency can be increased without increasing the size of the ceramic heater, there is an effect that the heat exchange unit and the like can also be reduced in size.
Furthermore, since a conventional core member is not required, there is an advantage that the manufacturing cost can be reduced.

  Next, an example (example) of the best mode of the present invention will be described.

a) First, the ceramic heater and heat exchange unit of this embodiment will be described.
The heat exchange unit of the present embodiment is used for warming washing water in a warm water washing toilet seat.

  As shown in FIG. 1, the heat exchange unit 1 includes a heat exchanger 3 that contains cleaning water, a ceramic heater 5 that is attached to the heat exchanger 3 and warms the cleaning water, and the ceramic heater 5 is connected to the heat exchanger 3. And a fixing member (flange) 6 to be fixed.

The heat exchanger 3 is a cylindrical container with a bottom, and is made of, for example, a resin made of nylon to which glass is added. A flange 6 is attached to one end of the heat exchanger 3 in the axial direction.
The flange 6 is an alumina member, and a ceramic heater 5 is inserted through the center of the flange 6 and is fixed and sealed with an adhesive 7 such as glass.

The ceramic heater 5 is a cylindrical member (inner diameter φ9.6 mm × outer diameter φ11.5 mm × axial length 105 mm) made of an alumina pipe-shaped sintered body.
Further, the front end side of the ceramic heater 5, that is, the heat generating portion 8 side on which the heat generation pattern 21 (see FIG. 2) is formed is disposed inside the heat exchanger 3, and the rear end side of the ceramic heater 5 is It protrudes from the heat exchanger 3 to the outside.

  A pair of external terminals 9 and 10 are formed on the surface of the rear end side of the ceramic heater 5, and the external terminals 9 and 10 are connected to the internal terminals 23 and 24 by through holes (not shown) (see FIG. 2). ) Is electrically connected.

  In particular, in this embodiment, the ceramic heater 5 has a structure in which the sheet-like heater member 11 is wound in a cylindrical shape (roll shape) as shown in FIG. 2A in a cross section perpendicular to the axial direction. is doing. That is, the ceramic heater 5 has a shape in which both ends in the circumferential direction, more specifically, the end portion 13 on the inner peripheral surface side and the end portion 15 on the outer peripheral surface side are overlapped (through one heater member 11). A through-hole 17 through which the washing water passes is formed in the axial direction.

  Specifically, the portion of the inner side of the ceramic heater 5 that is wound is a heating element as shown in FIG. 2B in the heater member 11 (in FIG. 2, the inner surface of the ceramic substrate 19 is shown). The left half of the figure (non-heat generating portion 26) in which 21 is not formed is wound and overlapped. On the other hand, the portion wound by 1 on the outer side is formed with the heating element 21. The right half (heat generating portion 28) is wound and overlapped.

  The heater member 11, as shown in FIG. 2B (showing the inner surface of the ceramic base 19 in the figure), generates heat on the inner surface of the alumina ceramic base 19 by energization. The heating element 21 is formed in a meandering shape by being brought close to one side of the heater member 11.

  Specifically, the heating element 21 is formed on the leading end side in the winding direction (arrow A direction) so that the arrow A direction and the direction in which the heating element 21 extends are perpendicular to each other. Internal terminals 23 and 24 are connected to both ends of the heating element 21.

  As a result, in the ceramic heater 5 (formed by being wound by a manufacturing method described later), the end portions 13 and 15 of the heater member 11 wound twice are overlapped, and there is no conventional slit. In the circumferential direction, the heating elements 21 are arranged substantially evenly.

  Therefore, in the heat exchange unit 1 having the above-described configuration, as shown in FIG. 1, when tap water is introduced in the direction of the arrow, the tap water passes through the internal through hole from the rear end side of the ceramic heater 5. It flows into 17 and flows out from the front end side.

  Then, when the tap water passes through the through-hole 17, the temperature is increased by being heated by the ceramic heater 5, and the tap water around the ceramic heater 5 is also heated by the ceramic heater 5 to increase the temperature. It is supplied to the outside of the heat exchanger 3 (from an outflow hole not shown) as washing water for hot water.

b) Next, a method for manufacturing the ceramic heater 5 and the heat exchange unit 1 of this embodiment will be described.
As shown in FIG. 3, first, a refractory metal such as tungsten is printed on a ceramic base sheet 25 which is a ceramic green sheet to be the ceramic base 19 (after firing). A heat generation pattern 27 and a terminal pattern 29 (collectively referred to as a conductive pattern 31) to be the internal terminals 23 and 24 are formed. Thereby, the heater sheet 33 to be the heater member 11 (after firing) is obtained.

  Next, the heater sheet 33 is wound around the surface of the iron processing core member 37 around which the release paper 35 coated with resin is coated on the surface of the paper to form a cylindrical wound body 39. Specifically, the heater sheet 33 is wound in the arrow A direction by the processing core member 37 from the side where the conductive pattern 31 is not formed (the right side of the figure). As the processing core member 37, a resin member such as polytetrafluoroethylene (PTFE) having high releasability may be used.

  As a result, similarly to FIG. 2A after firing, the heater sheet 33 is wound twice, and the end portions are indirectly overlapped in the circumferential direction. Specifically, a portion of the heater sheet 33 without the conductive pattern 31 is wound on the inner side, and a portion of the heater sheet 33 with the conductive pattern 31 is wound on the outer side.

  Returning to FIG. 3, the processing core member 37 is taken out from the cylindrical wound body 39 along the axial direction thereof. The processing core member 37 has a larger diameter on the take-out side, and the release paper 35 is wound around the outer periphery thereof, so that the processing core member 37 can be smoothly taken out.

  Next, the wound body 39 is fired under firing conditions in a reducing atmosphere at a temperature of about 1600 ° C., for example, so that the ceramic heater 5 having a shape around which the heater member 11 is wound is obtained.

  Next, as shown in FIG. 1, a ceramic flange 6 is externally fitted at a predetermined mounting position on the rear end side (right side of FIG. 1) of the ceramic heater 5, and the ceramic heater 5 and the flange 6 are further fitted. The space is joined by, for example, a glass adhesive 7.

  Thereafter, the front end side (left side in FIG. 1) of the ceramic heater 5 to which the flange 6 is attached is inserted into the heat exchanger 3, and the flange 6 is opened using the sealing material 41 such as an O-ring. The heat exchanger unit 1 including the ceramic heater 5 and the heat exchanger 3 is completed by abutting against the end portion 43 and tightening with screws (not shown).

  c) As described above, in the ceramic heater 5 of the present embodiment, the heater member 11 is wound twice, and the heating element 21 is uniformly arranged in the circumferential direction over the entire circumference, and the end portion of the heater member 11 is also provided. 13 and 15 have a configuration in which they are indirectly overlapped.

  Therefore, in this embodiment, there is no slit 1017 as in the prior art of FIG. That is, there is no non-heated region H in which the heating element 1019 is not formed, and as shown in FIG. 2A, the heating elements 21 are arranged at the same width and at the same intervals over the entire circumference of the ceramic heater 5. Has been.

  Therefore, the cleaning water can be heated uniformly and efficiently over the entire circumference of the ceramic heater 5, and the heating efficiency is high. Moreover, since heating efficiency is high, there exists an advantage that the ceramic heater 5 can be reduced in size. Furthermore, since the conventional ceramic core member 1009 is not required, the manufacturing cost can be reduced.

  As the heater member 11, an alumina ceramic sheet having a similar shape may be attached on the ceramic base 19 so as to cover the heating element 21.

Next, the second embodiment will be described, but the description of the same contents as the first embodiment will be omitted.
In the present embodiment, the heating elements are doubled. This will be specifically described below.
As shown in FIG. 4A, the heater member 53 is triple wrapped around the ceramic heater 51 of the present embodiment. In addition, the heating elements 55 are arranged in a double manner, and are almost uniformly arranged in the circumferential direction over the entire circumference.

  In this case, as shown in FIG. 4B, the heater member 53 is developed and the inside thereof (the surface of the ceramic substrate 57) is shown, and the heating element 55 is brought close to one side of the heater member 53 to form a meandering shape. Has been.

  That is, the heating element 55 is formed on the leading end side in the winding direction (arrow A direction) so that the arrow A direction and the direction in which the heating element 55 extends are perpendicular to each other. Note that the number of times the heating element 55 meanders (therefore, the length of the heating element 55: the width in the left-right direction in the figure) is almost double that of the first embodiment as the number of turns increases.

  In the present embodiment, there is an advantage that the heating performance is further enhanced by the configuration (two-layer structure) in which the heating elements 55 are arranged in a double manner, despite the size almost the same as that of the second embodiment.

Next, the third embodiment will be described, but the description of the same contents as the first embodiment will be omitted.
In the present embodiment, the heating elements are arranged so as to be biased with respect to the thickness direction of the ceramic heater. This will be specifically described below.

  As shown in FIG. 5A, in the ceramic heater 61 of the present embodiment, the heater member 63 is wound in a triple manner, and the heating elements 65 are arranged substantially evenly in the circumferential direction over the entire circumference.

In particular, in the present embodiment, the heating element 65 is provided only on the heater member 63 wound on the outermost side, and is not disposed on the heater member 63 having two inner layers.
Thereby, the fluid outside the ceramic heater 61 can be efficiently heated.

  In addition, as shown in FIG. 5B, the ceramic heater 71 of the application example has the heater member 73 wound around three times, and a part of the heating element 75 is overlapped at a portion indicated by a broken line 74, The heat generating body 75 is arrange | positioned without the clearance gap in the circumferential direction over the perimeter.

In particular, in the present embodiment, the heating element 75 is provided only on the heater member 73 wound on the innermost side, and is not disposed on the heater member 73 having two outer layers.
Thereby, the fluid inside the ceramic heater 71 can be efficiently heated.

Next, the fourth embodiment will be described, but the description of the same contents as the first embodiment will be omitted.
In the present embodiment, the arrangement of the heating elements in the circumferential direction is not uniform. This will be specifically described below.

  As shown in FIG. 6A, in the ceramic heater 81 of this embodiment, the heater member 83 is doubly wound as in the first embodiment, but the arrangement interval of the heating elements 85 in the circumferential direction is small. It is uneven.

  Specifically, in the portion where the end portions 87 and 89 of the heater member 83 are overlapped (upper part of the drawing), the arrangement interval of the heating elements 85 is dense, but on the opposite side, the arrangement interval of the heating elements 85 is small. It is rough.

  In this case, as shown in FIG. 6B, the heater member 83 is developed to show the inside (the surface of the ceramic substrate 88), and the heating element 85 is brought close to one side of the heater member 83 to form a meandering shape. In addition, the central side of the meandering heating element 85 is rough.

  As described above, in this embodiment, since the arrangement interval of the heating elements 85 in the portion where the end portions 88 and 89 of the ceramic heater 81 are overlapped is close, the volume (heat capacity) of the overlapped portion is increased. However, substantially uniform heating can be performed over the entire circumference.

Next, although Example 5 is demonstrated, description of the content similar to the said Example 1 is abbreviate | omitted.
In this embodiment, the widths of the heating elements in the circumferential direction are not uniform. This will be specifically described below.

  As shown in FIG. 7A, in the ceramic heater 91 of this embodiment, the heater member 93 is doubly wound as in the first embodiment, but the width of each heating element 95 in the circumferential direction is different. It is uneven.

  Specifically, in the portion where the end portions 97 and 99 of the heater member 93 are overlapped (upper part of the figure), the width of the heating element 95 is narrow (thus, the resistance is large and the heat generation amount is large). On the opposite side, the width of the heating element 95 is wide (therefore, the resistance is small and the heating value is small).

  In this case, as shown in FIG. 7B, the heater member 93 is expanded and the inside thereof (the surface of the ceramic substrate 98) is shown, and the heating element 95 is brought close to one side of the heater member 93 to form a meandering shape. In addition, the line width on the center side of the meandering heating element 95 is widened.

  As described above, in this embodiment, the line width of the heating element 95 in the portion where the end portions 97 and 99 of the ceramic heater 91 are overlapped is small. A substantially uniform heating can be performed over the circumference.

Next, the sixth embodiment will be described, but the description of the same contents as the first embodiment will be omitted.
In this embodiment, the number of turns of the heater member varies depending on the position in the axial direction. This will be specifically described below.

  As shown in FIG. 8A, in the ceramic heater 101 of this embodiment, the heater member 105 is double-wrapped on the tip side where the heating element 103 is arranged, as in the first embodiment. On the rear end side to which the cleaning water is supplied, the heater member 105 is wound in a single layer (shaded portion in the figure).

  As a result, as shown in FIG. 8B, the outer diameter of the ceramic heater 101 is smaller on the rear end side (right side in the figure) than on the front end side, and the double winding of the heater member 105 is large. A step 111 is formed between the diameter portion 107 and the single-winding small-diameter portion 109.

  When the ceramic heater 101 is manufactured, a heater sheet 112 having a special shape is used as shown in FIG. That is, one of the four sides of the ceramic base sheet 113 serving as the base of the heater sheet 112 (lower side in the figure), that is, one on the terminal pattern 117 side on the side where the heat generation pattern 115 is formed (right side in the figure). A ceramic base sheet 113 with a side (lower side in the figure) cut out in a strip shape is used. Then, similar to the first embodiment, the heater sheet 112 is wound in the direction of arrow A to obtain a wound body (not shown) similar to the first embodiment. Other processes are the same as those in the first embodiment.

  Further, as shown in FIG. 10A, when a pipe 119 for supplying cleaning water is connected to the rear end side of the ceramic heater 101 of this embodiment, the small diameter portion 109 on the rear end side of the ceramic heater 101 is used. The pipe 119 is fitted into the pipe 119, and the pipe 119 is pushed in until it hits the step 111.

  As shown in FIG. 9B, the through hole 121 of the pipe 119 is also provided with a step 123 having a shape corresponding to the step 111 of the ceramic heater 101 in order to prevent water leakage.

  In this embodiment, the same effects as those of the first embodiment are obtained, and the small diameter portion 109 and the step 111 are provided on the rear end side of the ceramic heater 101, so that there is an advantage that the connection of the pipe 119 is easy. .

Next, although Example 7 is demonstrated, description of the content similar to the said Example 1 is abbreviate | omitted.
As shown in FIG. 11, in the ceramic heater 131 of the present embodiment, the end portion 135 in the circumferential direction of the outer circumferential surface of the double-rolled heater member 133 is chamfered, and thereby inclined. A gentle and smooth chamfered portion 137 is formed.

That is, the end portion 135 of the outer peripheral surface of the heater member 133 is chamfered so that there is no step as in the first embodiment.
As a result, as a pipe (not shown) connected to the ceramic heater 131, an ordinary through hole having a perfect circular cross section can be used, which has an advantage of low cost and high sealing performance.

Next, the eighth embodiment will be described, but the description of the same contents as the first embodiment will be omitted.
This embodiment differs from the first embodiment in its manufacturing method and uses a core member similar to the conventional one. Hereinafter, the manufacturing method of the ceramic heater of a present Example is demonstrated.

  As shown in FIG. 12, first, a heater sheet 146 that is an unfired ceramic base sheet 145 on which a heat generation pattern 143 and the like are formed is wound around the surface of a cylindrical fired ceramic core member 141. In other words, the heater sheet 146 is wound around the surface of the core member 141 and the ends 147 and 149 are overlapped to form the wound body 151.

Thereafter, the wound body 151 and the core member 141 are integrally fired to manufacture the ceramic heater 153.
In this embodiment, since the heater sheet 146 is wound and the end portions 147 and 149 are overlapped with each other, there is no conventional slit. Therefore, since a heat generating body (not shown) can be arrange | positioned uniformly along the periphery, there exists an advantage that heating efficiency is good.

  The heater sheet 146 (and thus the heater member) may be wound twice or more instead of being wound once. In addition, in the case where the cleaning water is not allowed to flow through the axial center through hole of the core member 141, a solid core member may be used instead of the cylindrical core member 141.

Next, the ninth embodiment will be described, but the description of the same contents as the first embodiment will be omitted.
The present embodiment is different from the first embodiment in its manufacturing method and is characterized in that no processing core member is used. Hereinafter, the manufacturing method of the ceramic heater of a present Example is demonstrated.

  As shown in FIG. 13, first, a heater sheet 164, which is an unfired ceramic base sheet 163 on which a heat generation pattern 161 and the like are formed, is wound so that there is no space around the axis. That is, the wound body 163 is formed by winding the heater sheet 164 many times.

Thereafter, the wound body 163 is fired to manufacture the ceramic heater 165.
In this embodiment, since the wound body 163 around which the heater sheet 164 is wound is fired to produce the ceramic heater 165, there is no conventional slit. Therefore, since a heat generating body (not shown) can be arrange | positioned uniformly along the periphery, there exists an advantage that heating efficiency is good.

Next, Example 10 will be described, but description of the same contents as Example 1 will be omitted.
This embodiment is different from the first embodiment in its manufacturing method, and is characterized in that a processing core member made of wax is used. Hereinafter, the manufacturing method of the ceramic heater of a present Example is demonstrated.

In this embodiment, although not particularly shown, a wax processing core member having the same shape as the processing core member of FIG. 3 is used as the processing core member.
Specifically, a heater sheet, which is a ceramic base sheet on which a heat generation pattern is formed, is wound around the outer periphery of the processing core member, and then fired. During this firing, the wax disappears, so that a cylindrical ceramic heater is obtained.

  As the wax, for example, a paraffin wax that is sufficiently hard to wind the ceramic base sheet at room temperature and melts and disappears by heating during firing can be used.

Next, although Example 11 is demonstrated, description of the content similar to the said Example 8 is abbreviate | omitted.
The present embodiment is different from the eighth embodiment in the shape of the processing core member.
As shown in FIG. 14A, in this embodiment, a cylindrical processing core member 171 having a step 173 on its outer peripheral surface is used as the processing core member 171. Specifically, the processing core member 171 is formed with a step having a thickness difference of one heater sheet (not shown) in the circumferential direction (that is, a step 173 extending at the same height in the axial direction). is there.

When this processing core member 171 is used, a ceramic heater (not shown) having no step on the outer peripheral surface is obtained by winding the end of the heater sheet against the step 173.
In the present embodiment, there is an advantage that the strength of the entire ceramic heater is increased because a gap is hardly generated between the processing core member 171 and the heater sheet (and thus the heater member) wound around the outer peripheral surface thereof.

In the present embodiment, as shown in FIG. 14B, a processing core member 177 having a solid cylindrical shape and having a step 175 on the outer peripheral surface can also be used.
In addition, this invention is not limited to the said Example at all, and it cannot be overemphasized that it can implement with a various aspect in the range which does not deviate from the summary of this invention.

It is explanatory drawing which fractures | ruptures and shows the heat exchange unit of Example 1. FIG. (A) is sectional drawing which fractures | ruptures and shows the ceramic heater of Example 1 perpendicular | vertical to an axial direction, (b) is explanatory drawing which expand | deploys and shows a heater member. FIG. 3 is an explanatory view showing a method for manufacturing the ceramic heater of Example 1. (A) is sectional drawing which fractures | ruptures and shows the ceramic heater of Example 2 perpendicularly | vertically with an axial direction, (b) is explanatory drawing which expand | deploys and shows a heater member. (A) is sectional drawing which fractures | ruptures and shows the ceramic heater of Example 3 perpendicularly | vertically with an axial direction, (b) is sectional drawing which fractures | ruptures the ceramic heater of the application example perpendicularly | vertically with an axial direction. (A) is sectional drawing which fractures | ruptures and shows the ceramic heater of Example 4 perpendicular | vertical to an axial direction, (b) is explanatory drawing which expand | deploys and shows a heater member. (A) is sectional drawing which fractures | ruptures and shows the ceramic heater of Example 5 perpendicularly | vertically with an axial direction, (b) is explanatory drawing which expand | deploys and shows a heater member. (A) is sectional drawing which fractures | ruptures and shows the ceramic heater of Example 6 perpendicularly | vertically with an axial direction, (b) is a side view which shows the part. It is explanatory drawing which shows the manufacturing method of the ceramic heater of Example 6. FIG. (A) is explanatory drawing which shows the method of connecting the ceramic heater of Example 6 to a pipe, (b) is an end elevation which shows the end surface of a pipe. It is sectional drawing which fractures | ruptures and shows the ceramic heater of Example 7 perpendicular | vertical to an axial direction. It is explanatory drawing which shows the manufacturing method of the ceramic heater of Example 8. FIG. It is explanatory drawing which shows the manufacturing method of the ceramic heater of Example 9. FIG. (A) is a perspective view which shows the processing core member of the ceramic heater of Example 11, (b) is a perspective view which shows the other core member for processing. It is explanatory drawing which shows the manufacturing method of the ceramic heater of a prior art. It is sectional drawing which fractures | ruptures and shows the ceramic heater of a prior art perpendicularly | vertically with an axial direction.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Heat exchange unit 3 ... Heat exchanger 5, 51, 61, 71, 81, 91, 101, 131, 153, 165 ... Ceramic heater 6 ... Flange 11, 53, 63, 73, 83, 93, 105, 133 ... Heater member 13, 15, 87, 89, 97, 99, 135, 147, 149 ... End 19, 57, 88, 98 ... Ceramic substrate 21, 55, 65, 75, 85, 95, 103 ... Heating element

Claims (22)

  A ceramic heater in which a heater member having a heating element formed on a ceramic substrate is wound at least one turn and the heater members are overlapped with each other.   The ceramic heater according to claim 1, wherein the ceramic heater is a cylindrical body.   The ceramic heater according to claim 1 or 2, wherein ends of the heater member in the circumferential direction are directly or indirectly overlapped in the thickness direction of the heater member.   4. The ceramic heater according to claim 3, wherein a heat generating portion in which the heat generating element is formed among the heater members is at least partially overlapped in a thickness direction of the heater member.   5. The ceramic heater according to claim 3, wherein a non-heat generating portion in which the heating element is not formed in the heater member is at least partially overlapped in the thickness direction of the heater member.   The ceramic heater according to any one of claims 1 to 5, wherein the heating element is at least partially overlapped in the thickness direction of the heater member.   The chamfered part chamfered along the said circumferential direction was provided in the edge part of the outermost periphery among the edge parts of the circumferential direction of the said heater member, The said any one of Claims 1-6 characterized by the above-mentioned. Ceramic heater.   The ceramic heater according to any one of claims 1 to 7, wherein the heater member is wound in multiple layers, and the heating elements are laminated.   9. The ceramic heater according to claim 1, wherein the ceramic heater has a cylindrical shape, and an inner heating amount and an outer heating amount in the thickness direction are different from each other at a center in the thickness direction. Ceramic heater.   The ceramic heater according to any one of claims 1 to 9, wherein the ceramic heater has a cylindrical shape, and an arrangement interval of the heating elements is different in a circumferential direction thereof.   The ceramic heater according to claim 10, wherein an interval between the heating elements is closer as the thickness of the ceramic heater is larger.   The ceramic heater according to any one of claims 1 to 11, wherein the ceramic heater is cylindrical, and a cross-sectional area of the heat generating portion is different in a circumferential direction thereof.   The ceramic heater according to claim 12, wherein the cross-sectional area of the heating element is smaller as the thickness of the ceramic heater is larger.   The ceramic heater according to claim 1, wherein the number of windings of the heater member is different in the axial direction of the ceramic heater.   15. The ceramic according to claim 14, wherein the number of turns of the heater member at the end on the side of the heating element in the axial direction is greater than the number of turns of the heater member at the end opposite to the end on the side of the heating element. heater.   A heat exchange unit, wherein the ceramic heater according to any one of claims 1 to 15 is attached to a heat exchanger into which a fluid heated by the ceramic heater flows.   The flow path of the fluid in the heat exchange unit is provided with a flow path from a through hole penetrating the ceramic heater in an axial direction to a space on the outer peripheral surface side of the ceramic heater. The heat exchange unit described.   A warm water washing toilet seat comprising the heat exchange unit according to claim 16 or 17.   The heater sheet before firing in which the heat generation pattern is formed on the ceramic base sheet is wound around the core member for processing by one or more turns to form a wound body, and after removing the processing core member from the wound body, the winding A method for producing a ceramic heater, comprising firing an attached body to produce a ceramic heater.   A heater sheet before firing in which a heat generation pattern is formed on a ceramic base sheet is wound around a core member for processing made of a material that disappears during firing to form a wound body, and the wound body is fired, A method for producing a ceramic heater, comprising producing a ceramic heater by erasing the processing core member during firing.   A heater sheet before firing in which a heat generation pattern is formed on a ceramic base sheet is wound around one or more turns around a cylindrical or solid core member to form a wound body, and the wound body is fired to produce a ceramic heater. A method of manufacturing a ceramic heater.   A ceramic heater characterized in that a heater sheet before firing in which a heating pattern is formed on a ceramic base sheet is wound one or more times to form a solid wound body, and the wound body is fired to produce a ceramic heater. A method for manufacturing a heater.