JP2018085306A - Electric heater, air conditioner including electric heater, and method of manufacturing electric heater - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an electric heater with a temperature control function, including a heat generation/dissipation part which comprises a conductive resin and generates/dissipates heat by being energized when a voltage is applied between a first electrode part and a second electrode part.SOLUTION: An electric heater 1 includes a heat generation/dissipation part 1b which is connected to each of a first electrode part 1a and a second electrode part 1c and which comprises a conductive resin. The heat generation/dissipation part 1b generates/dissipates heat when a voltage is applied between the first electrode part 1a and the second electrode part 1c. The electric heater 1 includes a temperature control part 7.SELECTED DRAWING: Figure 2

Description

  The present invention relates to an electric heater that generates heat when energized, an air conditioner including the electric heater, and an electric heater manufacturing method.

  Conventionally, an electric heater that generates heat when energized is known. The electric heater is used for the purpose of warming a fluid. For example, there is an electric heater that is disposed in a ventilation path in an air conditioner and warms air passing through the ventilation path in the air conditioner in order to supply warm air to the outside. . As this type of electric heater, there is an electric heater described in Patent Document 1, for example.

  In the electric heater described in Patent Document 1, a heat generating portion is configured by a loop-shaped nichrome wire. In this electric heater, the nichrome wire generates heat when energized, and heat is released by releasing heat from the generated nichrome wire to the air. That is, in this electric heater, the nichrome wire as the heat generating part also functions as a heat radiating part. And in this electric heater, the heat-generating part comprised with the nichrome wire is arrange | positioned in the ventilation path in an air conditioner, and heat is given to the air which distribute | circulates the vicinity of the heat-generated nichrome wire.

Japanese Unexamined Patent Publication No. 60-080054

  In the electric heater described in Patent Document 1, the degree of heating is greatly different between air that passes in the vicinity of the nichrome wire and air that passes through a space far from the nichrome wire. For this reason, in this electric heater, the problem that the spatial temperature distribution of the warmed air (for example, warm air which an air conditioner supplies) becomes non-uniform | heterogenous arises. In particular, in this electric heater, since the heat radiating portion is a nichrome wire, a space range (hereinafter referred to as a heat radiating range) in which heat can be radiated (that is, heated air) tends to be narrowed. Therefore, in this electric heater, when trying to widen the heat dissipation range, it is necessary to take measures such as increasing the number of nichrome wires or using a large-diameter nichrome wire.

  However, since the nichrome wire is a metal and has a large mass, if the number of nichrome wires is increased or a large-diameter nichrome wire is used, the weight of the entire electric heater increases.

  Accordingly, the inventor of the present application has invented the electric heater described in Japanese Patent Application No. 2016-112053. The electric heater includes a first electrode portion (1a), a second electrode portion (1c), and a conductive resin connected to each of the first electrode portion and the second electrode portion. 1b). In this electric heater, when a voltage is applied between the first electrode portion and the second electrode portion, the heat generating heat radiating portion generates heat and dissipates heat by energizing the heat generating heat radiating portion.

  According to this electric heater, the heat radiating and radiating portion is made of a conductive resin, so that the heat radiating portion (i.e., compared to the case where the heat generating portion is made of metal like the electric heater of Patent Document 1 (that is, The mass per volume for the heat-generating and heat-dissipating part is reduced. Therefore, when the number and volume of the heat generating and radiating portions are increased in order to increase the heat dissipation range, the overall weight of the electric heater can be reduced as compared with the electric heater disclosed in Patent Document 1. In other words, the heat radiation range can be increased without increasing the weight of the electric heater as compared with the case where the heat generating and heat radiating portion is made of metal. Further, when a nichrome wire is used as in the electric heater described in Patent Document 1, there is a risk of causing a malfunction when the nichrome wire is burned out, but such a danger is also eliminated.

  Here, this type of electric heater preferably has a temperature control function.

  In view of the above points, the present invention includes a heat-dissipating part that is made of a conductive resin and that generates heat and dissipates heat when a voltage is applied between the first electrode part and the second electrode part. The purpose is to give the electric heater a temperature control function.

The invention according to claim 1 for achieving the above object is as follows:
A first electrode part (1a);
A second electrode part (1c);
When electrically connected to each of the first electrode part and the second electrode part and made of conductive resin, and a voltage is applied between the first electrode part and the second electrode part A heat-generating and heat-dissipating part (1b) that generates heat while being energized,
It is electrically connected in series to the first electrode part, the second electrode part, and the heat-dissipating heat radiating part, and is disposed so as to be able to receive heat from the heat-dissipating heat dissipating part. A temperature control unit that controls the temperature rise of the heat-dissipating part by making the current less likely to flow when the temperature exceeds the specific temperature. 7).

  In this electric heater, since the temperature control unit is provided, when an excessive current flows and exceeds a specific temperature, the electric resistance becomes high, so that the current hardly flows. Therefore, it is possible to prevent the heat generating and heat radiating portion from excessively generating heat exceeding the specific temperature.

  In the inventions according to the eighth and ninth aspects, the following preparation process and molding process are included as a method of manufacturing the electric heater. That is, in the preparation step, a cavity (300, 700, 701, 702, 800, 900) is formed as a space in which an integrated member composed of the first electrode part, the heat-dissipating part, and the second electrode part is formed. A mold for injection molding (200, 600) is prepared. Further, in the molding process, the first electrode portion and the second electrode portion are disposed in the cavity, and the molding resin, which is the material of the heat radiating portion, is melted, and the heat radiating portion of the cavity from the outside of the mold The molding resin is filled into the space. At this time, the material of the temperature control unit is injected from the outside of the mold into a space in the cavity where the temperature control unit is formed, and the temperature control unit is filled into the space. Then, the filled molding resin and the temperature control unit are cooled and solidified to obtain an integrated member composed of the first electrode unit, the heat-dissipating unit, and the second electrode unit.

  For this reason, according to this manufacturing method, the integrated member comprised by a 1st electrode part, a heat_generation | fever heat dissipation part, a 2nd electrode part, and a temperature control part can be manufactured easily, and an electric heater is manufactured easily. Can do. In particular, according to this manufacturing method, even if the shape of the heat generating and radiating portion and the shape of the temperature control portion are complicated, they can be easily formed. That is, it is possible to increase the degree of freedom of the shape of the heat radiation unit and the temperature control unit. Furthermore, even if it is the structure to which the heat-emitting / radiating part and the temperature control part are mutually connected, each shape of the heat-radiating / radiating part and the temperature control part can be easily made to correspond. Moreover, in this manufacturing method, the heat generating and heat radiating part that is the heat generating part and the heat radiating part can be formed integrally with the first electrode part and the second electrode part that are the electrodes. Therefore, in the electric heater manufactured by this manufacturing method, it becomes easy for a current to flow evenly from the first electrode portion and the second electrode portion that are electrodes to the heat generating heat radiating portion that is the heat generating portion and the heat radiating portion. For this reason, in the electric heater manufactured by this manufacturing method, it can radiate | emit uniformly in the predetermined space which is heat dissipation object.

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

It is the schematic about the indoor air-conditioning unit part of the air conditioner to which the electric heater which concerns on 1st Embodiment of this indication was applied. It is a perspective view about the electric heater which concerns on 1st Embodiment. It is a front view about the electric heater which concerns on 1st Embodiment. It is an end elevation which shows the IV-IV cross section in FIG. 3 about the electric heater which concerns on 1st Embodiment. It is a perspective view which shows only the 1st electrode part of the electric heater which concerns on 1st Embodiment. It is a perspective view which shows only the thermal radiation part of the electric heater which concerns on 1st Embodiment. It is a perspective view which shows only the 2nd electrode part of the electric heater which concerns on 1st Embodiment. It is a figure which shows the plane structure of a lower mold | type among the metal mold | dies for shaping | molding in the manufacturing process of the electric heater which concerns on 1st Embodiment. It is a figure which shows the structure of the IX-IX cross section in FIG. 8 of the metal mold | die in the manufacturing process of the electric heater which concerns on 1st Embodiment. It is a figure which shows the structure of the XX cross section in FIG. 8 of the metal mold | die in the manufacturing process of the electric heater which concerns on 1st Embodiment. It is a figure which shows the example manufactured using the metal mold | die shown in FIGS. It is a figure which shows the example manufactured using the metal mold | die different from the metal mold | die shown in FIGS. It is another figure which shows the example manufactured using the metal mold | die different from the metal mold | die shown in FIGS. It is another figure which shows the example manufactured using the metal mold | die different from the metal mold | die shown in FIGS. It is a perspective view about the electric heater concerning a 2nd embodiment of this indication. It is an end elevation equivalent to Drawing 4 in a 1st embodiment about an electric heater concerning a 2nd embodiment. It is a perspective view about an electric heater concerning a 3rd embodiment of this indication. It is sectional drawing about the electric heater which concerns on 3rd Embodiment. It is a perspective view about the electric heater which concerns on 4th Embodiment of this indication. It is sectional drawing about the electric heater which concerns on 4th Embodiment. In 2nd Embodiment, it is a figure which shows the modification which has arrange | positioned the electric heater around the air blower of an air conditioner.

  Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. In the following embodiments, the same or equivalent parts are denoted by the same reference numerals for description.

(First embodiment)
An air conditioner 100 to which the electric heater 1 according to the first embodiment of the present disclosure is applied will be described with reference to FIGS. The air conditioner 100 according to the present embodiment is an air conditioning unit that is mounted on a vehicle such as an automobile and that supplies conditioned air for adjusting the air temperature in a predetermined space. As shown in FIG. 1, an air conditioner 100 according to the present embodiment includes an air conditioning case 10. Inside the air conditioning case 10, a blower 2, a cooling heat exchanger 3, a heating heat exchanger 4, an air A mix door 5, blowing mode doors 6 to 8, and an electric heater 1 are provided.

  The air conditioner 100 according to the present embodiment basically warms the air in the predetermined space by supplying the air heated by the heating heat exchanger 4 to the predetermined space. In the air conditioner 100, the electric heater 1 basically functions as an auxiliary heating device for the heating heat exchanger 4, and is used for, for example, immediate heating. In addition, the air conditioner 100 cools the air in the predetermined space by supplying the air cooled by the cooling heat exchanger 3 to the predetermined space. That is, the air conditioner 100 supplies air heated by one or both of the heat exchanger 4 for heating and the electric heater 1 to a predetermined space. In addition, the air conditioner 100 supplies the air cooled by the cooling heat exchanger 3 to a predetermined space. The air conditioner 100 adjusts the temperature of air in the predetermined space by supplying air (that is, conditioned air) to the predetermined space in this way. The air conditioner 100 is usually mounted inside a vehicle instrument panel (not shown) located in the foremost part of the vehicle interior, and is used to adjust the temperature of air in the vehicle interior.

  As shown in FIG. 1, an air passage 10 a is formed inside the air conditioning case 10 to allow air to be sent into the passenger compartment. Outside air introduction ports 10aa and inside air introduction ports 10ab and 10ac are formed at the most upstream portion of the air passage 10a in the air conditioning case 10, and inside / outside air switching doors 91 and 92 for opening and closing these inlets 10aa, 10ab and 10ac are arranged. Yes. The air conditioner 100 blows air introduced from the inlets 10aa, 10ab, and 10ac (that is, outside air or inside air) through the inside of the air conditioning case 10 by the blower 2 toward the vehicle interior. In addition, on the side of the heating heat exchanger 4 inside the air conditioning case 10, the air after passing through the cooling heat exchanger 3 (that is, cold air) bypasses the heating heat exchanger 4 and flows cold air. A passage 10b is formed. The cool air passage 10b is a part of the air passage 10a. Further, a defroster air outlet 10ad, a face air outlet 10ae, and a foot air outlet 10af are formed in the most downstream portion of the air passage 10a in the air conditioning case 10, and an air outlet mode door 6 that opens and closes these air outlets 10ad, 10ae, and 10af. ~ 8 are arranged. Here, the defroster outlet 10ad is an outlet that blows out the conditioned air toward the window glass in front of the vehicle. The face outlet 10ae is an outlet that blows out the conditioned air toward the upper body of the occupant. The foot outlet 10af is an outlet that blows out the conditioned air toward the feet of the passengers.

  The blower 2 has a centrifugal blower fan 2a and a drive motor 2b. That is, the blower 2 blows air in the centrifugal direction of the centrifugal blower fan 2a (that is, rightward in FIG. 1) by rotating the centrifugal blower fan 2a by the driving motor 2b.

  The cooling heat exchanger 3 is a well-known refrigeration cycle evaporator. As shown in FIG. 1, the cooling heat exchanger 3 is disposed on the downstream side of the blower 2 in the air passage 10 a of the air conditioning case 10.

  The heating heat exchanger 4 uses hot water (that is, engine cooling water) from a vehicle engine (not shown) as a heat source and heats the air that has passed through the cooling heat exchanger 3 (that is, heater core). It is. As shown in FIG. 1, the heating heat exchanger 4 is disposed in the air passage 10 a of the air conditioning case 10 on the downstream side of the blower 2 and the cooling heat exchanger 3.

  The air mix door 5 is a plate-like door member that is rotatably supported by the air conditioning case 10. The air mix door 5 rotates to adjust the air volume ratio between the air passing through the heating heat exchanger 4 and the electric heater 1 and the air passing through the cold air passage 10b, and the temperature of the air blown out into the vehicle interior is adjusted. Adjust. As shown in FIG. 1, the air mix door 5 is disposed between the cooling heat exchanger 3 and the heating heat exchanger 4 in the air passage 10 a of the air conditioning case 10. The air-conditioning apparatus 100 according to the present embodiment uses the air-conditioning air whose temperature is adjusted by the air mix door 5 from one or more of the defroster outlet 10ad, the face outlet 10ae, and the foot outlet 10af to the vehicle interior. Blow out.

  The blowing mode doors 6 to 8 are plate-like door members that are rotatably supported by the air conditioning case 10. The blowing mode doors 6 to 8 are rotated to adjust the opening degree of the corresponding outlets 10ad, 10ae, and 10af, and adjust the air volume passing through the outlets 10ad, 10ae, and 10af. As shown in FIG. 1, the blow-out mode doors 6 to 8 are respectively arranged downstream of the cooling heat exchanger 3 and the heating heat exchanger 4 in the air passage 10 a of the air conditioning case 10. The air-conditioning apparatus 100 according to the present embodiment uses conditioned air whose air volume has been adjusted by the blow mode doors 6 to 8 from any one or more of the defroster outlet 10ad, the face outlet 10ae, and the foot outlet 10af. Blow out into the passenger compartment.

  The electric heater 1 is a heater that passes an electric current, changes electric energy into heat energy, and warms the object by using the generated heat, and is provided to warm air passing through the air passage 10a. As described above, the electric heater 1 is basically a heater used for immediate effect heating. As shown in FIG. 1, the electric heater 1 is arrange | positioned in the site | part just after the air blowing of the heat exchanger 4 for heating in the air path 10a. The air conditioner 100 according to the present embodiment warms the air passing through the air passage 10a by the electric heater 1 and blows the conditioned air warmed by the electric heater 1 into the vehicle interior.

  Hereinafter, a specific configuration of the electric heater 1 according to the present embodiment will be described with reference to FIGS. As shown in FIGS. 2 to 4, the electric heater 1 includes a first electrode portion 1a, a temperature control portion 7, a heat generating and radiating portion 1b, a second electrode portion 1c, a lead wire 1d, a lead wire 1e, and a positive terminal portion 1f. , A negative terminal portion 1g, and a control device 1h. In the electric heater 1 according to the present embodiment, the first electrode portion 1a, the temperature control portion 7, the heat generating and dissipating portion 1b, and the second electrode portion 1c are laminated and connected in this order. A positive electrode side terminal portion 1f is connected to the second electrode portion 1c via a lead wire 1d. Moreover, the negative electrode side terminal part 1g is connected to the 1st electrode part 1a via the lead wire 1e. The output portion of the control device 1h is connected to the positive terminal portion 1f. In the electric heater 1 according to the present embodiment, the energization to the heat radiating and radiating portion 1b is automatically controlled intermittently by the output of the control device 1h. The electric heater 1 functions as a heater that heats and dissipates heat when the voltage is applied between the first electrode portion 1a and the second electrode portion 1c, and warms the air passing through the air passage 10a. To do.

  The 1st electrode part 1a is a member which functions as an electrode, and as shown in FIG. 5, it is set as the structure by which several through-hole 1aa was formed in the plate-shaped member comprised with electroconductive metals, such as aluminum. . As shown in FIG. 4, each of the plurality of through holes 1aa penetrates in the direction A from the first electrode portion 1a toward the second electrode portion 1c.

  Specifically, the first electrode portion 1a in the present embodiment has a rectangular shape with a vertical width of 60 mm and a horizontal width of about 120 mm, and a thin plate shape with a plate thickness of about 1 mm. As shown in FIG. 5, in the present embodiment, the through holes 1aa are formed in a matrix in a rectangular shape with six vertically and twelve horizontally. Each of the plurality of through holes 1aa has a substantially square shape, and the interval between the holes is approximately 10 mm.

  In the present embodiment, the first electrode portion 1a may be replaced with a conductive material (for example, a conductive resin) other than the conductive metal.

  The temperature control unit 7 is electrically connected in series to the first electrode unit 1a, the heat-dissipating unit 1b, and the second electrode unit 1c. Moreover, the temperature control part 7 is arrange | positioned in contact with the heat-emitting / radiating part 1b. Therefore, the temperature control part 7 is arrange | positioned so that heat reception is possible from the heat_generation | fever heat dissipation part 1b.

  The temperature control unit 7 is a member made of a material having PTC (Positive Temperature Coefficient) characteristics (that is, a temperature control function). That is, the temperature control unit 7 is made of a material that increases the electrical resistance per unit temperature increase when the temperature exceeds a specific temperature than before the specific temperature is exceeded. Further, the temperature control unit 7 increases in electrical resistance as the temperature rises in a predetermined temperature range including the Curie point. The temperature control unit 7 controls the temperature rise in the electric circuit by making it difficult for current to flow when the temperature exceeds the specific temperature. Specifically, in this embodiment, the temperature control unit 7 is a coating film made of a material in which conductive powder is dispersed in an organic polymer.

  The heat-generating and heat-dissipating part 1b functions as a heat-dissipating part that dissipates heat to the air that passes through the air passage 10a. As shown in FIG. 6, a conductive material such as PPS (ie, polyphenylene sulfide resin) to which conductivity is added. It is set as the structure by which several through-hole 1ba was formed in the plate-shaped member comprised with resin. As shown in FIG. 4, each of the plurality of through holes 1ba penetrates in the direction A from the first electrode portion 1a toward the second electrode portion 1c. The heat-dissipating part 1b is disposed between the first electrode part 1a and the second electrode part 1c. The material of the heat-dissipating part 1b is made of a conductive resin that exhibits adhesion to the first and second electrode parts 1a and 1c by melting and solidifying by injection molding in a manufacturing method described later. Is particularly preferred. Moreover, since the heat-dissipating part 1b is a heat-dissipating part as well as a heat-dissipating part, a material having an electric resistance value suitable for generating a necessary amount of heat by heat generation is preferable. For example, the heat-dissipating part 1b has a heat resistance such as a melting point of 250 ° C. or higher. An excellent material is preferred. In addition, you may comprise the heat_generation | fever heat dissipation part 1b with resin with PTC characteristics, such as resin which mixed the conductive carbon and the polyethylene-type polymer, for example.

  Specifically, the heat-dissipating part 1b in the present embodiment has a rectangular shape with a vertical width of 60 mm and a horizontal width of about 120 mm, and a thin plate shape with a plate thickness of about 5 mm. As shown in FIG. 6, in the present embodiment, the through holes 1ba are formed in a matrix in a rectangular shape with six vertically and twelve horizontally. Each of the plurality of through holes 1ba has a substantially square shape, and an interval between each of the through holes 1ba is about 5 mm.

  As shown in FIG. 2 and FIG. 4, the heat-dissipating part 1b in this embodiment is connected to each of the first electrode part 1a and the second electrode part 1c. In the present embodiment, the heat generating / dissipating part 1b and the first electrode part 1a are bonded to each other, for example, by chemical bonding. Further, the heat generating / dissipating part 1b and the second electrode part 1c are also bonded to each other, for example, by chemical bonding. Thus, in the present embodiment, the heat-dissipating part 1b is directly connected to the first electrode part 1a and the second electrode part 1c. Thereby, the heat-dissipating part 1b is electrically connected to the first electrode part 1a and the second electrode part 1c. As described above, in this embodiment, the heat generating and heat radiating portion 1b and the first electrode portion 1a are directly bonded, and the heat generating and heat radiating portion 1b and the second electrode portion 1c are directly bonded to each other. Without being interposed, the heat-dissipating part 1b is connected to the first electrode part 1a and the second electrode part 1c. In the present embodiment, the heat-dissipating part 1b is indirectly connected to the first electrode part 1a and the second electrode part 1c via another conductive member (for example, a bonding material excellent in conductivity such as silver paste). It is good also as a structure connected to.

  As described above, the electric heater 1 according to this embodiment is configured such that a voltage is applied between the first electrode portion 1a and the second electrode portion 1c. Specifically, the electric heater 1 according to this embodiment is configured such that the first electrode portion 1a side has a higher potential than the second electrode portion 1c. The electric heater 1 may be replaced with one having a configuration in which the second electrode portion 1c side has a higher potential than the first electrode portion 1a.

  In the present embodiment, the heat-dissipating part 1b generates heat and dissipates heat when a voltage is applied between the first electrode part 1a and the second electrode part 1c. The conductive resin material constituting the heat generating and radiating part 1b is made conductive by mixing particulate conductive filler (for example, conductive particles made of metal, carbon, semiconductor, etc.) in the resin material. Can be used. In the electric heater 1 according to the present embodiment, it is possible to set a predetermined electric resistance value necessary for the electric heater 1 by adjusting the amount of conductive filler mixed in the heat radiating and radiating portion 1b.

  The 2nd electrode part 1c is a member which functions as an electrode, and as shown in FIG. 7, it is set as the structure by which several through-hole 1ca was formed in the plate-shaped member comprised with electroconductive metals, such as aluminum. . As shown in FIG. 4, each of the plurality of through holes 1ca penetrates in the direction A from the first electrode portion 1a toward the second electrode portion 1c.

  Specifically, the second electrode portion 1c in the present embodiment has a rectangular shape with a vertical width of 60 mm and a horizontal width of about 120 mm, and a thin plate shape with a plate thickness of about 1 mm. As shown in FIG. 7, in the present embodiment, the through holes 1ca are formed in a matrix in a rectangular shape with six vertically and twelve horizontally. Each of the plurality of through holes 1ca has a substantially square shape, and the interval between the holes is approximately 10 mm.

  In the present embodiment, the second electrode portion 1c may be replaced with a conductive material (for example, a conductive resin) other than the conductive metal.

  As shown in FIGS. 3 to 7, in the electric heater 1 according to the present embodiment, the heat generating and dissipating part 1 b is configured so that the hole shape of the through hole 1 ba substantially matches the hole shape of the through hole 1 aa of the first electrode part 1 a. The first electrode portion 1a is coupled. Further, the heat-dissipating part 1b is coupled to the second electrode part 1c so that the hole shape of the through hole 1ba substantially matches the hole shape of the through hole 1ca of the second electrode part 1c. As shown in FIG. 4, the electric heater 1 is oriented by one through-hole 1aa among a plurality, one corresponding through-hole 1ba among the plurality, and one corresponding through-hole 1ca among the plurality. One through-hole part 1i which penetrates A is comprised. That is, the electric heater 1 according to the present embodiment has a plurality of through-hole portions 1i configured as described above.

  Moreover, as shown in FIGS. 2-7, in this embodiment, the 1st electrode part 1a, the heat-dissipating part 1b, and the 2nd electrode part 1c are substantially the same in each vertical width and horizontal width, respectively. Are coupled so that their outermost contours substantially coincide with each other. For this reason, as for the heat_generation | fever heat dissipation part 1b in this embodiment, the substantially whole one surface side is covered with the 1st electrode part 1a, and the substantially whole other surface side is covered with the 2nd electrode part 1c.

  As described above, the first electrode portion 1a, the heat generating / dissipating portion 1b, and the second electrode portion 1c in the present embodiment are connected to each other and integrated.

  As described above, the electric heater 1 according to the present embodiment includes the heat-dissipating part 1b made of the conductive resin connected to each of the first electrode part 1a and the second electrode part 1c. The heat generating / dissipating part 1b generates heat and dissipates heat when a voltage is applied between the first electrode part 1a and the second electrode part 1c.

  For this reason, in this electric heater 1, since the heat-dissipating part 1b is made of a conductive resin, the heat-dissipating part is compared with the case where the heat-generating part is made of metal as in the electric heater of Patent Document 1. In other words, the mass per volume for the heat generating and radiating portion 1b is reduced. Therefore, in the electric heater 1 according to the present embodiment, the total weight of the electric heater 1 is larger than that of the electric heater disclosed in Patent Document 1 when the number and volume of the heat generating and radiating portions 1b are increased in order to increase the heat dissipation range. Can be reduced. That is, in the electric heater 1 according to the present embodiment, the heat radiation range can be increased without increasing the weight of the electric heater, as compared with the case where the heat generating and radiating portion is metal. In addition, when a nichrome wire is used as in the electric heater described in Patent Document 1, there is a risk of causing a malfunction when the nichrome wire is burned out. However, in the electric heater 1 according to the present embodiment, There is no danger like this.

  Moreover, the electric heater 1 according to the present embodiment includes a temperature control unit 7. The temperature control unit 7 is made of a material that increases the degree of increase in electrical resistance per unit temperature rise when the temperature exceeds a specific temperature than before the temperature exceeds the specific temperature. The temperature control unit 7 controls the temperature rise in the electric circuit by making it difficult for current to flow when the temperature exceeds the specific temperature.

  For this reason, in the electric heater 1 which concerns on this embodiment, since the temperature control part 7 is provided, when an excessive electric current flows and a specific temperature is exceeded, an electric resistance will become high and an electric current will hardly flow. It is possible to prevent excessive heat generation beyond a specific temperature.

  Further, there is a conventional electric heater having PTC characteristics described in Japanese Patent Laid-Open No. 2005-108808. In this electric heater, semiconductor ceramics having PTC characteristics is used as a member that functions as a heat generating part and also as a temperature control part. Specifically, in this electric heater, in order to cause the semiconductor ceramics to function as a heat generating part, as shown in FIG. 1 of the same publication, a plurality of granular semiconductor ceramics are sufficiently spaced apart from each other. It is arranged intermittently while emptying. This is because, if there is not enough space, heat is transferred between different semiconductor ceramics and deviates from the target heat generation performance. Thus, when using semiconductor ceramics as a temperature control part, it is forced to arrange | position a several semiconductor ceramic intermittently as described in FIG. 1 of the same gazette. For this reason, in order to keep the interval as described above, it is necessary to take measures such as increasing the space for installing the temperature control unit or reducing the temperature control unit. However, it is not preferable to increase the space in which the temperature control unit is installed. Particularly, when the electric heater 1 is used for a vehicle, space saving is particularly required, and it is difficult to cope with it. If the temperature control unit is made small, the PTC characteristics may not be sufficiently obtained. In contrast, in the present embodiment, the temperature control unit 7 is used as a functional unit specialized for temperature control, not as a heat generating unit. Therefore, it is not necessary to dispose the temperature control unit 7 intermittently with a sufficient interval, and the temperature control unit 7 can be continuously arranged in a space where the temperature control unit 7 is desired to be arranged. For this reason, a large-sized temperature control unit can be arranged in the space where the temperature control unit is installed (for example, it can be arranged on the entire surface of the space), and thereby, good PTC characteristics (that is, a temperature control function) ) Can be obtained. Thereby, for example, even in a situation where wind does not flow in the air conditioner 100, the temperature can be kept below a predetermined upper limit temperature, and overheating of the heat generating and radiating unit 1b can be prevented. Further, when the electric heater 1 is manufactured, depending on the manufacturing conditions, there are some cases where the heat generating and radiating portion 1b is likely to generate heat and difficult to mix. However, the temperature control unit 7 is provided, and the electric resistance of the portion that easily generates heat is provided. The temperature can be made uniform by increasing the value.

  Moreover, in this embodiment, the temperature control part 7 is a coating film comprised with the material which disperse | distributed electroconductive powder to the organic polymer.

  For this reason, in this embodiment, since the temperature control part 7 is comprised with the above coating films, compared with the case where it comprises with semiconductor ceramics, the 1st electrode part 1a and the 2nd electrode part 1c of a complicated shape are comprised. The temperature controller 7 having a complicated shape corresponding to the above can be easily formed. That is, in the electric heater 1 of the present embodiment, the degree of freedom of shape of the temperature control unit 7 is increased and the temperature control unit 7 can be easily formed. Moreover, in this electric heater 1, since the temperature control part 7 is the structure which has connected at least one among the 1st electrode part 1a and the 2nd electrode part 1c, and the heat-emitting / radiating part 1b, the temperature control part 7 is efficiently comprised. Thus, the excessive temperature rise of the heat radiating and radiating portion 1b can be efficiently suppressed.

  Furthermore, in the electric heater described in the above Japanese Patent Application Laid-Open No. 2005-108808, as described above, a semiconductor ceramic having PTC characteristics is used as a member that also functions as a temperature control unit. Since semiconductor ceramics is a fragile material, it becomes particularly fragile when the temperature control unit is made small. In addition, the size of semiconductor ceramics is likely to vary due to manufacturing reasons (that is, factors such as formulation, humidity, and temperature during manufacturing). For this reason, it is difficult to prepare a semiconductor ceramic having a desired size suitable for satisfying specifications required for an electric heater (for example, 900 to 1000 W). In addition, when the shape of the space where the semiconductor ceramics is installed is complex, the semiconductor ceramics (that is, the temperature control unit) must also be complicated to cope with this, but the semiconductor ceramics must be complicated. It is also difficult. On the other hand, the electric heater 1 according to the present embodiment has an advantage that the above-described problem does not occur because the temperature control unit 7 is configured by the coating film as described above. That is, in this embodiment, since the temperature control part 7 is comprised with the above coating films, as shown in FIG. 2, the temperature control part 7 can be formed not intermittently but continuously. . For this reason, in this embodiment, it can be set as the structure which can acquire sufficient PTC characteristic, without taking countermeasures, such as enlarging the space which installs the temperature control part 7, or making the temperature control part 7 small. . Moreover, in this embodiment, since the temperature control part 7 is comprised with the above coating films, it is hard to be broken rather than semiconductor ceramics. In addition, the required specifications of the electric heater 1 can be easily satisfied without preparing a semiconductor ceramic having a desired size. Moreover, in this embodiment, since the temperature control part 7 is comprised with the above coating films, the temperature control part 7 can also be made into a complicated shape easily.

  In addition, the electric heater 1 according to the present embodiment has a configuration using the heat generating and heat radiating portion 1b (that is, the heat generating portion and the heat radiating portion) made of a conductive resin. Compared with the electric heater etc. of No. gazette, it generates heat and dissipates efficiently. As a result, the overall configuration of the electric heater 1 (that is, the configuration of the first electrode portion 1a, the second electrode portion 1c, the heat generating and radiating portion 1b, etc.) is made smaller than the electric heater disclosed in Japanese Patent Application Laid-Open No. 2005-108808. However, the heater performance similar to the conventional one can be exhibited. Therefore, even if the electric heater 1 is miniaturized in order to cope with the space saving required for use in vehicles, the heater performance similar to the conventional one can be exhibited.

  In addition, the electric heater 1 according to the present embodiment has the first electrode portion 1a through the through-hole 1aa of the first electrode portion 1a, the through-hole 1ba of the heat-dissipating heat dissipation portion 1b, and the through-hole 1ca of the second electrode portion 1c. A through-hole portion 1i penetrating the first electrode portion 1a, the heat radiating and radiating portion 1b, and the second electrode portion 1c is formed in the direction A toward the two-electrode portion 1c.

  For this reason, in the electric heater 1 according to the present embodiment, the electric heater 1 is disposed so as to allow air to pass through the internal space 1j of the through hole portion 1i, and a voltage is generated between the first electrode portion 1a and the second electrode portion 1c. When is applied, the air passing through the internal space 1j of the through hole 1i can be warmed. That is, in the electric heater 1 according to this embodiment, when a voltage is applied between the first electrode portion 1a and the second electrode portion 1c, the first and second electrode portions 1a and 1c generate heat and generate heat. The heat radiating part 1b generates heat. And when air passes through the internal space 1j of the through-hole part 1i in the 1st, 2nd electrode parts 1a and 1c and the heat-radiating-heat-dissipating part 1b which generate | occur | produced heat, it can thermally radiate to this air and can warm this air. Further, in the electric heater 1 according to the present embodiment, the contact area between the heat radiating and radiating portion 1b and the internal space 1j of the through hole portion 1i is planar, so that the contact area is large. That is, the contact area between the heat radiating and radiating portion 1b and the air in the internal space 1j to be radiated is large. For this reason, in the electric heater 1 which concerns on this embodiment, the thermal radiation range can be widened. On the other hand, in the electric heater described in Patent Document 1, since the heat radiating portion is a nichrome wire, the heat radiating range is narrowed.

  In particular, in the electric heater 1 according to the present embodiment, a plurality of through-hole portions 1i are formed.

  For this reason, in the electric heater 1 which concerns on this embodiment, the thermal radiation range can be arrange | positioned widely by the multiple internal space 1j of the some through-hole part 1i being arrange | positioned. Therefore, in the electric heater 1 according to the present embodiment, the heat radiation range can be particularly widened and heat can be dissipated uniformly in space.

  The configuration of the electric heater 1 according to this embodiment has been described above. Next, the operation of the electric heater 1 according to this embodiment will be described.

  As an example, the case where the electric heater 1 is used at the time of heating in winter will be described. During the heating in winter, immediately after the vehicle engine is started, the hot water temperature of the vehicle engine is lowered to a very low temperature similar to the outside air temperature. For this reason, the heating heat exchanger 4 cannot heat the air using the hot water of the vehicle engine as a heat source. Therefore, with only the heat exchanger 4 for heating, heating is impossible in such a case, and the comfort in the passenger compartment is impaired.

  In the electric heater 1 according to the present embodiment, the control device 1h determines when the temperature of the hot water is low during winter heating, and automatically supplies a current-carrying circuit between the positive terminal portion 1f of the electric heater 1 and a vehicle battery (not shown). The power is turned on to energize the heat generating and radiating part 1b. In addition, the control apparatus 1h is that the hot water temperature detected by the water temperature sensor not shown is below a predetermined temperature, and is in the environmental condition required for vehicle interior heating (for example, the vehicle interior temperature is below a predetermined temperature). Etc.) and automatically energizes the heat generating and radiating portion 1b.

  In the electric heater 1 according to the present embodiment, the heat generating heat radiating portion 1b generates heat by energizing the heat generating heat radiating portion 1b. Thereby, the heat-radiating / dissipating part 1b directly heats the air passing through the air passage 10a. And the air conditioner 100 blows off the air (namely, warm air) heated with the electric heater 1 from the foot blower outlet 10af etc. to the vehicle interior. Thus, in the air conditioner 100 according to the present embodiment, the vehicle interior can be effectively and effectively heated even when the hot water temperature of the vehicle engine is low.

  More specifically, when the heater 2 is energized by the drive signal 2b of the blower 2 by the output signal of the control device 1h during the energization of the heat generating and radiating part 1b, the blower air of the blower 2 is subjected to heat exchange for cooling. After passing through the heater 3 and the heat exchanger 4 for heating, it passes through the internal space 1j of the through-hole part 1i in the heat radiating and radiating part 1b of the electric heater 1. At this time, since the surface of each through hole 1i directly faces the air flow in the air passage 10a, the heat generated by the heat generating and radiating portion 1b can be directly given to the air flow. The operation of the electric heater 1 according to this embodiment has been described above.

  Next, a method for manufacturing the electric heater 1 according to this embodiment will be described with reference to FIGS. As a whole, the electric heater 1 according to the present embodiment is completed through the same manufacturing process as that conventionally known as integral molding of resin and metal by injection molding. Therefore, in the following, only the characteristic steps in this manufacturing method will be described.

  First, as a preparation process, an injection mold 200 shown in FIGS. 8 to 10 is prepared. The mold 200 includes an upper mold 200a and a lower mold 200b. As shown in FIGS. 9 and 10, the lower mold 200b has a surface 200ba that is brought into contact with the upper mold 200a, and a recess 200bb formed on the surface 200ba. The lower mold 200b has a plurality of protrusions 200bc formed on the bottom surface of the recess 200bb. Each of the plurality of protrusions 200bc has a shape corresponding to each through hole 1i. In other words, when the upper mold 200a and the lower mold 200b are matched, the recess 200bb of the lower mold 200b and the cavity 300 that is a space between the protrusions 200bc and the upper mold 200a are the first electrode section 1a described above. , A space in which an integral member composed of the temperature control unit 7, the heat generating and radiating unit 1b, and the second electrode unit 1c is formed. As shown in FIG. 11, the cavity 300 includes, from above, a partial cavity 300 a as a space in which the first electrode portion 1 a is formed, a partial cavity 300 b as a space in which the temperature control unit 7 is formed, and a heat generating and radiating portion 1 b. It is divided into a partial cavity 300c as a space to be formed and a partial cavity 300d as a space in which the second electrode portion 1c is formed. The partial cavity 300a is a space corresponding to the outer shape of the first electrode portion 1a. The partial cavity 300 b is a space corresponding to the outer shape of the temperature control unit 7. The partial cavity 300c is a space corresponding to the outer shape of the heat generating / dissipating part 1b. The partial cavity 300d is a space corresponding to the outer shape of the second electrode portion 1c. Further, in the present manufacturing method, when the molding resin or metal is melted and solidified in the injection molding, the portions where the respective projections 200bc are located become cavities, whereby the respective through-hole portions 1i are formed. Further, the lower mold 200b is formed with a through hole 200bd that allows the outside of the mold 200 to communicate with the cavity 300. Specifically, the through hole 200bd is formed as a portion that communicates the outside of the mold 200 with the cavity 300. The through-hole 200bd is formed so that its internal space is connected to a partial cavity 300a that is a space in the cavity 300 in which the heat-dissipating part 1b is formed. In other words, the through-hole 200bd has an internal space formed of a material for the first electrode part 1a, a material for the temperature control part 7, a molding resin that is a material for the heat-dissipating part 1b, and a material for the second electrode part 1c. 200 is a hole for functioning as an injection passage 400 for injecting into the partial cavity 300a from the outside of 200.

  Next, as a molding step, first, as shown in FIG. 12, a molten metal for molding which is a material of the second electrode portion 1 c is injected from the injection passage 400 into the cavity 300. This molding resin is composed of a conductive metal such as zinc filler. Thus, the molding metal is filled into the partial cavity 300d. Next, as shown in FIG. 13, a melted molding resin, which is a material of the heat generating and radiating portion 1 b, is injected into the cavity 300 from the injection passage 400. This molding resin is composed of a conductive resin such as PPS. Thereby, the molding resin is filled into the partial cavity 300c. Next, as shown in FIG. 14, a conductive powder, which is a material for the temperature control unit 7, dispersed in an organic polymer is injected from the injection passage 400 into the cavity 300. Thereby, the material of the temperature control unit 7 is filled in the partial cavity 300b. Next, as shown in FIG. 15, a molten metal for molding which is a material of the first electrode portion 1 a is injected from the injection passage 400 into the cavity 300. This molding resin is composed of a conductive metal such as zinc filler. Thereby, the molding metal is filled into the partial cavity 300a. Then, the filled material is cooled and solidified. As a result, the first electrode portion 1a and the second electrode portion 1c are arranged in the cavity 300, and an integrated member constituted by the first electrode portion 1a, the temperature control portion 7, the heat generating and radiating portion 1b, and the second electrode portion 1c. Is obtained.

  The electric heater 1 according to this embodiment is completed through the preparation process and the molding process described above.

  For this reason, according to the manufacturing method described above, an integrated member composed of the first electrode part 1a, the temperature control part 7, the heat generating and radiating part 1b, and the second electrode part 1c can be easily manufactured. The electric heater 1 can be easily manufactured. Moreover, in this manufacturing method, the heat generating and heat radiating portion 1b which is the heat generating portion and the heat radiating portion can be integrally formed with the first electrode portion 1a and the second electrode portion 1c which are the electrodes. Therefore, in the electric heater 1 manufactured by this manufacturing method, it becomes easy for current to easily flow from the first electrode portion 1a and the second electrode portion 1c, which are electrodes, to the heat generating heat radiating portion 1b, which is a heat generating portion and a heat radiating portion. . For this reason, in the electric heater 1 manufactured by this manufacturing method, it can thermally radiate uniformly to the predetermined space which is a heat dissipation object. In addition, as a conventional electric heater, there exists a thing in which the heat generating part and the heat radiating part are separate. However, in this conventional electric heater, since a temperature gradient is generated between the heat generating portion and the heat radiating portion, it is difficult to uniformly radiate heat to a predetermined space to be radiated. Moreover, according to this manufacturing method, the complicated-shaped temperature control part 7 corresponding to the 1st electrode part 1a of a complicated shape and the 2nd electrode part 1c can be formed easily.

  As described above, the electric heater 1 according to this embodiment includes the heat-dissipating part 1b made of the conductive resin connected to each of the first electrode part 1a and the second electrode part 1c. The heat generating / dissipating part 1b generates heat and dissipates heat when a voltage is applied between the first electrode part 1a and the second electrode part 1c.

  For this reason, in this electric heater 1, when the heat generating part 1b as a heat radiating part is made of conductive resin, the heat generating part is made of metal like the electric heater of Patent Document 1. In comparison, the mass per volume of the heat radiating portion (that is, the heat radiating heat radiating portion 1b) is reduced. Therefore, in the electric heater 1 according to the present embodiment, the total weight of the electric heater 1 is larger than that of the electric heater disclosed in Patent Document 1 when the number and volume of the heat generating and radiating portions 1b are increased in order to increase the heat dissipation range. Can be reduced. That is, in the electric heater 1 according to the present embodiment, the heat radiation range can be increased without increasing the weight of the electric heater, as compared with the case where the heat generating and radiating portion is metal. In addition, when a nichrome wire is used as in the electric heater described in Patent Document 1, there is a risk of causing a malfunction when the nichrome wire is burned out. However, in the electric heater 1 according to the present embodiment, There is no danger like this.

  Moreover, the electric heater 1 according to the present embodiment includes a temperature control unit 7. The temperature control unit 7 is made of a material that increases the degree of increase in electrical resistance per unit temperature rise when the temperature exceeds a specific temperature than before the temperature exceeds the specific temperature. The temperature control unit 7 controls the temperature rise in the electric circuit by making it difficult for current to flow when the temperature exceeds the specific temperature.

  For this reason, in the electric heater 1 which concerns on this embodiment, since the temperature control part 7 is provided, when an excessive electric current flows and a specific temperature is exceeded, an electric resistance will become high and an electric current will hardly flow. It is possible to prevent excessive heat generation beyond a specific temperature.

  Moreover, in this embodiment, the temperature control part 7 is a coating film comprised with the material which disperse | distributed electroconductive powder to the organic polymer.

  For this reason, in this embodiment, since the temperature control part 7 is comprised with the above coating films, compared with the case where it comprises with semiconductor ceramics, the 1st electrode part 1a and the 2nd electrode part 1c of a complicated shape are comprised. The temperature controller 7 having a complicated shape corresponding to the above can be easily formed. That is, in the electric heater 1 of the present embodiment, the degree of freedom of shape of the temperature control unit 7 is increased and the temperature control unit 7 can be easily formed. Moreover, in this electric heater 1, since the temperature control part 7 is the structure which has connected at least one among the 1st electrode part 1a and the 2nd electrode part 1c, and the heat-emitting / radiating part 1b, the temperature control part 7 is efficiently comprised. Thus, the excessive temperature rise of the heat radiating and radiating portion 1b can be efficiently suppressed.

  In addition, the electric heater 1 according to the present embodiment has the first electrode portion 1a through the through-hole 1aa of the first electrode portion 1a, the through-hole 1ba of the heat-dissipating heat dissipation portion 1b, and the through-hole 1ca of the second electrode portion 1c. A through-hole portion 1i penetrating the first electrode portion 1a, the heat radiating and radiating portion 1b, and the second electrode portion 1c is formed in the direction A toward the two-electrode portion 1c.

  For this reason, in the electric heater 1 according to the present embodiment, the electric heater 1 is disposed so as to allow air to pass through the internal space 1j of the through hole portion 1i, and a voltage is generated between the first electrode portion 1a and the second electrode portion 1c. When is applied, the air passing through the internal space 1j of the through hole 1i can be warmed. That is, in the electric heater 1 according to this embodiment, when a voltage is applied between the first electrode portion 1a and the second electrode portion 1c, the first and second electrode portions 1a and 1c generate heat and generate heat. The heat radiating part 1b generates heat. And when air passes through the internal space 1j of the through-hole part 1i in the 1st, 2nd electrode parts 1a and 1c and the heat-radiating-heat-dissipating part 1b which generate | occur | produced heat, it can thermally radiate to this air and can warm this air. Further, in the electric heater 1 according to the present embodiment, the contact area between the heat radiating and radiating portion 1b and the internal space 1j of the through hole portion 1i is planar, so that the contact area is large. That is, the contact area between the heat radiating and radiating portion 1b and the air in the internal space 1j to be radiated is planar, so that the contact area is large. For this reason, in the electric heater 1 which concerns on this embodiment, the thermal radiation range can be widened. On the other hand, in the electric heater described in Patent Document 1, since the heat radiating portion is a nichrome wire, the heat radiating range is narrowed.

  In particular, in the electric heater 1 according to the present embodiment, a plurality of through-hole portions 1i are formed.

  For this reason, in the electric heater 1 which concerns on this embodiment, the thermal radiation range can be widened by the multiple internal space 1j of the several through-hole part 1i being arrange | positioned. Therefore, in the electric heater 1 according to the present embodiment, the heat radiation range can be particularly widened and heat can be dissipated uniformly in space.

  Moreover, the electric heater 1 which concerns on this embodiment is manufactured with the following manufacturing methods. That is, first, as a preparation process, an injection in which a cavity 300 is formed as a space in which an integrated member composed of the first electrode unit 1a, the temperature control unit 7, the heat generating and radiating unit 1b, and the second electrode unit 1c is formed. A molding die 200 is prepared. Next, as a molding process, the material of the temperature control unit 7 is injected from the outside of the mold 200 into the space 300b of the cavity 300 where the temperature control unit 7 is formed, and the temperature control unit is filled into the space 300b. To do. In addition, a melted molding resin that is a material of the heat-dissipating part 1b is injected from the outside of the mold 200 into the space 300c in the cavity 300 where the heat-dissipating part 1b is formed. The space 300c is filled. Then, the filled temperature control unit 7 and the molding resin are cooled and solidified. Thereby, the integrated member comprised by the 1st electrode part 1a, the temperature control part 7, the heat_generation | fever heat dissipation part 1b, and the 2nd electrode part 1c is obtained.

  For this reason, according to this manufacturing method, the integrated member comprised by the 1st electrode part 1a, the temperature control part 7, the heat-emitting / radiating part 1b, and the 2nd electrode part 1c can be manufactured easily, and the electric heater 1 Can be easily manufactured. In particular, according to this manufacturing method, even if the shape of the heat generating and radiating portion 1b is complicated, it can be easily formed. Moreover, in this manufacturing method, the heat generating and heat radiating portion 1b which is the heat generating portion and the heat radiating portion can be integrally formed with the first electrode portion 1a and the second electrode portion 1c which are the electrodes. Therefore, in the electric heater 1 manufactured by this manufacturing method, it becomes easy for current to easily flow from the first electrode portion 1a and the second electrode portion 1c, which are electrodes, to the heat generating heat radiating portion 1b, which is a heat generating portion and a heat radiating portion. . For this reason, in the electric heater 1 manufactured by this manufacturing method, it can thermally radiate uniformly to the predetermined space which is a heat dissipation object. In addition, as a conventional electric heater, there exists a thing in which the heat generating part and the heat radiating part are separate. However, in this conventional electric heater, since a temperature gradient is generated between the heat generating portion and the heat radiating portion, it is difficult to uniformly radiate heat to a predetermined space to be radiated. Moreover, according to this manufacturing method, the complicated-shaped temperature control part 7 corresponding to the 1st electrode part 1a of a complicated shape and the 2nd electrode part 1c can be formed easily.

  In particular, in this manufacturing method, in the molding step, a molding conductive metal or a conductive resin that is a material of the first electrode portion 1a is melted, and a molding conductive resin that is a material of the heat-dissipating heat radiating portion 1b. And a melt of the molding conductive metal or conductive resin that is the material of the second electrode portion 1c is injected into the cavity 300. Accordingly, the molding conductive metal or conductive resin is filled in the cavity 300, and the filled molding conductive metal or conductive resin is cooled and solidified. As a result, the first electrode portion 1a and the second electrode portion 1c are arranged in the cavity 300, and an integrated member constituted by the first electrode portion 1a, the temperature control portion 7, the heat generating and radiating portion 1b, and the second electrode portion 1c. Is obtained.

  For this reason, the integral member comprised by the 1st electrode part 1a, the temperature control part 7, the heat_generation | fever heat dissipation part 1b, and the 2nd electrode part 1c can be manufactured especially easily, and the electric heater 1 is manufactured especially easily. be able to.

(Second Embodiment)
A second embodiment of the present disclosure will be described with reference to FIGS. 15 and 16. In the present embodiment, the stacking order of the first electrode unit 1a, the temperature control unit 7, the heat generating and radiating unit 1b, and the second electrode unit 1c is changed with respect to the first embodiment. Since other aspects are the same as those in the first embodiment, description thereof is omitted here.

  In 1st Embodiment, it was the structure laminated | stacked in order of the 1st electrode part 1a, the temperature control part 7, the heat-emitting / radiating part 1b, and the 2nd electrode part 1c from the top. On the other hand, as shown in FIGS. 15 and 16, the present embodiment has a configuration in which the first electrode portion 1a, the heat-dissipating portion 1b, the temperature control portion 7, and the second electrode portion 1c are stacked in this order.

  Also in the present embodiment, the same effects as those described in the first embodiment can be obtained.

(Third embodiment)
A third embodiment of the present disclosure will be described with reference to FIGS. 17 and 18. This embodiment changes the shape of the 1st electrode part 1a of the electric heater 1, the temperature control part 7, the heat_generation | fever heat dissipation part 1b, and the 2nd electrode part 1c with respect to 1st Embodiment. Since this is the same as that of the first embodiment, description thereof is omitted here. In FIG. 17 and FIG. 18, illustration of the lead wire 1d, the lead wire 1e, the positive terminal portion 1f, the negative terminal portion 1g, and the control device 1h is omitted.

  As shown in FIGS. 17 and 18, in the present embodiment, the first electrode portion 1a and the second electrode portion 1c are each a rectangle having a vertical width of about 20 mm and a horizontal width of about 120 mm, and a plate thickness of about 6 mm. It is a shaped member. Note that the through holes 1aa and 1ba in the first embodiment are not formed in the first electrode portion 1a and the second electrode portion 1c in the present embodiment. Moreover, the temperature control part 7 is comprised by plate shape. As shown in FIG. 17, the contact surfaces of the temperature control unit 7 and the first electrode unit 1a are substantially coincident with each other.

  As shown in FIGS. 17 and 18, also in the electric heater 1 according to the present embodiment, as in the first embodiment, the conductive resin connected to each of the first electrode portion 1 a and the second electrode portion 1 c. The heat-dissipating part 1b composed of The heat generating / dissipating part 1b generates heat and dissipates heat when a voltage is applied between the first electrode part 1a and the second electrode part 1c.

  For this reason, also in this electric heater 1, as in the case of the first embodiment, when the number and volume of the heat radiating portions (that is, the heat radiating heat radiating portions 1b) are increased in order to increase the heat radiating range, Compared to the electric heater, the entire weight of the electric heater 1 can be reduced.

  As shown in FIGS. 17 and 18, in the present embodiment, the heat generating and radiating portion 1b is composed of a first fixing portion 1bb, a second fixing portion 1bc, and a plurality of radiating fins 1bd. 1st fixing | fixed part 1bb is a part which contacted and fixed with respect to the surface of the 1st electrode part 1a so that the circumference | surroundings of the 1st electrode part 1a may be enclosed among the heat_generation | fever heat dissipation parts 1b. 2nd fixing | fixed part 1bc is a part which contacted and fixed with respect to the surface of the 2nd electrode part 1c so that the circumference | surroundings of the 2nd electrode part 1c may be enclosed among the heat-emitting / radiating parts 1b. The radiating fin 1bd has a shape extending in the direction A from the first electrode portion 1a toward the second electrode portion 1c in the heat radiating heat radiating portion 1b, and is connected to the first fixing portion 1bb and the second fixing portion 1bc. Part. As shown in FIGS. 17 and 18, the plurality of heat radiating fins 1 bd are each formed in a plate shape, and are arranged in the same direction so as to leave a predetermined space 500 in the thickness direction of the plate shape. Thus, the predetermined space 500 is in contact with a surface having a large surface area among the plate-shaped radiating fins 1bd. 1st fixing | fixed part 1bb, 2nd fixing | fixed part 1bc, and the thermal radiation fin 1bd are integrally comprised by conductive resin, such as PPS.

  For this reason, in the electric heater 1 according to the present embodiment, the electric heater 1 is disposed in the air passage 10a so as to allow air to pass through the predetermined space 500 between the plurality of heat dissipating fins 1bd. When a voltage is applied between the electrodes 1c, the air passing through the predetermined space 500 can be warmed. That is, when a voltage is applied between the first electrode portion 1a and the second electrode portion 1c, the first and second electrode portions 1a and 1c generate heat and the heat generating and radiating portion 1b generates heat. And when air passes through the predetermined space 500 between the heat-radiating fins 1bd that have generated heat, heat can be radiated to the air and the air can be warmed.

  In particular, in the electric heater 1 according to the present embodiment, the plurality of radiating fins 1bd are each formed in a plate shape, and are arranged so as to leave a predetermined space 500 in the thickness direction of the plate shape.

  For this reason, in the electric heater 1 according to the present embodiment, the predetermined space 500 is in contact with a surface having a large surface area among the heat-radiating fins 1bd each having a plate shape. That is, the contact area between the heat radiating fin 1bd, which is a heat radiating portion, and the predetermined space 500, which is a heat radiating target, is large. Therefore, in the electric heater 1 which concerns on this embodiment, the contact part with the heat dissipation object in the heat radiating part (namely, heat radiating fin 1bd) is planar, and thus the heat radiating range can be widened. On the other hand, in the electric heater described in Patent Document 1, since the heat radiating portion is a nichrome wire, the heat radiating range is narrowed.

  The electric heater 1 according to this embodiment can also be manufactured by injection molding as described in the first embodiment.

(Other embodiments)
The present disclosure is not limited to the above-described embodiment, and can be appropriately changed within the scope described in the claims.

  For example, in the air conditioner 100 according to the first to third embodiments, the electric heater 1 may be arranged in an annular shape so as to surround the blower 2 as shown in FIG. In addition, the arrow Y1 in FIG. 21 is the rotation direction of the centrifugal blower fan 2a, and the arrow Y2 is the direction of the blown air flow due to the rotation of the centrifugal blower fan 2a.

(Summary)
In the first aspect shown in part or all of the above embodiments, in the electric heater, the heat-dissipating part made of conductive resin connected to each of the first electrode part and the second electrode part. And a temperature control unit. The heat generating and radiating part generates heat and dissipates heat when a voltage is applied between the first electrode part and the second electrode part.

  In a second aspect, in the electric heater according to the first aspect, the temperature control unit is a coating film made of a material in which conductive powder is dispersed in an organic polymer.

  For this reason, compared with the case where it comprises with semiconductor ceramics, the complicated-shaped temperature control part corresponding to the 1st electrode part of a complicated shape and the 2nd electrode part can be formed easily. That is, in the manufacture of the electric heater, the degree of freedom in shape of the temperature control unit is increased, and the temperature control unit can be easily formed. In addition, since the temperature control unit is configured to connect at least one of the first electrode unit and the second electrode unit and the heat radiation unit, current control is efficiently performed by the temperature control unit, and heat generation is efficiently performed. An excessive temperature rise in the heat radiating portion can be suppressed.

  In the third aspect, in the electric heater according to the first or second aspect, the through hole of the first electrode part, the through hole of the heat-dissipating part, and the through hole of the second electrode part are separated from the first electrode part. A through-hole portion penetrating the first electrode portion, the heat-dissipating heat dissipation portion, and the second electrode portion 1c is configured in a direction toward the second electrode portion.

  For this reason, an electric heater is disposed so as to allow air to pass through the internal space of the through-hole portion, and passes through the internal space of the through-hole portion when a voltage is applied between the first electrode portion and the second electrode portion. Can warm the air. That is, when a voltage is applied between the first electrode part and the second electrode part, the heat generating and radiating part generates heat. And air passes through the internal space of the through-hole part in the heat-generating heat-radiating part that has generated heat. Thereby, since heat is radiated to the air from the heat-generating and heat-radiating portion, the air is warmed.

  According to a fourth aspect, in the electric heater according to the second aspect, a plurality of through-hole portions are formed in the electric heater according to the third aspect.

  For this reason, the heat radiation range can be widely arranged by arranging a plurality of internal spaces of the plurality of through-hole portions. Therefore, in particular, the heat radiation range can be widened and heat can be dissipated uniformly in space.

  According to a fifth aspect, in the electric heater according to the first or second aspect, the heat-dissipating part has a plurality of heat-dissipating fins extending in a direction from the first electrode part toward the second electrode part.

  For this reason, when an electric heater is disposed in the air passage so as to allow air to pass through a predetermined space between the plurality of radiating fins, and a voltage is applied between the first electrode portion and the second electrode portion, the predetermined value is obtained. The air passing through the space can be warmed. That is, when a voltage is applied between the first electrode portion and the second electrode portion, the first and second electrode portions generate heat and the heat generating and radiating portion generates heat. And when air passes through the predetermined space between the plurality of heat-radiating fins that have generated heat, heat can be radiated to the air and the air can be warmed.

  In the sixth aspect, in the electric heater according to the fifth aspect, each of the plurality of heat dissipating fins has a plate shape and is arranged with a predetermined space between each other in the thickness direction of the plate shape.

  For this reason, in this electric heater, a surface having a large surface area is in contact with the predetermined space among the respective fins having a plate shape. That is, the contact area between the heat dissipating fin that is the heat dissipating part and the predetermined space that is the heat dissipating object is increased. Therefore, the heat radiation range can be widened because the contact portion of the heat radiation portion (that is, the heat radiation fin) with the heat radiation target is planar.

  According to the seventh aspect, the air conditioner includes the electric heater according to the first to sixth aspects. Thereby, the effect by the above-mentioned 1st-6th viewpoint is acquired.

  Moreover, in the 8th viewpoint, it manufactures as follows as a manufacturing method of the electric heater which concerns on a 1st-7th viewpoint. That is, first, as a preparation step, a mold for injection molding in which a cavity is formed as a space in which an integrated member composed of a first electrode portion, a temperature control portion, a heat generating and radiating portion, and a second electrode portion is formed. Prepare. Next, as a molding process, the material of the temperature control unit is injected from the outside of the mold into the space in the cavity where the temperature control unit is formed, the temperature control unit is filled into the space, A material obtained by melting a molding resin, which is a material, is injected from the outside of a mold into a space in a cavity where a heat-dissipating part is formed, the molding resin is filled into the space, and the temperature control unit is filled The molding resin is cooled and solidified. Thereby, the integrated member comprised by a 1st electrode part, a temperature control part, a heat-emitting / radiating part, and a 2nd electrode part is obtained.

  For this reason, according to this manufacturing method, the integrated member comprised from a 1st electrode part, a temperature control part, a heat-radiating part, and a 2nd electrode part can be manufactured easily, and an electric heater is manufactured easily. be able to. In particular, according to this manufacturing method, even if the shape of the heat-dissipating part is complicated, it can be easily formed. Moreover, in this manufacturing method, the heat generating and heat radiating part that is the heat generating part and the heat radiating part can be formed integrally with the first electrode part and the second electrode part that are the electrodes. Therefore, in the electric heater manufactured by this manufacturing method, it becomes easy for a current to flow evenly from the first electrode portion and the second electrode portion that are electrodes to the heat generating heat radiating portion that is the heat generating portion and the heat radiating portion. For this reason, in the electric heater manufactured by this manufacturing method, it can radiate | emit uniformly in the predetermined space which is heat dissipation object. Moreover, according to this manufacturing method, the complicated-shaped temperature control part corresponding to the 1st electrode part of a complicated shape, and the 2nd electrode part can be formed easily.

  Further, in the ninth aspect, in the method for manufacturing the electric heater according to the eighth aspect, in the molding step, a molding conductive metal or conductive resin that is a material of the first electrode portion is melted, heat generation A material obtained by melting a molding conductive resin that is a material of the heat radiating portion and a material obtained by melting a molding conductive metal or a conductive resin that is a material of the second electrode portion are injected into the cavity. Thereby, the conductive metal or conductive resin for molding is filled in the cavity, and the filled conductive metal or conductive resin for molding is cooled and solidified. Thereby, while arrange | positioning a 1st electrode part and a 2nd electrode part in a cavity, the integral member comprised by a 1st electrode part, a temperature control part, an exothermic heat radiation part, and a 2nd electrode part is obtained.

  For this reason, the integrated member comprised by a 1st electrode part, a temperature control part, a heat-radiating part, and a 2nd electrode part can be manufactured especially easily, and an electric heater can be manufactured especially easily.

DESCRIPTION OF SYMBOLS 1 Electric heater 1a 1st electrode part 1c 2nd electrode part 1b Exothermic heat radiation part 7 Temperature control part 100 Air conditioner 200,600 Mold

Claims (9)

A first electrode part (1a);
A second electrode part (1c);
When electrically connected to each of the first electrode part and the second electrode part and made of conductive resin, and a voltage is applied between the first electrode part and the second electrode part A heat-generating and heat-dissipating part (1b) that generates heat while being energized,
It is electrically connected in series to the first electrode part, the second electrode part, and the heat-dissipating heat radiating part, and is disposed so as to be able to receive heat from the heat-dissipating heat dissipating part. A temperature control unit that controls the temperature rise of the heat-dissipating part by making the current less likely to flow when the temperature exceeds the specific temperature. 7) and an electric heater.   The temperature control unit is a coating film made of a material in which conductive powder is dispersed in an organic polymer, and connects at least one of the first electrode unit and the second electrode unit and the heat-dissipating unit. The electric heater according to claim 1.   The first electrode unit, the heat generating / dissipating unit, and the second electrode unit include one or more through-hole units (1i) penetrating the first electrode unit, the heat generating / dissipating unit, and the second electrode unit. The electric heater according to claim 1 or 2 which has).   The electric heater according to claim 3, wherein the one or more through-hole portions are a plurality of the through-hole portions. The heat-dissipating part has a plurality of heat-dissipating fins (1bd) extending in the direction (A) from the first electrode part toward the second electrode part,
The electric heater according to claim 1 or 2, wherein the plurality of heat dissipating fins are arranged with a predetermined space (500) therebetween.   6. The electric heater according to claim 5, wherein each of the plurality of heat dissipating fins has a plate shape, and is arranged with the predetermined space therebetween in the thickness direction of the plate shape. An air conditioner having an air passage (10a) and supplying air passing through the air passage to a predetermined space,
An air conditioner comprising the electric heater according to any one of claims 1 to 6 in the air passage. A first electrode part (1a);
A second electrode part (1c);
When electrically connected to each of the first electrode part and the second electrode part and made of conductive resin, and a voltage is applied between the first electrode part and the second electrode part A heat-generating and heat-dissipating part (1b) that generates heat while being energized,
It is electrically connected in series to the first electrode part, the second electrode part, and the heat-dissipating heat radiating part, and is disposed so as to be able to receive heat from the heat-dissipating heat dissipating part. A temperature control unit that controls the temperature rise of the heat-dissipating part by making the current less likely to flow when the temperature exceeds the specific temperature. 7) and a method of manufacturing an electric heater comprising:
Injection molding in which a cavity (300, 700, 701, 702, 800, 900) is formed as a space in which an integrated member composed of the first electrode part, the heat-dissipating part, and the second electrode part is formed. A preparation step of preparing a mold (200, 600) for use;
The first electrode part and the second electrode part are disposed in the cavity, and the material of the temperature control part is injected from the outside of the mold into a space where the temperature control part is formed in the cavity. The temperature control unit is filled in the space, and the molding resin that is the material of the heat radiation unit is melted from the outside of the mold into the space where the heat radiation unit is formed. Injecting, filling the molding resin into the space, and cooling and solidifying the filled temperature control unit and the molding resin, the first electrode unit, the temperature control unit, the heat generation heat dissipation unit, And a molding step of obtaining an integral member composed of the second electrode portion. In the molding step,
A molten conductive metal or conductive resin that is a material of the first electrode part, a molten molten conductive resin that is a material of the heat-dissipating part, and the second electrode The molten material of the molding conductive metal or conductive resin, which is the material of the part, is injected into the cavity, filled into the cavity, and the filled molding conductive metal or conductive resin is cooled. Then, by solidifying, the first electrode part and the second electrode part are arranged in the cavity, and an integrated member constituted by the first electrode part, the heat-dissipating part, and the second electrode part is provided. The manufacturing method of the electric heater of Claim 8 obtained.

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