JP5894479B2 - heater - Google Patents

Description

  The present invention relates to a heater. More particularly, the present invention relates to a heater that can be used to heat lubricating fluid such as engine oil and transmission fluid.

  Some machines operate while rubbing parts together. For example, in an internal combustion engine such as an engine, many parts rub against each other in the process of a piston moving up and down in a cylinder. If the parts rub against each other in this way, the parts may be worn or heated, and the machine may malfunction.

  Therefore, a lubricating fluid is used in order to reduce friction when parts rub against each other to suppress wear and heat generation. For example, engine oil is used as a lubricating fluid to suppress wear and heat generation of parts in the engine. Thus, in order to operate a machine that operates while rubbing parts together, a lubricating fluid is indispensable. However, when such a lubricating fluid is in a low temperature state, the viscosity of the lubricating fluid is increased. As a result, there arises a problem that the friction cannot be reduced sufficiently. Further, when the viscosity of the lubricating fluid becomes high, there also arises a problem that the lubricating fluid cannot be supplied to the target location.

  In order to cope with this problem, a lubricating fluid is heated using a heater. As a result, the viscosity of the lubricating fluid can be appropriately reduced, and the friction can be satisfactorily reduced by the lubricating fluid. However, if the lubricating fluid is excessively heated, there is a disadvantage that the lubricating fluid is deteriorated. Therefore, various heaters having a mechanism that does not excessively heat the lubricating fluid have been proposed (for example, Patent Documents 1 to 3).

JP 2003-74789 A JP 63-16114 A Japanese Utility Model Publication No. 63-12607

  However, with the conventional heater, it has been difficult to quickly raise the temperature of the lubricating fluid while keeping the mechanism that does not excessively heat the lubricating fluid effective. For example, Patent Document 1 describes a structure for preventing freezing of lubricating oil in which a heater is housed in a shell and the lubricating oil is indirectly heated. In the anti-freezing structure described in Patent Literature 1, since the lubricating oil is indirectly heated, the deterioration of the lubricating oil can be prevented. However, in the antifreezing structure described in Patent Document 1, it is considered difficult to quickly raise the temperature of the lubricating oil because the heater is housed in the shell.

  Further, Patent Document 2 describes an engine oil heating device in which a radiator fin that does not generate heat is attached to a heater. Patent Document 3 describes an oil heater in which a heat radiating member that does not generate heat is attached to the heater. As in Patent Documents 2 and 3, by attaching a heat radiating member or the like to the heater, the heat transfer area of the heater (in other words, the heat exchange area) can be increased. However, since the radiating fins and the radiating members attached to the heater do not generate heat by themselves, it is considered difficult to quickly raise the temperature of the lubricating oil.

  In addition, in order to realize a rapid temperature increase, the size of the heater has to be increased. However, in automobiles and the like, there are spatial restrictions in the vehicle, and it has been difficult to use a large heater as a heating device for an engine. For this reason, development of a heater that is small and capable of quickly raising the temperature is desired.

  Further, in such a heater, it is necessary to take measures for insulation from piping or the like through which lubricating oil flows. In other words, such a heater requires a measure for preventing current from flowing through the piping or the like because current flows in order to cause the heater to generate heat. In addition, when a heater is disposed in a pipe through which lubricating oil flows, it is necessary to take measures for heat insulation so that heat generated by the heater does not escape to the outside.

  The present invention has been made in view of the above-described problems, and provides a small heater that can quickly raise the temperature of a lubricating fluid such as engine oil or transmission fluid.

  In order to solve the above-described problems, the present invention provides the following heaters.

[1] A heater main body, a housing for housing the heater main body, and a resin material disposed at least at a part between the heater main body and the housing, wherein the heater main body has a flow path for a lubricating fluid. A cylindrical honeycomb structure portion having partition walls that partition and form a plurality of cells extending from one end surface to the other end surface, and a pair of electrode portions disposed on the side surface of the honeycomb structure portion, and the housing An inlet for the lubricating system fluid to flow in and an outlet for the lubricating system fluid to flow out through the cell formed in the heater main body, and the heater body is configured to cover a side surface of the heater body. The partition wall of the honeycomb structure portion is made of a material mainly composed of ceramics, the partition wall generates heat when energized, and the partition wall is made of SiC, metal-impregnated S. The heater which has as a main component 1 type chosen from the group which consists of iC, metal composite SiC, and metal composite Si3N4, and the material of the said housing is resin .
[2] The heater according to [1], wherein the housing and the resin material are integrated.
[3] The heater according to [1], wherein a heat insulating material is disposed between the heater body and the housing inside the housing.

[ 4 ] The resin material is between the heater body and the housing on the one end face side of the heater body, and between the heater body and the housing on the other end face side of the heater body, The heater according to [2] or [3] , which is disposed at least.

[ 5 ] A part of the pair of electrode portions extends through the housing to the outside of the housing, and the resin material is the pair of electrodes in a portion where the pair of electrode portions penetrates the housing. The heater according to [2] or [3] , which is disposed at least between a portion and the housing.

[ 6 ] In the above [2] or [3] , the resin material is disposed between the heater body and the housing so as to cover at least the entire region of the pair of electrodes disposed in the heater body . The heater described.

[ 7 ] The above [2] or [ 7 ], wherein each of the pair of electrode portions includes an electrode substrate disposed on a side surface of the honeycomb structure portion and a rod-shaped electrode portion disposed so as to be connected to the electrode substrate . 3] .

[ 8 ] The heater according to [2] or [3] , wherein the heat resistant temperature of the resin material is 80 ° C. or higher.

[ 9 ] The heater according to [2] or [3] , wherein the specific resistance of the resin material is 10 ⁹ Ω · cm or more.

  The heater of the present invention includes a heater body, a housing that houses the heater body, and a resin material that is disposed at least in part between the heater body and the housing. The heater main body is disposed on a side surface of the cylindrical honeycomb structure portion having partition walls that partition and form a plurality of cells extending from one end face to the other end face that serve as a flow path for the lubricating fluid. A pair of electrode portions. Further, the housing has an inflow port through which the lubricating system fluid flows in and an outflow port through which the lubricating system fluid that has passed through the cell formed in the heater body flows out. The housing houses the heater body so as to cover the side surface of the heater body. In the heater of the present invention, the partition walls of the honeycomb structure portion are made of a material mainly composed of ceramics. The partition generates heat when energized.

  According to the heater of the present invention, the temperature of the lubricating fluid can be quickly increased without excessively heating the lubricating fluid. Further, even when the heater size is small, the temperature of the lubricating fluid can be quickly raised.

  Furthermore, since the resin material is disposed at least at a part between the heater body and the housing, electrical insulation between the heater body and the housing can be obtained mainly. Moreover, the said resin material functions also as a heat insulation layer of a heater main body. Thereby, the heat insulation of a heater can be improved. For example, by disposing the resin material, heat dissipation to the outside of the housing can be suppressed when the heater body generates heat. Furthermore, the resin material also functions as a seal layer between the heater body and the housing. Thereby, the sealing performance between the heater body and the housing can be improved. For example, by arranging the resin material, it plays a role of suppressing leakage of a lubricating fluid that is a heating target between the heater body and the housing.

It is a perspective view showing typically one embodiment of the heater of the present invention. It is a top view which shows typically one end surface of the heater shown in FIG. It is a top view which shows typically the upper surface of the heater shown in FIG. It is sectional drawing which shows the A-A 'cross section in FIG. 3 typically. It is sectional drawing which shows the B-B 'cross section in FIG. 3 typically. It is a perspective view which shows typically the heater main body in the heater shown in FIG. It is a top view which shows typically one end surface of the heater main body shown in FIG. It is sectional drawing which shows other embodiment of the heater of this invention typically. It is sectional drawing which shows other embodiment of the heater of this invention typically. It is sectional drawing which shows other embodiment of the heater of this invention typically. It is sectional drawing which shows other embodiment of the heater of this invention typically. It is sectional drawing which shows other embodiment of the heater of this invention typically. It is sectional drawing which shows other embodiment of the heater of this invention typically. It is sectional drawing which shows other embodiment of the heater of this invention typically. It is sectional drawing which shows other embodiment of the heater of this invention typically. It is sectional drawing which shows other embodiment of the heater of this invention typically. It is a perspective view which shows typically other embodiment of the heater of this invention. FIG. 17 is a cross-sectional view schematically showing a cross section of the heater shown in FIG. 16 perpendicular to the flow direction of the lubricating fluid flowing in the heater body. It is a perspective view which shows typically the heater main body in the heater shown in FIG. It is sectional drawing which shows other embodiment of the heater of this invention typically. It is a perspective view which shows typically other embodiment of the heater of this invention. It is a perspective view which shows typically the heater main body in the heater shown in FIG. It is a perspective view which shows typically other embodiment of the heater of this invention. FIG. 23 is a cross-sectional view schematically showing a cross section of the heater shown in FIG. 22 that is perpendicular to the flow direction of the lubricating fluid flowing in the heater body. FIG. 23 is a cross-sectional view schematically showing a cross section of the heater shown in FIG. 22 parallel to the flow direction of the lubricating fluid flowing in the heater body. It is a perspective view which shows typically the heater main body of the heater shown in FIG. FIG. 26 is a developed perspective view schematically showing a developed state of the heater body shown in FIG. 25. It is a graph which shows the relationship between the heating time of a heater, and the temperature of a lubrication system fluid. It is explanatory drawing for demonstrating the test method of the electrical heating test in an Example. It is a perspective view which shows typically the heater main body used for further another embodiment of the heater of this invention. It is a perspective view which shows typically the heater main body used for further another embodiment of the heater of this invention.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. The present invention is not limited to the following embodiments, and changes, modifications, and improvements can be added without departing from the scope of the present invention.

(1) Heater:
One embodiment of the heater of the present invention is a heater 100 as shown in FIGS. The heater 100 according to the present embodiment includes a heater body 50, a housing 51 that houses the heater body 50, and a resin material 52 that is disposed at least partially between the heater body 50 and the housing 51.

  Here, FIG. 1 is a perspective view schematically showing an embodiment of the heater of the present invention. FIG. 2 is a plan view schematically showing one end face of the heater shown in FIG. FIG. 3 is a plan view schematically showing the upper surface of the heater shown in FIG. FIG. 4 is a cross-sectional view schematically showing the A-A ′ cross section in FIG. 3. FIG. 5 is a sectional view schematically showing a B-B ′ section in FIG. 3.

  The heater body 50 used in the heater 100 of the present embodiment is as shown in FIGS. Here, FIG. 6 is a perspective view schematically showing a heater body in the heater shown in FIG. 7 is a plan view schematically showing one end face of the heater body shown in FIG.

  As shown in FIGS. 6 and 7, the heater body 50 includes a tubular honeycomb structure portion 4 and a pair of electrode portions 21. The tubular honeycomb structure portion 4 includes a partition wall 1 that partitions and forms a plurality of cells 2 extending from one end surface 11 to the other end surface 12 serving as a flow path for the lubricating system fluid. A pair of electrode portions 21 is disposed on the side surface 5 of the honeycomb structure portion 4. The partition walls 1 of the honeycomb structure part 4 are made of a material mainly composed of ceramics. The partition wall 1 generates heat when energized. That is, in the heater of the present embodiment, the partition walls 1 of the honeycomb structure portion 4 serve as a heating element for heating the lubricating fluid.

  As shown in FIGS. 1 to 5, the housing 51 of the heater 100 of the present embodiment houses the heater body 50 so as to cover the side surface side of the heater body 50. The housing 51 has an inflow port 55 through which the lubricating system fluid flows in and an outflow port 56 through which the lubricating system fluid that has passed through the cell 2 formed in the heater body 50 flows out. The housing 51 of the heater 100 according to the present embodiment includes a housing body 51a having an opening on one surface and a lid 51b for closing the opening of the housing body 51a. That is, the heater main body 50 is disposed inside the housing main body 51a, and then the lid 51b is disposed on the housing main body 51a, whereby the heater main body 50 is accommodated in the housing 51.

  According to the heater 100 of this embodiment, the temperature of the lubricating fluid can be quickly raised without excessively heating the lubricating fluid. Moreover, even when the size of the heater 100 is small, the temperature of the lubricating fluid can be quickly raised. That is, as described above, in the heater 100 of the present embodiment, the partition wall 1 itself generates heat when energized. For this reason, the lubricating fluid can be continuously heated by the partition wall 1 in the course of the lubricating fluid flowing through the cell 2.

  For example, in a heater that heats the honeycomb structure portion with another heat source without causing the partition wall itself of the honeycomb structure portion to generate heat, it is difficult to heat the lubricating fluid well. That is, in the process of heating the lubricating fluid by the heater, heat exchange is performed between the lubricating fluid flowing in the cell and the partition wall. In a heater in which the partition wall itself does not generate heat, heating of the partition wall by another heat source cannot catch up, and it is difficult to quickly raise the temperature of the lubricating fluid. In addition, in a heater in which the partition wall itself does not generate heat, it is conceivable to increase another heat source to increase the heat transferred to the partition wall. However, such a method increases the size of the entire heater. In an automobile or the like, there is a spatial limitation in the vehicle, and it is difficult to use a large heater as a heating device for an engine.

  In addition, since the honeycomb structure portion 4 has a honeycomb structure having partition walls 1 that partition and form a plurality of cells 2, the contact area with the lubricating fluid can be increased. For this reason, the lubricating fluid flowing in the cell 2 can be heated satisfactorily, and the temperature of the lubricating fluid can be quickly raised. That is, in the heater 100 of the present embodiment, the lubricating fluid that has flowed into the heater is divided into small portions, and the divided lubricating fluid flows in each cell 2. When the lubricating fluid is subdivided in this way, the contact area between the lubricating fluid and the partition wall 1 increases. Along with this, the amount of heat transfer due to the contact between the partition wall 1 and the lubricating fluid increases. Further, when the amount of heat transfer between the partition wall 1 and the lubricating fluid increases, the amount of heat transferred becomes larger than the amount of heat dissipated by thermal diffusion within the lubricating fluid. For this reason, the temperature of the lubricating fluid is likely to rise more quickly.

  In the heater 100 of the present embodiment, the temperature of the lubricating fluid can be reliably increased even when the amount of heat generated per unit area of the partition wall 1 is reduced. This is because the heater 100 of this embodiment can continue to heat the lubricating fluid in the flow path constituted by the cells 2. If the calorific value per unit area of the partition wall 1 is reduced, it is possible to prevent the lubricating fluid from being heated excessively. Therefore, in the heater 100 of this embodiment, the temperature of the lubricating fluid can be quickly raised without excessively heating the lubricating fluid. Further, since the lubricating fluid is not heated excessively in this way, deterioration of the lubricating fluid can be effectively suppressed.

  Furthermore, in the heater 100 of the present embodiment, a resin material 52 is disposed at least at a part between the heater body 50 and the housing 51. For this reason, electrical insulation between the heater body 50 and the housing 51 can be obtained mainly. Further, the resin material 52 also functions as a heat insulating layer of the heater body 50. Thereby, the heat insulation of the heater 100 can be improved. For example, by disposing the resin material 52, it is possible to suppress heat radiation to the outside of the housing 51 when the heater body 50 generates heat. Further, the resin material 52 also functions as a seal layer between the heater body 50 and the housing 51. Thereby, the sealing performance between the heater body 50 and the housing 51 can be improved. For example, by disposing the resin material 52, the resin material 52 plays a role of suppressing leakage of the lubricating fluid that is a heating target between the heater body and the housing.

  In this specification, “lubricating fluid” means a general term for fluids used for lubricating mechanical parts. Examples of the fluid used for lubricating the mechanical system parts include engine oil, transmission fluid, gear oil, differential oil, brake fluid, and power steering fluid.

  The heater of this embodiment can be used as a heater for heating a lubricating fluid such as an engine oil or transmission fluid of an automobile, for example. Generally, when an automobile is run in winter or is run in a cold region, the lubricating fluid tends to be low in temperature. If the lubricating fluid is in a low temperature state, its viscosity will increase. As a result, for the engine and transmission, the operation time increases while the friction generated in the parts is large. If the engine or transmission is operated in such a state, the fuel efficiency is deteriorated.

  If the heater of this embodiment is used, the temperature of engine oil or transmission fluid can be raised rapidly. As a result, the time during which the engine oil and transmission fluid are at a low temperature can be shortened. As a result, the fuel consumption of the automobile can be improved.

  In general, transmission fluid contributes more to the deterioration of fuel efficiency than engine oil. With conventional heaters, large heaters had to be used to sufficiently heat the transmission fluid. In the heater of the present embodiment, the transmission fluid can be sufficiently heated even when the heater is downsized. Thereby, the fuel consumption of a motor vehicle can be improved more. As described above, the heater according to the present embodiment exhibits its effect sufficiently when the space for installing the heater is limited, such as an automobile.

  Hereinafter, the heater of this embodiment is demonstrated in detail for every component.

(1-1) Heater body:
As shown in FIGS. 6 and 7, the heater body has a tubular honeycomb structure portion 4 and a pair of electrode portions 21. The tubular honeycomb structure portion 4 includes partition walls 1 that partition and form a plurality of cells 2 extending from one end face 11 to the other end face 12 that serve as a flow path for the lubricating fluid. In this heater body, a pair of electrode portions 21 are arranged on the side surface 5 of the honeycomb structure portion 4.

  The honeycomb structure portion 4 may further include an outer peripheral wall 3 disposed on the outermost periphery so as to surround the partition wall 1. 6 and 7 show an example in which the honeycomb structure portion 4 further includes an outer peripheral wall 3. A pair of electrode portions 21 are disposed on the side surface 5 of the honeycomb structure portion 4 constituted by the outer peripheral wall 3. The partition wall 1 and the outer peripheral wall 3 may be made of the same material or different materials.

The partition wall 1 is made of a material mainly composed of ceramics. Here, in the present specification, “having ceramics as a main component” means containing 50% by mass or more of ceramics. That is, the partition wall made of a material mainly composed of ceramics means a partition wall containing 50% by mass or more of ceramics. Examples of “ceramics that generate heat upon energization” applicable to the honeycomb structure of the present embodiment include SiC, metal-impregnated SiC, metal composite SiC, and metal composite Si ₃ N ₄ .

  In the heater of this embodiment, it is preferable that the specific resistance of the partition wall is 0.01 to 50 Ω · cm. In the heater of the present embodiment, the specific resistance of the partition wall is more preferably 0.03 to 10 Ω · cm, and particularly preferably 0.07 to 5 Ω · cm. By setting the specific resistance of the partition wall within the above numerical range, a heater capable of quickly raising the temperature of a lubricating fluid such as engine oil or transmission fluid can be obtained. In addition, the honeycomb structure can be sufficiently reduced in size.

  The SiC described above includes recrystallized SiC and reaction sintered SiC. For example, the recrystallized SiC is manufactured as follows. First, a raw material containing SiC powder, an organic binder, and “water or an organic solvent” is mixed and kneaded to prepare a clay. Next, this clay is molded to produce a molded body. Next, the obtained molded body is fired at 1600 to 2300 ° C. in an inert gas atmosphere to obtain a fired body. What is obtained in this way is “recrystallized SiC”. And the obtained sintered body becomes mainly porous. Recrystallized SiC can change the specific resistance by changing the raw material, particle size, impurity amount, and the like. For example, the specific resistance can be changed by dissolving impurities in SiC. Specifically, by firing in a nitrogen atmosphere, nitrogen can be dissolved in SiC to reduce the specific resistance of recrystallized SiC.

  Reaction-sintered SiC is SiC generated by utilizing a reaction between raw materials. Examples of the reaction-sintered SiC include porous reaction-sintered SiC and dense reaction-sintered SiC. The porous reaction-sintered SiC is produced, for example, as follows. First, a clay is prepared by mixing and kneading silicon nitride powder, carbonaceous material, silicon carbide and graphite powder. The carbonaceous substance is a substance that reduces silicon nitride. Examples of the carbonaceous material include solid carbon powders such as carbon black and acetylene black, resins such as phenol, furan, and polyimide. Next, this clay is molded to produce a molded body. Next, the molded body is primarily fired in a non-oxidizing atmosphere to obtain a primary fired body. Next, the obtained primary fired body is heated in an oxidizing atmosphere and decarburized to remove the remaining graphite. Next, the “decarburized primary fired body” is secondarily fired at 1600 to 2500 ° C. in a non-oxidizing atmosphere to obtain a secondary fired body. What is obtained in this way is “porous reaction sintered SiC”.

  Dense reaction-sintered SiC is produced, for example, as follows. First, SiC powder and graphite powder are mixed and kneaded to prepare a clay. Next, this clay is molded to produce a molded body. Next, this molded body is impregnated with “molten silicon (Si)”. Thereby, the carbon which comprises graphite and the silicon | silicone impregnated are made to react, and SiC is produced | generated. As described above, pores are easily eliminated by “impregnating” the molten body with “molten silicon (Si)”. That is, the pores are easily blocked. Therefore, a dense molded body can be obtained. The product thus obtained is “dense reaction sintered SiC”.

  Examples of the “metal-impregnated SiC” include Si-impregnated SiC, SiC impregnated with metal Si and other types of metals, and the like. Examples of the “other types of metals” include Al, Ni, Cu, Ag, Be, Mg, and Ti. When the partition wall is made of the above-described material mainly composed of “metal-impregnated SiC”, the partition wall has excellent heat resistance, thermal shock resistance, oxidation resistance, and corrosion resistance. “Corrosion resistance” means resistance to the corrosive action caused by acid or alkali.

  Examples of the metal-impregnated SiC include those obtained by impregnating a porous body mainly composed of SiC particles with a molten metal. For this reason, the metal-impregnated SiC becomes a dense body having relatively few pores.

  “Si-impregnated SiC” is a concept generically referring to a sintered body containing metal Si and SiC as constituent components. Metal Si means metal silicon. In Si-impregnated SiC, the surface of the SiC particles is surrounded by solidified metal Si. Accordingly, the Si-impregnated SiC has a structure in which a plurality of SiC particles are bonded to each other through metal Si.

  “SiC impregnated with metal Si and other types of metals” is a concept generically referring to sintered bodies containing metal Si, other types of metals, and SiC as constituent components. In SiC impregnated with metal Si and other types of metals, the surface of the SiC particles is surrounded by solidified products of metal Si and other types of metals. Thereby, SiC impregnated with metal Si and other types of metals has a structure in which a plurality of SiC particles are bonded to each other through metal Si and other types of metals.

  When the partition wall is made of a material mainly composed of metal-impregnated SiC, the specific resistance of the partition wall can be adjusted by adjusting the amount of metal impregnated. When the partition wall is made of a material mainly composed of metal-impregnated SiC, generally, the specific resistance of the partition wall becomes smaller as the amount of metal to be impregnated increases.

  Examples of the above-mentioned “metal composite SiC” include Si composite SiC, SiC obtained by composite sintering of metal Si and other types of metals, and the like. Examples of the “other types of metals” include Al, Ni, Cu, Ag, Be, Mg, and Ti.

  Examples of the metal composite SiC include those obtained by mixing and sintering SiC particles and metal powder. When the SiC particles and the metal powder are mixed and sintered, the sintering proceeds at the contact point where the SiC particles and the metal powder are in contact with each other. For this reason, the metal composite SiC becomes a porous body in which a relatively large number of pores are formed. In the metal composite SiC, pores of a porous body are formed while taking a structure in which SiC particles are interconnected via a metal phase made of metal powder. For example, Si composite SiC has a structure in which SiC particles are bonded to each other through metal Si while forming pores in a form in which a metal Si phase is bonded to the surface of SiC particles. Also in SiC in which metal Si and other types of metals are combined and sintered, the same structure as that of the metal composite SiC is taken.

  When the partition wall is made of a material mainly composed of metal composite SiC, the specific resistance of the partition wall can be adjusted by adjusting the amount and components of the metal to be combined. When the partition is made of a material mainly composed of metal composite SiC, generally, the specific resistance of the partition becomes smaller as the amount of metal to be combined increases.

  In the heater of the present embodiment, the amount of heat generated per unit surface area of the partition wall depends on the size of the honeycomb structure, the specific resistance of the partition wall, the partition wall thickness, the cell density, and the like. For example, when the size of the honeycomb structure portion is limited, the amount of heat generated per unit surface area of the partition wall can be adjusted by adjusting the partition wall thickness and cell density. Thereby, it can be set as the heater which does not heat a lubrication system fluid excessively. In addition, when there is a sufficient space for the heater, the size of the honeycomb structure can be adjusted to adjust the amount of heat generated by the heater. The size of the honeycomb structure part means the length in the cell extending direction of the honeycomb structure part or the size of the cross section orthogonal to the cell extending direction of the honeycomb structure part. Hereinafter, “the length of the honeycomb structure portion in the cell extending direction” may be simply referred to as “the length of the honeycomb structure portion”. Further, “the size of the cross section perpendicular to the cell extending direction of the honeycomb structure portion” may be simply referred to as “the size of the cross section of the honeycomb structure portion”.

  For example, when the length of the honeycomb structure portion can be increased, the distance for heating the lubricating fluid can be increased. Thereby, a lubrication system fluid can be heated favorably. Further, if the lubricating fluid can be sufficiently heated by increasing the length of the honeycomb structure portion, the specific resistance of the partition walls may be relatively reduced.

  On the other hand, when the length of the honeycomb structure and the size of the cross section are restricted, the calorific value per unit surface area of the partition should be adjusted by adjusting the specific resistance of the partition, the thickness of the partition, the cell density, etc. Is preferred.

  For example, the specific resistance of the partition wall can be adjusted by adjusting the porosity of the partition wall. In general, the smaller the porosity of the partition wall, the smaller the specific resistance of the partition wall.

  Moreover, the preferable range of the porosity of a partition changes with main components of a partition. For example, when metal composite SiC is the main component, the porosity of the partition walls is preferably 30 to 90%. Moreover, when metal composite SiC is a main component, many open pores exist in the partition wall, and the pores become large. And the partition which has metal composite SiC as a main component has many communicating vents which connect between adjacent cells. For this reason, this continuous vent allows the lubricating fluid to pass through the partition wall. Accordingly, the contact area between the partition wall and the lubricating fluid increases. Therefore, a heater including a honeycomb structure having partition walls mainly composed of metal composite SiC has improved heating efficiency (that is, heat exchange efficiency). The heating efficiency can be expressed by “conversion efficiency” described later. On the other hand, for example, when metal-impregnated SiC is the main component, the porosity of the partition walls is preferably 0 to 10%. Further, when the metal-impregnated SiC is a main component, the pores of the partition walls are reduced and the open pores are reduced. Therefore, it is difficult for the lubricating fluid to enter the partition wall mainly composed of metal-impregnated SiC. Therefore, the lubricating system fluid that remains in the pores of the partition wall and stops flowing is reduced. For this reason, in the case of the partition wall mainly composed of metal-impregnated SiC, it is possible to prevent the lubricating fluid from being overheated and deteriorated. Further, since there are no pores communicating between the cells, the lubricating fluid does not pass through the partition walls. Therefore, only the lubricating system fluid can flow in the cell.

  In addition, the specific resistance of the partition wall can be adjusted by the type and purity (impurity amount) of SiC used as the partition wall material. Examples of SiC include α-SiC and β-SiC. In addition, the specific resistance of the partition walls can be adjusted by adjusting the mixing ratio of α-SiC or β-SiC.

  In addition, the specific resistance of the partition changes depending on the amount of impurities in the metal contained in the partition material. Moreover, an alloy can also be used as a metal contained in the material as a main component. In addition, the metal can be alloyed when the honeycomb structure is manufactured. By doing in this way, the specific resistance of a partition can be changed.

In the heater of this embodiment, the partition wall thickness is preferably 0.1 to 0.51 mm. Moreover, it is preferable that the cell density of a honeycomb structure part is 15-280 cells / cm < ² >. By using the honeycomb structure configured as described above, the temperature of the lubricating fluid can be quickly increased without excessively heating the lubricating fluid. In the heater of the present embodiment, it is more preferable that the partition wall thickness is 0.1 to 0.51 mm, and the cell density of the honeycomb structure portion is 15 to 280 cells / cm ² .

Moreover, in the heater of this embodiment, it is more preferable that the partition wall thickness is 0.25 to 0.51 mm and the cell density is 15 to 62 cells / cm ² . It is particularly preferable that the partition wall thickness is 0.30 to 0.38 mm and the cell density is 23 to 54 cells / cm ² . By using the honeycomb structure configured as described above, it is possible to reduce the pressure loss when the lubricating fluid flows in the cell.

  The heater body preferably has an insulating layer having a dielectric breakdown strength of 10 to 1000 V / μm on the surface of the partition walls of the honeycomb structure. The dielectric breakdown strength of the insulating layer is more preferably 100 to 1000 V / μm. Lubricating fluids may contain metallic wear powder or moisture generated from parts. In particular, most of the metallic wear powder is removed by an oil filter or the like, but there are some that remain in the lubricating fluid without being removed. For this reason, when the heater is used for a long period of time, the metallic wear powder remaining without being removed may adhere to the partition walls or be deposited and clogged. In such a case, the heater may be short-circuited. When the surface of the partition walls of the honeycomb structure portion has an electrical insulating layer (hereinafter also simply referred to as “insulating”) having a dielectric breakdown strength of 10 to 1000 V / μm, metallic wear powder contained in the lubricating fluid is separated from the partition walls. It is possible to prevent the heater from being short-circuited due to clogging due to adhesion or deposition.

  An example of the insulating layer is an oxide film formed by oxidizing a ceramic component contained in a partition wall. Such an oxide film can be formed by high-temperature treatment in an oxidizing atmosphere.

The insulating layer may be a ceramic coating layer, a SiO ₂ glass coating layer, or a coating layer of a mixture of ceramics and “SiO ₂ glass”.

Examples of the ceramic coating layer include a layer mainly composed of oxides such as Al ₂ O ₃ , MgO, ZrO ₂ , TiO ₂ and CeO _2, and a layer mainly composed of nitride. Among “things mainly containing oxides” and “things mainly containing nitrides”, “things mainly containing oxides” have higher stability in the atmosphere. On the other hand, the “having nitride as a main component” is more excellent in heat conduction. Examples of the SiO ₂ -based glass coat layer include those containing SiO ₂ as a main component. Examples of the coating layer of a mixture of ceramics and SiO ₂ glass include those having a main component of a mixture of SiO ₂ and “components such as Al ₂ O ₃ , MgO, ZrO ₂ , TiO ₂ , and CeO ₂ ”. be able to. The constituent components of the insulating layer can be appropriately selected according to the required value of withstand voltage.

A wet method or a dry method can be employed to form the ceramic coat layer, the SiO ₂ glass coat layer, and the coat layer of the mixture of ceramic and SiO ₂ glass, respectively.

  As a wet method, the honeycomb sintered body is immersed in one of the insulating layer forming slurry, the insulating layer forming colloid, and the insulating layer forming solution, and then the excess is removed and dried. The method of baking can be mentioned.

For example, when forming an “insulating layer mainly composed of oxide”, the insulating layer forming slurry and the insulating layer forming colloid include metal sources such as Al, Mg, Si, Zr, Ti, and Ce, or Those containing the oxide can be used. The “insulating layer mainly composed of oxide” is an insulating layer mainly composed of Al ₂ O ₃ , MgO, SiO ₂ , ZrO ₂ , TiO ₂ , CeO ₂ or the like. As the insulating layer forming solution, a metal alkoxide solution such as Al (OC ₃ H ₇ ) ₃ , Si (OC ₂ H ₅ ) ₄ can be used. The sintering temperature in the wet method can be appropriately determined depending on the main component. The sintering temperature in the wet method is, for example, preferably 1100 to 1200 ° C. in the case of an insulating layer mainly composed of SiO ₂ . In the case of an insulating layer mainly composed of Al ₂ O ₃ , the temperature is preferably 1300 to 1400 ° C.

When forming the “insulating layer mainly composed of nitride”, the honeycomb formed body is immersed in one of the insulating layer forming slurry, the insulating layer forming colloid, and the insulating layer forming solution, and then the excess Remove and dry. Thereafter, nitriding is performed in a reducing atmosphere containing nitrogen or ammonia. In this manner, an insulating layer containing nitride as a main component can be formed. Examples of the nitride include AlN, Si ₃ N _{4, and the} like that have insulating properties and high thermal conductivity.

  Examples of the dry method include an electrostatic spray method. For example, the insulating layer can be formed by electrostatic spraying as follows. First, a voltage is applied to an insulating substance powder (insulating particles) or “slurry containing insulating particles” to make it negative (or positive). Thereafter, the charged “insulating particles or slurry containing insulating particles” is sprayed onto the positively (or negatively) honeycomb structure. In this way, an insulating layer is formed.

  The film thickness of the insulating layer can be appropriately set according to the desired withstand voltage. When the thickness of the insulating layer is thick, the thermal resistance increases to heat the lubricating fluid, although the insulating property increases. This is because the insulating layer tends to have lower thermal conductivity than the partition. Furthermore, the pressure loss of the heater increases. Therefore, it is preferable that the thickness of the insulating layer is as thin as possible within a range where the insulating property can be secured. Specifically, the thickness of the insulating layer is preferably smaller than the thickness of the partition wall. More specifically, although depending on the dielectric breakdown strength of each material, the thickness of the insulating layer is preferably 10 μm or less, more preferably 5 μm or less, and particularly preferably 3 μm or less. When the film thickness of the insulating layer is the value described above, it is possible to prevent an increase in the pressure loss of the honeycomb structure portion while keeping the thermal resistance low. The film thickness of an insulating layer means the average film thickness of an insulating layer. The film thickness of the insulating layer is a value measured by observing with an optical microscope or an electron microscope using a cross-sectional sample. Here, the “cross-section sample” is a sample obtained by cutting out a part of the heater body, and is a sample having a cut surface orthogonal to the wall surface of the partition wall. For example, when the insulating layer is an oxide film, the firing temperature is preferably set to 1200 to 1400 ° C. in order to form the oxide film having the above thickness. It is also a preferable method to form an oxide film by baking in a water vapor atmosphere. Furthermore, the film thickness of the oxide film can be adjusted by adjusting the baking time. The longer the firing time, the thicker the oxide film.

Furthermore, in the heater of the present embodiment, an oxide film is formed on the surface of the partition wall by oxidizing SiC and generating SiO ₂ . When an oxide film is formed on the surface of the partition wall, high temperature treatment is performed in an oxidizing atmosphere such as air. When the main component of the partition walls is SiC, Si-impregnated SiC, or Si composite SiC as in the honeycomb structure provided in the heater of the present embodiment, for example, heat treatment is performed at 1200 ° C. to 1400 ° C. in the atmosphere. Thus, an oxide film can be formed on the surface of the partition wall.

  The shape of the honeycomb structure portion is not particularly limited, and for example, the end surface may be a cylindrical shape (cylindrical shape), the bottom surface may be an oval shape, the end surface may be a polygonal shape, or the like. Examples of the polygon include a quadrangle, a pentagon, a hexagon, a heptagon, and an octagon. 1 to 7 show an example in which the shape of the honeycomb structure portion 4 is a tubular shape having a square end surface.

  It is preferable that the shape of the cell 2 in the cross section orthogonal to the extending direction of the cell 2 is a quadrangle, a hexagon, an octagon, or a combination thereof. Further, the shape of the cell 2 in the cross section may be circular.

  An outer peripheral wall is a wall which comprises the side surface of a honeycomb structure part. The outer peripheral wall may be formed together with the partition walls in the process of manufacturing the honeycomb structure portion. For example, the partition wall and the outer peripheral wall may be produced by extrusion molding at a time. Of course, it is not necessary to form an outer peripheral wall at the time of extrusion molding. For example, the outer peripheral wall can be formed by coating a ceramic material on the outer peripheral portion of the partition wall that defines the cell.

The outer peripheral wall 3 is preferably made of a material mainly composed of ceramics. The outer peripheral wall 3 may be made of the same material as the partition wall 1, or may be made of a material different from that of the partition wall 1. Examples of the material of the outer peripheral wall include SiC, metal-impregnated SiC, metal composite SiC, metal composite Si ₃ N _{4 and the} like.

  The outer peripheral wall of the honeycomb structure is more preferably thick. That the outer peripheral wall is thick means that the outer peripheral wall is thicker than the partition wall. When the outer peripheral wall is thick, the strength of the outer peripheral wall as a structure increases. Therefore, it is possible to improve resistance to thermal stress at the time of joining the electrode portions. As a result, it becomes easy to suppress the generation of cracks in the outer peripheral wall. Further, if the outer peripheral wall is thick, the heat capacity of the outer peripheral wall increases. Therefore, the temperature rise of the outer peripheral wall during energization can be reduced. Here, the outer peripheral wall tends to overheat because the contact area with the lubricating fluid such as engine oil is small. Therefore, as described above, it is preferable to reduce the temperature rise of the outer peripheral wall during energization. In addition, when a resin is used in at least a part of the heater housing, the resin may deteriorate and be damaged due to local overheating of the heater. Therefore, it is possible to suppress damage due to deterioration of the resin by making the outer peripheral wall of the honeycomb structure portion thick.

  Although the thickness of an outer peripheral wall is based also on the porosity of an outer peripheral wall, etc., 0.3-5 mm is preferable and 0.5-3 mm is still more preferable.

  Further, it is more preferable that the outer peripheral wall of the honeycomb structure portion is dense. When the outer peripheral wall is dense, it is possible to prevent the lubricating fluid from leaking outside the heater body through the outer peripheral wall. When the heater is housed in the housing, a sealing material may be disposed on the outer periphery of the heater body in order to prevent the lubricating fluid from leaking into the housing. If the outer peripheral wall is made dense, it is possible to suppress the leakage of the lubricating fluid to the outside of the heater as described above, so that the sealing material becomes unnecessary. As described above, the conventional heater is generally configured so that the lubricating fluid does not leak outside the heater body. However, in the heater of the present embodiment, the housing and the heater Lubricating fluid may be actively flowed between the main body. In other words, the lubricating fluid may be heated by actively flowing the lubricating fluid outside the heater body and using the outer surface of the outer peripheral wall of the honeycomb structure portion.

The “dense outer peripheral wall” is preferably one that has been densified by impregnation with metal, for example. Further, the “dense outer peripheral wall” may be formed of dense “Al ₂ O ₃ , MgO, SiO ₂ , Si ₃ N ₄ , AlN, or BN”, or a composite thereof.

  The honeycomb structure portion having such a “dense outer peripheral wall” includes, for example, “a material forming the partition wall” and “a material forming the outer wall” of a different type from the “material forming the partition wall”. It can be produced by coextrusion.

In addition, the honeycomb structure portion having “the outer peripheral wall densified by being impregnated with metal” is preferably formed by impregnating metal into a dried honeycomb formed body or a fired honeycomb sintered body. Note that Si is preferable as the metal to be impregnated. In order to impregnate the dried honeycomb formed body or the fired honeycomb sintered body with the metal, the amount of metal to be impregnated (for example, the amount of impregnated Si) is adjusted so that only the outer peripheral wall is impregnated. There is a method of impregnating with metal. Alternatively, there is a method in which an impregnation inhibiting material is coated on both end faces of the dried honeycomb formed body or the fired honeycomb sintered body, or a plate-like jig is placed on both end faces. By these methods, the outer peripheral wall can be preferentially impregnated with metal. Examples of the impregnation inhibitor include oxides, particularly Al ₂ O ₃ .

  The pair of electrode portions 21 are electrodes for energizing the partition walls 1 of the honeycomb structure portion 4. One electrode portion 21 and the other electrode portion 21 of the pair of electrode portions 21 are disposed on the side surface 5 of the honeycomb structure portion 4 so as to sandwich the honeycomb structure portion 4 from the side. By applying a voltage between the pair of electrode portions 21, the partition wall 1 is energized, and the honeycomb structure portion 4 generates heat.

  Examples of the material of the pair of electrode portions 21 include stainless steel, copper, nickel, aluminum, molybdenum, tungsten, rhodium, cobalt, chromium, niobium, tantalum, gold, silver, platinum, palladium, and alloys of these metals. be able to. The pair of electrode portions 21 are formed using a composite material such as a Cu / W composite material, a Cu / Mo composite material, an Ag / W composite material, a SiC / Al composite material, or a C / Cu composite material. There may be. “Cu / W composite” means a copper tungsten composite. “Cu / Mo composite” means a copper molybdenum composite. “Ag / W composite” means a silver-tungsten composite. “SiC / Al composite material” means a composite material of SiC and aluminum. “C / Cu composite” means a composite of carbon and copper.

  At this time, it is desirable that the material of the electrode part has a low electrical resistance, a low thermal expansion coefficient, and a thermal expansion coefficient close to that of the ceramic of the honeycomb structure part. The reason why it is desirable that the electric resistance is low is that if the electric resistance is high, a problem may occur due to heat generation of the electrode part itself when energized. The reason why it is desirable that the thermal expansion coefficient is low is as follows. This is because, when the thermal expansion coefficient of the electrode material is higher than that of ceramics, the thermal stress generated at the time of joining the electrode parts becomes large, which may cause problems due to interface peeling or generation of cracks on the ceramic side.

  The material of the electrode part can be appropriately selected in consideration of the balance of generation of cracks in the ceramic due to thermal stress, peeling of the electrode interface, heat generation of the electrode part itself, cost, and the like. For example, although aluminum has a low electrical resistance and a high coefficient of thermal expansion, the electrode portion may be easily peeled off due to thermal stress. Stainless steel may have a problem in terms of heat generation of the electrode part itself because of its relatively high electrical resistance. In addition, regarding noble metal materials such as gold, silver, platinum, palladium, and rhodium, although the electrical resistance of gold and silver is particularly low, it may cause a problem in material cost. In the electrode part formed using the composite material described above, in addition to low electrical resistance, the thermal expansion coefficient is lower than that of other pure metals such as aluminum, and the thermal expansion coefficient constitutes the honeycomb structure part. Since it is close to ceramics, the effect of reducing thermal stress during thermal cycling can be expected. The same effect can be obtained even with a material having a lower coefficient of thermal expansion than other metals, such as molybdenum and tungsten.

  Each of the pair of electrode portions 21 is preferably formed in a strip shape extending in the extending direction of the cells 2 of the honeycomb structure portion 4. In addition, in the cross section orthogonal to the extending direction of the cells 2, it is preferable that one electrode portion 21 is disposed on the opposite side of the other electrode portion 21 with the center of the honeycomb structure portion 4 interposed therebetween. FIGS. 1 to 7 show an example in which a pair of electrode portions 21 is disposed on two side surfaces 5 facing each other of the honeycomb structure portion 4 whose end face is formed in a rectangular tube shape. By configuring in this way, it is possible to suppress an uneven temperature distribution of the honeycomb structure portion 4 when a voltage is applied between the pair of electrode portions 21.

  Moreover, it is preferable that the shape of the electrode portion is “the area of the joint portion of the electrode portion is smaller than the area of the shape surrounding the outer periphery of the electrode portion”. Further, in the heater of the present embodiment, the shape of the electrode portion may be a shape “a corner portion is formed in a curved shape in a rectangle”. The shape of such an electrode part is a shape in which thermal stress is reduced. Therefore, “after the electrode portion and the honeycomb structure portion are joined, cracks in the honeycomb structure portion or peeling of the electrode portion from the honeycomb structure portion” are suppressed. Furthermore, even under a use environment where heating and cooling are repeated, it is possible to prevent the electrode part from being peeled off from the honeycomb structure part or causing cracks in the honeycomb structure part.

  For example, in FIG. 4, the shape of the electrode portion 21 is a shape in which a corner portion is formed in a curved shape in a rectangle. Furthermore, in FIG. 4, the shape of the electrode part 21 is a plate shape in which a plurality of holes are formed. The thermal stress of the electrode part 21 is reduced by setting the shape of the electrode part 21 to “a rectangular shape with corners formed in a curved shape” and “a plate shape in which a plurality of holes are formed”. In addition, about the shape of the electrode part 21, it is not limited to the shape mentioned above. For example, it may be a shape satisfying only one of “a shape in which a corner portion is formed in a curved shape in a rectangle” and “a plate shape in which a plurality of holes are formed”.

  The pair of electrode portions 21 may have terminal portions for ensuring electrical connection with a power source or the like. For example, the “terminal portion” may be formed on a part of the pair of electrode portions 21. As such an electrode part, what has "the main part of an electrode part" and "the protrusion part extended from the main part of an electrode part" can be mentioned. The main body of the electrode portion is the portion that is actually disposed on the side surface of the honeycomb structure portion.

  Each of the pair of electrode portions 21 may have a part of the pair of electrode portions 21 extending through the housing 51 to the outside of the housing 51. Part of the pair of electrode portions 21 extending to the outside of the housing 51 is preferably the above-described protruding portion. By comprising in this way, it can energize simply with respect to the partition 1 of the heater main body 50 accommodated in the housing 51. FIG.

  When producing a heater body in which a pair of electrode portions are disposed on two side surfaces of a honeycomb structure portion, a plate-like or film-like electrode portion is produced separately from the honeycomb structure portion, and the produced electrode portion is It is preferable to join the two side surfaces of the honeycomb structure. As a method of joining the pair of electrode parts to the side surface of the honeycomb structure part, for example, a conductive bonding material is disposed on the side surface of the honeycomb structure part, and the electrode part and the side surface of the honeycomb structure part are connected by this conductive bonding material. The method of joining can be mentioned. In the heater main body used for the heater of this embodiment, it is preferable that the conductive bonding material described above is baked at 60 to 200 ° C. to form a conductive bonding portion.

  This is because when the conductive bonding material is fired at 60 to 200 ° C., the honeycomb structure portion 4 and the pair of electrode portions 21 are connected via the conductive bonding material (the conductive bonding portion 23 after firing). It means to be joined. In this specification, “sintering” an object to be fired (for example, a conductive bonding material) means melting a part of the object to be fired by heating and bonding the components of the object to be fired. This means that the product is a fired product (for example, a conductive joint). When the conductive bonding material is fired to become a conductive bonding portion that is a fired product, the honeycomb structure portion and the electrode portion are bonded via the conductive bonding portion.

  Here, the conductive paste containing “polyamide resin, aliphatic amine and silver flake” is referred to as conductive paste A. Also, a conductive paste containing “silver compound, silicate solution and water” is referred to as conductive paste B. A conductive paste containing “nickel powder and silicate solution” is referred to as conductive paste C. Here, it is preferable that 30-60 mass% of nickel powder is contained with respect to the whole conductive paste C. Further, a conductive paste containing “aluminum oxide, graphite and silicate solution” is referred to as a conductive paste D. In this case, the conductive bonding material is preferably one selected from the group consisting of conductive paste A, conductive paste B, conductive paste C, and conductive paste D. Therefore, it is preferable that the conductive bonding portion 23 is obtained by firing one selected from the group consisting of the conductive paste A, the conductive paste B, the conductive paste C, and the conductive paste D. By making the material of the conductive joint portion 23 as described above, the heater body of the heater of the present embodiment has good heat generation performance due to energization. Furthermore, the heater body of the heater of the present embodiment has a bonding temperature lower than that of general brazing bonding. That is, the bonding temperature is 200 ° C. or lower. Therefore, since thermal stress is reduced, it is possible to prevent cracks from occurring in the honeycomb structure portion when the honeycomb structure portion mainly composed of ceramics and the electrode portion are joined. Furthermore, the heater main body of the heater of the present embodiment can prevent the electrode portion from peeling off from the honeycomb structure portion.

  Moreover, the electroconductive joining part which joins a pair of electrode part and a honeycomb structure part may contain the metal formed by the thermal spraying method, the cold spray method, or the plating method. Such a conductive joint portion functions as an “electrode” together with a pair of electrode portions. In addition, such a conductive joint is preferable in that it can be directly formed as a layer having low electric resistance on the surface of the honeycomb structure. Thereby, a big electric current can be sent through a heater main body.

  Examples of the material of the conductive joint portion include the same materials as those of the electrode portions described so far. As the material of the conductive joint portion, it is desirable that the electrical resistance is low, the thermal expansion coefficient is low, and the thermal expansion coefficient is close to that of the ceramics of the honeycomb structure portion, as in the above-described electrode portion. If the electrical resistance is high, a problem may occur due to heat generation of the conductive joint itself during energization. If the thermal expansion coefficient is higher than that of ceramics, the interface between the conductive joint and the honeycomb structure may be peeled off or cracks may be generated in the honeycomb structure.

  Examples of the thermal spraying method include a plasma spraying method, a high-speed flame spraying method (HVOF method), an arc spraying method, and a flame spraying method.

  Specific examples of the method for forming the conductive joint by the thermal spraying method include the following methods. First, of the side surfaces of the honeycomb structure portion, two side surfaces (electrode portion disposition surfaces) on which the electrode portions are disposed are sandblasted. By this sandblasting, the surface on which the electrode part is disposed is roughened, and the oxide film layer is removed from the surface on which the electrode part is disposed. Next, a protective cover is provided on the side surface other than the electrode portion installation surface so as to cover the side surface. Next, the powder raw material heated and melted is sprayed onto the electrode portion arrangement surface. In this way, a coating film to be a conductive joint can be formed on the electrode portion-providing surface. Examples of the powder raw material include pure nickel, nickel alloy, pure aluminum, aluminum alloy, pure copper, copper alloy, pure molybdenum, and pure tungsten. Further, the temperature at which the powder raw material is heated and melted varies depending on the thermal spraying method, and is preferably set as appropriate.

  According to such a thermal spraying method, it is difficult to completely densify the conductive joint. That is, according to the thermal spraying method, it is possible to produce a conductive joint in which a plurality of pores are formed inside the conductive joint. Such a conductive joint has an improved relaxation function against thermal stress because Young's modulus decreases due to the formation of pores.

  Specific examples of the method for forming the conductive joint by the cold spray method include the following methods. First, in the same manner as the above-described thermal spraying method, the electrode portion disposition surface is sandblasted, and a protective cover is disposed on the side surface other than the electrode portion disposition surface so as to cover this side surface. Next, using a gas such as nitrogen gas, argon gas, air, or the like at about 200 to 600 ° C. as the carrier gas, the powder raw material is caused to collide with the electrode portion arrangement surface at an ultra high speed. In this way, the powder raw material is plastically deformed in the solid phase state by colliding the powder raw material with the electrode portion arrangement surface at an ultrahigh speed. In this way, a coating film derived from the powder raw material can be formed on the electrode part arrangement surface. The carrier gas is set at a temperature lower than the melting point or softening point of the powder raw material.

  What can be used as a powder raw material in the cold spray method is mainly a soft metal that is more easily plastically deformed than the powder raw material that can be used in the above-described thermal spraying method. Moreover, since the melting temperature of the powder raw material is lower than that of the thermal spraying method in the cold spray method, thermal alteration and oxidation of the powder raw material are difficult to occur. Therefore, there is an advantage that it is close to the material characteristics of the bulk (solid mass).

  Examples of the powder raw material include pure nickel, pure aluminum, and pure copper.

  Specific examples of the method for forming the conductive joint by plating include the following methods. First, in the same manner as the thermal spraying method, the electrode portion disposition surface is sandblasted, and a protective cover is disposed on a side surface other than the electrode portion disposition surface so as to cover the side surface. Next, a plating process is performed on the electrode portion arrangement surface. In this way, a coating film that becomes a conductive joint can be formed on the surface of the electrode part.

  Examples of the plating method include an electroless plating method, an electrolytic plating method, or a combination of these. In the electroless plating method, it tends to be difficult to form a conductive joint having a large film thickness. Therefore, after forming a lower layer (ie, a first layer made of a conductive joint) by an electroless plating method, an upper layer (ie, a second layer made of a conductive joint) is formed on the lower layer by an electrolytic plating method. can do. By combining the electroless plating method and the electrolytic plating method in this way, a thick conductive joint can be formed.

  Examples of the plating material used for the plating method include pure nickel and pure copper.

  Note that the conductive joint can be formed by a combination of methods such as thermal spraying, cold spraying, and plating. For example, after the lower layer is formed by an electroless plating method, the upper layer can be formed on the lower layer by a cold spray method. In addition, what consists of this lower layer and an upper layer becomes a conductive junction. By combining a plurality of methods in this way, the conductive joint can be formed thick. In each of the above methods, the sand blasting process and the operation of disposing the protective cover may be adopted as appropriate.

  Next, another embodiment of the heater of the present invention will be described. Another embodiment of the heater of the present invention is a heater 300 as shown in FIGS. In the heater 300, the configuration of the pair of electrodes 21 of the heater body 60 is different from the pair of electrode portions described so far. That is, as shown in FIG. 18, each of the pair of electrode portions 21 includes an electrode substrate 22a disposed on the side surface of the honeycomb structure portion 4, and a rod-shaped electrode portion 22b disposed so as to be connected to the electrode substrate 22a. Consists of. The electrode substrate 22a is bonded to the side surface 5 of the honeycomb structure portion 4 via the conductive bonding portion 23, and a part thereof is along the side surface where the pair of electrode portions 21 of the honeycomb structure portion 4 are not provided. It is preferable that it is bent. The bent portions of the pair of electrode portions 21 are preferably not in contact with the honeycomb structure portion 4.

  In the heater 300 of this embodiment as shown in FIGS. 16 and 17, the rod-shaped electrode portion 22 b penetrates the housing 51 to form a terminal portion for a power source or the like. It is preferable that a member having a sealing property such as an O-ring 53 is disposed at a portion where the rod-shaped electrode portion 22 b penetrates the housing 51. By comprising in this way, the sealing performance (pressure | voltage resistance) of the site | part through which the rod-shaped electrode part 22b penetrates the housing 51 can be improved. Further, by providing a rod-shaped electrode portion having a diameter as shown in FIGS. 16 to 18, there is an effect of suppressing heat generation of the electrode portion itself when a large current is passed.

  Here, FIG. 16 is a perspective view schematically showing another embodiment of the heater of the present invention. FIG. 17 is a cross-sectional view schematically showing a cross section of the heater shown in FIG. 16 perpendicular to the flow direction of the lubricating fluid flowing in the heater body. FIG. 18 is a perspective view schematically showing a heater body in the heater shown in FIG. 16 to 18, the same components as those shown in FIGS. 1 and 6 are denoted by the same reference numerals and description thereof is omitted.

(1-2) Housing:
As shown in FIGS. 1 to 5, the housing 51 is a housing that houses the heater body 50 so as to cover the side surface side of the heater body 50. The housing 51 has an inflow port 55 into which the lubricating system fluid flows in and an outflow port 56 through which the lubricating system fluid that has passed through the cell 2 formed in the heater body 50 flows out. The inflow port 55 and the outflow port 56 are connected to a pipe or the like through which the lubrication system fluid flows, and the lubrication system fluid flows into the heater 100.

There are no particular restrictions on the material of the housing. For example, the material of the housing is preferably a metal or a resin. The housing of the present invention is made of resin. By forming the housing from metal, it is possible to obtain a housing having excellent mechanical strength and heat resistance. Further, it is easy to form a connection portion with a pipe through which the lubricating fluid flows. Furthermore, the metal material has an advantage that the housing can be processed by welding or the like. For this reason, by using a metal material, it is generally possible to produce a housing with excellent reliability when using a heater. On the other hand, in recent years, it is also possible to use a resin material that has been put into practical use from the viewpoint of weight reduction of a vehicle. By forming the housing from resin, electrical insulation between the heater body and the housing can be obtained. In the heater of this embodiment, a resin material is disposed at least at a part between the heater body and the housing. For this reason, electrical insulation between the heater body and the housing is realized by the resin material. As described above, by forming the housing from resin, the insulation between the heater body and the housing can be made more reliable. In addition, since the resin material generally has a lower thermal conductivity than the metal material, it has a heat insulating effect for confining the heat heated by the heater inside the housing.

  Examples of the metal forming the housing include iron alloys such as stainless steel (SUS), aluminum alloys, magnesium alloys, and copper alloys. The housing preferably has a low thermal conductivity from the viewpoint of suppressing heat loss when the heater generates heat. For this reason, for example, as the metal forming the housing, it is possible to suitably use stainless steel that has low thermal conductivity and is a general-purpose material that can be processed into a casing. Moreover, when a lightweight property is required, an aluminum alloy, a magnesium alloy, or the like can be applied.

  Further, the resin forming the housing is preferably a resin having heat resistance to such an extent that it is not deformed by the heated lubricating fluid. Specifically, ethylene propylene diene monomer copolymer (EPDM), ethylene propylene copolymer, polyimide, polyamideimide, silicone, fluorine elastomer, epoxy resin, phenol resin, melamine resin, urea resin, unsaturated polyester resin, alkyd Resin, polyurethane, thermosetting polyimide, polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyvinylidene chloride, polystyrene (PS), polyvinyl acetate, polytetrafluoroethylene, acrylonitrile butadiene styrene (ABS) Resin, acrylonitrile styrene (AS) resin, acrylic resin, polyamide, nylon, polyacetal, polycarbonate, modified polyphenylene ether, polybutylene terephthalate (PBT), polyethylene Ethylene terephthalate (PET), cyclic polyolefin, polyphenylene sulfide (PPS), polytetrafluoroethylene, polysulfone, polyether sulfone, amorphous polyarylate, liquid crystal polymer, polyether ether ketone, thermoplastic polyimide, thermoplastic polyurethane (TPU) ), Methyl methacrylate styrene (MS), polymethyl methacrylate (PMMA), polydimethylsiloxane (PDMS), and the like. Further, the resin forming the housing may be a resin composite material in which glass fibers or the like are added to the above-described resins. By using a resin composite material, there is an effect of reducing heat stress by improving heat resistance and reducing thermal expansion (in other words, improving durability). Glass fibers or the like can be used as the reinforcing fibers, and when insulating properties are required, insulating fibers are suitable. For this reason, when increasing the output of the heater, it is preferable to use a resin composite with improved heat resistance as the resin forming the housing.

  The inlet and outlet of the housing are inlets and outlets of a flow path through which the lubricating system fluid flows in or out. The inflow port and the outflow port of the housing may be configured to be able to be directly connected to the piping through which the lubricating fluid flows. Moreover, the connection mechanism with the said piping may be further connected to the inflow port and outflow port of a housing. For example, a pipe joint (also referred to as a flange joint) can be mentioned as the “connecting mechanism with piping”. Further, the “connecting mechanism with the piping” may further include an expanded pipe portion whose diameter gradually increases toward the inflow port, a narrow tube portion whose diameter decreases gradually from the outflow port, and the like.

  There is no particular limitation on the size of the housing. However, it is necessary to have a size that can accommodate the heater body. Moreover, it is preferable that the size of the housing is such that there is a certain gap between the housing and the heater body when the heater body is housed. A resin material is disposed in the gap. Moreover, you may further arrange | position a heat insulating material between a housing and a heater main body. By disposing a heat insulating material, it is possible to have a heat insulating structure that suppresses the heat generated by the heater from escaping into and out of the housing. As the heat insulating material, an inorganic fiber heat insulating material is preferable from the viewpoint of heat resistance when heating the heater. As the heat insulating material, ceramic fibers, alumina fibers, silica fibers, fiber mats such as glass wool and rock wool, sheets, blankets and the like can be used. In addition, although it is possible to impart heat insulation to the resin materials described so far, the “heat insulation material” used in the heater of the present embodiment and the above “resin material” are separate components. It is. That is, the “heat insulating material” here does not include the “resin material” used in the heater of the present embodiment. Further, even when the resin material is not disposed at all the portions of the gap (that is, when the resin material is disposed only at a part of the gap), the gap serves as an air layer, and the heat insulating layer of the heater body. Become.

  For example, as shown in FIG. 5, in the heater 100 of the present embodiment, a resin material 52 is disposed on the outer peripheral side of the heater body 50, and there is a gap between the resin material 52 and the housing 51. Also good.

  Moreover, in the heater of this embodiment, you may arrange | position in the state which laminated | stacked 2 or more types of resin materials between the heater main body and the housing. That is, even if the first resin material 52a and the second resin material 52b are stacked between the heater main body 50 and the housing 51 as in the heater 401 shown in FIG. Good. There is no restriction | limiting in particular about the kind of resin of the 1st resin material 52a and the 2nd resin material 52b. For example, as the first resin material 52a disposed on the heater body 50 side, a fluorine-based resin or the like can be used. Further, as the second resin material 52b disposed on the housing 51 side, a silicone resin, a fluorine resin, or the like can be used. In addition, about selection of a resin material, it can change suitably by attaching importance to insulation, heat insulation, and heat resistance. Moreover, you may form the 1st resin material 52a and the 2nd resin material 52b as follows. For example, the first resin material 52 a is formed by coating a resin on the side surface of the heater body 50. And about the 2nd resin material 52b, you may form by filling resin between the heater main body 50 and the housing 51 which coated the 1st resin material 52a. FIG. 10 is a cross-sectional view schematically showing still another embodiment of the heater of the present invention. The cross section shown in FIG. 10 is a cross section perpendicular to the flow direction of the lubricating fluid flowing in the heater body. In FIG. 10, the same components as those shown in FIG. 5 are denoted by the same reference numerals and description thereof is omitted.

  Moreover, in the heater of this embodiment, the resin material and the heat insulating material may be arrange | positioned between the heater main body and the housing. That is, as in the heaters 402A and 402B shown in FIGS. 11A and 11B, the resin material 52 and the heat insulating material 57 are laminated between the heater body 50 (heater body 60 in FIG. 11B) and the housing 51. It may be arranged in. The heat insulating material 57 may be laminated with a heat insulating material and a silicone resin, a fluorine resin, or the like. Moreover, in the heaters 402A and 402B shown in FIGS. 11A and 11B, the resin material 52 and the heat insulating material 57 may be formed as follows. For example, the resin material 52 is formed by coating a resin on the side surface of the heater body 50 (heater body 60 in FIG. 11B). And about the heat insulating material 57, you may form by filling a heat insulating material and resin between the heater main body 50 (FIG. 11B heater main body 60) coated with the resin material 52, and the housing 51. .

  Moreover, in the heater of this embodiment, it may be arrange | positioned in the state which laminated | stacked the resin material, the heat insulating material, and the resin material between the heater main body and the housing. For example, in the heater 406 shown in FIG. 15, the resin material 52 is first arranged so as to cover the heater body 60. The heat insulating material 57 is disposed outside the resin material 52, and the resin material 52 is disposed outside the heat insulating material 57. The outermost resin material 52 is disposed so as to cover the inner surface of the housing 51. The heat insulating material 57 in FIG. 15 can be the same as the heat insulating material 57 of the heaters 402A and 402B shown in FIGS. 11A and 11B.

  Moreover, when the material of the housing is resin, the housing and the resin material may be integrated. That is, the housing in the heater of the present embodiment may be formed by a resin material arranged outside the heater body. The resin material functions as an insulating layer, a heat insulating layer, a seal layer, or the like between the housing and the heater body. When the material of the housing is resin, the function of the resin material can be extended to the entire housing by integrating the housing and the resin material. For example, the heater 403 shown in FIG. 12 is a heater provided with a resin-made housing 71 having the functions of both a housing and a resin material as described above. As such a resin housing 71, for example, a housing using a thermosetting epoxy resin can be cited as a suitable example. As a result, it is possible to integrate the thermosetting resin into the outer periphery of the honeycomb so as to be cast (ie, a mold). Moreover, you may use the reinforced resin composite material which added the glass fiber etc. to the epoxy resin. In the case of a reinforced resin composite material, there is an effect of reducing thermal stress by improving heat resistance and reducing thermal expansion. As the reinforcing fiber, glass fiber or the like can be used, and since the insulating property is required for the housing body, the insulating fiber is suitable. The housing 71 also serves as the resin material 72 in the heater 403 of this embodiment.

  As described above, in the heater of the present embodiment, if the resin material is disposed at least in a portion between the housing and the heater body, the structure inside the housing, etc. It can be appropriately changed according to the form.

  FIG. 11A, FIG. 11B, FIG. 12 and FIG. 15 are cross-sectional views schematically showing still another embodiment of the heater of the present invention. 11A, FIG. 11B, FIG. 12 and FIG. 15 are cross sections perpendicular to the flow direction of the lubricating fluid flowing in the heater body. 11A, FIG. 11B, FIG. 12, and FIG. 15, components that are configured in the same manner as the elements shown in FIG. 5 and FIG.

  “Integrating the housing and the resin material” means that the housing and the resin material are configured as one member. Therefore, the “integrated housing and resin material” includes a housing and a resin material formed as a single member by molding once when the housing and the resin material are molded using a predetermined resin. In addition, “integrated housing and resin material” include those in which a contact portion between the housing and the resin material is joined.

  In the heater 100 of the present embodiment shown in FIGS. 1 to 5, the housing 51 has an electrode extraction portion 54 for taking out the pair of electrode portions 21 of the heater main body 50 housed therein. . A portion on the tip end side of the pair of electrode portions 21 is exposed to the outside from the electrode extraction portion 54, and electrical connection to the pair of electrode portions 21 is enabled.

  In the electrode extraction portion 54, an O-ring 53 is disposed at a location where the pair of electrode portions 21 penetrates the housing 51. With this O-ring 53, pressure resistance (sealability) at a portion penetrating the housing 51 is ensured. Here, the pressure resistance means the performance of suppressing the leakage of the lubricating fluid to the outside of the housing when the lubricating fluid flows inside the housing. In the heater of this embodiment, the pressure resistance as described above is necessary so that no problem occurs in the heater operation.

  Moreover, in the heater of this embodiment, you may actively flow a lubrication system fluid on the outer side of a heater main body. For example, the heater 404 shown in FIG. 13 is a heater configured such that a lubricating fluid flows between the heater body 60 and the housing 51. By comprising in this way, a lubrication system fluid can be heated using the surface outside the outer peripheral wall 3 of the honeycomb structure part 4. FIG. Thus, the heating efficiency of the heater 404 can be improved by effectively utilizing the heat generated in the outer peripheral wall 3. Of course, in the heater 404 shown in FIG. 13, the lubricating fluid flows also in the cells 2 of the honeycomb structure portion 4, and the lubricating fluid can be heated also in the cells 2.

  In the heater 404 shown in FIG. 13, it is preferable that at least a resin material 52 is disposed on the surface of the pair of electrode portions 21 of the heater body 60 to ensure insulation of the pair of electrode portions 21. That is, the lubricating fluid may be positively contacted with the outer peripheral wall 3 of the honeycomb structure portion 4, but it is preferable that the lubricating fluid is not in contact with the pair of electrode portions 21. The insulation with respect to the pair of electrode portions 21 can be performed by the resin material 52 as described above. Further, when the housing 51 is made of metal such as SUS, it is preferable to arrange the resin material 52 on the inner surface of the housing 51 to ensure the insulation of the housing 51. FIG. 13 is a cross-sectional view schematically showing still another embodiment of the heater of the present invention. The cross section shown in FIG. 13 is a cross section perpendicular to the flow direction of the lubricating fluid flowing in the heater body. In FIG. 13, the same components as those shown in FIG. 17 are denoted by the same reference numerals and description thereof is omitted.

  In the heater 403 shown in FIG. 12, the housing 71 is made of resin, and the housing 71 and the resin material 72 are integrated. However, the housing may be made of resin alone. For example, in the heater 405 shown in FIG. 14, the housing 73 is made of resin. The housing 73 can be formed using an epoxy resin, a fluorine resin, or the like. The resin material 52 covering the heater body 60 can also be formed using an epoxy resin, a fluorine resin, or the like. In the heater 405 shown in FIG. 14, a heat insulating material 57 is filled between the housing 73 and the resin material 52. The housing 73 has an electrode extraction portion 74 at a portion where the pair of electrode portions 21 extend from the housing 73. And in the electrode extraction part 74, the O-ring 53 is arrange | positioned in the location where a pair of electrode part 21 penetrates. FIG. 14 is a cross-sectional view schematically showing still another embodiment of the heater of the present invention. The cross section shown in FIG. 14 is a cross section perpendicular to the flow direction of the lubricating fluid flowing through the heater body. In FIG. 14, the same components as those shown in FIG. 17 are denoted by the same reference numerals and description thereof is omitted.

(1-3) Resin material:
The resin material is disposed at least at a part between the heater body and the housing. This resin material functions as an insulating layer, a heat insulating layer, a seal layer, and the like between the housing and the heater body in the heater of this embodiment.

  As shown in FIGS. 1 to 5, the resin material 52 is preferably disposed between the heater body 50 and the housing 51 on one end face side of the heater body 50. The resin material 52 is preferably disposed between the heater body 50 and the housing 51 on the other end face side of the heater body 50. By comprising in this way, the insulation of the heater main body 50 and heat insulation can be improved more. Moreover, the sealing performance with respect to the lubrication system fluid on one end face side and the other end face side of the heater body 50 can be improved. That is, by disposing the resin material 52 in this way, it is possible to prevent the lubricating fluid that is the heating target from leaking between the heater body 50 and the housing 51.

  Since the heater of this embodiment applies a resin material in a housing, it can be suitably used as a heater having a heat generation temperature of the heater body up to about 200 ° C. to 250 ° C. A lubricating fluid for heating flows inside the heater and receives heat from the heater body. In other words, the lubricating fluid takes heat away from the heater body. Therefore, the lubricating fluid acts as a kind of coolant for the heater. As a result, even if the heater body generates heat to a high temperature, the actual temperature of the resin material outside the heater body tends to be low. However, it is necessary to design a heater in consideration of the heat resistance range of the resin material.

  Moreover, as shown in FIGS. 1-5, the resin material 52 is arrange | positioned at least between a pair of electrode part 21 and the housing 51 in the site | part through which a pair of electrode part 21 penetrates a housing. preferable. With this configuration, it is possible to prevent leakage of the lubricating fluid from a portion where a part of the pair of electrode portions 21 penetrates the housing 51. As described above, it is more preferable that the O-ring 53 is disposed in a portion penetrating the housing 51 from the viewpoint of ensuring pressure resistance. In the heater of this embodiment, it is preferable that the resin material is disposed so as to cover at least the entire region of the pair of electrode portions disposed in the heater body. By comprising in this way, the insulation of a heater main body can be ensured.

  Further, like the heater 200 shown in FIGS. 8 and 9, the resin material 52 may be disposed between the heater body 50 and the housing 51 so as to cover the entire side of the heater body 50. Here, FIG.8 and FIG.9 is sectional drawing which shows typically other embodiment of the heater of this invention. FIG. 8 is a cross section obtained by cutting the heater at the same position as the cross section shown in FIG. FIG. 9 is a cross section of the heater cut at the same position as the cross section shown in FIG. In FIG.8 and FIG.9, about the component comprised similarly to the component of the heater shown in FIGS. 1-5, the same code | symbol is attached | subjected and description is abbreviate | omitted.

  Thus, by disposing the resin material 52 so as to cover the entire side of the heater main body 50, the insulating properties, heat insulating properties, and sealing properties can be further improved.

  As shown in FIGS. 1 to 5, when the resin material 52 is disposed at a specific location, the resin material 52 formed in a predetermined shape is appropriately disposed between the heater body 50 and the housing 51. On the other hand, as shown in FIGS. 8 and 9, when the resin material 52 is disposed so as to cover the entire side of the heater body 50, it is preferable to form the resin material 52 as follows. For example, a molten resin is filled between the heater main body 50 and the housing 51, and the molten resin is solidified to form a resin material 52 in a shape that casts the heater (that is, a mold). In addition, before the heater body 50 is housed in the housing 51, a resin material 52 is formed by applying a resin to the entire side of the heater body 50 in advance. And the heater main body 50 in which the resin material 52 was formed in the side surface is accommodated in the housing 51. FIG. By forming the resin material 52 by such a method, the resin material 52 covering the entire side of the heater body 50 can be easily produced.

  Further, as described above, the housing and the resin material may be integrated. In such a case, as shown in FIG. 12, a housing 71 and a resin material 72 integrated on the side surface of the heater body 60 can be formed by integral molding with a predetermined resin.

  The resin forming the resin material is preferably a resin having heat resistance to such an extent that it is not deformed by a heated lubricating fluid. Specifically, ethylene propylene diene monomer copolymer (EPDM), ethylene propylene copolymer, polyimide, polyamideimide, silicone, fluorine elastomer, epoxy resin, phenol resin, melamine resin, urea resin, unsaturated polyester resin, alkyd Resin, polyurethane, thermosetting polyimide, polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyvinylidene chloride, polystyrene (PS), polyvinyl acetate, polytetrafluoroethylene, acrylonitrile butadiene styrene (ABS) Resin, acrylonitrile styrene (AS) resin, acrylic resin, polyamide, nylon, polyacetal, polycarbonate, modified polyphenylene ether, polybutylene terephthalate (PBT), polyethylene Ethylene terephthalate (PET), cyclic polyolefin, polyphenylene sulfide (PPS), polytetrafluoroethylene, polysulfone, polyether sulfone, amorphous polyarylate, liquid crystal polymer, polyether ether ketone, thermoplastic polyimide, thermoplastic polyurethane (TPU) ), Methyl methacrylate styrene (MS), polymethyl methacrylate (PMMA), polydimethylsiloxane (PDMS), and the like. Moreover, the resin composite material which added glass fiber etc. to each resin mentioned above as resin which forms a resin material may be sufficient. By using a resin composite material, there is an effect of reducing heat stress by improving heat resistance and reducing thermal expansion (in other words, improving durability). Glass fibers or the like can be used as the reinforcing fibers, and when insulating properties are required, insulating fibers are suitable. For this reason, when increasing the output of the heater, it is preferable to use a resin composite material with improved heat resistance as the resin forming the resin material.

  Moreover, in order to make a resin material function effectively as a heat insulation layer and a sealing layer, it is preferable that the heat-resistant temperature of a resin material is 80 degreeC or more. Furthermore, the heat resistant temperature of the resin material is preferably 100 ° C. or higher, and more preferably 120 ° C. or higher.

  In this specification, “heat-resistant temperature” means any one of the temperatures shown in the following [1] and [2]. That is, when “the heat resistant temperature of the resin material is 100 ° C. or higher”, one of the temperatures shown in the following [1] and [2] is 100 ° C. or higher. Of course, in the case of “the heat resistant temperature of the resin material is 100 ° C. or higher”, both the temperatures shown in the following [1] and [2] may be 100 ° C. or higher. As another standard for the heat resistant temperature, there is the following [3] for the case of long-time exposure at high temperatures.

[1] Deflection temperature under load: The temperature at which the two points of a rectangular test piece are supported in a heating bath and the temperature is raised while a load is applied to the center of the test piece and deformation occurs.
[2] Vicat softening temperature: When two ends of a rectangular test piece are supported in a heating bath, the temperature rises with the end face of a constant cross-sectional area pressed against the center of the test piece, and deformation occurs temperature.
[3] UL standard temperature: a temperature at which physical properties are halved by high temperature exposure for several tens of thousands of hours.

In order for the resin material to function effectively as an insulating layer, the specific resistance of the resin material is preferably 10 ⁹ Ω · cm or more. Furthermore, the specific resistance of the resin material, is preferably ^{10 10 Ω} · cm or more, and particularly preferably ^{10 12 Ω} · cm or more.

(2) Still another embodiment of the heater:
Next, still another embodiment of the heater of the present invention will be described. As still another embodiment of the heater of the present invention, heaters having various vibration absorbing structures as described below can be cited. The heater of the present invention is mounted around an engine of an automobile or the like and can be used for heating a lubricating fluid such as engine oil or transmission fluid. At this time, acceleration is generated by engine vibration. For this reason, by setting it as the heater provided with the following vibration absorption structures, the impact by vibration can be relieved and it can be set as the heater excellent in durability.

  As the first vibration absorbing structure, a structure in which an O-ring or packing made of resin, rubber, or the like is disposed at a portion where the electrode portion of the heater body penetrates the housing can be exemplified. For example, the O-ring 53 shown in FIGS. 4 and 5 can be a first vibration absorption structure by using a resin or rubber O-ring 53.

  Moreover, the structure which has arrange | positioned the buffer member in each part of a heater can be mentioned as a 2nd vibration absorption structure. Examples of the buffer member include those made of resin and rubber. Examples of the location where the buffer member is disposed include a portion between the heater main body and the housing, an electrode portion of the heater main body penetrating the housing, and the like. The resin material 52 disposed between the heater main body 50 and the housing 51 as shown in FIG. 9 also serves as the above-described buffer member.

  Moreover, as a third vibration absorbing structure, a structure in which a stretchable vibration absorbing portion is provided on a part of the pair of electrode portions of the heater body can be exemplified. As the vibration absorbing portion that can be expanded and contracted, a bellows-shaped one that can expand and contract in a predetermined direction can be exemplified. In the heater of the present embodiment, since the heater body is fixed at a portion where the pair of electrode portions penetrates the housing, strong vibration may be applied to the pair of electrode portions. Therefore, the vibration applied to the heater body can be satisfactorily absorbed by using a pair of electrode portions provided with such a stretchable vibration absorbing portion.

  For example, as a heater provided with the third vibration absorbing structure, a heater 500 as shown in FIG. 19 can be exemplified. In the heater 500 shown in FIG. 19, an example in which a bellows-like vibration absorbing portion 42 is provided in a part of the pair of electrode portions 41 is shown. The bellows-like vibration absorbing portions 42 of the pair of electrode portions 41 are preferably located inside the housing 51. Thereby, the vibration added to the heater main body 70 accommodated in the housing 51 can be favorably absorbed. FIG. 19 is a cross-sectional view schematically showing still another embodiment of the heater of the present invention. The cross section shown in FIG. 19 is a cross section perpendicular to the flow direction of the lubricating fluid flowing in the heater body. In FIG. 19, the same components as those shown in FIG. 5 are denoted by the same reference numerals and description thereof is omitted.

  As the fourth vibration absorbing structure, a structure in which the following connection method is employed in the electrical connection method for the pair of electrode portions of the heater body can be exemplified. As an electrical connection method for the pair of electrode portions, for example, each pair of electrode portions is connected to a cable for electrical connection in the housing, and the cable for electrical connection is pulled out of the housing. And a method of making an electrical connection. As another connection method, for example, a connector insertion port for inserting a connector for electrical connection is formed in a housing that houses the heater body. A method of inserting an electrical connection connector from a connector insertion port of the housing and electrically connecting the pair of electrode portions of the heater body housed and fixed in the housing can be mentioned. In this connection method, the pair of electrode portions are housed in the housing together with the honeycomb structure portion. That is, since the pair of electrode portions are not configured to penetrate the housing and extend to the outside, vibration applied to the housing is difficult to be transmitted to the heater body.

  As still another embodiment of the heater of the present invention, a heater configured such that a pair of electrode portions extend to the outside from the inflow side or the outflow side of the housing can be exemplified. In other words, the heater 100 shown in FIG. 1 is configured such that the pair of electrode portions 21 are extended from the side surface of the housing 51 to the outside. You may be comprised so that it may extend outside from the side. An example of such a heater is a heater 600 shown in FIG. FIG. 20 is a perspective view schematically showing still another embodiment of the heater of the present invention. FIG. 21 is a perspective view schematically showing a heater body in the heater shown in FIG. 20 and 21, the same components as those shown in FIGS. 1 to 5 are denoted by the same reference numerals and description thereof is omitted. 20 and 21, the pair of electrode portions 43 are configured to extend to the outside from the outflow port 56 side of the housing 81. By configuring the pair of electrode parts 43 to supply power from the outlet 56 side, heat removal from the pair of electrode parts 43 can be suppressed. As a result, the lubricating fluid can be heated to a more uniform temperature. Further, in such a heater 600, compared to a configuration in which electric power is supplied from the upper part of the side surface of the housing to the pair of electrode parts, a temperature gradient of the lubricating fluid is difficult to be applied at the upper part and the lower part in the housing. Presumed to be.

  As shown in FIG. 21, each electrode portion 43 of the heater body 80 includes an electrode substrate 43 a disposed on the side surface 5 of the honeycomb structure portion 4, and extends from the electrode substrate 43 to the downstream side in the flow direction of the lubricating fluid. It has the electrode terminal part 43b taken out. The electrode terminal portion 43b is configured to extend to the outside from the outlet 56 (see FIG. 20) side of the housing 81 (see FIG. 20).

  As still another embodiment of the heater of the present invention, a heater 700 as shown in FIGS. This heater 700 is a housing in which a heater main body 90 as shown in FIGS. 25 and 26 is housed in a housing 91. A resin material 52 and a heat insulating material 57 are disposed between the housing 91 and the heater main body 90. Here, FIG. 22 is a perspective view schematically showing still another embodiment of the heater of the present invention. FIG. 23 is a cross-sectional view schematically showing a cross section of the heater 700 shown in FIG. 22 perpendicular to the flow direction of the lubricating fluid flowing in the heater body. FIG. 25 is a cross-sectional view schematically showing a cross section of the heater 700 shown in FIG. 22 parallel to the flow direction of the lubricating fluid flowing through the heater body. FIG. 25 is a perspective view schematically showing a heater body of the heater 700 shown in FIG. FIG. 26 is a developed perspective view schematically showing the developed state of the heater body 90 shown in FIG.

  As shown in FIGS. 22 to 26, the housing 91 in the heater 700 of the present embodiment includes a housing main body 91a having an opening on one surface, and a lid 91b for closing the opening of the housing main body 91a. It is configured. The heater body 90 includes the honeycomb structure portion 4 and a pair of electrode portions 31.

  In the heater 700 of this embodiment, each electrode part 31 is comprised from the electrode board | substrate 31a, the electrode terminal part 31b, and the electrode board | substrate connection part 31c. The electrode substrate 31 a is disposed on the side surface 5 of the honeycomb structure part 4 to apply a voltage to the honeycomb structure part 4. 25 and 26 show an example in which the electrode substrate 31a is formed in a comb shape. The electrode substrate connecting portion 31c is a portion for connecting the electrode substrate 31a and the electrode terminal portion 31b. In the heater 700 of this embodiment, the electrode substrate connecting portions 31c of the pair of electrode portions 31 are sandwiched between the housing main body 91a and the lid portion 91b in a state where the electrode substrate connecting portions 31c are stacked via the electrically insulating sealing material 35. ing. The electrode terminal portion 31b extends from the electrode substrate connecting portion 31c sandwiched between the housing main body 91a and the lid portion 91b.

  In the heater 700 of the present embodiment, the electrode substrate connection portion 31c stacked via the seal material 35 is sandwiched between the housing main body 91a and the lid portion 91b, whereby the electrode portion 31 is removed from the housing 91. Has been done. For this reason, the heater 700 of this embodiment is excellent in pressure resistance. That is, with this configuration, it is possible to prevent the lubricating fluid from leaking out from the electrode 31 extraction location when the lubricating fluid flows in the heater 700.

  In addition, as other embodiments of the heater of the present invention, a heater including the following heater body can be exemplified. A heater main body 152 shown in FIG. 29 includes a tubular honeycomb structure portion 4 and a pair of electrode portions 24 bonded to the side surface 5 of the honeycomb structure portion 4 via the conductive bonding portion 23. The honeycomb structure part 4 has a partition wall 1 that partitions and forms a plurality of cells 2 extending from one end surface 11 to the other end surface 12 that serve as a flow path for the lubricating fluid, and an outer peripheral wall 3 that is positioned at the outermost periphery. . The partition 1 is made of a material mainly composed of ceramics and generates heat when energized. The conductive joint portion 23 is disposed on the two side surfaces 5 of the honeycomb structure portion 4. Via this conductive joint portion 23, an electrode portion 24 having a corner formed in a curved shape is joined. It is preferable that the electroconductive joining part 23 is a thing containing the metal formed by the thermal spraying method, the cold spray method, or the plating method. Such a heater main body 152 can also be used as the heater of the present embodiment by being housed in a housing, similarly to the heater main body 50 shown in FIG.

  As another embodiment of the heater of the present invention, a heater provided with a heater body 153 shown in FIG. 30 can be mentioned. A heater main body 153 shown in FIG. 30 includes a tubular honeycomb structure portion 4 and a pair of electrode portions 25 joined to the side surface 5 of the honeycomb structure portion 4 via a conductive joint portion 23. The electrode part 25 has an electrode substrate 26a and a rod-like electrode part 26b arranged so as to be connected to the electrode substrate 26a. Also in such a heater main body 153, it can be set as the heater of this embodiment by accommodating in a housing similarly to the heater main body 60 shown in FIG. In the case of the heater main body 153, it is preferable that a wire from an external power source or the like is connected to the rod-shaped electrode portion 26b. Each electrode substrate 26 a of the pair of electrode portions 25 is bonded to the side surface 5 of the honeycomb structure portion 4 via the conductive bonding portion 23, and a part of the electrode substrate 26 a is arranged with the pair of electrode portions 25 of the honeycomb structure portion 4. It is preferable that it bends along the side surface which is not provided. Here, FIG.29 and FIG.30 is a perspective view which shows typically the heater main body used for further another embodiment of the heater of this invention. 29 and 30, the same components as those shown in FIGS. 6 and 18 are denoted by the same reference numerals and description thereof is omitted.

(3) Heater manufacturing method:
Next, a method for manufacturing the heater of this embodiment will be described. In addition, about the method of manufacturing the heater of this embodiment, it is not limited to the following manufacturing methods.

  First, an example of producing a honeycomb structure part mainly composed of Si composite SiC will be described. SiC powder, metallic Si powder, water, organic binder, etc. are mixed and kneaded to prepare a clay. Then, this clay is formed into a honeycomb shape to produce a honeycomb formed body. Thereafter, the obtained honeycomb formed body is fired in an inert gas atmosphere, whereby a honeycomb structure part mainly composed of Si composite SiC can be manufactured.

  Next, an example of manufacturing a honeycomb structure mainly composed of Si-impregnated SiC will be described. First, SiC powder, metal Si powder, water, an organic binder, etc. are mixed and kneaded to prepare a clay. Then, this clay is formed into a honeycomb shape to produce a honeycomb formed body. Thereafter, the resulting honeycomb formed body is fired in an inert gas atmosphere to form a honeycomb structure. Thereafter, the resulting honeycomb structure is impregnated with Si in an inert gas atmosphere, whereby a honeycomb structure portion mainly composed of Si-impregnated SiC can be produced. The production of recrystallized SiC and reaction-sintered SiC is as described above.

  In the above-described method for manufacturing a honeycomb structure mainly composed of Si-impregnated SiC, SiC powder, water, an organic binder, and the like may be mixed and kneaded to prepare a clay. That is, the raw material for the clay does not need to contain the metal Si powder.

In addition, as the material constituting the partition wall and the outer peripheral wall, silicon carbide, Fe-16Cr-8Al, SrTiO ₃ (perovslite), Fe ₂ O ₃ (corundum), SnO ₃ (rutile), ZnO (wurzeite), etc. Can be mentioned. By using such a material, the specific resistance of the partition walls and the outer peripheral wall can be set to 0.01 to 50 Ω · cm. The specific resistance of silicon carbide generally has a wide width of 1 to 1000 Ω · cm, and if SiC is used alone, it is preferably within the specific resistance range described above. Further, in the case of compounding with Si and Si-based alloy, although it depends on the microstructure, it is possible to apply up to a specific resistance of 1000 Ω · cm. The specific resistance of Fe-16Cr-8Al is 0.03 Ω · cm. The specific resistance of SrTiO ₃ (perovslite) is 0.1 Ω · cm or less. The specific resistance of Fe ₂ O ₃ (corundum) is about 10 Ω · cm. The specific resistance of SnO ₃ (rutile) is 0.1 Ω · cm or less. The specific resistance of ZnO (wurzite) is 0.1 Ω · cm or less.

  Further, when the honeycomb structure portion is manufactured, the value of metal Si content / (Si content + SiC content) is preferably 5 to 50. The value of metal Si content / (Si content + SiC content) is more preferably 10-40. By comprising in this way, the specific resistance can be made into a suitable magnitude | size, maintaining the intensity | strength of a partition or an outer peripheral wall.

  In order to have insulation on the partition wall surface, for example, an oxide film may be formed on the surface of the partition wall by performing a high temperature treatment at 1200 ° C. for 6 hours in the atmosphere.

  Next, a pair of electrode portions disposed on the side surface of the honeycomb structure portion is formed. Examples of the material of the electrode part include stainless steel, copper, nickel, aluminum, molybdenum, tungsten, rhodium, cobalt, chromium, niobium, tantalum, gold, silver, platinum, palladium, and alloys of these metals. . As described above, the material of the electrode part can be appropriately selected in consideration of the balance of the generation of cracks in the ceramic due to thermal stress, the peeling of the electrode interface, the heat generation of the electrode part itself, the cost, and the like. In addition, the electrode part has a low thermal expansion coefficient, and its thermal expansion coefficient is close to that of ceramics in the honeycomb structure part, so that it is effective in reducing thermal stress during thermal cycling. Molybdenum, tungsten, Cu / W composite You may form using composite materials, such as a material, Cu / Mo composite material, Ag / W composite material, SiC / Al composite material, C / Cu composite material.

  Next, the formed electrode part is attached to the side surface of the honeycomb structure part. In this manner, a heater body used for the heater of this embodiment is manufactured.

  Next, a housing used for the heater of this embodiment is formed. When the material of the housing is metal, a housing, which is a housing of a size that can accommodate the heater body, is produced by a conventionally known method. Examples of the method for producing the housing include hot and cold press molding, forging, extrusion, welding, and the like.

  When the material of the housing is resin, a housing that is a housing of a size that can accommodate the heater body is produced. Examples of the method for producing the resin housing include methods such as resin molding, injection molding, extrusion molding, hollow molding, thermoforming, and compression molding. Further, when the housing is made of resin, the housing can be manufactured by molding in a state where the heater body is accommodated. That is, the housing can be manufactured so as to actually cover the heater body, instead of separately manufacturing the housing as a container.

  Further, when the housing is made of resin, the resin material disposed between the heater body and the housing and the housing may be integrally formed. At this time, a housing integrated with a resin material may be separately manufactured as a container. Moreover, you may produce the housing integrated with the resin material in the state which accommodated the heater main body.

  Next, when the resin material is not integrated with the housing, a resin material to be disposed between the heater body and the housing is produced. The resin material is preferably disposed on one end face side and the other end face side of the heater body and formed in a shape that closes the space between the heater body and the housing. In addition, when a part of the pair of electrode portions extends through the housing to the outside of the housing, the pair of electrode portions are formed so as to close the gap between the portions penetrating the housing. Those are preferred. By arranging the resin material in this manner, electrical insulation between the heater body and the housing can be obtained mainly. Moreover, the said resin material functions also as a heat insulation layer of a heater main body. Moreover, by arranging the resin material in this manner, it plays a role of suppressing leakage of the lubricating fluid that is the heating target between the heater body and the housing.

  Moreover, you may arrange | position a resin material so that the whole region of a pair of electrode part arrange | positioned at least at a heater main body may be covered. As described above, by disposing the resin material so as to cover at least the entire region of the pair of electrode portions, sufficient insulation required for the heater body can be ensured. Moreover, you may form a resin material so that the whole side surface side area of a heater main body may be covered. In the case of arranging a resin material so as to cover at least the entire pair of electrode parts or to cover the entire side surface of the heater body, the resin is applied to the side surface of the heater body and the resin is solidified. A resin material may be formed.

  Next, the heater main body is accommodated in the housing, and a resin material is appropriately disposed between the heater main body and the housing. As described above, the heater of this embodiment can be manufactured. In the case where the housing is manufactured in a state where the heater main body is stored, the step of storing the heater main body is omitted. Moreover, when the housing integrated with the resin material is produced, the step of arranging the resin material is omitted. When the resin material is formed so as to cover the entire side surface side of the heater body, the heater body formed with the resin material so as to cover the entire side surface side is housed in the housing. As described above, the heater of this embodiment can be manufactured.

  Here, a specific example of a method for manufacturing the heater 402A as shown in FIG. 11A will be described. First, the honeycomb structure part 4 is produced by the method described above. Next, the electrode part 21 is joined to two surfaces arranged in parallel among the side surfaces 5 of the honeycomb structure part 4. The electrode portion 21 can be formed of Ni, Cu, Mo, W, a Cu / W composite material, or the like. Thereby, the heater main body 50 by which a pair of electrode part 21 is arrange | positioned at the two side surfaces 5 of the honeycomb structure part 4 can be produced.

  Next, a resin material 52 is formed by coating the outer peripheral portion of the obtained heater body 50 (more specifically, the side surface 5 of the honeycomb structure portion 4) with resin. As the resin to be coated, a fluorine resin or the like can be used. The coating of the resin can be performed at a temperature of about 150 ° C. in the air, for example.

Next, a heat insulating material 57 is further disposed so as to further cover the resin material 52 disposed on the side surface 5 of the honeycomb structure portion 4. As the heat insulating material 57, a ceramic fiber sheet (Al ₂ O ₃ —SiO ₂ or the like) can be used. Although not shown in FIG. 11A, a resin sheet may be further disposed so as to further cover the heat insulating material 57. As the resin sheet, a sheet made of a silicone resin, a fluorine resin, or the like can be used.

  Next, the heater main body 50 in which the resin material 52 and the heat insulating material 57 are arranged on the outer peripheral portion is arranged in a housing body made of SUS. Thereafter, a cover made of SUS is arranged on the housing body so that a part of the pair of electrode portions 21 is exposed. The heater main body 50 is accommodated in the housing 51 by joining the housing main body and the lid portion by, for example, laser welding. As the lid portion, it is preferable to provide an electrode extraction portion 54 at a portion through which the pair of electrode portions 21 penetrate, and an O-ring 53 made of a fluorine-based resin or the like is disposed inside the electrode extraction portion 54.

  Further, it is preferable to further dispose a resin material 52 such as a silicone resin or a fluorine resin at a boundary portion where the pair of electrode portions 21 are exposed to the outside from the electrode extraction portion 54. That is, it is preferable to seal the boundary portion where the pair of electrode portions 21 are exposed to the outside by the resin material 52. By comprising in this way, the insulation at the time of connecting the terminal for electricity supply etc. to a pair of electrode part 21 can be ensured favorable. In this way, the heater 402A as shown in FIG. 11A can be manufactured.

  Next, a specific example of a method for manufacturing the heater 403 as shown in FIG. 12 will be described. The heater 403 shown in FIG. 12 is a unit in which the resin material 72 and the housing 71 are integrated. First, the honeycomb structure part 4 is produced by the method described above. Next, the electrode part 21 is joined to two surfaces arranged in parallel among the side surfaces 5 of the honeycomb structure part 4. The electrode part 21 can be formed of Ni, Cu or the like. Thereby, the heater main body 60 in which the pair of electrode portions 21 are disposed on the two side surfaces 5 of the honeycomb structure portion 4 can be manufactured.

  Next, a mold for forming the housing 71 is prepared. That is, a mold having a concave shape (in other words, a cavity space) corresponding to the shape of the housing 71 to be manufactured is prepared. When manufacturing the housing 71, first, the heater body 60 is placed in a prepared mold. Next, a thermosetting resin to which a curing agent is added is poured into the concave shape of the mold at room temperature in the atmosphere. As the resin, for example, a thermosetting epoxy resin or the like can be used. After the poured resin is cured, the heater body 60 covered with the resin is taken out from the mold. The housing 71 is manufactured by processing the surface of the resin covering the heater body 60 into a predetermined shape. In this way, the heater 403 as shown in FIG. 12 can be manufactured.

  Further, the “heater main body covered with resin” taken out from the mold described above may be further housed in a SUS housing 51 as shown in FIG. 11A to produce a heater. When producing such a heater, it is preferable to dispose a resin sheet on the outside of the heater main body covered with resin and store it in the housing. By comprising in this way, the heater excellent in insulation, heat insulation, and sealing performance can be obtained.

  EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples, but the present invention is not limited to these examples.

( Reference Example 1)
First, the honeycomb structure part which has Si composite SiC as a main component was produced. Specifically, SiC powder, metal Si powder, water, and an organic binder were mixed and kneaded to prepare a clay. Next, this clay was formed into a honeycomb shape to prepare a honeycomb formed body. Next, the obtained honeycomb formed body was fired in an inert gas atmosphere, so that a honeycomb structure part containing Si composite SiC as a main component was produced. The porosity of the obtained Si composite SiC honeycomb was 40%.

The shape of the honeycomb structure part was a cylindrical shape having a square end face. The length of each side of the quadrilateral end face was 38 mm. The length of the honeycomb structure portion in the cell extending direction was 50 mm. The partition wall thickness was 0.38 mm. The thickness of the outer peripheral wall was 0.38 mm. The cell density of the honeycomb structure part was 47 cells / cm ² . The specific resistance of the partition walls and the outer peripheral wall was 30 Ω · cm.

  Thereafter, the honeycomb structure was oxidized in the atmosphere to form an insulating oxide film on the surfaces of the partition walls and the outer peripheral wall. Thereafter, of the four surfaces of the outer peripheral wall of the honeycomb structure portion, each of a pair of opposing surfaces was subjected to surface processing to remove the oxide film, and then an electrode portion was disposed to produce a heater body. Here, as an electrode joining method, the electrode part is joined to the outer peripheral wall of the honeycomb structure part by using a conductive paste containing nickel powder and a silicate solution as a conductive joining material and firing in the air. did. As each electrode part, what has the main part of the electrode part actually arrange | positioned on the side surface of a honeycomb structure part, and the protrusion part extended from the main body of the electrode part was used. The main body of the electrode portion has a surface having the same size as the side surface of the honeycomb structure portion to be arranged. The protruding portion of the electrode portion serves as a terminal portion for ensuring electrical connection with the power source. The material of the electrode part was pure metal nickel (Ni). In addition, the electrode part used what roughened the surface by sandblasting. Thus, a heater body in which a pair of electrode portions was disposed on the two side surfaces of the honeycomb structure portion was manufactured.

  Next, as shown in FIG. 5, a resin material 52 was formed by coating a resin on the outer peripheral portion (more specifically, the side surface 5 of the honeycomb structure portion 4) of the obtained heater main body 50. Fluorine resin was used as the resin to be coated. The resin coating was performed in air at a temperature condition of about 150 ° C. The thickness of the resin material 52 was about 1 to 2 mm.

  Next, a housing 51 for housing the heater body 50 was produced. The housing 51 is composed of a housing main body 51a for housing the heater main body 50 and a lid portion 51b serving as a lid of the housing main body 51a. The housing 51 is a housing having a size that allows a gap of about 0.5 mm between the housing 51 and the heater body 50 coated with a resin material when the heater body 50 is housed in the housing 51. In the housing 51, an inflow port through which the lubricating system fluid flows and an outflow port through which the lubricating system fluid flows out are formed. The material of the housing 51 is stainless steel (SUS304), which is a general-purpose material. The thickness of the metal material constituting the housing 51 was 1.5 mm. As the lid portion 51 b, an electrode extraction portion 54 is provided in a portion through which the pair of electrode portions 21 penetrates, and an O-ring 53 made of a fluorine-based resin is disposed inside the electrode extraction portion 54.

The heater main body 50 in which the resin material 52 is arranged on the outer peripheral portion is arranged in a housing main body 51a made of SUS. Thereafter, the same SUS304 lid 51b as that of the housing main body was disposed in the housing main body 51a such that a part of the pair of electrode portions 21 was exposed. The housing main body 51 a and the lid portion 51 b were joined by laser welding, and the heater main body 50 was accommodated in the housing 51. In this way, the heater of Reference Example 1 was produced.

  Table 1 shows the material of the electrode part, the structure of the electrode part, the structure of the housing, the material of the partition, the porosity (%) of the partition, and the specific resistance (Ω · cm) of the partition and the outer peripheral wall. “Plate type” in the column of “Structure of electrode part” in Table 1 means an electrode part 21 as shown in FIG. That is, each electrode part 21 is formed in a single flat plate shape, and a part of the electrode part 21 arranged on the side surface 5 of the honeycomb structure part 4 is drawn to the outside of the housing 51. To do. In addition, “bar type” in the column of “electrode part structure” in Tables 1 to 4 is an electrode in which the electrode part 21 is arranged on the side surface of the honeycomb structure part 4 as shown in FIGS. It means a structure composed of a substrate 22a and a rod-shaped electrode portion 22b arranged so as to be connected to the electrode substrate 22a.

The “housing structure” in Tables 1 to 4 refers to the structure in the housing of the heater of each reference example / example. FIG. 5, FIG. 10, FIG. 11A, FIG. 11B, FIG. 14 and the structure shown in FIG. 23 are taken as an example. That is, when the “housing structure” is FIG. 5, the resin material is disposed so as to cover the outer periphery of the heater body, and the heater body covered with the resin material has a gap between the resin material and the housing. It shows that it is a heater of the structure accommodated in the housing in the provided state. In addition, when the “housing structure” is FIG. 10, it is indicated that the resin material disposed so as to cover the heater body is a heater having two layers. When the “housing structure” is FIG. 11A and FIG. 11B, this indicates that the heater has a configuration in which a resin material is disposed so as to cover the heater body, and further, a heat insulating material is disposed so as to cover the resin material. . In FIG. 11A, the “structure of the electrode portion” is “flat plate type”. Further, in FIG. 11B, the “structure of the electrode portion” is “bar type”. When the “housing structure” is FIG. 12, it indicates that the resin material and the housing are integrated. When the “housing structure” is FIG. 13, it indicates that the heater is configured so that the lubricating fluid flows also outside the outer peripheral wall of the honeycomb structure portion. In the heater as shown in FIG. 13, the lubricating system fluid can be heated using the outer surface of the outer peripheral wall of the honeycomb structure. When “the structure of the housing” is FIG. 14, it indicates that the housing is formed of a resin material. When the “housing structure” is FIG. 23, it is indicated that the electrode portion is a heater composed of an electrode substrate, an electrode terminal portion, and an electrode substrate connecting portion. In such a heater, each electrode substrate connecting portion of the pair of electrode portions is sandwiched between the housing body and the lid portion in a state where the electrode substrate connecting portions are stacked via an electrically insulating sealing material.

Using the obtained heater of Reference Example 1, an energization heating test was performed by the following method. Table 1 shows the conversion efficiency (%) of Reference Example 1 obtained from the results of the electric heating test.

[Electric heating test]
First, the heater 800 of each reference example and example is installed in an electric heating test apparatus 900 as shown in FIG. The electric heating test apparatus 900 includes a pipe 95 through which a lubricating fluid circulates. A pump 94 is connected to the pipe 95, and the lubricating fluid circulates in the pipe 95 by driving the pump 94. The pipe 95 is provided with a valve 98 and a flow meter 99. Further, thermocouples T1 and T2 and pressure gauges P1 and P2 are arranged on the inlet and outlet sides of the heater 800, respectively. Thereby, the temperature and pressure of the lubricating fluid flowing in from the inlet of the housing of the heater 800 and the temperature and pressure of the lubricating fluid flowing out of the outlet of the housing of the heater 800 can be measured. The cooler 96 is used to adjust the initial temperature of the lubricating fluid. FIG. 28 is an explanatory diagram for explaining a test method of an energization heating test in Examples.

  As described above, the heater 800 is installed in the electric heating test apparatus 900, the pump 94 is driven, and the lubricating fluid is passed through the heater 800. An applied voltage (V) having a value as shown in Table 1 is applied to the heater body of the heater 800 through which the lubricating system fluid has passed, and the lubricating system fluid is heated by the heater 800. While measuring the temperature of the lubricating fluid flowing in from the inlet of the housing and the temperature of the lubricating fluid flowing out of the outlet of the housing with thermocouples T1 and T2, the lubricating fluid flowing out of the outlet of the housing The time (seconds) until the temperature reaches 60 ° C. is measured. As the lubricating fluid, commercially available engine oil (grade: 0W-30, “Mobile 1 (trade name)” manufactured by ExxonMobil) was used. Table 1 shows the applied voltage (V), the flow rate (L / min) of the lubricating fluid that passes through the heater, and the initial temperature (° C.) of the lubricating fluid. The initial temperature of the lubricating fluid is the temperature of the lubricating fluid before being heated by the heater.

  Based on the measured temperature of the lubricating fluid and the time to reach 60 ° C., the conversion efficiency (%) of the heater subjected to the electric heating test was determined based on the following formula (1). Here, the conversion efficiency is the time average value during the test. The “heat transfer amount to the lubricating fluid” in the following formula (1) is a value calculated from the following formula (2). The “input power amount” in the following formula (1) is a value calculated from the following formula (3). It should be noted that the “temperature difference of the lubrication system fluid” in the expression (2) means “the lubrication system fluid flowing out from the outlet of the housing when the temperature of the lubrication system fluid flowing out from the outlet reaches 60 ° C.” It means the value of the difference between “temperature” and “temperature of the lubricating fluid flowing in from the inlet of the housing”.

Conversion efficiency (%) = Heat transfer to lubrication system fluid / Input power amount (1)
Heat transfer amount to lubrication system fluid = Flow rate of lubrication system fluid x Specific heat x Temperature difference of lubrication system fluid (2)
Input power amount = power (W) × time (seconds) (3)

In this energization heating test, the test was performed by adjusting the value of the applied voltage applied to the heater body in accordance with the value of the specific resistance of the honeycomb structure portion of the heater body of each reference example and example. That is, the heater body having a relatively large specific resistance value was set as a “high resistance product”, and the applied voltage was set in the range of 100 to 400V. In addition, the heater body having a relatively small specific resistance value was set as a “low resistance product”, and the applied voltage was set in the range of 10 to 60V.

  As a typical example of the result of heating the lubricating fluid with the heater, the relationship between the heating time of the heater and the temperature of the lubricating fluid under the condition that the flow velocity of the lubricating fluid is 7.5 L / min and the heater applied voltage is 300 V Is shown in FIG. In FIG. 27, temperatures before and after passing through the heater are shown. From this, it was found that the temperature of the lubricating fluid increased from 30 ° C. to 60 ° C. in about 40 seconds. In this test, the heater heating power was turned off in 50 seconds.

  As for the effect of each condition factor, increasing the applied voltage to the heater increased the input power to the lubricating fluid and showed a tendency for the lubricating fluid to increase in temperature in a short time. With respect to the flow rate of the lubricating fluid, the effect on the heating time was small with respect to the effect of the applied voltage.

( Reference Examples 2-14)
A heater was produced in the same manner as in Reference Example 1 except that the material of the electrode part, the structure of the electrode part, and the structure of the housing were changed as shown in Table 1. Using the obtained heater, an energization heating test was conducted in the same manner as in Reference Example 1. Table 1 shows the conversion efficiency (%) obtained from the results of the electric heating test. Table 1 shows the applied voltage (V), the flow rate (L / min) of the lubricating fluid passing through the heater, and the initial temperature (° C.) of the lubricating fluid in the electric heating test.

In Reference Examples 2 to 5 in which “Housing Structure” is FIG. 10, a resin material coated as in Reference Example 1 was used as the first resin material 52 a. And the 2nd resin material 52b was arrange | positioned so that this 1st resin material 52a might be covered. As the second resin material 52b, the following resin material mat was used. A silicone resin having a thickness of 2 mm was used as a mat for the resin material.

In Reference Examples 6 to 14 where the “housing structure” is FIG. 11A, a ceramic fiber sheet (Al 2 O 3 —SiO 2) having a thickness of 5 mm was used as the breaker. In the reference example of FIG. 11B in “housing structure”, a ceramic fiber sheet (Al 2 O 3 —SiO 2 system) having a thickness of 5 mm was used as the breaker material, as in Reference Examples 6 to 14. In Reference Examples 12 to 14, pure metal copper (Cu) was used as the material of the electrode portion.

( Reference Examples 15-30)
A heater was produced in the same manner as in Reference Example 1, except that the electrode part material, the electrode part structure, the housing structure, and the partition wall material were changed as shown in Table 2. In Reference Examples 15 to 30, the structure of the electrode part is “bar-shaped”. This rod-shaped electrode portion has a cylindrical shape with an end face diameter of 6 mm.

Using the heaters of the obtained Reference Examples 15 to 30, an electric heating test was performed in the same manner as in Reference Example 1. Table 2 shows the conversion efficiency (%) obtained from the results of the electric heating test. Table 2 shows the applied voltage (V), the flow rate (L / min) of the lubricating fluid passing through the heater, and the initial temperature (° C.) of the lubricating fluid in the electric heating test.

In Reference Examples 18 to 20 and Reference Examples 24 to 30, the partition wall material was “recrystallized SiC”. A method for manufacturing a honeycomb structure portion having partition walls made of recrystallized SiC is as follows. First, raw materials containing SiC powder, an organic binder, and “water or an organic solvent” were mixed and kneaded to prepare a clay. Next, this kneaded material was formed to produce a honeycomb formed body. Next, the obtained formed body was fired at a predetermined temperature (1600 to 2300 ° C.) in a nitrogen gas atmosphere to produce a honeycomb structure part.

( Reference Examples 31-38)
A heater was produced in the same manner as in Reference Example 1 except that the material of the electrode part, the structure of the electrode part, the structure of the housing, and the material of the partition walls were changed as shown in Table 3. Here, in Reference Examples 33 and 34 and Reference Examples 35 and 36, pure metals Mo and W were used as the material of the electrode portions. Using the obtained heater, an energization heating test was conducted in the same manner as in Reference Example 1. Table 3 shows the conversion efficiency (%) obtained from the results of the electric heating test. Table 3 shows the applied voltage (V), the flow rate (L / min) of the lubricating fluid passing through the heater, and the initial temperature (° C.) of the lubricating fluid in the electric heating test.

In Reference Examples 31 and 32, the material of the partition walls was “reactive sintered SiC (porous)”. “Reactive sintered SiC (porous)” refers to porous reactive sintered SiC. The manufacturing method of the honeycomb structure part which has the partition which consists of reaction sintering SiC (porous) is as follows. First, a clay is prepared by mixing and kneading silicon nitride powder, carbonaceous material, silicon carbide and graphite powder. Next, this kneaded material was formed to produce a honeycomb formed body. Next, the molded body was primarily fired in a non-oxidizing atmosphere to obtain a primary fired body. Next, the obtained primary fired body was heated and decarburized in an oxidizing atmosphere to remove the remaining graphite. Next, the “decarburized primary fired body” was subjected to secondary firing at a predetermined temperature (1600 to 2500 ° C.) in a non-oxidizing atmosphere to obtain a secondary fired body. The obtained secondary fired body becomes a honeycomb structure part.

In Reference Examples 37 and 38, a copper tungsten composite material was used as the material of the electrode portion. The composite material used was a tungsten (W) volume fraction of 85%. In the column of “Material of power section” in Table 3, the copper tungsten composite material is described as “Cu / W”.

(Examples 39 to 42)
The material of the electrode part, the structure of the electrode part, the structure of the housing, and the material of the partition were changed as shown in Table 3, and a heater in which the resin material and the housing were integrated was produced by the following method. First, a heater body having a honeycomb structure according to the partition material shown in Table 3 was manufactured. Next, a mold for forming the housing was prepared. That is, a mold having a concave shape corresponding to the shape of the housing to be manufactured was prepared. In this mold, the heater main body after electrode joining is arranged, and further, after inserting an O-ring made of a fluororesin into a predetermined position on the outer periphery of the electrode part, in the concave shape of the mold, in the atmosphere, At room temperature, a thermosetting resin added with a curing agent is poured. As the resin, a thermosetting epoxy resin was used. After the poured resin was cured, the heater main body covered with the resin was taken out from the mold. The surface of the resin covering the heater body was processed to produce a housing from the resin covering the heater body. Using the obtained heater, an energization heating test was conducted in the same manner as in Reference Example 1. Table 3 shows the conversion efficiency (%) obtained from the results of the electric heating test. Table 3 shows the applied voltage (V), the flow rate (L / min) of the lubricating fluid passing through the heater, and the initial temperature (° C.) of the lubricating fluid in the electric heating test.

(Examples 43 to 46)
A heater in which the material of the electrode part, the structure of the electrode part, the structure of the housing, and the material of the partition are changed as shown in Table 3 and the housing is made of resin (that is, the “housing structure” is the heater of FIG. 14). Was prepared by the following method. First, a heater body having a honeycomb structure according to the partition material shown in Table 3 was manufactured. In the same manner as in Reference Example 1, the outer peripheral portion of the heater body was coated with a resin to form a resin material. Apart from this heater body, a housing was made using a fluorine-based resin. The fluororesin used for the housing was 5 mm thick. The obtained resin housing accommodates a heater main body coated with resin and disposed with a resin material, and further between the housing and the heater main body, the same ceramic fiber sheet (Al2O3-SiO2 type) as described above. The heater was prepared by arranging the heat insulating material. Using the obtained heater, an energization heating test was conducted in the same manner as in Reference Example 1. Table 3 shows the conversion efficiency (%) obtained from the results of the electric heating test. Table 3 shows the applied voltage (V), the flow rate (L / min) of the lubricating fluid passing through the heater, and the initial temperature (° C.) of the lubricating fluid in the electric heating test.

( Reference Examples 47-50)
The material of the electrode part, the structure of the electrode part, the structure of the housing, and the material of the partition walls were changed as shown in Table 4 to produce a heater configured to allow the lubricating fluid to flow outside the honeycomb structure part. That is, in the heaters of Reference Examples 47 to 50, the “housing structure” is the heater of FIG. Using the obtained heater, an energization heating test was conducted in the same manner as in Reference Example 1. Table 4 shows the conversion efficiency (%) obtained from the results of the electric heating test. Table 4 shows the applied voltage (V), the flow rate (L / min) of the lubricating fluid passing through the heater, and the initial temperature (° C.) of the lubricating fluid in the energization heating test. In Reference Examples 47 to 50, a resin material was coated on the inside of the housing. The thickness of the resin material coated on the inside of the housing is about 2 mm. In addition, a fluorine resin was used as the resin material.

( Reference Examples 51-54)
The material of the electrode part, the structure of the electrode part, the structure of the housing, and the material of the partition walls were changed as shown in Table 4 to produce a heater having a structure as shown in FIG. Using the obtained heater, an energization heating test was conducted in the same manner as in Reference Example 1. Table 4 shows the conversion efficiency (%) obtained from the results of the electric heating test. Table 4 shows the applied voltage (V), the flow rate (L / min) of the lubricating fluid passing through the heater, and the initial temperature (° C.) of the lubricating fluid in the energization heating test.

( Reference Examples 55 and 56)
The material of the electrode part, the structure of the electrode part, the structure of the housing, and the material of the partition walls were changed as shown in Table 4 to produce a heater having a structure as shown in FIG. 11B. In this reference example, the test was performed in a state where the low temperature operation was simulated and the initial temperature of the lubricating fluid was lowered to 0 ° C. Using the obtained heater, an energization heating test was conducted in the same manner as in Reference Example 1. Table 4 shows the conversion efficiency (%) obtained from the results of the electric heating test. Table 4 shows the applied voltage (V), the flow rate (L / min) of the lubricating fluid passing through the heater, and the initial temperature (° C.) of the lubricating fluid in the energization heating test.

(result)
As shown in Tables 1 to 4, the heaters of Reference Examples 1 to 38, Examples 39 to 46, and Reference Examples 47 to 56 had high conversion efficiency in the electric heating test. Thus, in the heaters of Reference Examples 1 to 38, Examples 39 to 46, and Reference Examples 47 to 56, since the resin material is disposed between the housing and the heater body, the insulation of the heater body is ensured. In addition, it can be seen that the heat heated by the heater body is prevented from diffusing outside through the housing. Furthermore, the conversion efficiency could be further improved by using a ceramic fiber sheet heat insulating material in addition to the resin material or making the housing made of resin. Moreover, the weight of the heater could be reduced by using a resin housing. In Reference Examples 55 and 56, since the initial temperature of the lubricating fluid was lowered to 0 ° C., the viscosity at the time of start-up increased, and the lubricating fluid at the time of passing through the honeycomb as compared with the initial temperature of 30 ° C. Although the pressure loss was high, there was no problem in operation and it was a good heater.

In addition, by utilizing the resin material extensively like the heaters of Reference Examples 1 to 38, Examples 39 to 46, and Reference Examples 47 to 56, it is possible to produce a housing structure with a simple and low temperature process as well as weight reduction. It became. In addition, by using a heater body having a honeycomb-shaped honeycomb structure part and a pair of electrode parts arranged on the side surface, the heater body can be downsized, heated quickly, and highly converted compared to conventional heaters. It turns out to gain efficiency. The housing structure and the arrangement of the resin material and the like inside the housing are preferably determined as appropriate in consideration of the conversion efficiency described above and the strength design and durability required for the heater.

  The present invention can be used as a heater that can be used to heat lubricating fluid such as engine oil and transmission fluid.

1: partition wall, 2: cell, 3: outer peripheral wall, 4: honeycomb structure part, 5: side face, 11: one end face, 12: the other end face, 21: electrode part, 22a: electrode substrate, 22b: electrode part, 23: Conductive joint portion, 24: Electrode portion, 25 electrode portion, 26a: Electrode substrate, 26b: Electrode portion, 31: Electrode portion, 31a: Electrode substrate, 31b: Electrode terminal portion, 31c: Electrode substrate connecting portion, 35 : Seal material, 41: Electrode part, 42: Vibration absorption part, 43: Electrode part, 43a: Electrode substrate, 43b: Electrode terminal part, 50, 60, 70, 80, 90: Heater main body, 51, 61, 71, 73, 81, 91: Housing, 51a: Housing body, 51b: Lid, 52, 72: Resin material, 52a: First resin material, 52b: Second resin material, 53: O-ring, 54: Electrode extraction Part, 55: inlet, 56: outlet, 57: disconnection Material: 74: Electrode extraction part, 91a: Housing body, 91b: Cover part, 94: Pump, 95: Piping, 96: Cooler, 98: Valve, 99: Flow meter, 100, 200, 300, 401, 402A, 402B , 403, 404, 405, 406, 500, 600, 700, 800: heater, 152: 153: heater body, 900: current heating test device, P1, P2: pressure gauge, T1, T2: thermocouple.

Claims (9)

A heater body, a housing for housing the heater body, and a resin material disposed at least in part between the heater body and the housing,
The heater body is disposed on a side surface of the honeycomb structure having a cylindrical honeycomb structure having partition walls that define and form a plurality of cells extending from one end face to the other end face serving as a flow path for the lubricating fluid. A pair of electrode portions,
The housing has an inflow port through which the lubricating system fluid flows in and an outflow port through which the lubricating system fluid that has passed through the cell formed in the heater body flows out, and covers the side surface side of the heater body. Store the heater body,
The partition walls of the honeycomb structure portion are made of a material mainly composed of ceramics, and the partition walls generate heat when energized ,
The partition wall is mainly composed of one selected from the group consisting of SiC, metal-impregnated SiC, metal composite SiC, and metal composite Si ₃ N ₄ .
A heater in which a material of the housing is resin . The heater according to claim 1 , wherein the housing and the resin material are integrated. The heater according to claim 1 , wherein a heat insulating material is disposed between the heater body and the housing inside the housing. The resin material is at least disposed between the heater body and the housing on the one end face side of the heater body and between the heater body and the housing on the other end face side of the heater body. The heater according to claim 2 or 3 . A part of the pair of electrode portions extends through the housing to the outside of the housing,
The heater according to claim 2 or 3 , wherein the resin material is disposed at least between the pair of electrode portions and the housing in a portion where the pair of electrode portions penetrates the housing. The heater according to claim 2 or 3 , wherein the resin material is disposed between the heater body and the housing so as to cover at least the entire region of the pair of electrode portions disposed in the heater body. 4. The heater according to claim 2 , wherein each of the pair of electrode portions includes an electrode substrate disposed on a side surface of the honeycomb structure portion and a rod-shaped electrode portion disposed so as to be connected to the electrode substrate. . The heater according to claim 2 or 3 , wherein the heat resistant temperature of the resin material is 80 ° C or higher. The heater according to claim 2 or 3, wherein a specific resistance of the resin material is 10 ⁹ Ω · cm or more.

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