JP6936575B2 - Electric heaters for vehicle air conditioners and their manufacturing methods - Google Patents

Description

The present invention relates to, for example, the structure and manufacturing method of an electric heater provided in a vehicle air conditioner mounted on an automobile or the like, and in particular, transfers the heat of a heating element generated by the supply of electric power to the air conditioner air. It belongs to the technical field of structures with fins.

Conventionally, for example, an air conditioner for a vehicle may be provided with an electric heater for heating air for air conditioning (see, for example, Patent Documents 1 and 2). The electric heater is provided with a PTC element and fins for heat dissipation and a spring element for compressing the PTC element and fins in the stacking direction. The PTC element, fins and spring elements are laminated by a holding frame. It is held at.

In Patent Documents 1 and 2, a plurality of columns extending from the upper side portion to the lower side portion of the holding frame and connecting the upper side portion and the lower side portion are provided. The columns extend straight in the vertical direction and are arranged at equal intervals in the width direction of the holding frame. Then, the air conditioning air is heated by the heat of the PTC element while passing through the inside of the holding frame and passing through the fins.

Further, the holding frames of Patent Documents 1 and 2 include an upper housing and a lower housing divided into two in the flow direction of external air. Then, at the time of manufacturing the electric heaters of Patent Documents 1 and 2, first, the PTC element and the fins are assembled in a laminated state on the upper housing. In this state, the lower housing is assembled to the upper housing, and at this time, the spring element is pushed into the upper housing to apply a compressive force to the PTC element and the fins in the stacking direction. By assembling the lower housing to the upper housing, the PTC element and the fins are held from both sides in the flow direction of the external air, and are compressed in the stacking direction.

Japanese Patent No. 4880648 Japanese Patent No. 4939490

By the way, in Patent Documents 1 and 2, after the PTC element and the fin are assembled to the upper housing, the spring element is pushed into the upper housing by the lower housing when the lower housing is assembled, and the PTC element, the fin and the spring are pushed into the upper housing. The elements cannot be assembled to the upper housing at once, and must be assembled at different timings, resulting in poor workability.

Therefore, it is conceivable to assemble the PTC element, the fin, and the spring element to the upper housing at once, and then assemble the lower housing to the upper housing. However, in this case, the lower housing is assembled to the upper housing after the PTC element, the fin, and the spring element are assembled to apply the compressive force of the spring element. Therefore, before assembling the lower housing to the upper housing, that is, when the upper housing is open, the compressive force due to the spring element always acts on the PTC element and the fins, so that even a small vibration or the like is used. The PTC element and fins may pop out from the open portion of the upper housing due to the elastic force of the spring element and may be disassembled, so it cannot be said that the assembly workability is good.

Further, at the time of manufacturing, a part of the lower housing is inserted between the spring element and the inner surface of the upper housing while the compressive force of the spring element is constantly acting on the PTC element and the fins. The force required at the start of assembling the lower housing becomes large, which may also cause deterioration of the assembling workability.

The present invention has been made in view of the above points, and an object of the present invention is to improve the assembling workability when the heating element and the fins are assembled to the holding frame in a laminated state.

In order to achieve the above object, in the present invention, the spring member exerts a force in the stacking direction on the heating element and the fins before combining the first frame constituent member and the second frame constituent member constituting the holding frame. I tried not to let you.

In the first invention, a heating element that generates heat by supplying electric power, fins that are arranged in a state of being laminated on the heating element, and the heating element and the fins that are arranged on one side in the stacking direction and generate the heat. The holding frame includes a one-side spring member for applying a compressive force in the stacking direction to the body and the fins, and a holding frame for accommodating the heating element, the fins, and the one-side spring member and holding them in a stacked state. In the electric heater of the vehicle air conditioner in which the air conditioner air blown into the frame is heated by passing through the fins, the holding frame is a first frame arranged on one side in the flow direction of the air conditioner air. The constituent members and the second frame constituent members arranged on the other side are combined and configured, and the first frame constituent members are arranged on one side and the other side in the stacking direction of the heating element and the fins, respectively. The first and second holding wall portions and the first holding wall portion extend to the second holding wall portion, and the one-side spring member, the heating element, and the fins are held from one side in the flow direction of the air conditioning air. The distance between the first holding wall portion and the second holding wall portion is such that the heating element, the fin, and the one are in a laminated state without applying an external force in the stacking direction. The second frame constituent member is set to be equal to or larger than the total dimension in the stacking direction of the side spring members, and the second frame constituent member has a first joint portion that is coupled to the first holding wall portion and a second joint portion that is coupled to the second holding wall portion. And the other-side connecting portion that extends from the first coupling portion to the second coupling portion and holds the one-side spring member, the heating element, and the fins from the other side in the flow direction of the air conditioning air, and the first The first coupling portion has a one-side spring compression portion that is inserted between the holding wall portion and the one-side spring member to elastically deform the one-side spring member in the stacking direction of the heating element and the fins. It has a fitting hole that opens on the side of the first frame constituent member, and the first holding wall portion is inserted into the fitting hole, and the second holding wall portion is fitted. The second joint portion has a fitting hole that opens on the side of the second frame constituent member, and the second joint portion has a joint plate portion that protrudes toward the first frame constituent member side, and the fitting of the second holding wall portion. The joint plate portion of the second joint portion is fitted into the hole in a state of being inserted, the one-side spring member is adjacent to the fin, and the one-side spring member is along the fin. A flat plate-shaped substrate portion extending from the spring, an upstream elastically deformed portion extending from an edge portion on the upstream side in the flow direction of air conditioning air in the substrate portion, and an edge portion on the downstream side in the flow direction of air conditioning air in the substrate portion. The upstream elastically deformed portion is provided with a downstream elastically deformed portion extending from the above, and the upstream elastically deformed portion extends diagonally toward the downstream side in the flow direction of air conditioning air while being separated from the substrate portion, and then the tip side approaches the substrate portion. The downstream elastically deformed portion extends diagonally toward the upstream side in the flow direction of the air conditioning air while being separated from the substrate portion, and then bends in the direction in which the tip side approaches the substrate portion. A ridge portion extending in the insertion direction is formed on the surface of the one-side spring compression portion on the one-side spring member side.

That is, at the time of manufacturing an electric heater, first, a heating element and fins are laminated and arranged between the first holding wall portion and the second holding wall portion of the first frame constituent member, and one side is one side in the stacking direction. Place the spring member. At this time, the total dimensions of the heating elements, fins, and one-side spring members in the laminated state in a laminated state without applying an external force in the stacking direction are secured at least the distance between the first holding wall portion and the second holding wall portion. Therefore, the compressive force of the spring member does not act on the heating element and fins. Therefore, even before assembling the second frame constituent member to the first frame constituent member, the heating element and fins are less likely to pop out from the first frame constituent member, and the assembling workability is improved.

Then, when the second frame constituent member is assembled to the first frame constituent member, when the one-side spring compression portion is inserted between the first holding wall portion and the one-side spring member, the compressive force of the one-side spring member acts. Therefore, the force required at the start of assembly is small, which also improves the assembly workability.

When the second frame constituent member is assembled to the first frame constituent member, the first joint portion of the second frame constituent member is connected to the first holding wall portion of the first frame constituent member, and the second coupling portion of the second frame constituent member is joined. The portion is connected to the second holding wall portion of the first frame constituent member. As a result, the heating element, the fins, and the one-side spring member are held by the one-side connecting portion and the one-side connecting portion from both sides in the flow direction of the air conditioning air.

Further, when the second frame constituent member is assembled to the first frame constituent member, when the one-side spring compression portion is inserted between the first holding wall portion and the spring member, the ridge portion of the one-side spring compression portion is on one side. It will come into contact with the spring member. As a result, the sliding area between the one-side spring compression portion and the one-side spring member is reduced, and the sliding resistance is reduced.

According to the second invention, in the first invention, the distance between the first holding wall portion and the second holding wall portion is such that the heating element, the fins, and the heating element are in a laminated state without applying an external force in the stacking direction. It is characterized in that it is set to be larger than the total dimension in the stacking direction of the one-side spring member.

According to this configuration, the total dimension in the stacking direction of the heating element, the fin, and the one-side spring member in the laminated state without applying an external force in the stacking direction is the distance between the first holding wall portion and the second holding wall portion. Is smaller than. As a result, even if there is some dimensional error in the stacking direction in the heating element, fins, and one-side spring member, the compressive force of the spring member is applied to the heating element before assembling the second frame component to the first frame component. And does not act on fins. As a result, the heating element and fins are less likely to pop out from the first frame constituent member, and the force required at the start of assembly can be reduced.

In the first or second invention, the third invention is arranged on the other side of the heating element and the fins in the stacking direction, and is a spring on the other side for applying a compressive force in the stacking direction to the heating element and the fins. The distance between the first holding wall portion and the second holding wall portion, which is provided with a member, is such that the heating element, the fin, the one-side spring member, and the others are in a laminated state without applying an external force in the stacking direction. The second frame constituent member is set to be equal to or larger than the total dimension in the stacking direction of the side spring members, and the second frame constituent member is inserted between the second holding wall portion and the other side spring member, and the other side spring member is inserted into the heating element and the other side spring member. It is characterized by having a spring compression portion on the other side that elastically deforms in the stacking direction of the fins.

According to this configuration, when assembling the second frame constituent member to the first frame constituent member, when the other side spring compression portion is inserted between the first holding wall portion and the other side spring member, the force required at the start of assembly is required. Is small, which also improves the assembly workability. Then, when the second frame constituent member is assembled to the first frame constituent member, the heating element and the fins are compressed from both sides in the stacking direction by the one-side spring member and the other-side spring member.

In the fourth invention, a heating element that generates heat by supplying electric power, fins that are arranged in a state of being laminated on the heating element, and the heating element and the fins that are arranged on one side in the stacking direction and generate the heat. It is provided with a one-side spring member for applying a compressive force in the stacking direction to the body and the fins, and a holding frame for accommodating the heating element, the fins and the one-side spring member and holding them in a laminated state. The side spring member is adjacent to the fin, and the one-side spring member extends from a flat plate-shaped substrate portion extending along the fin and an edge portion on the substrate portion on the upstream side in the flow direction of air conditioning air. The upstream side elastically deformed portion and the downstream side elastically deformed portion extending from the edge portion on the downstream side in the flow direction of the air conditioning air in the substrate portion are provided. After extending diagonally toward the downstream side in the flow direction, the tip side extends so as to bend in a direction approaching the substrate portion, and the downstream elastically deformed portion is upstream in the flow direction of air conditioning air while being separated from the substrate portion. A vehicle in which the tip side extends so as to bend in a direction approaching the substrate portion after extending diagonally toward the side, and the air conditioning air blown into the inside of the holding frame passes through the fins and is heated. In the method for manufacturing an electric heater of an air conditioner for air use, the heating element and the fins are laminated between the first holding wall portion and the second holding wall portion of the first frame constituent member constituting the holding frame, and the heating element and the fins are laminated. The one-side spring member is arranged on the first holding wall side between the first holding wall portion and the second holding wall portion in a state where no external force is applied in the stacking direction, and then the holding frame. The first joint portion is coupled to the first holding wall portion by inserting the first holding wall portion into the fitting hole of the first joint portion of the second frame constituent member constituting the above and fitting the first holding wall portion. By inserting the joint plate portion of the second joint portion of the second frame constituent member into the fitting hole of the second holding wall portion and fitting the second frame portion. A step of connecting the joint portion to the second holding wall portion and a ridge portion extending in the insertion direction are formed on the surface of the one-side spring compression portion of the second frame component member on the one-side spring member side. The step of inserting the one-side spring compression portion between the first holding wall portion and the one-side spring member to elastically deform the one-side spring member in the stacking direction of the heating element and the fins is performed. A one-sided connecting portion that connects the first holding wall portion and the second holding wall portion of one frame constituent member, and the first holding wall portion. (2) The heating element, the fins, and the one-side spring member are held from both sides in the air flow direction by the first connecting portion of the frame constituent member and the other connecting portion connecting the second connecting portion. It is characterized by.

According to this configuration, a heating element and fins are laminated and arranged between the first holding wall portion and the second holding wall portion of the first frame constituent member, and the one-side spring member is arranged on one side in the laminating direction. In this state, the compressive force of the spring member does not act on the heating element and fins, so the heating element and fins are still on the first frame component even before the second frame component is assembled to the first frame component. It becomes difficult to pop out from the air, and the assembly workability is improved.

When the one-side spring compression part is inserted between the first holding wall part and the one-side spring member, the compression force by the one-side spring member does not act, so the force required at the start of assembly can be small. Also improves assembly workability.

According to the first and fourth inventions, before combining the first frame constituent member and the second frame constituent member constituting the holding frame, the one-side spring member assembled to the first frame constituent member is a heating element and fins. Since the force in the stacking direction is not applied to the heating element, the heating element and the fins are less likely to pop out from the first frame constituent member, and the force required at the start of assembly is small. Thereby, the assembly workability can be improved.

Further, since a ridge portion extending in the insertion direction is formed on the surface of the one-side spring compression portion of the second frame component member on the one-side spring member side, when the second frame component member is assembled to the first frame component member, When the one-side spring compression portion is inserted between the first holding wall portion and the spring member, the sliding resistance between the one-side spring compression portion and the one-side spring member can be reduced. Thereby, the assembly workability can be further improved.

According to the second invention, the distance between the first holding wall portion and the second holding wall portion is made larger than the total dimension of the heating element, the fin, and the one-side spring member in the stacking direction. Even if there is some dimensional error in the stacking direction, the assembly workability can be improved.

According to the third invention, the heating element and the fins can be compressed from both sides in the stacking direction by the one-side spring member and the other-side spring member, and in this case, the assembling workability can be improved.

It is a perspective view which looked at the electric heater of the vehicle air-conditioning apparatus which concerns on Embodiment 1 from the upstream side in the flow direction of the air-conditioning air. It is a perspective view which shows the state which the upstream frame component member and the left and right cap members of an electric heater are removed. FIG. 3 is an enlarged perspective view showing the vicinity of the upper part of the electric heater in FIG. 2. FIG. 2 is a sectional view taken along line IV-IV in FIG. FIG. 5 is a sectional view taken along line VV in FIG. FIG. 2 is a view corresponding to FIG. 2 according to the second embodiment.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. It should be noted that the following description of the preferred embodiment is essentially merely an example and is not intended to limit the present invention, its application or its use.

(Embodiment 1)
FIG. 1 shows an electric heater 1 of a vehicle air conditioner according to the first embodiment of the present invention. The electric heater 1 is a heater that is arranged inside a vehicle air conditioner (not shown) and is used to heat the air conditioning air introduced into the vehicle air conditioner from the outside or the inside of the vehicle. The vehicle air conditioner is mounted inside an instrument panel (not shown) in the vehicle interior of an automobile, for example, and can control the temperature of the air conditioner air and supply it to various parts of the vehicle interior. There is. Specifically, although not shown, the vehicle air conditioner includes a casing, a blower fan, a cooling heat exchanger, and the electric heater. The blower fan and cooling heat exchanger are housed inside the casing. The blower fan is for sending air for air conditioning. The cooling heat exchanger is for cooling the air conditioning air. The electric heater 1 is arranged inside the casing on the downstream side of the cooling heat exchanger in the flow direction of the air conditioning air, and is for heating the air conditioning air. Further, an air mix damper is arranged inside the casing. The air mix damper is for changing the temperature of the conditioned air by changing the amount of air passing through the electric heater 1. Further, a defroster damper, a vent damper and a heat damper are also arranged inside the casing. The defroster damper is for changing the amount of air conditioning air blown toward the inner surface of the front window (not shown), and the vent damper is for changing the amount of air conditioning air blown toward the upper body of the occupant. The heat damper is for changing the amount of air-conditioning air blown toward the vicinity of the occupant's feet. The structure of the vehicle air conditioner is not limited to the above structure.

The electric heater 1 includes an upper heating element 50, a central first heating element 51, a central second heating element 52, a lower heating element 53, a plurality of fins 54, and an upper spring member (one-side spring member) 55. The holding frame 60 is provided, and when viewed from the flow direction of the air conditioning air, it has a long rectangular shape in the left-right direction as a whole. The upper heating element 50, the central first heating element 51, the central second heating element 52, and the lower heating element 53 generate heat by supplying electric power from a battery or the like (not shown) mounted on the vehicle. It has the same structure with a PTC element (not shown) and has a long plate shape in the left-right direction. A plurality of PTC elements are arranged so as to be arranged in the left-right direction inside each of the upper heating element 50, the central first heating element 51, the central second heating element 52, and the lower heating element 53.

In the description of this embodiment, the upstream side and the downstream side in the flow direction of the air conditioning air are defined as shown in FIG. 4, but the air conditioning air may be arranged so as to flow in the opposite direction. Further, the left side and the right side of the electric heater 1 are defined as shown in each figure, but this may or may not coincide with the left side and the right side of the vehicle. Further, the upper side and the lower side of the electric heater 1 are defined as shown in each figure, but this may or may not coincide with the upper side and the lower side of the vehicle.

As shown in FIG. 2, the upper heating element 50 is arranged above the electric heater 1. At the right end of the upper heating element 50, an electrode plate 50a connected to the PTC element is provided so as to project to the right. The central portion first heating element 51 is arranged closer to the upper side in the vertical central portion of the electric heater 1. At the right end of the central first heating element 51, an electrode plate 51a connected to the PTC element is provided so as to project to the right. The central portion second heating element 52 is arranged closer to the lower side in the vertical central portion of the electric heater 1. At the right end of the central second heating element 52, an electrode plate 52a connected to the PTC element is provided so as to project to the right. The lower heating element 53 is arranged below the electric heater 1. At the right end of the lower heating element 53, an electrode plate 53a connected to the PTC element is provided so as to project to the right.

The left ends of the upper heating element 50, the central first heating element 51, the central second heating element 52, and the lower heating element 53 project to the left of the left end of the fins 54. Further, the right end portion of the upper heating element 50, the central first heating element 51, the central second heating element 52, and the lower heating element 53 protrudes to the right side of the left end portion of the fin 54.

The fin 54 is a corrugated fin having a continuous wavy shape that is long in the left-right direction. The member constituting the fin 54 is, for example, a thin plate material made of an aluminum alloy. The fins 54 are arranged on the upper and lower surfaces of the upper heating element 50, the upper and lower surfaces of the central first heating element 51, the upper and lower surfaces of the central second heating element 52, and the upper and lower surfaces of the lower heating element 53, respectively. ing. That is, the fin 54 and the upper heating element 50, the central first heating element 51, the central second heating element 52, and the lower heating element 53 are laminated. Further, since the fins 54 are in contact with the upper heating element 50, the central first heating element 51, the central second heating element 52, and the lower heating element 53, the upper heating element 50, the central first heating element 51, The heat of the central second heating element 52 and the lower heating element 53 is efficiently transferred to the fins 54.

As shown in FIG. 3 and the like, since the fin 54 is a corrugated fin, a large number of ridges 54a are formed on the upper portion and the lower portion of the fin 54 at intervals in the left-right direction. The portion of the fin 54 between the upper ridge 54a and the lower ridge 54a has a flat plate shape extending substantially in the vertical direction.

As shown in FIG. 2, an upper insulating plate 56 extending in the left-right direction is arranged between the two fins 54 and 54 arranged between the upper heating element 50 and the central first heating element 51. Has been done. The fins 54 are in contact with the upper surface and the lower surface of the upper insulating plate 56, respectively. Further, an intermediate insulating plate 57 extending in the left-right direction is arranged between the two fins 54 and 54 arranged between the central portion first heating element 51 and the central portion second heating element 52. There is. The fins 54 are in contact with the upper surface and the lower surface of the intermediate insulating plate 57, respectively. Further, a lower insulating plate 58 extending in the left-right direction is arranged between the two fins 54 and 54 arranged between the central second heating element 52 and the lower heating element 53. The fins 54 are in contact with the upper surface and the lower surface of the lower insulating plate 58, respectively.

The upper insulating plate 56, the intermediate insulating plate 57, and the lower insulating plate 58 are made of, for example, a resin material having electrical insulation, so that the fins 54 and 54 arranged in the vertical direction are not electrically connected. It is a member of. The thickness (vertical dimensions) of the upper insulating plate 56, the intermediate insulating plate 57, and the lower insulating plate 58 is the upper heating element 50, the central first heating element 51, the central second heating element 52, and the lower heating element 53. It is set thinner than the thickness of. Further, the left end portion of the upper insulating plate 56, the intermediate insulating plate 57, and the lower insulating plate 58 protrudes to the left side from the left end portion of the fin 54. Further, the right end portions of the upper insulating plate 56, the intermediate insulating plate 57, and the lower insulating plate 58 project to the right side of the left end portion of the fin 54.

The upper spring member 55 is arranged so as to be adjacent to the upper portion of the fin 54 located at the upper end portion of the electric heater 1, that is, on one side of the heating elements 50 to 53 and the fin 54 in the stacking direction. The upper spring member 55 is for applying an urging force so as to compress the heating elements 50 to 53, the insulating plates 56 to 58, and the fins 54 held by the holding frame 60 in the stacking direction, and the whole is elastic. It is composed of a metal material that has. As shown in FIG. 4 and the like, the upper spring member 55 has a substrate portion 55a extending in the left-right direction along the upper portion of the fin 54 and an upstream elasticity extending from the edge portion of the substrate portion 55a on the upstream side in the air flow direction. The deformed portion 55b and the downstream elastic deformed portion 55c extending from the edge portion on the downstream side in the flow direction of the air conditioning air in the substrate portion 55a are provided.

The upstream elastically deformed portion 55b extends upward from the substrate portion 55a and diagonally toward the downstream side in the flow direction of the air conditioning air, and then the tip end side bends downward and extends. The downstream elastically deformed portion 55c extends upward from the substrate portion 55a and diagonally toward the upstream side in the flow direction of the air conditioning air, and then the tip end side bends downward and extends. The upstream elastically deformed portion 55b and the downstream elastically deformed portion 55c are elastically deformed downward.

As shown in FIG. 5, the holding frame 60 includes an upper heating element 50, a central first heating element 51, a central second heating element 52, a lower heating element 53, fins 54, an upper spring member 55, and an upper insulating plate 56. , The intermediate insulating plate 57 and the lower insulating plate 58 are accommodated and held in a laminated state. Most of the vertical intermediate portion of the holding frame 6 is open, and the air conditioning air blown into the holding frame 6 passes through the fins 54 and is heated.

The holding frame 60 is arranged on the upstream side frame component (second frame component) 70 arranged on the upstream side (one side) of the air conditioning air flow direction and on the downstream side (other side) of the air conditioning air flow direction. It has a downstream side frame constituent member (first frame constituent member) 80, and is configured by combining these upstream side frame constituent member 70 and the downstream side frame constituent member 80. The upstream frame component 70 and the downstream frame component 80 are formed by injection molding a resin material having electrical insulation. The air-conditioning air flow direction may be opposite to the direction shown in FIG. 4. In this case, the frame component 70 is arranged on the downstream side in the air-conditioning air flow direction, and the frame component 80 is arranged. It will be located on the upstream side in the flow direction of air conditioning air.

The downstream frame component 80 includes a downstream upper side portion 81 arranged on one side (upper side) of the heating elements 50 to 53 and the fins 54 in the stacking direction, and the other side (lower) of the heating elements 50 to 53 and the fins 54 in the stacking direction. It has a downstream side lower side portion 82 arranged on the side) and a downstream side connecting portion 83. The downstream upper side portion 81 extends in the left-right direction. A plurality of upper holding wall portions (first holding wall portions) 81a projecting to the upstream side and extending in the left-right direction are formed on the surface of the downstream upper side portion 81 on the upstream side in the flow direction of the air conditioning air. The upper holding wall portions 81a are arranged at intervals in the left-right direction, but may be continuous wall portions in the left-right direction.

The lower side portion 82 on the downstream side is formed with a lower holding wall portion (second holding wall portion) 82a that projects toward the upstream side in the flow direction of the air conditioning air and extends in the left-right direction. The lower holding wall portion 82a is formed with a fitting hole 82b that opens on the upstream side in the flow direction of the air conditioning air long in the left-right direction.

As shown in FIG. 4, between the upper holding wall portion 81a and the lower holding wall portion 82a of the downstream frame constituent member 80, heating elements 50 to 53, fins 54, an upper spring member 55, and an insulating plate 56 to 58 are arranged. The heating elements 50 to 53, the fins 54, and the insulating plates 56 to 58 are laminated in the order described above. On the other hand, the upper spring member 55 is arranged between the fin 54 arranged at the top and the upper side portion 81 on the downstream side. The distance between the upper holding wall portion 81a and the lower holding wall portion 82a of the downstream frame component 80 is such that the heating elements 50 to 53, the fins 54, and the insulating plate 56 to be in a laminated state without applying an external force in the stacking direction. It is set to be equal to or larger than the total dimension of the 58 and the upper spring member 55 in the stacking direction. Not applying an external force in the stacking direction means that the upper spring member 55 is not elastically deformed by being in a free state, and the heating elements 50 to 53 and the fins 54 are also not deformed.

Specifically, the distance between the upper holding wall portion 81a and the lower holding wall portion 82a is the distance between the lower surface (inner surface) 81b of the upper holding wall portion 81a and the upper surface (inner surface) 82c of the lower holding wall portion 82a. .. Then, the dimensions of the heating elements 50 to 53 in the stacking direction (thickness direction), the dimensions of the fins 54 in the stacking direction (height), the dimensions of the upper spring member 55 in the stacking direction (thickness direction), and the stacking of the insulating plates 56 to 58. The distance between the lower surface 81b of the upper holding wall portion 81a and the upper surface 82c of the lower holding wall portion 82a is wider by the dimension S than the dimension obtained by adding all the dimensions in the direction (thickness direction).

The dimension S may be 0, and between the upper holding wall portion 81a and the lower holding wall portion 82a, a heating element 50 to 53, fins 54, an upper spring member 55, and an insulating plate 56 to 58 The dimensions may be set so that the compressive force does not act on these members in the state where the above-mentioned members are arranged. Further, since there are manufacturing tolerances between the heating elements 50 to 53, the fins 54, the upper spring member 55, and the insulating plates 56 to 58, the dimension S is set to, for example, several mm or more in consideration of these tolerances. Is preferable. As a result, even if the heating elements 50 to 53, the fins 54, the upper spring member 55, and the insulating plates 56 to 58 all have positive dimensions within the tolerance range, they are placed below the upper holding wall portion 81a. It is possible to prevent the compressive force of the upper spring member 55 from acting in the state of being arranged between the side holding wall portion 82a and the side holding wall portion 82a.

The downstream connecting portion 83 has a rod shape extending from the upper holding wall portion 81a to the lower holding wall portion 82a, and connects the upper holding wall portion 81a and the lower holding wall portion 82a in a state of maintaining the above-mentioned spacing. It is the part to do. The downstream connecting portion 83 is positioned on the downstream side in the flow direction of the air conditioning air, and connects the heating elements 50 to 53, the fins 54, the upper spring member 55, and the insulating plates 56 to 58 downstream in the flow direction of the air conditioning air. Hold from the side. A plurality of downstream connecting portions 83 are provided at intervals in the left-right direction, and air conditioning air flows between the downstream connecting portions 83. The downstream connecting portion 83 may extend in the vertical direction or may extend diagonally.

The upstream frame component 70 includes the upstream upper side portion (first coupling portion) 71 arranged on one side (upper side) of the heating elements 50 to 53 and the fins 54 in the stacking direction, and the heating elements 50 to 53 and the fins 54. Intermediate between the upstream lower side portion (second coupling portion) 72 arranged on the other side (lower side) in the stacking direction, the left side connecting portion (other side connecting portion) 73, and the right side connecting portion (other side connecting portion) 74. It has a connecting portion (other side connecting portion) 75 and a spring compression portion (one side spring compression portion) 76. The upstream side upper side portion 71 extends in the left-right direction. On the upstream side upper side portion 71, a fitting hole 71a that opens on the downstream side in the flow direction of the air conditioning air is formed long in the left-right direction so as to correspond to the upper holding wall portion 81a of the downstream side frame constituent member 80. There is. The upper holding wall portion 81a of the downstream frame constituent member 80 is fitted into the fitting hole 71a in a state of being inserted, and the upstream side upper side portion 71 is coupled to the upper holding wall portion 81a.

On the surface of the lower side portion 72 on the upstream side on the downstream side in the flow direction of the air conditioning air, the coupling plate portion 72a protruding to the downstream side and extending in the left-right direction corresponds to the fitting hole 82b of the downstream frame constituent member 80. Is formed in. The coupling plate portion 72a is fitted in a state of being inserted into the fitting hole 82b of the downstream frame constituent member 80, and the upstream side lower side portion 72 is coupled to the lower holding wall portion 82a.

The spring compression portion 76 is located below the upstream upper side portion 71, and has a plate shape extending in the left-right direction as a whole. The spring compression portion 76 is inserted into the gap between the upper holding wall portion 81a of the downstream frame constituent member 80 and the upper spring member 55, and the upper spring member 55 is inserted in the stacking direction of the heating elements 50 to 53 and the fins 54. It is for elastic deformation. The vertical dimension, which is the thickness dimension of the spring compression portion 76, is set longer than the above dimension S, and as shown in FIG. 5, the upper spring member 55 can be elastically deformed by, for example, 1 mm or more. There is. The compressive force of the upper spring member 55 can be adjusted by adjusting the thickness of the spring compression portion 76. Specifically, the upper spring member is such that the heating elements 50 to 53, the fins 54, and the like do not shift in position. It is preferable to set a compressive force of 55.

The downstream side of the spring compression portion 76 in the flow direction of the air conditioning air is the tip side in the insertion direction into the gap, and the thickness of the tip side of the spring compression portion 76 is set to become thinner toward the tip. .. As a result, the tip end side of the spring compression portion 76 can be easily inserted into the gap.

As shown in FIG. 3, the surface of the spring compression portion 76 on the upper spring member 55 side, that is, the lower surface 76a of the spring compression portion 76 extends in the left-right direction. On the lower surface 76a of the spring compression portion 76, a plurality of ridge portions 76b extending in the insertion direction into the gap are formed at intervals in the left-right direction. The ridge portion 76b is continuous from the upstream side to the downstream side in the flow direction of the air conditioning air on the lower surface 76a of the spring compression portion 76. The ridge portion 76b is in contact with the upstream elastic deformation portion 55b and the downstream elastic deformation portion 55c of the upper spring member 55. As a result, when the spring compression portion 76 is inserted into the gap, the sliding area with the upper spring member 55 is reduced, and the sliding resistance can be reduced. The number of ridges 76b is not particularly limited.

As shown in FIGS. 1 and 2, the left side connecting portion 73 has a rod shape extending from the left side of the upstream side upper side portion 71 to the left side of the upstream side lower side portion 72. Further, the right side connecting portion 74 has a rod shape extending from the right side of the upstream side upper side portion 71 to the right side of the upstream side lower side portion 72. Further, the intermediate connecting portion 75 has a rod shape extending from the left-right intermediate portion of the upstream upper side portion 71 to the left-right intermediate portion of the upstream lower side portion 72.

The left side connecting portion 73, the right side connecting portion 74, and the intermediate connecting portion 75 are portions that connect the upstream side upper side portion 71 and the upstream side lower side portion 72 in a state of maintaining a predetermined interval. Further, the left side connecting portion 73, the right side connecting portion 74, and the intermediate connecting portion 75 are positioned on the upstream side in the flow direction of the air conditioning air, and the heating elements 50 to 53, the fins 54, the upper spring member 55, and the insulating plate. 56 to 58 are held from the upstream side in the flow direction of the air conditioning air. Air conditioning air flows between the left side connecting portion 73, the right side connecting portion 74, and the intermediate connecting portion 75. The left side connecting portion 73, the right side connecting portion 74, and the intermediate connecting portion 75 may extend in the vertical direction or may extend diagonally.

Further, as shown in FIG. 1, a left side cap member 91 and a right side cap member 92 are provided at the left end portion and the right end portion of the electric heater 1, respectively. The left side cap member 91 is formed so as to cover the left end portion of the upstream side frame constituent member 70 and the downstream side frame constituent member 80, and is formed so as to fit into the left end portion. Further, the right side cap member 92 is formed so as to cover the right end portion of the upstream side frame constituent member 70 and the downstream side frame constituent member 80, and is formed so as to fit into the right end portion.

(Manufacturing method of electric heater)
Next, the procedure for assembling the electric heater 1 configured as described above will be described. First, as shown in FIG. 4, the upper heating element 50, the central first heating element 51, the central second heating element 52, the lower heating element 53, the fins 54, the upper insulating plate 56, the intermediate insulating plate 57 and the lower side. The insulating plates 58 are laminated and housed inside the downstream frame component 80. That is, the heating elements 50 to 53, the fins 54, and the insulating plates 56 to 58 are laminated in the order described above, and arranged between the upper holding wall portion 81a and the lower holding wall portion 82a of the downstream frame constituent member 80. Further, the upper spring member 55 is arranged between the fin 54 arranged at the top and the upper side portion 81 on the downstream side.

At this time, the distance between the upper holding wall portion 81a and the lower holding wall portion 82a of the downstream frame constituent member 80 is in the stacking direction of the heating elements 50 to 53, the fins 54, the insulating plates 56 to 58, and the upper spring member 55. Since the total dimensions or more are secured, the compressive force of the upper spring member 55 does not act on the heating elements 50 to 53 and the fins 54. Therefore, even before assembling the upstream frame constituent member 70 to the downstream frame constituent member 80, the heating elements 50 to 53 and the fins 54 are less likely to pop out from the downstream frame constituent member 80, and the assembling workability is good. become.

Then, when the upstream frame constituent member 70 is assembled to the downstream frame constituent member 80, when the spring compression portion 76 is inserted between the upper holding wall portion 81a and the upper spring member 55, the compressive force of the upper spring member 55 acts. Since this is not done, the force required at the start of assembly is small, which also improves the assembly workability.

When the spring compression portion 76 is inserted between the upper holding wall portion 81a and the upper spring member 55, the upper spring member 55 elastically deforms in the stacking direction of the heating elements 50 to 53 and the fins 54, whereby the heating elements 50 to 50 to Since the 53, the fins 54 and the insulating plates 56 to 58 are compressed in the stacking direction, the backlash of the heating elements 50 to 53, the fins 54 and the insulating plates 56 to 58 is eliminated.

Further, when the upstream frame constituent member 70 is assembled to the downstream frame constituent member 80, the upper holding wall portion 81a of the downstream frame constituent member 80 is fitted in the fitting hole 71a of the upstream frame constituent member 70. The upper side portion 71 on the upstream side is coupled to the upper holding wall portion 81a. Further, the lower coupling plate portion 72a of the upstream frame constituent member 70 is fitted in a state of being inserted into the fitting hole 82b of the downstream frame constituent member 80, and the upstream lower side portion 72 is the lower holding wall portion. Combines with 82a. As a result, the heating elements 50 to 53, the fins 54, the insulating plates 56 to 58, and the upper spring member 55 are air-conditioned by the left side connecting portion 73, the right side connecting portion 74 and the intermediate connecting portion 75, and the downstream side connecting portion 83. It is held from both sides in the flow direction of. Finally, the left side cap member 91 and the right side cap member 92 are assembled to the holding frame 60.

(Effect of embodiment)
As described above, according to this embodiment, the upper spring member assembled to the downstream frame constituent member 80 before combining the upstream frame constituent member 70 and the downstream frame constituent member 80 constituting the holding frame 60. It is possible to prevent the 55 from applying a force in the stacking direction to the heating elements 50 to 53, the fins 54 and the insulating plates 56 to 58. As a result, the heating elements 50 to 53, the fins 54, and the insulating plates 56 to 58 are less likely to pop out from the downstream frame component 80, and the force required at the start of assembly is small, so that the assembly workability is improved. Can be done.

Further, the distance between the upper holding wall portion 81a and the lower holding wall portion 82a of the downstream frame component 80 is the total of the heating elements 50 to 53, the fins 54, the insulating plates 56 to 58, and the upper spring member 55 in the stacking direction. Since the size is larger than the size, the assembling workability can be improved even if the heating elements 50 to 53, the fins 54, and the like have some dimensional errors in the stacking direction.

Further, since the ridge portion 76b extending in the insertion direction is formed in the spring compression portion 76 of the upstream frame component 70, the spring compression is performed when the spring compression portion 76 is inserted between the upper holding wall portion 81a and the upper spring member 55. The sliding resistance between the portion 76 and the upper spring member 55 can be reduced. Thereby, the assembly workability can be further improved.

(Embodiment 2)
FIG. 6 shows the electric heater 1 according to the second embodiment of the present invention, and is a diagram corresponding to FIG. In the second embodiment, the number of heating elements, fins, insulating plates, spring members, their arrangement, and the structure of the holding frame are different from those of the first embodiment, and other parts are the same as those of the first embodiment. Therefore, hereinafter, the same parts as those in the first embodiment are designated by the same reference numerals, the description thereof will be omitted, and the different parts will be described in detail.

In the second embodiment, six heating elements 101 to 106 are provided, and four insulating plates 107 to 110 are provided. Further, in addition to the upper spring member 55, a lower spring member (other side spring member) 111 is also provided. The lower spring member 111 is configured in the same manner as the upper spring member 55, and exerts an urging force so as to compress the heating elements 101 to 106, the insulating plates 107 to 110, and the fins 54 held by the holding frame 60 in the stacking direction. It is for action.

A plurality of lower holding wall portions (second holding wall portions) 82d are formed on the downstream side lower side portion 82 of the downstream side frame constituent member 80. The lower holding wall portions 82d are arranged at intervals in the left-right direction, but may be continuous wall portions in the left-right direction.

Further, in the upstream side lower side portion 72 of the upstream side frame constituent member 70, a fitting hole (not shown) that opens on the downstream side in the flow direction of the air conditioning air is provided in the lower holding wall portion of the downstream side frame constituent member 80. It is formed long in the left-right direction so as to correspond to 82d. The lower holding wall portion 82d of the downstream frame component 80 is fitted into the fitting hole in a state of being inserted, and the upstream lower side portion 72 is coupled to the lower holding wall portion 82d.

Further, in the second embodiment, the distance between the upper holding wall portion 81a and the lower holding wall portion 82d of the downstream side frame constituent member 80 of the downstream side frame constituent member 80 is the heating elements 101 to 106, the fins 54, and the insulating plate. More than the total dimensions of 107 to 110, the upper spring member 55, and the lower spring member 111 in the stacking direction are secured.

Further, the upstream frame constituent member 70 is inserted between the lower holding wall portion 82d and the lower spring member 111 to elastically deform the lower spring member 111 in the stacking direction of the heating elements 101 to 106 and the fins 54. It has a spring compression unit (other side spring compression unit) 77. The spring compression portion 77 is located above the upper side lower side portion 72 on the upstream side, has a plate shape extending in the left-right direction as a whole, and is configured in the same manner as the upper spring compression portion 76.

According to the second embodiment, the heating elements 101 to 106, the insulating plates 107 to 110, and the fins 54 can be compressed by the upper spring member 55 and the lower spring member 111.

The above embodiments are merely exemplary in all respects and should not be construed in a limited way. Furthermore, all modifications and modifications that fall within the equivalent scope of the claims are within the scope of the present invention.

As described above, the present invention can be used, for example, in an air conditioner mounted on an automobile.

1 Electric heater 50 to 53, 101 to 106 Heating element 54 Fin 55 Upper spring member (one side spring member)
60 Holding frame 70 Upstream frame component (second frame component)
71 Upstream upper side (first joint)
72 Upstream lower side (second joint)
73 Left side connecting part (other side connecting part)
74 Right side connecting part (other side connecting part)
75 Intermediate connecting part (other side connecting part)
76 Spring compression part (one-side spring compression part)
77 Spring compression part (other side spring compression part)
80 Downstream frame component (first frame component)
83 Connecting part (one side connecting part)
81a Upper holding wall part (first holding wall part)
82a Lower holding wall (second holding wall)
111 Lower spring member (other spring member)

Claims (4)

A heating element that generates heat due to the supply of electric power,
Fins arranged in a state of being laminated on the heating element, and
A spring member on one side, which is arranged on one side of the heating element and the fins in the stacking direction and for applying a compressive force in the stacking direction to the heating element and the fins.
A holding frame for accommodating the heating element, the fins, and the one-side spring member and holding them in a laminated state is provided.
In the electric heater of the vehicle air conditioner in which the air conditioner air blown into the holding frame is heated by passing through the fins.
The holding frame is composed of a combination of a first frame component arranged on one side in the flow direction of air conditioning air and a second frame component arranged on the other side.
The first frame constituent member includes first and second holding wall portions arranged on one side and the other side in the stacking direction of the heating element and the fins, respectively, and the first holding wall portion to the second holding wall portion. It also has a one-sided spring member, a heating element, and a one-sided connecting portion that holds the fins from one side in the flow direction of air conditioning air.
The distance between the first holding wall portion and the second holding wall portion is equal to or greater than the total dimension in the stacking direction of the heating element, the fins, and the one-side spring member in a laminated state without applying an external force in the stacking direction. Set to
The second frame constituent member includes a first joint portion that is coupled to the first holding wall portion, a second joint portion that is coupled to the second holding wall portion, and from the first joint portion to the second joint portion. As it extends, it is inserted between the other side connecting portion that holds the one side spring member, the heating element, and the fins from the other side in the flow direction of the air conditioning air, and the first holding wall portion and the one side spring member. It has a heating element and a one-side spring compression portion that elastically deforms the one-side spring member in the stacking direction of the fins.
The first joint portion has a fitting hole that opens on the side of the first frame constituent member, and the first holding wall portion is fitted into the fitting hole in a state of being inserted.
The second holding wall portion has a fitting hole that opens on the second frame component side.
The second joint portion has a joint plate portion that projects toward the first frame constituent member side, and the joint plate portion of the second joint portion is inserted into the fitting hole of the second holding wall portion. Fitted in a loose state,
The one-side spring member is adjacent to the fin and
The one-side spring member includes a flat plate-shaped substrate portion extending along the fin, an upstream elastically deformed portion extending from an edge portion on the upstream side in the flow direction of air conditioning air in the substrate portion, and an air conditioning substrate portion. It is equipped with a downstream elastically deformed portion extending from the downstream edge in the air flow direction.
The upstream elastically deformed portion extends diagonally toward the downstream side in the flow direction of the air conditioning air while being separated from the substrate portion, and then extends so that the tip side bends in a direction approaching the substrate portion.
The downstream elastically deformed portion extends diagonally toward the upstream side in the flow direction of the air conditioning air while being separated from the substrate portion, and then extends so that the tip side bends in a direction approaching the substrate portion.
An electric heater for a vehicle air conditioner, characterized in that a ridge portion extending in the insertion direction is formed on a surface of the one-side spring compression portion on the one-side spring member side. In the electric heater of the vehicle air conditioner according to claim 1,
The distance between the first holding wall portion and the second holding wall portion is based on the total dimensions in the stacking direction of the heating element, the fins, and the one-side spring member in a laminated state without applying an external force in the stacking direction. An electric heater for vehicle air conditioners, which is characterized by being set large. In the electric heater of the vehicle air conditioner according to claim 1 or 2.
It is provided on the other side of the heating element and the fins in the stacking direction, and is provided with a spring member on the other side for applying a compressive force in the stacking direction to the heating element and the fins.
The distance between the first holding wall portion and the second holding wall portion is the distance between the heating element, the fins, the one-side spring member, and the other-side spring member in a laminated state without applying an external force in the stacking direction. Set to be greater than or equal to the total dimensions in the stacking direction
The second frame constituent member is inserted between the second holding wall portion and the other side spring member to elastically deform the other side spring member in the stacking direction of the heating element and the fins. An electric heater for a vehicle air conditioner, which is characterized by having and. A heating element that generates heat due to the supply of electric power,
Fins arranged in a state of being laminated on the heating element, and
A spring member on one side, which is arranged on one side of the heating element and the fins in the stacking direction and for applying a compressive force in the stacking direction to the heating element and the fins.
A holding frame for accommodating the heating element, the fins, and the one-side spring member and holding them in a laminated state is provided.
The one-side spring member is adjacent to the fin and
The one-side spring member includes a flat plate-shaped substrate portion extending along the fin, an upstream elastically deformed portion extending from an edge portion on the upstream side in the flow direction of air conditioning air in the substrate portion, and an air conditioning substrate portion. It is equipped with a downstream elastically deformed portion extending from the downstream edge in the air flow direction.
The upstream elastically deformed portion extends diagonally toward the downstream side in the flow direction of the air conditioning air while being separated from the substrate portion, and then extends so that the tip side bends in a direction approaching the substrate portion.
The downstream elastically deformed portion extends diagonally toward the upstream side in the flow direction of the air conditioning air while being separated from the substrate portion, and then extends so that the tip side bends in the direction approaching the substrate portion.
In a method for manufacturing an electric heater of a vehicle air conditioner in which air for air conditioning blown into the inside of the holding frame is heated by passing through the fins.
The heating element and the fins are laminated between the first holding wall portion and the second holding wall portion of the first frame constituent member constituting the holding frame, and the one-side spring member is subjected to an external force in the stacking direction. In a state where it does not act, it is arranged on the side of the first holding wall portion between the first holding wall portion and the second holding wall portion.
After that, the first joint portion is fitted into the first joint portion by inserting the first holding wall portion into the fitting hole of the first joint portion of the second frame constituent member constituting the holding frame. The step of joining to the holding wall portion and the connecting plate portion of the second connecting portion of the second frame constituent member are inserted into the fitting holes of the second holding wall portion and fitted. As a result, the step of connecting the second connecting portion to the second holding wall portion and the ridge portion extending in the insertion direction on the surface of the one-side spring compression portion of the second frame component member on the one-side spring member side are provided. A step of forming the one-side spring compression portion and inserting the one-side spring compression portion between the first holding wall portion and the one-side spring member to elastically deform the one-side spring member in the stacking direction of the heating element and the fins. And
The one-sided connecting portion that connects the first holding wall portion and the second holding wall portion of the first frame constituent member is connected to the first joint portion and the second joint portion of the second frame constituent member. A method for manufacturing an electric heater for a vehicle air conditioner, which comprises holding the heating element, the fin, and the one-side spring member from both sides in the flow direction of air for air conditioning by means of a connecting portion on the other side.

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