JP6982390B2 - Manufacturing method of electric heater for vehicle air conditioner - Google Patents

Description

The present invention relates to, for example, a method for manufacturing an electric heater provided in a vehicle air conditioner mounted on an automobile or the like.

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 element are laminated by a frame type frame. It is held in a state.

In Patent Documents 1 and 2, a plurality of columns extending from the upper side portion to the lower side portion of the frame formwork 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 frame. Then, the air conditioning air is heated by the heat of the PTC element while passing through the inside of the frame and passing through the fins.

Further, the frame type 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. When 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.

Japanese Patent No. 4880648 Japanese Patent No. 4939490

By the way, when the spring element is provided as in Patent Documents 1 and 2, the fins are compressed in the stacking direction by the spring element, and the fins subjected to this compressive force are made of a thin plate material. , The distance between adjacent peaks of the fins, that is, the fin pitch may be deformed in a direction deviating from the design value. If the fin pitch deviates from the design value, the ventilation resistance deteriorates, which in turn deteriorates the heating performance of the electric heater.

Therefore, a structure is conceivable in which a plate material connecting adjacent mountain portions is brazed to the fins so that the fin pitch does not shift even when the compression force of the spring element is applied. However, if this is done, the number of parts will increase and the cost will increase, and the dimensional tolerance in the height direction of the fins will increase due to the presence of the plate material, and as a result, the compressive force due to the spring element will be within the appropriate range. May be difficult.

The present invention has been made in view of this point, and an object of the present invention is to suppress an increase in cost and suppress a deviation in fin pitch to obtain high heating performance by an electric heater.

In order to achieve the above object, in the present invention, an engaging portion that engages with a mountain of fins is provided.

The first invention is for applying a compressive force in the stacking direction to a heating element that generates heat by supplying electric power, a corrugated fin that is arranged in a state of being laminated on the heating element, and the heating element and the fins. It has a spring member, a first frame constituent member and a second frame constituent member arranged on the downstream side and the upstream side in the flow direction of air conditioning air, respectively, and accommodates and laminates the heating element, the fin, and the spring member. The first frame configuration in the method for manufacturing an electric heater of a vehicle air conditioner, which comprises a holding frame for holding in a state and in which air for air conditioning blown into the holding frame is heated by passing through the fins. the member is disposed between the mountain adjacent the fin disposed on one end of the stacking direction of the fins protrude is disposed on one end of the stacking direction from the contact surface that abuts the A frame-side engaging portion consisting of a ridge portion that engages with a mountain is provided, the ridge portion has a shape that is long in the passage direction of air conditioning air, and the width of the ridge portion increases toward the tip in the protrusion direction. leave narrow, the fins as well as arranged to be located at one end of the stacking direction, after laminating alternately the heating body and the fins, and the heating body and the fins as described above laminated, the heating body and a spring member disposed in the other end of the stacking direction of the fin, and housed in the first frame component, said fins are arranged on one end of the stacking direction to the abutment surface equivalent After the fins are brought into contact with each other, the frame-side engaging portion is arranged between the adjacent ridges of the fins, and the spring compression portion of the second frame constituent member is replaced with the first frame constituent member while being engaged with the ridges. the spring member Nde push inwardly elastically deformed in the stacking direction of the second frame component, characterized in that assembling the first frame component above.

According to this configuration, a compressive force in the stacking direction acts on the fins by the spring member while the heating element, the fin, and the spring member are held by the holding frame. At this time, since the frame-side engaging portion of the holding frame is engaged with the fin ridges arranged at the ends in the stacking direction, the positions of the fin ridges are less likely to shift. That is, even if the plate material is not brazed to the fins, the fin pitch does not easily deviate from the design value, so that the ventilation resistance is kept good.

Further, since the ridges provided on the contact surface of the fins in the holding frame are arranged between the adjacent ridges of the fins, the positions of the ridges are less likely to shift, and the ventilation resistance can be kept good.

According to the first invention, since the frame-side engaging portion provided on the holding frame is engaged with the mountain of fins, the electric heater suppresses the deviation of the fin pitch while suppressing the increase in cost. High heating performance can be obtained.

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 sectional view taken along line VI-VI in FIG. It is a perspective view which shows the state which the fin is separated upward from the lower side part of the downstream side of the downstream side frame constituent member. It is a figure which shows the lower part of FIG. 6 enlarged. It is a perspective view which shows the state which the fin is separated from the lower insulating plate in the vertical direction.

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.

FIG. 1 shows an electric heater 1 of a vehicle air conditioner according to an embodiment of the present invention. The electric heater 1 is a heater arranged inside a vehicle air conditioner (not shown) and for heating 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 in the flow direction of the air conditioning air with respect to the cooling heat exchanger, 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 has a long rectangular shape in the left-right direction as a whole when viewed from the flow direction of the air-conditioning air. 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 also 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 continuous corrugated fin 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 fin 54 is 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. Fins 54 are arranged at the ends of the heating elements 50 to 53 and the fins 54 in the stacking direction, that is, at the lower ends.

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 first heating element 51 and the central 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 dimension) 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 of the left end portion of the fin 54. Further, the right end portion of the upper insulating plate 56, the intermediate insulating plate 57 and the lower insulating plate 58 protrudes 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 exerting 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 flow direction of the air conditioning air. 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 elastic deformation 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 elastic deformation portion 55b and the downstream elastic deformation portion 55c are elastically deformed in the downward direction.

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 purpose is to accommodate the intermediate insulating plate 57 and the lower insulating plate 58 and hold them in a laminated state. Most of the vertical intermediate portion of the holding frame 6 is open so that 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 the 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 made by injection molding a resin material having electrical insulation. The flow direction of the air conditioning air may be opposite to the direction shown in FIG. 4. In this case, the frame constituent member 70 is arranged on the downstream side in the flow direction of the air conditioning air, and the frame constituent member 80 is placed. It will be located on the upstream side in the flow direction of the 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 that project to the upstream side and extend in the left-right direction are formed on the surface of the downstream side upper side portion 81 on the upstream side in the flow direction of the air conditioning air. The upper holding wall portion 81a is arranged at intervals in the left-right direction, but may be a wall portion continuous 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. In the lower holding wall portion 82a, a fitting hole 82b that opens on the upstream side in the flow direction of the air conditioning air is formed 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 side frame constituent member 80, a heating element 50 to 53, fins 54, an upper spring member 55, and an insulating plate are provided. 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 lower side upper side portion 81. 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. The fact that the external force in the stacking direction is not applied means that the upper spring member 55 is in a free state and is not elastically deformed, 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 are provided. 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 the heating elements 50 to 53, the fins 54, the upper spring member 55, and the insulating plates 56 to 58 have manufacturing tolerances, 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.

As shown in FIGS. 6 to 8, the upper surface 82c of the downstream lower side portion 82 of the downstream side frame constituent member 80 is a contact surface with which the lower portion of the fin 54 arranged at the lower end portion abuts. On the upper surface 82c of the lower side portion 82 on the downstream side, a plurality of ridge portions 82e arranged between the adjacent ridges 54a and 54a of the fins 54 are spaced in the left-right direction so as to correspond to the distance between the ridges 54a and 54a. It is formed open. The ridge portion 82e is a frame-side engaging portion that engages with the ridges 54a and 54a of the fin 54 from the left-right direction. By engaging the ridges 82e with the ridges 54a and 54a of the fins 54 from the left-right direction, it is possible to prevent the ridges 54a from shifting in the left-right direction when the fins 54 are compressed. The frame-side engaging portion may be formed of, for example, a protrusion or the like.

The downstream side 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 side connecting portion 83 is positioned on the downstream 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 plates 56 to 58 are located 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.

Further, as shown in FIG. 9, on the lower surface of the lower insulating plate 58, mountains 54a and 54a adjacent to the fins 54 projecting downward from the insulating plate 58 and arranged under the insulating plate 58. A plurality of ridges 58a arranged between them are formed at intervals in the left-right direction so as to correspond to the distance between the ridges 54a and 54a. The ridge portion 58a of the insulating plate 58 is a plate-side engaging portion that engages with the ridges 54a and 54a of the fin 54 from the left-right direction. By engaging the ridges 58a of the insulating plate 58 with the ridges 54a and 54a of the fins 54 from the left-right direction, it is possible to prevent the ridges 54a from shifting in the left-right direction when the fins 54 are compressed. ..

Further, as shown in FIG. 6, the upper surface of the lower insulating plate 58 protrudes upward from the insulating plate 58 and is located between the adjacent ridges 54a and 54a of the fins 54 arranged on the upper side of the insulating plate 58. A plurality of ridges 58b to be arranged are formed at intervals in the left-right direction so as to correspond to the distance between the ridges 54a and 54a. The ridge portion 58b of the insulating plate 58 is a plate-side engaging portion that engages with the ridges 54a and 54a of the fins 54 from the left-right direction. By engaging the ridges 58b of the insulating plate 58 with the ridges 54a and 54a of the fins 54 from the left-right direction, it is possible to prevent the ridges 54a from shifting in the left-right direction when the fins 54 are compressed. .. The plate-side engaging portion may be formed of, for example, a protrusion or the like.

Similar plate-side engaging portions can be provided on the upper insulating plate 56 and the intermediate insulating plate 57.

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. In the upstream side upper side portion 71, a fitting hole 71a that opens on the downstream side in the flow direction of 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 side 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 side 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 side 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 side 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 a 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 be fitted to 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 be fitted to 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 element 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 a state of being inserted into 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 provided with air for air conditioning 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 ridge portion 82e of the downstream side lower side portion 82 of the downstream side frame constituent member 80 is engaged with the mountain 54a of the fin 54 arranged at the lower end portion. Therefore, the position of the mountain 54a of the fin 54 is less likely to shift. That is, even if the plate material is not brazed to the fins 54, the fin pitch does not easily deviate from the design value, so that the ventilation resistance can be kept good and the high heating performance by the electric heater 1 can be obtained.

Further, since the insulating plates 56 to 58 arranged between the fins 54 and 54 are provided with the ridges 58a and 58b that engage with the ridges 54a of the fins 54, the fin pitch shifts located in the middle portion in the stacking direction. Can be suppressed.

Further, before combining the upstream frame constituent member 70 and the downstream frame constituent member 80 constituting the holding frame 60, the upper spring member 55 assembled to the downstream frame constituent member 80 is a heating element 50 to 53, fins 54 and It is possible to prevent the force in the stacking direction from acting on 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 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 size is larger than the size, the assembling workability can be improved even if there is some dimensional error in the stacking direction in the heating elements 50 to 53, the fins 54, and the like.

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.

The above embodiments are merely exemplary in all respects and should not be construed in a limited way. Further, all modifications and modifications belonging to 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 Heating element 54 Fin 55 Upper spring member 56 to 58 Insulation plates 58a, 58b Protrusions (plate side engagement)
60 Holding frame 82c Upper surface (contact surface) of the lower side on the downstream side
82e Protruding part (frame side engaging part)

Claims (1)

A heating element that generates heat due to the supply of electric power,
Corrugated fins arranged in a state of being laminated on the heating element, and
A spring member for applying a compressive force in the stacking direction to the heating element and the fins,
It has a first frame component and a second frame component arranged on the downstream side and the upstream side in the flow direction of the air conditioning air, respectively, and also accommodates the heating element, the fin, and the spring member and holds them in a laminated state. Equipped with a holding frame,
In a method for manufacturing an electric heater for a vehicle air conditioner in which air for air conditioning blown into the holding frame is heated by passing through the fins.
Above the first frame component, while the mountain adjacent the fin disposed on one end of the stacking direction of the fins protrude is disposed on one end of the stacking direction from the contact surface that contacts A frame-side engaging portion is provided, which is arranged in a ridge and is composed of a ridge portion that engages with the mountain. Make it narrower toward the tip of the direction,
The fins as well as arranged to be located at one end of the stacking direction, after stacking the heating body and the fins alternately,
And the stacked above the heating element and the fins, and a spring member disposed in the other end of the stacking direction of the heating body and the fins, and housed in the first frame component, one end of the stacking direction after the placed the fin is in contact with the abutment surface, while engaged to the mountain placing the frame-side engagement portion between the mountain adjacent the said fin, said second frame the spring member Nde push inwardly of the spring compression portion of the structural member the first frame component is elastically deformed in the stacking direction, characterized in that assembling the second frame component to the first frame component above A method for manufacturing an electric heater for a vehicle air conditioner.

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