KR20060084816A - Ceramic heater, heat exchange unit, warm water washing toilet seat and method for manufacturing the ceramic heater - Google Patents

Abstract

(Problem) Provides a ceramic heater, a heat exchange unit, a hot water washing toilet and a ceramic heater which can be compact, have high heating efficiency, and can reduce manufacturing costs.

(Solution means) The ceramic heater 5 has a shape in which a ceramic heater member 11 is wound twice in a cylindrical shape, and both ends thereof in the circumferential direction are overlapped, and a through hole through which the washing water passes in the axial direction. (17) is formed. That is, the heater member 11 is a heating element 21 formed in a meandering shape on the surface of the ceramic base 19 made of alumina, and the ceramic heater 5 is formed by the heater member 11 which is a roll-shaped sintered body. have. Therefore, in this ceramic heater 5, there is no slit as in the prior art, and the heat generator 21 is arranged almost evenly in the circumferential direction of the ceramic heater 5.

Description

CERAMIC HEATER, HEAT EXCHANGE UNIT, WARM WATER WASHING TOILET SEAT AND METHOD FOR MANUFACTURING THE CERAMIC HEATER}

1 is an explanatory view showing a heat exchange unit of Example 1 by breaking

2 is a cross-sectional view showing the ceramic heater of Example 1 broken vertically with the axial direction, and (b) is an explanatory diagram showing the development of the heater member.

3 is an explanatory view showing a method of manufacturing a ceramic heater of Example 1

(A) is sectional drawing which showed the ceramic heater of Example 2 broken vertically and axially, and (b) is explanatory drawing which showed the heater member unfolded.

5 is a cross-sectional view showing the ceramic heater of Example 3 broken vertically and axially, and (b) is a cross-sectional view showing the ceramic heater broken vertically and axially of the application example.

(A) is sectional drawing which showed the ceramic heater of Example 4 broken vertically and axially, (b) is explanatory drawing which showed the heater member unfolded.

7 is a cross-sectional view showing the ceramic heater of Example 5 broken vertically with the axial direction, and (b) is an explanatory diagram showing the development of the heater member.

8 is a cross-sectional view showing the ceramic heater of Example 6 broken vertically with the axial direction, and (b) is a side view showing a part thereof;

9 is an explanatory view showing a method of manufacturing a ceramic heater of Example 6

10 is an explanatory view showing a method of connecting the ceramic heater of Example 6 to a pipe, and (b) is an end view showing an end face of the pipe.

11 is a cross-sectional view of the ceramic heater of Example 7 broken vertically with the axial direction;

12 is an explanatory diagram showing a method for manufacturing a ceramic heater of Example 8

13 is an explanatory diagram showing a method for manufacturing a ceramic heater of Example 9

(A) is a perspective view which shows the processing core member of the ceramic heater of Example 11, (b) is a perspective view which shows the other processing core member.

15 is an explanatory diagram showing a method of manufacturing a ceramic heater of the prior art.

16 is a cross-sectional view showing a ceramic heater of the prior art broken vertically and axially;

Explanation of symbols on the main parts of the drawings

1-heat exchanger unit 3-heat exchanger

5, 51, 61, 71, 81, 91, 101, 131, 153, 165-ceramic heater

6-flange

11, 53, 63, 73, 83, 93, 105, 133-heater element

13, 15, 87, 89, 97, 99, 135, 147, 149-end

19, 57, 88, 98-ceramic gas

21, 55, 65, 75, 85, 95, 103-heating element

The present invention relates to a ceramic heater, a heat exchanger unit, a hot water washing toilet and a ceramic heater used in, for example, a hot water washing toilet, an electric water heater, a 24-hour bath, a soldering iron, petroleum heating, and an oxygen sensor. It is about.

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

When manufacturing this ceramic heater, for example, as shown in FIG. 15, first, a heating pattern 1003 made of a high melting point metal such as tungsten is printed on the ceramic green sheet 1001, and ceramic paste is used thereon. Then, another ceramic green sheet 1005 is bonded to produce a heater sheet 1007. Thereafter, the heater sheet 1007 is cut to cut out the single heater sheet 1007. Next, the ceramic sheet (alumina paste) or the like is wound on the surface of the fired cylindrical core member 1009, and the heater sheet 1007 is wound and bonded to form a winding body 1011. Thereafter, the winding body 1011 is fired integrally to complete the ceramic heater 1013 (see Patent Documents 1 and 2).

[Patent Document 1] Japanese Patent Application Laid-Open No. 9-7741 (Fig. 1, page 2)

[Patent Document 2] Japanese Unexamined Patent Publication No. Hei 9-7742 (Fig. 1, page 2)

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

Therefore, since the heating element 1019 {the heat generation pattern 1003 is fired} does not exist in the portion of the slit 1017, the washing water flowing in the vicinity thereof cannot be heated, and the heating efficiency of the washing water or the like is poor. There was a problem.

As a countermeasure, it is conceivable to increase the outer diameter of the ceramic heater or to increase the dimension in the axial direction when increasing the region heated by the heating element. However, in this case, the size of the ceramic heater is increased, which is not preferable.

That is, it is not preferable because the size and the cost of manufacturing increase in size and the size of the hot water washing toilet in which the ceramic heater is used increases in size.

The present invention has been made in view of the above problems, and an object thereof is to provide a ceramic heater, a heat exchange unit, a hot water washing toilet and a ceramic heater which can be compact and have high heating efficiency and can reduce manufacturing costs.

(1) The invention of claim 1 has a ceramic heater characterized in that a heater member on which a heating element is formed is wound on at least one or more times, and the heater members overlap each other.

Since the heater member has a configuration in which the heater member is wound and overlapped, there is no slit formed on the core member as in the prior art. Therefore, since the heat generating element can be arranged around the entire circumference of the ceramic heater, a fluid such as washing water can be heated around the entire circumference of the ceramic heater, and the heating efficiency is high. In addition, since the heating efficiency is high, the ceramic heater can be miniaturized and the manufacturing cost can be reduced.

In addition, since the present invention relates to the structure of a fired ceramic heater, the heating element, the ceramic gas, and the heater member are fired.

(2) The invention of claim 2 is based on the ceramic heater according to claim 1, wherein the ceramic heater is a cylindrical body.

The present invention illustrates the configuration of a ceramic heater.

(3) The invention of claim 3 is characterized in that the ends of the heater member in the circumferential direction (for example, in the circumferential direction) overlap each other directly or indirectly in the thickness direction of the heater member. The ceramic heater is the point.

The present invention illustrates the configuration of a ceramic heater. For example, when the heater member is wound once, the ends are directly overlapped with each other, and when the heater member is wound twice or more, the ends are indirectly overlapped with each other through the heater member other than the end.

(4) In the invention of claim 4, the heater according to claim 3 is characterized in that at least part of the heat generating portion in which the heating element is formed is overlapped in the thickness direction of the heater member.

In the present invention, at least a portion of the heat generating portion is overlapped, so there is no slit between the ends of the heater member as in the prior art. Therefore, since the heat generating element can be arranged around the entire circumference of the ceramic heater, the washing water and the like can be heated around the entire circumference of the ceramic heater.

(5) The invention according to claim 5 is a ceramic heater according to claim 3 or 4, wherein a non-heating portion in which the heating element is not formed in the heater member is overlapped at least partially in the thickness direction of the heater member. .

In the present invention, since the non-heating portion is wound to form a tubular body, the strength of the ceramic heater can be increased by using this tubular body as a structure.

(6) In the sixth aspect of the present invention, there is provided the ceramic heater according to any one of claims 1 to 5, wherein the heating element is at least partially overlapped in the thickness direction of the heater member.

(7) The invention of claim 7 includes a chamfer formed with a chamfer along the circumferential direction at an end of the outer circumferential end of the heater member in the circumferential direction. The ceramic heater described in the paragraph is the main point.

In the present invention, the outermost end of the wound heater member (the part where the winding ends) is chamfered along the circumferential direction. As a result, the stepped portion of the heater member is smooth so that there is no step (or the step becomes small). Thus, for example, the use of a seal member such as a rubber hose makes it easier to attach the ceramic heater to the heat exchanger, and thus has high practicality. In addition, it is advantageous in terms of cost because a hose having a round cross section, for example, can be used instead of a hose having a special shape corresponding to the step.

(8) In the invention of claim 8, the ceramic heater according to any one of claims 1 to 7 is characterized in that the heater member has a configuration in which multiple heaters are wound and the heating elements are laminated.

In the present invention, since the heater member is wound in multiple to form a multiple laminated structure, the heating elements can be laminated. That is, since the part which generates heat | fever can be made more than a single thing, not only can it be made compact but it has high heating capability.

(9) In the invention of claim 9, the ceramic heater has a tubular shape, and the heat generation amount in the inner side and the heat generation amount in the outer side in the thickness direction are different from each other in the middle of the thickness direction. The ceramic heater described in the paragraph is the main point.

In the present invention, the amount of heat generated differs between the outer circumferential side and the inner circumferential side of the ceramic heater, for example, by winding multiple heater members with the arrangement of the heating elements to one side. Therefore, when the amount of heat generated inside is increased by, for example, the shape of the heat generating element disposed inside, it is effective when the fluid flowing inside the cylindrical shape is intensively heated. In addition, for example, when the amount of heat generated on the outside is increased, it is effective in the case of intensively heating the fluid flowing outside the cylindrical shape.

(10) In the invention of claim 10, the ceramic heater has a tubular shape, and arrangement intervals of the heating elements are different in the circumferential direction. .

For example, in the case where the ends of the heater member are overlapped, the thickness of the ceramic heater becomes thicker at the overlapped portion, but in the present invention, the arrangement intervals of the heating elements (in the circumferential direction) are different, for example. By increasing the calorific value of the overlapped portion, the heating state (in the circumferential direction) of the ceramic heater can be made uniform.

(11) In the invention of claim 11, the arrangement interval of the heating element is closer as the thickness of the ceramic heater becomes thicker.

The larger the thickness of the ceramic heater is, the larger the heat capacity is. In the present invention, the larger the thickness of the ceramic heater is, the closer the arrangement intervals of the heating elements become. Therefore, the heating state in the circumferential direction of the ceramic heater can be made uniform.

(12) In the invention of claim 12, the ceramic heater has a tubular shape, and the ceramic heater according to any one of claims 1 to 11 is characterized in that the cross-sectional area of the heating element is different in the circumferential direction thereof.

For example, in the case where the ends of the heater member are overlapped, the thickness of the ceramic heater becomes thicker at the overlapped portions, but in the present invention, the cross-sectional area of the heating element (in the circumferential direction) is different, for example, By increasing the calorific value, the heating state (in the circumferential direction) of the ceramic heater can be made uniform.

(13) In the invention of claim 13, the ceramic heater according to claim 12 is characterized in that the cross-sectional area of the heating element is smaller as the thickness of the ceramic heater becomes thicker.

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

(14) The invention of claim 14 is a ceramic heater according to any one of claims 1 to 13, wherein the ceramic heater has a different winding number of the heater member in its axial direction.

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

(15) The invention according to claim 15 is characterized in that the number of windings of the heater member at the end in the axial direction is smaller than the number of windings of the heater member at positions other than the ends. Make a point.

In the present invention, since the number of windings of the heater member at the end in the axial direction of the ceramic heater is small, a step (in the axial direction) can be formed between the portion on the central side where the number of windings is large. As a result, when the hose is inserted into the end portion of the ceramic heater, for example, the stepped portion functions as a fixed end, thus making it easy to connect the hose.

(16) The invention of claim 16 is a heat exchange unit, wherein the ceramic heater according to any one of claims 1 to 15 is attached to a heat exchanger through which the fluid heated by the ceramic heater flows in and out. .

The present invention exemplifies a heat exchange unit having the above-mentioned ceramic heater.

(17) The invention of claim 17 is characterized in that the flow path of the fluid in the heat exchange unit includes a flow path reaching a space on the outer circumferential surface side of the ceramic heater from a through hole traversing the ceramic heater in the axial direction. The heat exchange unit according to claim 16 is the main point.

This invention shows the flow path of the fluid in a heat exchange unit. In the present invention, the fluid is efficiently heated by flowing the fluid from the space on the inner circumferential side of the ceramic heater (that is, the through hole) to the space on the outer circumferential side of the ceramic heater (that is, the space sandwiched between the outer circumferential surface of the ceramic heater and the inner circumferential surface of the heat exchanger). can do.

(18) The invention of claim 18 is a hot water cleaning toilet characterized in that the heat exchange unit according to claim 16 or 17 is provided.

The present invention exemplifies the warm water washing toilet having the heat exchange unit described above.

(19) In the invention of claim 19, a winding body is formed by winding a heater sheet before firing in which a heating pattern is formed on a ceramic gas sheet to a core member for removal, and after removing the core member for processing from the winding body, firing the winding body. The manufacturing method of the ceramic heater characterized by manufacturing a ceramic heater is a summary.

In the present invention, instead of firing integrally the ceramic core member and the heater sheet to be a heater member wound thereon, the core member for processing is taken out from the winding body wound around the heater sheet, and only the winding body is fired to burn the ceramic heater. Since manufacturing, it is possible to eliminate the defects caused by using the conventional core member.

That is, since the slit which was unavoidable with the conventional ceramic heater can be removed by the method of this invention, a heat generating body can be arrange | positioned over the perimeter of a ceramic heater. Therefore, the heating efficiency can be improved without enlarging a heater.

In addition, since the heating efficiency can be increased without increasing the size of the ceramic heater, there is an effect that the heat exchange unit can be downsized.

In addition, since there is no need for a conventional core member, there is an advantage that the manufacturing cost can be reduced.

The heater sheet is, for example, a sheet-like member in which an unfired heating pattern is formed on the surface of the unfired ceramic base sheet. As the core member, a fired or prefired ceramic member can be employed (the same applies hereinafter).

(20) The invention of claim 20 forms a winding body by winding a heater sheet before firing in which a heating pattern is formed on a ceramic gas sheet to a core member for processing made of a material that is lost during firing, one or more times to form a winding body. In addition to the firing, the ceramic heater is manufactured by dissipating the processing core member during the firing to produce the ceramic heater.

In the present invention, a processing core member made of a material lost during firing, such as lost wax, is used as the processing core member. Therefore, there exists an advantage that the operation | work which removes a core member for a process after baking is unnecessary.

(21) According to the invention of claim 21, a winding body is formed by winding a heater sheet before firing in which a heating pattern is formed on a ceramic gas sheet at least once in a cylindrical or solid core member to form a winding body. The manufacturing method of a ceramic heater characterized by baking is manufactured.

Since the slit of the conventional ceramic heater can be eliminated by the method of this invention, a heat generating body can be arrange | positioned over the perimeter of a ceramic heater. Therefore, the heating efficiency can be improved without enlarging a heater.

In addition, since the heating efficiency can be increased without increasing the size of the ceramic heater, there is an effect that the heat exchange unit can be downsized.

(22) The invention of claim 22 is characterized in that the heater sheet before firing in which the heating pattern is formed on the ceramic gas sheet is wound one or more times to form a solid winding body, and the winding body is fired to manufacture a ceramic heater. The manufacturing method of the ceramic heater made into the summary is made.

Since the slit of the conventional ceramic heater can be eliminated by the method of this invention, a heat generating body can be arrange | positioned over the perimeter of a ceramic heater. Therefore, the heating efficiency can be improved without enlarging a heater.

In addition, since the heating efficiency can be increased without increasing the size of the ceramic heater, there is an effect that the heat exchange unit can be downsized.

In addition, since there is no need for a conventional core member, there is an advantage that the manufacturing cost can be reduced.

(The best form to carry out invention)

Next, the best form example (example) of this invention is demonstrated.

Example 1

a) First, the ceramic heater and the heat exchange unit of this embodiment will be described.

The heat exchange unit of this embodiment is used to warm the washing water in the warm water washing toilet.

As illustrated in FIG. 1, the heat exchange unit 1 is attached to a heat exchanger 3 accommodating washing water and a ceramic heater 5 and ceramic heater 5 attached to the heat exchanger 3 to heat the washing water. A fixing member (flange) 6 fixed to the machine 3 is provided.

The heat exchanger 3 is a bottomed cylindrical container, for example, made of resin made of nylon with glass added thereto. A flange 6 is attached to one end in the axial direction of the heat exchanger 3.

The flange 6 is an alumina member, and a ceramic heater 5 penetrates through the center of the alumina member and is fixed by an adhesive 7 such as glass and sealed.

The ceramic heater 5 is a cylindrical member made of an alumina pipe-shaped sintered body (inner diameter 9.6 mm x outer diameter ø 11.5 mm x axial length 105 mm).

In addition, the tip end side of the ceramic heater 5, that is, the heat generating part 8 side on which the heat generating pattern 21 (see FIG. 2) is formed, is arranged inside the heat exchanger 3, and is located after the ceramic heater 5. The end side projects outward from the heat exchanger 3.

In addition, a pair of external terminals 9 and 10 are formed on the surface of the rear end side of the ceramic heater 5, and the external terminals 9 and 10 are provided with respective internal terminals 23, through through holes, not shown. 24) (refer FIG. 2) is electrically connected.

In particular, in the present embodiment, as shown in the cross-section perpendicular to the axial direction in Fig. 2 (a), the ceramic heater 5 has a structure in which the sheet-shaped heater member 11 is wound in a cylindrical shape (roll shape) multiplely. Have. That is, the ceramic heater 5 has a shape in which both ends in the circumferential direction thereof, in particular, the end 13 on the inner circumferential surface side and the end 15 on the outer circumferential surface side (over one heater member 11 are sandwiched). In the axial direction, a through hole 17 through which the washing water passes is formed.

Specifically, the first wound portion inside the ceramic heater 5 is developed in the heater member 11, as shown in FIG. 2 (b) (in the same figure, the inner surface of the ceramic base 19 is shown. }, The left half portion (non-heating portion 26) of the same drawing that the heating element 21 is not formed is wound and overlapped, and the portion wound once outside the same part is the right half drawing of the same drawing in which the heating element 21 is formed. {Heating unit 28} is wound and overlapped.

As shown in Fig. 2 (b), the heater member 11 is energized to the inner surface of the ceramic base 19 made of alumina. It is provided with the heat generating body 21 which generate | occur | produces heat, The heat generating body 21 is gathered in one side of the heater member 11, and is formed in meandering shape.

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

As a result, in the ceramic heater 5 (formed and wound by the manufacturing method described later), the ends 13 and 15 of the double-wound heater member 11 overlap each other, and the slit as in the prior art Since the heat generating element 21 is almost evenly arranged in the circumferential direction, there is no.

Therefore, in the heat exchange unit 1 having the above-described configuration, when tap water is introduced in the direction of the arrow as shown in Fig. 1, the tap water is formed with through holes 17 therein from the rear end side of the ceramic heater 5. ) Flows out from the tip end side.

When the tap water passes through the through-hole 17, the tap water is heated by the ceramic heater 5 to raise the temperature, and the tap water around the ceramic heater 5 is also heated by the ceramic heater 5 to raise the temperature. It is raised and supplied out of the heat exchanger 3 as washing water of hot water (from the outflow hole not shown).

b) Next, the manufacturing method of the ceramic heater 5 and the heat exchange unit 1 of this embodiment is demonstrated.

As shown in Fig. 3, a high melting point metal such as tungsten is first printed on a ceramic base sheet 25, which is a ceramic green sheet to be a ceramic base 19 (after firing), and then (after firing) a heating element 21 ) And a terminal pattern 29 (generally referred to as the conductive pattern 31) to be the internal pattern 23 or the internal terminals 23 and 24. Thereby, the heater sheet 33 used as the heater member 11 is obtained (after baking).

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

As a result, the heater sheet 33 is wound twice like the said FIG. 2 (a) after baking, and it is in the state which the edge part overlaps indirectly in the circumferential direction. In detail, the state in which the heater sheet 33 of the portion without the conductive pattern 31 is wound once and the heater sheet 33 of the portion having the conductive pattern 31 is wound once is inside. do.

Returning to FIG. 3, the core member 37 for processing is taken out from the cylindrical winding body 39 along the axial direction. Since the diameter of the take-out side becomes large and the release paper 35 is wound on the outer periphery of this process core member 37, the process core member 37 can be taken out smoothly.

Next, by firing the winding body 39 under a firing condition in a reducing atmosphere of, for example, a temperature of about 1600 ° C, a ceramic heater 5 having a shape in which the heater member 11 is wound can be obtained.

Next, as shown in FIG. 1, the ceramic flange 6 is inserted from the outside at a predetermined attachment position on the rear end side (right side of FIG. 1) of the ceramic heater 5, and the ceramic heater 5 is further inserted. ) And the flange 6 are joined by the glass adhesive 7, for example.

Then, the front end side (left side of FIG. 1) of the ceramic heater 5 with the flange 6 is inserted into the heat exchanger 3, and the flange 6 is inserted into a material 41 such as a ring. The heat exchanger unit 1 is brought into contact with the open end 43 of the heat exchanger 3, and fastened by a screw (not shown) to complete the heat exchange unit 1 composed of the ceramic heater 5 and the heat exchanger 3.

c) As described above, in the ceramic heater 5 of the present embodiment, the heater member 11 is double-wound and the heating element 21 is evenly disposed in the circumferential direction over the entire circumference, and the heater member 11 is The ends 13, 15 have an indirectly overlapping configuration.

Therefore, in this embodiment, there is no slit 1017 as in the prior art of FIG. That is, there is no non-heating region H in which the heating element 1019 is not formed, and as shown in FIG. 2 (a), the heating element 21 also has the same width over the entire circumference of the ceramic heater 5. They are arranged at equal intervals.

Therefore, the washing water can be heated uniformly and efficiently around the entire circumference of the ceramic heater 5, and the heating efficiency is high. In addition, since the heating efficiency is high, there is an advantage that the ceramic heater 5 can be miniaturized. In addition, since there is no need for the ceramic core member 1009 as in the prior art, the manufacturing cost can be reduced.

As the heater member 11, an alumina ceramic sheet of the same shape may be affixed on the ceramic base 19 so as to cover the heat generating element 21 thereon.

Example 2

Next, Example 2 will be described, but description of the same contents as in Example 1 will be omitted.

In this embodiment, the heating elements are arranged in duplicate. It demonstrates concretely below.

As shown in Fig. 4A, in the ceramic heater 51 of this embodiment, the heater member 53 is wound in triplicate. In addition, the heat generating elements 55 are arranged in duplicate, and are arranged almost evenly in the circumferential direction over the entire circumference.

In this case, as shown in Fig. 4 (b), the heater member 53 is developed and its interior (the surface of the ceramic body 57) is shown, so that the heating element 55 collects on one side of the heater member 53 and meanders. It is formed in a shape.

That is, the heating element 55 is formed in the tip part side of the winding direction (arrow A direction) so that the arrow A direction and the extending direction of the said heating element 55 may become perpendicular | vertical. In addition, the number of times the heating element 55 meanders (thus the length of the heating element 55: the width | variety in the left-right direction in the same figure) is nearly doubled with the said Example 1 with the increase of the said winding number.

In the present embodiment, the heating element 55 is arranged in two layers (two-layer structure), which has the advantage that the heating performance is higher even though it is almost the same size as in the second embodiment.

Example 3

Next, Example 3 will be described, but description of the same contents as in Example 1 will be omitted.

In this embodiment, the heat generators are arranged with respect to the thickness direction of the ceramic heater. It demonstrates concretely below.

As shown in Fig. 5 (a), the ceramic heater 61 of the present embodiment has the heater member 63 wound in three, and the heating elements 65 are arranged almost evenly in the circumferential direction over the entire circumference. have.

In particular, in the present embodiment, the heating element 65 is formed only on the heater member 63 wound on the outermost side, and is not disposed on the heater member 63, which is the inner two layers.

Thereby, the fluid outside the ceramic heater 61 can be heated efficiently.

In addition, as shown in the application example in FIG. 5 (b), the ceramic heater 71 of the application example has the heater member 73 wound in triplicate and the heating element 75 in the portion indicated by the broken line 74. A part of superimposition overlaps and the heat generating body 75 is arrange | positioned without gap in the circumferential direction over the whole circumference.

In particular, in the present embodiment, the heating element 75 is formed only on the heater member 73 wound on the innermost side, and is not disposed on the heater member 73 which is the outer two layers.

Thereby, the fluid inside the ceramic heater 71 can be heated efficiently.

Example 4

Next, Example 4 will be described, but description of the same contents as in Example 1 will be omitted.

In this embodiment, the arrangement of the heating elements in the circumferential direction is uneven. It demonstrates concretely below.

As shown in Fig. 6A, in the ceramic heater 81 of the present embodiment, the heater member 83 is wound twice in the same manner as in the first embodiment, but the arrangement intervals of the heating elements 85 in the circumferential direction are uneven. .

Specifically, in the portion where the ends 87 and 89 of the heater member 83 overlap (the upper part of the figure), the spacing of the heating elements 85 is close, but on the opposite side, the spacing of the heating elements 85 becomes sparse. have.

In this case, as shown in Fig. 6 (b), the heater member 83 is developed and its interior (the surface of the ceramic body 88) is shown, so that the heating element 85 is biased to one side of the heater member 83. In addition to being formed in a shape, the central side of the meandering heating element 85 is sparse.

Thus, in this embodiment, since the arrangement | positioning interval of the heat generating body 85 of the part which overlaps the edge part 87,89 of the ceramic heater 81 becomes close, even if the volume (heat capacity) of the overlapping part becomes large, Almost even heating can be performed over the entire circumference.

Example 5

Next, Example 5 will be described, but description of the same contents as in Example 1 will be omitted.

In this embodiment, the widths of the heating elements are nonuniform in the circumferential direction. It demonstrates concretely below.

As shown in Fig. 7A, in the ceramic heater 91 of this embodiment, the heater member 93 is wound twice in the same manner as in the first embodiment, but the widths of the heating elements 95 are non-uniform in the circumferential direction. .

Specifically, in the portion where the ends 97 and 99 of the heater member 93 overlap (the upper part of the figure), the width of the heating element 95 is narrow (and thus the resistance is large and the amount of heat is generated), but on the opposite side, the heating element The width of 95 is wide (therefore, the resistance is small and the amount of heat generated is small).

In this case, as shown in Fig. 7 (b), the heater member 93 is developed and its interior (the surface of the ceramic body 98) is shown, so that the heating element 95 is biased to one side of the heater member 93. In addition to being formed in a shape, the line width at the center of the meandering heating element 95 is widened.

Thus, in the present embodiment, since the line width of the heat generating element 95 of the portion where the ends 97, 99 of the ceramic heater 91 overlap is small, the heat capacity of the overlapping portion becomes large almost over the entire circumference. Equal heating can be performed.

Example 6

Next, Example 6 will be described, but description of the same contents as in Example 1 will be omitted.

In this embodiment, the number of windings of the heater member varies depending on the position in the axial direction. It demonstrates concretely below.

As shown in Fig. 8A, in the ceramic heater 101 of the present embodiment, the heater member 105 is wound twice in the tip end side where the heating element 103 is disposed, but the washing water is supplied. On the rear end side, the heater member 105 is wound in a single line (illustrated in the same drawing).

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

In the case of manufacturing the ceramic heater 101, as shown in Fig. 9, a heater sheet 112 having a special shape is used. That is, half of one side (lower side of the drawing) of the four sides of the ceramic gas sheet 113 serving as the base of the heater sheet 112, that is, the terminal on the side (right side of the drawing) on which the heating pattern 115 is formed. A ceramic gas sheet 113 cut out of one side (lower side of the figure) on the pattern 117 side in a long, thin rectangular shape is used. And similarly to the said Example 1, this heater sheet 112 is wound in the arrow A direction, and the winding body similar to Example 1 (not shown) is obtained. The other processing is the same as that of the first embodiment.

As shown in Fig. 10A, when the pipe 119 for supplying the washing water is connected to the rear end side of the ceramic heater 101 of this embodiment, the rear end side of the ceramic heater 101 is connected. The pipe 119 is inserted into the small diameter portion 109, and the pipe 119 is press-fitted until it reaches the step 111.

In addition, as shown in FIG. 10 (b), the stepped hole 123 having a shape corresponding to the stepped 111 of the ceramic heater 101 is also prevented from leaking into the through hole 121 of the pipe 119. Is formed.

In the present embodiment, the same effect as in the first embodiment is shown, and since the small diameter portion 109 and the step 111 are formed on the rear end side of the ceramic heater 101, the connection of the pipe 119 is easy. There is an advantage.

Example 7

Next, Example 7 will be described, but description of the same contents as in Example 1 will be omitted.

As shown in Fig. 11, in the ceramic heater 131 of the present embodiment, chamfering is applied to the end 135 in the circumferential direction of the outer circumferential surface of the heater member 133 wound in duplicate, thereby inclining. Is gentle and smooth chamfer 137 is formed.

That is, the edge part 135 of the outer peripheral surface of the heater member 133 is chamfered so that there may be no step | step like the said 1st Example.

Thereby, since the pipe (not shown) which connects to the ceramic heater 131 can use a round-shaped cross section of a normal through-hole, it has the advantage of low cost and high practicality.

Example 8

Next, Example 8 will be described, but description of the same contents as in Example 1 will be omitted.

This embodiment is different from the first embodiment in the manufacturing method, and uses the same core member as in the prior art. Hereinafter, the manufacturing method of the ceramic heater of a present Example is demonstrated.

As shown in FIG. 12, the heater sheet 146 which is the unbaked ceramic gas sheet 145 having the heat generating pattern 143 or the like formed on the surface of the cylindrical fired ceramic core member 141 is first wound. That is, the heater sheet 146 is wound on the surface of the core member 141 in a single layer, and the windings 151 are formed by overlapping the ends 147 and 149 with each other.

Thereafter, the winding body 151 and the core member 141 are fired integrally to manufacture the ceramic heater 153.

In this embodiment, since the heater sheet 146 is rolled up and the ends 147 and 149 overlap each other, there is no conventional slit. Therefore, since the heating element (not shown) can be arranged uniformly along the circumference, there is an advantage that the heating efficiency is good.

In addition, the heater sheet 146 (that is, the heater member) may not be wound in one, but may be wound in two or more. In the case where the washing water does not flow through the through-hole of the shaft center of the core member 141, a solid core member may be used instead of the cylindrical core member 141.

Example 9

Next, Example 9 will be described, but description of the same contents as in Example 1 will be omitted.

This embodiment differs from the first embodiment in that its manufacturing method is characterized in that the core member for processing is not used. Hereinafter, the manufacturing method of the ceramic heater of a present Example is demonstrated.

As shown in Fig. 13, first, the heater sheet 164, which is the unbaked ceramic gas sheet 163, on which the heat generating pattern 161 is formed, is rolled up so as not to have a space in the center of the shaft. That is, the winding body 163 is formed by winding up the heater sheet 164 in several times.

Thereafter, the winding body 163 is fired to manufacture a ceramic heater 165.

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

Example 10

Next, Example 10 will be described, but description of the same contents as in Example 1 will be omitted.

This embodiment differs from the said Example 1 in the manufacturing method, and is characterized by using the wax core | mold process core member. Hereinafter, the manufacturing method of the ceramic heater of a present Example is demonstrated.

Although not particularly shown in the present embodiment, a wax core for a workpiece made of wax having the same shape as that for the core of FIG. 3 is used as the core for processing.

Specifically, a heater sheet, which is a ceramic gas sheet having a heat generating pattern, is wound around the outer circumference of the core member for processing, and then fired. During the firing, the wax disappears, and thus a cylindrical ceramic heater is obtained.

As the wax, for example, paraffin wax, which is hard enough to be wound around the ceramic gas sheet and melted and lost by heating at the time of firing, can be used.

Example 11

Next, Example 11 will be described, but description of the same contents as in Example 8 will be omitted.

This embodiment is different from the eighth embodiment in the shape of the core member for processing.

As shown in Fig. 14A, in this embodiment, a cylindrical core member 171 having a step 173 on its outer circumferential surface is used as the core member 171 for processing. In detail, the processing core member 171 is provided with the step | step (that is, the step | step 173 extended to the same height in an axial direction) with the difference of the thickness of one sheet of a heater sheet (not shown) in the circumferential direction.

In the case of using the core member 171 for processing, a ceramic heater (not shown) having no step on the outer circumferential surface can be obtained by applying the end of the heater sheet to the step 173 so as to be wound.

In this embodiment, since a gap is hardly formed between the core member 171 for processing and the heater sheet (that is, the heater member) wound on the outer circumferential surface thereof, there is an advantage that the strength of the entire ceramic heater is increased.

In addition, in the present embodiment, as shown in Fig. 14B, a machining core member 177 having a solid cylindrical shape and similarly provided with a step 175 on the outer circumferential surface may be used.

In addition, this invention is not limited to the said Example at all, Needless to say that it can implement in various aspects in the range which does not deviate from the summary of this invention.

As described above, according to the method of manufacturing the ceramic heater, the heat exchange unit, the hot water washing toilet and the ceramic heater of the present invention, the heating efficiency is compact and the manufacturing cost can be reduced.

Claims (22)

And a heater member on which a heating element is formed on the ceramic body is wound at least once, and the heater members overlap each other. The method according to claim 1, And the ceramic heater is a tubular body. The method according to claim 1 or 2, Ceramic heaters, characterized in that the ends of the heater member in the circumferential direction overlap directly or indirectly in the thickness direction of the heater member. The method according to claim 3, At least a portion of the heater member in which the heating element is formed, the heating element formed in the ceramic heater, characterized in that overlapping in the thickness direction of the heater member. The method according to claim 3 or 4, And a non-heat generating portion in which the heating element is not formed among the heater members is overlapped at least partially in the thickness direction of the heater member. The method according to any one of claims 1 to 5, And the heating element is at least partially overlapped in the thickness direction of the heater member. The method according to any one of claims 1 to 6, And a chamfer portion formed with chamfers along the circumferential direction at an end of the outermost circumference of an end portion of the circumferential direction of the heater member. The method according to any one of claims 1 to 7, The heater is wound in multiple, the ceramic heater, characterized in that the heating element is laminated. The method according to any one of claims 1 to 8, The ceramic heater has a cylindrical shape, and the heat generation amount in the inner side in the thickness direction and the heat generation amount in the outer side are different from each other in the center of the thickness direction. The method according to any one of claims 1 to 9, The ceramic heater has a cylindrical shape, and the arrangement interval of the heating elements is different in the circumferential direction thereof. The method according to claim 10, Arrangement interval of the heating element is a ceramic heater, characterized in that the closer the thickness of the ceramic heater. The method according to any one of claims 1 to 11, The ceramic heater is cylindrical and has a different cross-sectional area of the heating element in a circumferential direction thereof. The method according to claim 12, The cross section of the heating element is a ceramic heater, characterized in that the thicker the thickness of the ceramic heater. The method according to any one of claims 1 to 13, The ceramic heater is characterized in that the number of windings of the heater member is different in the axial direction. The method according to claim 14, And the number of windings of the heater member at the end of the heating element side in the axial direction is larger than the number of windings of the heater member at the end on the side opposite to the end of the heating element side. A heat exchange unit according to any one of claims 1 to 15, wherein the ceramic heater according to any one of claims 1 to 15 is attached to a heat exchanger through which a fluid heated by the ceramic heater flows in and out. The method according to claim 16, And a flow passage reaching the space on the outer circumferential surface side of the ceramic heater from a through hole traversing the ceramic heater in the axial direction as the flow passage of the fluid in the heat exchange unit. A hot water cleaning toilet comprising the heat exchange unit according to claim 16 or 17. The heater sheet before firing, in which the heating pattern is formed on the ceramic gas sheet, is wound on the core member for processing at least once to form a winding body, and after removing the processing core member from the winding body, the winding body is fired to form a ceramic heater. Method for producing a ceramic heater, characterized in that the manufacturing. The heater sheet before firing in which the heating pattern is formed on the ceramic gas sheet is wound on at least one wound core member made of a material which is lost during firing to form a winding body, and the winding body is baked, The manufacturing method of the ceramic heater, characterized in that to produce a ceramic heater by causing the core member to be lost. The winding sheet is formed by winding the heater sheet before firing in which the heating pattern is formed on the ceramic gas sheet at least once in a cylindrical or solid core member to form a winding body, and firing the winding body to produce a ceramic heater. A method of manufacturing a ceramic heater, characterized in that. A method of manufacturing a ceramic heater, comprising: winding a heater sheet before firing in which a heating pattern is formed on a ceramic gas sheet, one or more times to form a solid winding body, and firing the winding body to produce a ceramic heater.

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