WO2005021941A1 - Electric heater manufacturing method - Google Patents
Electric heater manufacturing method Download PDFInfo
- Publication number
- WO2005021941A1 WO2005021941A1 PCT/KR2004/002150 KR2004002150W WO2005021941A1 WO 2005021941 A1 WO2005021941 A1 WO 2005021941A1 KR 2004002150 W KR2004002150 W KR 2004002150W WO 2005021941 A1 WO2005021941 A1 WO 2005021941A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- heating element
- strips
- electric heater
- brazing
- forming
- Prior art date
Links
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN A CARRIER GAS OR AIR
- F23C13/00—Apparatus in which combustion takes place in the presence of catalytic material
- F23C13/02—Apparatus in which combustion takes place in the presence of catalytic material characterised by arrangements for starting the operation, e.g. for heating the catalytic material to operating temperature
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/023—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles
- F01N3/027—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using electric or magnetic heating means
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
- F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
- F01N3/2006—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating
- F01N3/2013—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating using electric or magnetic heating means
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01C—RESISTORS
- H01C3/00—Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids
- H01C3/10—Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids the resistive element having zig-zag or sinusoidal configuration
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN A CARRIER GAS OR AIR
- F23C2900/00—Special features of, or arrangements for combustion apparatus using fluid fuels or solid fuels suspended in air; Combustion processes therefor
- F23C2900/13001—Details of catalytic combustors
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
Definitions
- the present invention relates to a method of manufacturing an electric heater, and more particularly to a method of manufacturing an electric heater comprising the steps of forming the strips to have a predetermined shape with some portion of the strips made of a non-brazing material, which is not bonded to other members, and removing the material after brazing the strips.
- an internal combustion engine for a vehicle discharges a great quantity of harmful exhaust gas when burning fuel, and a catalyst is used for reducing the amount of exhaust gas.
- the catalyst is usually coated on a ceramic-based substrate, and serves to convert the harmful exhaust gas into harmless carbon dioxide or the like.
- the ceramic-based substrate is vulnerable to thermal impact caused by the exothermic reaction accompanied with catalytic activation and oxidation during a chemical reaction, or by a vibration of the vehicle.
- physical or chemical damage to the ceramic substrates such as poisoning by sulfur and the like contained in the fuel, frequently occurs.
- a metal substrate with a catalyst coated thereon has been suggested, instead of the ceramic (mainly, Codierite) substrate with a noble metal as the catalyst coated thereon.
- the metal substrate is manufactured by alternately laminating a corrugated strip and a flat strip, each being made of a thin metal plate, winding the laminated metal strips, and brazing the metal strips in a vacuum furnace with a filling metal applied to the wound metal strips for increasing the binding force between the metal strips. At this time, the metal strips are bonded to each other by brazing the flat/corrugated strips, which are previously wound as an integral component and then inserted in a can.
- the metal substrate produced by brazing is formed with extremely minute apertures, and may be used after coating the catalyst on the metal substrate. While the metal substrate basically has a similar structure to that of the ceramic substrate, it has very strong thermal and mechanical impact resistances, compared with the conventional ceramic substrate.
- the metal substrate has been available primarily in the field of two-wheel vehicles, which discharge exhaust gas at a very high temperature with a high flux.
- an exhaust gases emission reducing method in which a catalytic converter is located adjacent to the engine in order to reduce the amount of unburned hydrocarbons discharged during a cold start or idling of the engine.
- an electric heater based on the principle of the metal substrate, which activates the catalyst in a short period of time by operating of the electric heater during the cold start.
- a diesel particulate filter is used to reduce smoke of the diesel engine.
- a technology available for the diesel particulate filter there are a trapping technology using a ceramic filter, and a regeneration technology for periodically oxidizing or burning trapped smoke.
- the electric heater having the metal substrate has been employed for the regeneration technology.
- the electric heater used for the regeneration technology generally has several sheets of thin plates stacked on each other, which are used when manufacturing the metal substrate, as described above.
- corrugated strips having different cell sizes are alternately laminated, and are then bonded to each other.
- the corrugated strips form a non-uniform bonding surface, causing deterioration in bonding force after being brazed.
- it is difficult to bring the above method to practical use not only due to the difficulty of winding the heating element with the strips laminated to each other, but also due to non- uniformity of resistance, the structure, and the electrical properties of heating element.
- the present invention has been made in view of the above problems, and it is an object of the present invention to provide a method of manufacturing an electric heater, wherein a space between wound portions of the heating element can be maintained by forming some portion of strips with a material, not being brazed to other members, inserted between the wound portions of the heating element, and then removing the material after brazing the strips.
- the above and other objects can be accomplished by the provision of a method of manufacturing an electric heater with strips laminated therein for purifying exhaust gas discharged from a vehicle, the method comprising the steps of: forming the strips to have a predetermined shape with some portion of the strips made of a non-brazing material, brazing the predetermined shape the strips, and removing the non-brazing material from the brazed strips.
- the non-brazing material may be a dummy heating element.
- a mantle may be used as a jig.
- Fig. 1 shows a conventional heating element with strips laminated therein
- Fig. 2 shows a heating element with strips laminated therein according to one embodiment of the present invention
- Fig. 3 shows the heating element of Fig. 2 mounted on winding member
- Figs. 4 to 7 show a process of forming a central portion of the heating element
- Figs. 8 to 13 show a process of forming an outer portion of the heating element.
- the electric heater for vehicles of the present invention is applied to an apparatus for purifying exhaust gas discharged from the vehicles.
- the electric heater of the invention is manufactured by a process comprising the steps of laminating corrugated strips and flat strips, which are made of a thin metal plate, to form a heating element, applying a solvent or a sheet-type bonding agent to the heating element, mounting a radiant heat prevention film on the heating element, and brazing the heating element in a vacuum furnace.
- the electric heater is divided into at least two portions, for example, into an inner electric heater portion and an outer electric heater portion, and thermal capacities of the inner and outer electric heater portions are independently controlled.
- the inner electric heater portion and the outer electric heater portion are separated from each other by means of mantles, in which electrodes and the mantles are used to supply power to the heating element, and then to apply current to the heating element.
- the number of the electrodes and the mantles is provided corresponding to the number of the separated portions of the electric heater.
- the electrodes and the mantles are connected to the heating element and an outer canning, and act to increase the overall mechanical/thermal strengths of the electric heater.
- the method of manufacturing the electric heater comprises the steps of laminating flat strips or corrugated strips and strips alternately formed with corrugations thereon, forming a heating element of a desired shape using the laminated strips, connecting mantles and electrodes to the strips of the heating element having the desired shape, applying a bonding agent to an assembly of the heating element and the mantles, mounting a radiant heat prevention film on the assembly of the heating element and the mantles, and brazing the assembly of the heating element and the mantles mounted with the radiant heat prevention film.
- MVF is inserted between the strips of the formed heating element for the step of brazing the strips.
- a material which is not brazed to the other members of the electric heater, that is, a non-brazing material is inserted between the strips of the heating element. Accordingly, by removing the non-brazing material after brazing, the heating element having a predetermined shape is formed.
- the non-brazing material is preferably a heating element without the metal brazing filler between the heating elements.
- Such a non-brazing heating element is referred to as a dummy heating element, and since it is not bonded to the other members when brazing, the dummy heating element is inserted when forming the heating element, and is then removed after brazing. Furthermore, such a heating element is used as the non-brazing material, which is the same as that of the heating element having the metal brazing filler, so that there is no chemical reaction between the heating element having the metal brazing filler and the non-brazing material due to thermal variation, thereby ensuring stability when forming the heating element. In other words, the heating element itself is used as a jig when forming the electric heater.
- a mantle When forming the electric heater using the non-brazing material, a mantle may also be used as a jig. Since the mantle is shaped to be located at a predetermined position in the electric heater, the heating element can be manufactured to have a predetermined shape by forming the heating element corresponding to the shape of the mantle. When locating the dummy heating element, the strips of the heating element are laminated to a predetermined thickness, and the dummy heating elements are then laminated on upper and lower surfaces of the heating element. Then, except a space between the dummy heating element and the upper and lower surfaces of the heating element, a space between the strips of the heating element is filled with the bonding agent.
- Fig. 1 shows a conventional heating element 10 with strips laminated therein
- Fig. 2 shows a heating element 20 with strips laminated therein according to one embodiment of the present invention.
- the general heating element 10 comprises corrugated or flat-shaped strips 1 with a metal brazing filler 2 filled between the strips.
- the heating element 20 comprises corrugated or flat-shaped strips 1, together with a metal brazing filler 2 filled between the strips, at the central portion of the heating element 20, and dummy heating elements 3 respectively laminated on the upper and lower surfaces of the central portion of the heating element 20 without applying the filler metal onto the upper and lower surfaces thereof. That is, the dummy heating element 3 is used as the non-brazing material.
- Fig. 3 shows the heating element 20 mounted on a winding member 100.
- Fig. 4 to 7 show sequential processes for forming the central portion of the heating element 20. In Figs. 4 and 5, mantles 200 are inserted while rotating the winding member 100 in order to form the central portion of the heating element 20.
- FIG. 6 shows the heating element 20 having the dummy heating element 3 and the filler metal 2 with the mantles 200 provided around the heating element 20 after removing the winding member 100.
- Fig. 7 shows the heating element 20 with the mantles 200 and the dummy heating element 3 removed therefrom after brazing. Accordingly, as shown in Fig. 7, a predetermined shape of the heating element 20 is formed while a space between wound portions of the heating element 20 is maintained.
- Figs. 8 to 13 show sequential processes of forming an outer portion of the heating element 20. In Fig. 8, the heating element 20 is positioned on winding members 110, and is deformed by means of the mantle 200. In Fig.
- additional winding members 120 are respectively positioned at both ends of the heating element 20 along with the winding members 110, and both ends of the heating element 20 are bent by rotating the winding members 120 inwardly in a state that the mantle 200 and the heating element 20 adjoin each other by the process of Fig. 8.
- Fig. 10 with the winding members 110 located at the same positions as those of Fig. 9 and the winding members 120 located at different positions from that of Fig. 9, both ends of the heating element 20 are bent again by rotating both ends in opposite directions to that of Fig. 9.
- another mantle 210 is provided around the outer periphery of the heating element 20 after the process of Fig. 10, thereby deforming the heating element 20.
- Fig. 12 shows a completed heating element 20.
- Fig. 13 shows the outer portion of the heating element 20 having a predetermined shape, with the mantles 200 and 210, and the dummy heating element 3 removed therefrom after brazing.
- the heating element when producing the - heating element for the electric heater, the heating element can be uniformly manufactured, and the problem of deviation of the heating element is overcome. Further, with the dummy heating element, the dummy heating element presses the heating element, thereby strengthening a bonding force when brazing. Additionally, the mantles can be manufactured at the same time of forming the heating element.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Health & Medical Sciences (AREA)
- Toxicology (AREA)
- Exhaust Gas After Treatment (AREA)
Abstract
A method of manufacturing an electric heater comprising the steps of forming the strips to have a predetermined shape with some portion of the strips made of a non-brazing material, which is not bonded to other members, and removing the material after brazing the strips. The method comprises the steps of forming the strips to have a predetermined shape with some portion of the strips made of a non-brazing material, brazing the predetermined shape the strips, and removing the non-brazing material from the brazed strips.
Description
ELECTRIC HEATER MANUFACTURING METHOD
Technical Field
The present invention relates to a method of manufacturing an electric heater, and more particularly to a method of manufacturing an electric heater comprising the steps of forming the strips to have a predetermined shape with some portion of the strips made of a non-brazing material, which is not bonded to other members, and removing the material after brazing the strips.
Background Art
Generally, an internal combustion engine for a vehicle discharges a great quantity of harmful exhaust gas when burning fuel, and a catalyst is used for reducing the amount of exhaust gas. The catalyst is usually coated on a ceramic-based substrate, and serves to convert the harmful exhaust gas into harmless carbon dioxide or the like. However, the ceramic-based substrate is vulnerable to thermal impact caused by the exothermic reaction accompanied with catalytic activation and oxidation during a chemical reaction, or by a vibration of the vehicle. In addition, physical or chemical damage to the ceramic substrates, such as poisoning by sulfur and the like contained in the fuel, frequently occurs. In order to solve these problems, a metal substrate with a catalyst coated thereon has been suggested, instead of the ceramic (mainly, Codierite) substrate with a noble metal as the catalyst coated thereon. The metal substrate is manufactured by alternately laminating a corrugated strip and a flat strip, each being made of a thin metal plate, winding the laminated metal strips, and brazing the metal strips in a vacuum furnace with a filling metal applied to the wound metal strips for increasing the binding force between the metal strips. At this time, the metal strips are bonded to each other by brazing the flat/corrugated strips, which are previously wound as an integral component and then inserted in a can. As with the conventional ceramic substrate, the metal substrate produced by brazing is formed with extremely minute apertures, and may be used after coating the catalyst on the metal substrate. While the metal substrate basically has a similar structure to that of the
ceramic substrate, it has very strong thermal and mechanical impact resistances, compared with the conventional ceramic substrate. Accordingly, the metal substrate has been available primarily in the field of two-wheel vehicles, which discharge exhaust gas at a very high temperature with a high flux. Particularly, according to a recent trend of strengthening regulations aimed at reduction of exhaust gases emission, in case of a gasoline engine, there is an exhaust gases emission reducing method, in which a catalytic converter is located adjacent to the engine in order to reduce the amount of unburned hydrocarbons discharged during a cold start or idling of the engine. Alternatively, there is another exhaust gas emissions reducing method using an electric heater based on the principle of the metal substrate, which activates the catalyst in a short period of time by operating of the electric heater during the cold start. Meanwhile, in case of a diesel engine, a diesel particulate filter is used to reduce smoke of the diesel engine. As for a technology available for the diesel particulate filter, there are a trapping technology using a ceramic filter, and a regeneration technology for periodically oxidizing or burning trapped smoke. Recently, the electric heater having the metal substrate has been employed for the regeneration technology. Here, the electric heater used for the regeneration technology generally has several sheets of thin plates stacked on each other, which are used when manufacturing the metal substrate, as described above. Meanwhile, when manufacturing the electrical- heater using the metal strip, corrugated strips having different cell sizes are alternately laminated, and are then bonded to each other. Accordingly, the corrugated strips form a non-uniform bonding surface, causing deterioration in bonding force after being brazed. Moreover, it is difficult to bring the above method to practical use, not only due to the difficulty of winding the heating element with the strips laminated to each other, but also due to non- uniformity of resistance, the structure, and the electrical properties of heating element. Furthermore, it is difficult to maintain a space between wound portions of the heating element, and the bonding force between the wound portions of the heating element becomes weak due to expansion of the strip when brazing.
Disclosure of the Invention
Therefore, the present invention has been made in view of the above problems, and it is an object of the present invention to provide a method of manufacturing an electric heater, wherein a space between wound portions of the heating element can be maintained by forming some portion of strips with a material, not being brazed to other members, inserted between the wound portions of the heating element, and then removing the material after brazing the strips. In accordance with an aspect of the present invention, the above and other objects can be accomplished by the provision of a method of manufacturing an electric heater with strips laminated therein for purifying exhaust gas discharged from a vehicle, the method comprising the steps of: forming the strips to have a predetermined shape with some portion of the strips made of a non-brazing material, brazing the predetermined shape the strips, and removing the non-brazing material from the brazed strips. The non-brazing material may be a dummy heating element. At the step of forming the strips using the non-brazing material, a mantle may be used as a jig.
Brief Description of the Drawings
The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which: Fig. 1 shows a conventional heating element with strips laminated therein; Fig. 2 shows a heating element with strips laminated therein according to one embodiment of the present invention; Fig. 3 shows the heating element of Fig. 2 mounted on winding member; Figs. 4 to 7 show a process of forming a central portion of the heating element; and Figs. 8 to 13 show a process of forming an outer portion of the heating element.
Best Mode for Carrying Out the Invention
The present invention will now be described in detail as follows. The electric heater for vehicles of the present invention is applied to an apparatus for purifying exhaust gas discharged from the vehicles. The electric heater of the invention is manufactured by a process comprising the steps of laminating corrugated strips and flat strips, which are made of a thin metal plate, to form a heating element, applying a solvent or a sheet-type bonding agent to the heating element, mounting a radiant heat prevention film on the heating element, and brazing the heating element in a vacuum furnace. In the case of a separated electric heater, the electric heater is divided into at least two portions, for example, into an inner electric heater portion and an outer electric heater portion, and thermal capacities of the inner and outer electric heater portions are independently controlled. At this time, the inner electric heater portion and the outer electric heater portion are separated from each other by means of mantles, in which electrodes and the mantles are used to supply power to the heating element, and then to apply current to the heating element. The number of the electrodes and the mantles is provided corresponding to the number of the separated portions of the electric heater. The electrodes and the mantles are connected to the heating element and an outer canning, and act to increase the overall mechanical/thermal strengths of the electric heater. A general method of manufacturing the electric heater as described above will be described in detail as follows. The method of manufacturing the electric heater comprises the steps of laminating flat strips or corrugated strips and strips alternately formed with corrugations thereon, forming a heating element of a desired shape using the laminated strips, connecting mantles and electrodes to the strips of the heating element having the desired shape, applying a bonding agent to an assembly of the heating element and the mantles, mounting a radiant heat prevention film on the assembly of the heating element and the mantles, and brazing the assembly of the heating element and the mantles mounted with the radiant heat prevention film. Generally, when manufacturing the electric heater, a metal brazing filler
(MBF) is inserted between the strips of the formed heating element for the step of brazing the strips. As one aspect of the present invention, when forming the heating element,
a material, which is not brazed to the other members of the electric heater, that is, a non-brazing material is inserted between the strips of the heating element. Accordingly, by removing the non-brazing material after brazing, the heating element having a predetermined shape is formed. The non-brazing material is preferably a heating element without the metal brazing filler between the heating elements. Such a non-brazing heating element is referred to as a dummy heating element, and since it is not bonded to the other members when brazing, the dummy heating element is inserted when forming the heating element, and is then removed after brazing. Furthermore, such a heating element is used as the non-brazing material, which is the same as that of the heating element having the metal brazing filler, so that there is no chemical reaction between the heating element having the metal brazing filler and the non-brazing material due to thermal variation, thereby ensuring stability when forming the heating element. In other words, the heating element itself is used as a jig when forming the electric heater. When forming the electric heater using the non-brazing material, a mantle may also be used as a jig. Since the mantle is shaped to be located at a predetermined position in the electric heater, the heating element can be manufactured to have a predetermined shape by forming the heating element corresponding to the shape of the mantle. When locating the dummy heating element, the strips of the heating element are laminated to a predetermined thickness, and the dummy heating elements are then laminated on upper and lower surfaces of the heating element. Then, except a space between the dummy heating element and the upper and lower surfaces of the heating element, a space between the strips of the heating element is filled with the bonding agent. Finally, with these members wound as a unit heating element body, a heating element for the electric heater is formed. An embodiment of the present invention will now be described with reference to the drawings. Fig. 1 shows a conventional heating element 10 with strips laminated therein, and Fig. 2 shows a heating element 20 with strips laminated therein according to one embodiment of the present invention.
The general heating element 10 comprises corrugated or flat-shaped strips 1 with a metal brazing filler 2 filled between the strips. However, according to one embodiment of the present invention, the heating element 20 comprises corrugated or flat-shaped strips 1, together with a metal brazing filler 2 filled between the strips, at the central portion of the heating element 20, and dummy heating elements 3 respectively laminated on the upper and lower surfaces of the central portion of the heating element 20 without applying the filler metal onto the upper and lower surfaces thereof. That is, the dummy heating element 3 is used as the non-brazing material. Fig. 3 shows the heating element 20 mounted on a winding member 100. Fig. 4 to 7 show sequential processes for forming the central portion of the heating element 20. In Figs. 4 and 5, mantles 200 are inserted while rotating the winding member 100 in order to form the central portion of the heating element 20. Fig. 6 shows the heating element 20 having the dummy heating element 3 and the filler metal 2 with the mantles 200 provided around the heating element 20 after removing the winding member 100. Fig. 7 shows the heating element 20 with the mantles 200 and the dummy heating element 3 removed therefrom after brazing. Accordingly, as shown in Fig. 7, a predetermined shape of the heating element 20 is formed while a space between wound portions of the heating element 20 is maintained. Figs. 8 to 13 show sequential processes of forming an outer portion of the heating element 20. In Fig. 8, the heating element 20 is positioned on winding members 110, and is deformed by means of the mantle 200. In Fig. 9, additional winding members 120 are respectively positioned at both ends of the heating element 20 along with the winding members 110, and both ends of the heating element 20 are bent by rotating the winding members 120 inwardly in a state that the mantle 200 and the heating element 20 adjoin each other by the process of Fig. 8. In Fig. 10, with the winding members 110 located at the same positions as those of Fig. 9 and the winding members 120 located at different positions from
that of Fig. 9, both ends of the heating element 20 are bent again by rotating both ends in opposite directions to that of Fig. 9. In Fig. 11, another mantle 210 is provided around the outer periphery of the heating element 20 after the process of Fig. 10, thereby deforming the heating element 20. Fig. 12 shows a completed heating element 20. Fig. 13 shows the outer portion of the heating element 20 having a predetermined shape, with the mantles 200 and 210, and the dummy heating element 3 removed therefrom after brazing. By assembling the central portion of the heating element 20 and the outer portion of the heating element 20, the electric heater is completed.
Industrial Applicability
As apparent from the above description, when producing the - heating element for the electric heater, the heating element can be uniformly manufactured, and the problem of deviation of the heating element is overcome. Further, with the dummy heating element, the dummy heating element presses the heating element, thereby strengthening a bonding force when brazing. Additionally, the mantles can be manufactured at the same time of forming the heating element. Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
Claims
1. A method of manufacturing an electric heater with strips laminated therein for purifying exhaust gas discharged from a vehicle, the method comprising the steps of: forming the strips to have a predetermined shape with some portion of the strips made of a non-brazing material; brazing the predetermined shape the strips; and removing the non-brazing material from the brazed strips.
2. The method as set forth in claim 1, wherein the non-brazing material is a dummy heating element.
3. The method as set forth in claim 1, wherein at the step of forming the strips using the non-brazing material, a mantle is as a jig.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| KR10-2003-0060292A KR100534082B1 (en) | 2003-08-29 | 2003-08-29 | Electric heater manufacturing method |
| KR10-2003-0060292 | 2003-08-29 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2005021941A1 true WO2005021941A1 (en) | 2005-03-10 |
Family
ID=34270629
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/KR2004/002150 WO2005021941A1 (en) | 2003-08-29 | 2004-08-26 | Electric heater manufacturing method |
Country Status (2)
| Country | Link |
|---|---|
| KR (1) | KR100534082B1 (en) |
| WO (1) | WO2005021941A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2022504563A (en) * | 2018-10-09 | 2022-01-13 | ヴィテスコ テクノロジーズ ゲー・エム・ベー・ハー | Heating disc that can be heated electrically |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5942173A (en) * | 1982-08-31 | 1984-03-08 | Tsuchiya Mfg Co Ltd | Brazing method of honeycomb body made of metal |
| JPH06106245A (en) * | 1992-09-29 | 1994-04-19 | Matsushita Electric Ind Co Ltd | Method for machining metal strip |
| JPH09173870A (en) * | 1995-12-27 | 1997-07-08 | Usui Internatl Ind Co Ltd | Metal carrier |
-
2003
- 2003-08-29 KR KR10-2003-0060292A patent/KR100534082B1/en not_active IP Right Cessation
-
2004
- 2004-08-26 WO PCT/KR2004/002150 patent/WO2005021941A1/en active Application Filing
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5942173A (en) * | 1982-08-31 | 1984-03-08 | Tsuchiya Mfg Co Ltd | Brazing method of honeycomb body made of metal |
| JPH06106245A (en) * | 1992-09-29 | 1994-04-19 | Matsushita Electric Ind Co Ltd | Method for machining metal strip |
| JPH09173870A (en) * | 1995-12-27 | 1997-07-08 | Usui Internatl Ind Co Ltd | Metal carrier |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2022504563A (en) * | 2018-10-09 | 2022-01-13 | ヴィテスコ テクノロジーズ ゲー・エム・ベー・ハー | Heating disc that can be heated electrically |
Also Published As
| Publication number | Publication date |
|---|---|
| KR20050022671A (en) | 2005-03-08 |
| KR100534082B1 (en) | 2005-12-07 |
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