WO2018101407A1 - Electric heater and method for manufacturing same - Google Patents

Abstract

An electric heater (1) is provided with: a plurality of PTC elements (2) for generating heat by electric current passing therethrough; a plurality of electrode plates (3) for applying electric current to the PTC elements (2); a plurality of heat dissipation fins (4) for dissipating heat transferred from the PTC elements (2); a resin plate (5) for providing insulation between the electrode plates (3) having different polarities; and a pressing spring (7) for pressing a laminate (10) from both sides in the lamination direction (H). In projection ranges (R), on the surface in the lamination direction (H) of the resin plate (5), which respectively are the arrangement portions projected in the lamination direction (H) of the PTC elements (2), a plurality of protruding portions (51), protruding as compared to the surface, are provided, respectively. The protruding portion (51) in each projection range (R) has a deformed portion obtained by plastic deformation due to contact with the electrode plates (3).

Description

Electric heater and method for manufacturing the same Cross-reference of related applications

This application is based on Japanese Patent Application No. 2016-234975 filed on December 2, 2016, the contents of which are incorporated herein by reference.

The present disclosure relates to an electric heater that uses heat generated when a PTC element is energized and a method for manufacturing the same.

An electric heater using a PTC (Positive Temperature Coefficient) element is used, for example, as an in-vehicle auxiliary heating heater. The electric heater is composed of an electrode plate for energizing the PTC element, a pair of heat dissipating fins for dissipating heat transmitted from the PTC element, and a pair of layers disposed in the stacking direction of the laminate of the PTC element, the electrode plate and the heat dissipating fin. A frame, a pressing spring for pressing the pair of frames from both sides in the stacking direction, and the like are provided. In an electric heater, in order to effectively conduct electricity from the electrode plate to the PTC element and to conduct heat from the PTC element to the radiating fin, a plurality of laterally arranged PTC elements are as evenly distributed as possible to the electrode plate and the radiating fin. The device is made to contact.

For example, in the electric heater disclosed in Patent Document 1, bent portions for pressing the PTC elements arranged in the lateral direction are formed in a pair of frames. And the site | part in which each PTC element is arrange | positioned in a laminated body is pressed by each bending part, and it is trying for each PTC element to closely_contact | adhere to an electrode plate and a radiation fin.

Further, for example, in the car air conditioner power consumption heater of Patent Document 2, a warped elastic contact portion is provided at a position on the electrode plate facing a portion where a plurality of PTC elements are arranged in the lateral direction. When the laminated body is pressed by a pressing spring, a portion where each PTC element is arranged is pressed by the elastic contact portion so that each PTC element is in close contact with the electrode plate and the radiation fin.

JP 2009-152172 A Chinese Patent CN10173324

In order to further improve the performance of the heater, there is still room for improvement in Patent Documents 1 and 2. That is, as a result of the research and development by the inventors, in order to more effectively conduct electricity from the electrode plate to the PTC element and conduct heat from the PTC element to the radiation fin, all the PTC elements, the electrode plates, and the radiation fins It has been found that it is effective to form a state where is pressed and contacted with as much force as possible.

In Patent Document 1, by bending a frame using a pressing spring, each bent portion of the frame presses a portion of the laminated body where each PTC element is arranged. Therefore, the force with which each PTC element is pressed against the electrode plate and the heat radiating fin varies depending on how the frame bends. As a result, the magnitude of the pressing force acting on each PTC element depends on the magnitude of the frame manufacturing error and deformation. Therefore, in Cited Document 1, there is a possibility that variations occur in the force with which each PTC element is pressed against the electrode plate and the heat radiating fin.

In Patent Document 2, the amount of elastic deformation of each elastic contact portion in the electrode plate varies depending on the difference in the thickness in the stacking direction of the arrangement site of each PTC element in the laminate. Therefore, the force with which the PTC element is pressed against the electrode plate and the heat radiating fin is different for each elastic contact portion, and the PTC element facing the elastic contact portion that is greatly elastically deformed is pressed with a larger force. Therefore, also in the cited document 2, there is a possibility that variations occur in the force with which each PTC element is pressed against the electrode plate and the heat radiating fin.

The present disclosure has been obtained in an attempt to provide an electric heater capable of improving the heater performance and a manufacturing method thereof.

One aspect of the present disclosure generates a plurality of PTC elements that generate heat when energized and are arranged in a lateral direction;
A plurality of electrode plates stacked on both sides of the PTC element in a stacking direction orthogonal to the lateral direction, and for energizing the PTC element;
A plurality of heat dissipating fins that are laminated on both sides of the PTC element in the laminating direction and for radiating heat transmitted from the PTC element;
One or a plurality of resin plates laminated in the laminating direction of the electrode plates or the radiating fins, and insulating between the electrode plates having different polarities;
A pressing spring that presses the laminated body of the PTC element, the electrode plate, the radiation fin, and the resin plate from both sides in the laminating direction,
Of the electrode plate, the radiation fin, and the resin plate, any one of the electrode plate, the radiation fin, and the resin plate is a projection forming member having a projection, and the projection forming member is excluded. When any one of the above is a convex contact member that contacts the convex part,
The convex portions are respectively provided in a plurality of projection ranges obtained by projecting arrangement portions of the plurality of PTC elements on the surface in the stacking direction of the convex portion forming member in the stacking direction, respectively.
At least one of the convex part and the convex part contact member in all the projection ranges is an electric heater having a deformed part due to plastic deformation.

Another aspect of the present disclosure includes a plurality of PTC elements that generate heat when energized and are arranged in a lateral direction;
A plurality of electrode plates stacked on both sides of the PTC element in a stacking direction orthogonal to the lateral direction, and for energizing the PTC element;
A plurality of heat dissipating fins that are laminated on both sides of the PTC element in the laminating direction and for radiating heat transmitted from the PTC element;
One or a plurality of resin plates laminated in the laminating direction of the electrode plates or the radiating fins, and insulating between the electrode plates having different polarities;
A pair of frames laminated at both ends in the laminating direction of a laminate of the PTC element, the electrode plate, the radiating fin, and the resin plate;
A pressing spring that presses the stacked body from both sides in the stacking direction via the pair of frames;
Any of the electrode plate, the radiating fin, the resin plate, and the frame is a convex forming member having a convex portion, and the convex plate forming member is excluded, and the electrode plate, the radiating fin, and the resin When any one of the plate and the frame is a convex contact member that contacts the convex part,
The convex portions are respectively provided in a plurality of projection ranges obtained by projecting arrangement portions of the plurality of PTC elements on the surface in the stacking direction of the convex portion forming member in the stacking direction, respectively.
At least one of the convex part and the convex part contact member in all the projection ranges is an electric heater having a deformed part due to plastic deformation.

Still another aspect of the present disclosure includes a plurality of PTC elements that generate heat when energized and are arranged in a lateral direction;
A plurality of electrode plates stacked on both sides of the PTC element in a stacking direction orthogonal to the lateral direction, and for energizing the PTC element;
A plurality of heat dissipating fins that are laminated on both sides of the PTC element in the laminating direction and for radiating heat transmitted from the PTC element;
One or a plurality of resin plates laminated in the laminating direction of the electrode plates or the radiating fins, and insulating between the electrode plates having different polarities;
In a method of manufacturing an electric heater, comprising: a pressing spring that presses the stacked body of the PTC element, the electrode plate, the heat radiation fin, and the resin plate from both sides in the stacking direction.
Of the electrode plate, the radiation fin, and the resin plate, any one of the electrode plate, the radiation fin, and the resin plate is a projection forming member having a projection, and the projection forming member is excluded. When any one of the above is a convex contact member that contacts the convex part,
The convex portions are respectively provided in a plurality of projection ranges obtained by projecting the arrangement portions of the plurality of PTC elements on the surface in the stacking direction of the convex portion forming member in the stacking direction, respectively.
When the laminate is pressed from both sides in the stacking direction by the pressing spring, at least one of the convex portions and the convex portion contact members in all the projection ranges is plastically deformed, In the method of manufacturing an electric heater, a deformed portion is formed on at least one of the convex portion and the convex portion contact member within a projection range.

In the electric heater according to the one aspect, each PTC element is provided with a deformed portion formed by plastic deformation in at least one of the electrode plate, the heat radiating fin, and the resin plate, which are in contact with each other. The device is designed to make the force pressed by the fins as uniform as possible in all PTC elements. Specifically, any one of the electrode plate, the heat radiating fin, and the resin plate is a convex portion forming member having a convex portion, and the other is a convex portion contact member that contacts the convex portion. The convex portions are respectively provided in a plurality of projection ranges obtained by projecting the arrangement sites of the plurality of PTC elements in the stacking direction on the surface in the stacking direction of the convex portion forming member. At least one of the convex contact members has a deformed portion due to plastic deformation.

And, within the projection range of all the PTC elements, the convex portion and the convex portion contact member are in contact with each other, and at least one of all the convex portions and the convex portion contact member has a deformed portion that is plastically deformed. The deformed portion is formed as a trace or a mark in which the convex portion is crushed so as to be lowered by plastic deformation, or a trace or a mark in which the surface of the convex portion contact member is recessed. Further, since the deformed portion is formed by plastic deformation, unlike the case formed by elastic deformation, the phenomenon that the pressing force generated at each convex portion varies depending on the amount of deformation hardly occurs.

Thus, in the electric heater according to the one aspect, by utilizing the plastic deformation of at least one of the convex portion and the convex portion contact member, the manufacturing process generated in each of the PTC element, the electrode plate, the heat radiation fin, and the resin plate. Even if the thickness in the stacking direction is different at each position in the lateral direction where the PTC elements are arranged due to dimensional error, deformation, etc., all the PTC elements, the electrode plates, and the radiation fins are pressed with the same force as much as possible. In this way, a contact state can be formed. Here, the “thickness in the stacking direction” refers to the total thickness of the single stacking direction of the PTC element, the electrode plate, the radiation fin, and the resin plate in the projection range of each PTC element.

Thereby, energization from the electrode plate to all the PTC elements and heat conduction from all the PTC elements to the radiation fins can be performed more effectively. Therefore, according to the electric heater of the one aspect, the heater performance can be further improved.

In the electric heater of the other aspect, a frame is included in the convex portion forming member and the convex portion contact member. Other configurations are the same as those of the electric heater according to the embodiment. Therefore, according to the electric heater of the other aspect, the heater performance can be further improved as in the case of the electric heater of the one aspect.

In the manufacturing method of the electric heater, when the laminate is pressed from both sides in the stacking direction by the pressing spring, at least one of the projecting portion and the projecting portion contact member within the entire projection range is caused by plastic deformation. A deformation part is formed. Thereby, according to the manufacturing method of an electric heater, the electric heater which can further improve heater performance can be manufactured easily.

In addition, although the code | symbol of the parenthesis of each component shown in 1 aspect of this indication shows the correspondence with the code | symbol in the figure in embodiment, each component is not limited only to the content of embodiment.

Objects, features, advantages, and the like of the present disclosure will become more apparent from the following detailed description with reference to the accompanying drawings. The drawings of the present disclosure are shown below.
FIG. 3 is an explanatory diagram showing an electric heater according to the first embodiment. Explanatory drawing which expands and shows a part of electric heater concerning Embodiment 1. FIG. Sectional drawing which shows the state which cut | disconnected the electric heater concerning Embodiment 1 in the lamination direction. Explanatory drawing shown in the state which decomposed | disassembled the electric heater concerning Embodiment 1. FIG. Explanatory drawing shown in the state which decomposed | disassembled the principal part of the electric heater concerning Embodiment 1. FIG. Explanatory drawing shown in the state which decomposed | disassembled the principal part of the other electric heater concerning Embodiment 1. FIG. Explanatory drawing which shows typically the convex part formation member and convex part contact member before each convex part which plastically deforms concerning Embodiment 1. FIG. Explanatory drawing which shows typically the convex part formation member and convex part contact member after each convex part which plastically deforms concerning Embodiment 1. FIG. Explanatory drawing which shows a pair of member before each elastic deformation part elastically deforms concerning a comparison form. Explanatory drawing which shows a pair of member after each elastic deformation part elastically deformed concerning a comparison form. Explanatory drawing shown in the state which decomposed | disassembled the principal part of the electric heater concerning Embodiment 2. FIG. Sectional drawing shown in the state which cut | disconnected the electric heater concerning Embodiment 2 in the lamination direction. Explanatory drawing shown in the state which decomposed | disassembled the principal part of the other electric heater concerning Embodiment 2. FIG. Explanatory drawing which shows typically the convex part formation member and convex part contact member before the convex part contact member which plastically deforms concerning Embodiment 2. FIG. Explanatory drawing which shows typically the convex part formation member and convex part contact member after the plastic deformation of the convex part contact member concerning Embodiment 2. FIG. Explanatory drawing shown in the state which decomposed | disassembled the principal part of the electric heater concerning Embodiment 3. FIG. Sectional drawing which shows the state which cut | disconnected the electric heater concerning Embodiment 3 in the lamination direction. Explanatory drawing shown in the state which decomposed | disassembled the principal part of the electric heater concerning Embodiment 4. FIG. Sectional drawing which shows the state which cut | disconnected the electric heater concerning Embodiment 4 in the lamination direction. Explanatory drawing shown in the state which decomposed | disassembled the principal part of the other electric heater concerning Embodiment 4. FIG. Explanatory drawing which shows the electric heater concerning Embodiment 5. FIG. Explanatory drawing which expands and shows a part of electric heater concerning Embodiment 5. FIG. Sectional drawing which shows the state which cut | disconnected the electric heater concerning Embodiment 5 in the lamination direction. Explanatory drawing shown in the state which decomposed | disassembled the principal part of the electric heater concerning Embodiment 5. FIG. Explanatory drawing shown in the state which decomposed | disassembled the principal part of the other electric heater concerning Embodiment 5. FIG. Explanatory drawing shown in the state which decomposed | disassembled the principal part of the electric heater concerning Embodiment 6. FIG. Sectional drawing which shows the state which cut | disconnected the electric heater concerning Embodiment 6 in the lamination direction.

A preferred embodiment of the electric heater described above will be described with reference to the drawings.
As shown in FIGS. 1, 2, and 4, the electric heater 1 of this embodiment includes a plurality of PTC elements 2, a plurality of electrode plates 3, a plurality of heat radiation fins 4, a resin plate 5, and a pressing spring 7. The PTC elements 2 generate heat when energized, and a plurality of PTC elements 2 are arranged in the horizontal direction W. The electrode plates 3 are stacked on both sides of the PTC element 2 in the stacking direction H perpendicular to the lateral direction W, and are used to energize the PTC element 2. The radiating fins 4 are stacked on both sides of the PTC element 2 in the stacking direction H, and are for radiating heat transmitted from the PTC element 2.

The resin plate 5 is stacked in the stacking direction H of the electrode plates 3 or the radiating fins 4 and is for insulating between the electrode plates 3 having different polarities. The pressing spring 7 presses the laminated body 10 of the PTC element 2, the electrode plate 3, the radiation fin 4 and the resin plate 5 from both sides in the laminating direction H.

In the electric heater 1, the resin plate 5 is a convex portion forming member 11, and the electrode plate 3 is a convex portion contact member 12 that is in contact with the convex portion 51. As shown in FIGS. 3 and 5, the arrangement site in the lateral direction W and the depth direction D of the PTC element 2 on the surface 501 in the laminating direction H of the resin plate 5 as the convex portion forming member 11 is projected in the laminating direction H. In each projection range R, a convex portion 51 that protrudes from the surface 501 is provided. The convex portion 51 in each projection range R has a deformed portion 511 that is plastically deformed in contact with the electrode plate 3 as the convex portion contact member 12.

Below, it explains in full detail about the electric heater 1 of this form.
The electric heater 1 is provided in a vehicle separately from an air conditioner such as an air conditioner, and is used to assist heating by the air conditioner or instead of heating by the air conditioner. In particular, the electric heater 1 can be used to compensate for a decrease in the heat source of the vehicle due to the high efficiency of the engine, and is also used for a vehicle having no heat source such as an EV (electric vehicle) or an FCV (fuel cell vehicle). You can also.

In this embodiment, the lateral direction W refers to a direction in which the electrode plate 3, the heat radiation fin 4, the resin plate 5, and the like are formed in a long shape. The stacking direction H is a direction perpendicular to the lateral direction W and in which the PTC element 2, the electrode plate 3, the heat radiation fin 4, the resin plate 5, and the like are stacked. A direction perpendicular to the lateral direction W and the stacking direction H is referred to as a depth direction D, and the depth direction D is a direction in which a fluid such as air for air conditioning passes through the electric heater 1.

The PTC element 2 is configured by using a semiconductor or the like, and has PTC (positive temperature coefficient) characteristics that generate heat when energized and increase in electrical resistance as the temperature rises. When the PTC element 2 generates heat above a predetermined temperature, the PTC element 2 is maintained at a substantially constant temperature due to an increase in electrical resistance. The PTC element 2 is formed in a plate shape, and generates heat when a voltage is applied between a pair of surfaces having the largest area.

As shown in FIG. 3, the PTC element 2 is held by a plate-shaped positioning plate 21 made of resin. A plurality of arrangement holes 211 in which the PTC elements 2 are arranged are formed in the positioning plate 21 at predetermined intervals in the lateral direction W. The plurality of arrangement holes 211 are formed so as to penetrate in the stacking direction H of the positioning plate 21. Four PTC elements 2 of this embodiment are arranged in each arrangement hole 211 of the positioning plate 21 in a state of being arranged in the lateral direction W at a predetermined interval. For example, 4 to 6 PTC elements 2 can be arranged on the positioning plate 21. The thickness in the stacking direction H of the portion of the positioning plate 21 where the PTC element 2 is disposed is desirably thinner than the PTC element 2 so that the electrode plate 3 or the radiation fin 4 can easily come into contact with the PTC element 2. . The positioning plate 21 is provided with a projection 212 for positioning in the depth direction D with respect to the electrode plate 3 or the radiating fin 4 laminated on the positioning plate 21. By adjusting the height of the protrusion 212, the electrode plate 3 and the radiation fin 4 can be simultaneously positioned with respect to the positioning plate 21. The protrusions 212 of this embodiment are formed continuously on the edges on both sides in the depth direction D of the positioning plate.

As shown in FIG. 5, the electrode plate 3 applies a voltage for energizing the PTC element 2. One of the pair of electrode plates 3 stacked on both sides in the stacking direction H of the PTC element 2 is connected to a positive power source, and the other is connected to a negative power source (ground). In the figure, the electrode plate 3 connected to the positive power source is indicated by (+), and the electrode plate 3 connected to the negative power source is indicated by (−). The electrode plate 3 of this embodiment is made of a material plated with tin on a brass plate as a metal having excellent conductivity. As other materials, the electrode plate 3 can be made of a copper material made of copper or a copper alloy, an aluminum material made of aluminum or an aluminum alloy, or the like. Each electrode plate 3 is pulled out in the lateral direction W from one end in the lateral direction W in order to apply a voltage.

2 and 5, the radiating fin 4 conducts and transfers heat with the PTC element 2 and transfers heat with a fluid such as heating air. One of the pair of radiating fins 4 stacked on both sides in the stacking direction H of the PTC element 2 is connected to the positive power source via the electrode plate 3, and the other is connected to the negative power source via the electrode plate 3. The The radiating fin 4 is configured by a pair of flat plates 42 that are in contact with the PTC element 2, the electrode plate 3, and the like, and a corrugated plate 43 joined between the pair of flat plates 42. The pair of flat plates 42 are disposed on both sides in the stacking direction H of the radiating fins 4. The fluid heated by the electric heater 1 passes through a through gap 431 formed between the pair of flat plates 42 by the corrugated plate 43, and is heated by the radiating fins 4. The heat radiation fin 4 of this embodiment is made of an aluminum material made of aluminum or an aluminum alloy, or a copper-based material made of copper or a copper alloy, as a metal having excellent conductivity and heat transfer.

As shown in FIGS. 3 and 5, the resin plate 5 is for insulating between the electrode plates 3 and the radiation fins 4 having different polarities connected to a positive power source or a negative power source. The resin plate 5 of this embodiment is made of 66 nylon as a thermoplastic resin. In addition, the resin plate 5 can be made of nylon resin, PBT (polybutylene terephthalate resin), PPS (polyphenylene sulfide resin), or the like. The resin plate 5 is formed with a protrusion 52 for positioning in the depth direction D with respect to the electrode plate 3 (or the heat radiating fin 4) laminated on the resin plate 5. By adjusting the height of the protrusion 52, the electrode plate 3 and the radiation fin 4 can be simultaneously positioned with respect to the resin plate 5. The protrusions 52 of this embodiment are formed continuously on the edges on both sides in the depth direction D of the resin plate 5.

As shown in FIGS. 1 to 3, a pair of frames 6A and 6B are laminated at both ends in the laminating direction H of the laminated body 10 of the PTC element 2, the electrode plate 3, the radiation fins 4, and the resin plate 5. The pair of frames 6 </ b> A and 6 </ b> B are used to receive the pressing force (load) from the pressing spring 7 and to bring the PTC element 2, the electrode plate 3, the heat radiating fin 4, and the resin plate 5 in the laminated body 10 into close contact with each other. By using the pair of frames 6 </ b> A and 6 </ b> B, the rigidity of the electric heater 1 can be increased, and the pressing force applied to the laminated body 10 from the pressing spring 7 can be applied equally to the plurality of PTC elements 2. It becomes easy.

The frames 6A and 6B are made of metal and are formed in a cylindrical shape having a hollow hole 62 penetrating in the lateral direction W. The frames 6A and 6B can be formed in a cylindrical shape by bending a flat plate and having a slit between the bent ends. A part of the pressing spring 7 is inserted into the hollow holes 62 of the frames 6A and 6B. The frames 6A and 6B of this embodiment are made of SUS430. In addition, the frames 6A and 6B can be made of a SUS (stainless steel) material such as SUS304, a steel material such as SECC (electrogalvanized steel plate), or the like.

The pressing springs 7 are arranged on both sides in the lateral direction W of the laminated body 10 and press the laminated body 10 from both sides in the laminating direction H via a pair of frames 6A and 6B on both sides in the lateral direction W. The pressing spring 7 extends in the stacking direction H and is formed to be bent from both sides of the spring center portion 71, with a spring center portion 71 disposed opposite to the end portion in the lateral direction W of the stack body 10. And a pair of sandwiching portions 72 for sandwiching. A pair of clamping part 72 is inserted in the hollow hole 62 of each flame | frame 6A, 6B, and clamps the laminated body 10 via each flame | frame 6A, 6B. The interval between the pair of sandwiching portions 72 is widened by the laminate 10 and the pair of frames 6A and 6B, so that the laminate 10 is laminated from the pair of sandwiching portions 72 to the laminate 10 and the pair of frames 6A and 6B. The pressing force for maintaining the pressure acts.

As shown in FIGS. 1 and 4, resin-made covers 81 that engage with both ends of the pair of frames 6 </ b> A and 6 </ b> B in the lateral direction W are provided at both ends in the lateral direction W of the laminate 10. . The cover 81 located on the side from which the electrode plate 3 is drawn is provided with a connector 82 for connecting the plurality of electrode plates 3 to a positive power source and a negative power source in a vehicle battery.

As shown in FIGS. 3 to 5, in the laminated body 10 of the electric heater 1 of the present embodiment, a plurality of PTC elements 2 are arranged in four stages, and the electrode plates 3 are arranged on both sides in the stacking direction H of the PTC elements 2. And the radiation fin 4 is arrange | positioned. The electrode plate 3 and the heat radiation fin 4 are alternately connected to a positive power source and a negative power source. The resin plate 5 is located at the end of the stacked body 10 in the stacking direction H. Each electrode plate 3 in the laminated body 10 can be separately supplied with voltages from a positive power source and a negative power source. The electric heater 1 switches the presence / absence of energization to each electrode plate 3 in the laminated body 10, thereby performing a partial heating operation for energizing a plurality of PTC elements 2 in a specific lamination position, A full heating operation for energizing the PTC element 2 is possible.

As shown in FIGS. 3 and 5, the arrangement positions in the lateral direction W and the depth direction D of each PTC element 2 in the laminated body 10 of this embodiment are coincident when viewed along the laminating direction H. The projection range R of each PTC element 2 is uniquely determined. For example, in the case where the number of stages in which the plurality of PTC elements 2 are stacked increases, there may be a case where the positions of the plurality of PTC elements 2 in the stacked body 10 in the lateral direction W and the depth direction D do not match. In this case, when the laminated body 10 is viewed along the laminating direction H, the convex portion 51 may be formed at a portion where the projection ranges R of the plurality of PTC elements 2 in the laminated body 10 overlap each other. it can.

Further, as shown in FIG. 6, it may be assumed that a part of the PTC element 2 is eliminated and a portion where the PTC element 2 is eliminated is filled with a positioning plate 21 for power adjustment. In this case, the positioning plate 21 is pressed by the pressing spring 7 at a place where the PTC element 2 is not provided, so that each projection range R in the entire laminate 10 is pressed evenly.

As shown in FIG. 5, each electrode plate 3 in the electric heater 1 having the laminated body 10 is alternately connected to the positive power source, the negative power source, the positive power source, the negative power source, and the positive power source in order from one side in the stacking direction H. Is done. The resin plate 5 is disposed between the electrode plate 3 and the frame 6B, which is the outermost end in the stacking direction H of the stacked body 10 and located at one end in the stacking direction H. The resin plate 5 is positioned at the other end portion in the stacking direction H via the electrode plate 3 and the radiation fin 4 positioned at one end portion in the stacking direction H, the frames 6A and 6B, and the pressing spring 7. The electrode plate 3 and the heat radiating fin 4 are prevented from conducting. When the resin plate 5 energizes the plurality of PTC elements 2 positioned at one end in the stacking direction H and the plurality of PTC elements 2 positioned at the other end in the stacking direction H independently of each other. Used to insulate the two.

The convex portion 51 of this embodiment is provided on the surface 501 of the resin plate 5 facing the electrode plate 3. The convex portions 51 are respectively provided in four projection ranges R obtained by projecting the arrangement site of the four PTC elements 2 in the stacking direction H on the resin plate 5. Each convex part 51 is provided in the center part of each projection range R, respectively. A plurality of convex portions 51 may be provided in each projection range R. Further, the convex portion 51 is not necessarily provided at the center of each projection range R, and a plurality of projections 51 may be provided at a site around the center of each projection range R.

The hardness of the resin plate 5 as the convex portion forming member 11 of this embodiment is lower than the hardness of the electrode plate 3 as the convex portion contact member 12. As shown in FIGS. 7 and 8, when the resin plate 5 and the electrode plate 3 are in contact with each other, and the pressing force by the pressing spring 7 acts between them, the electrode plate 3 causes each convex portion on the resin plate 5 to move. The tip portion of 51 is crushed by plastic deformation so that the height protruding from the surface 501 is low. At this time, most of the material located at the tip of each convex portion 51 flows from between each convex portion 51 and the electrode plate 3 around each convex portion 51. In this manner, a mark or a mark that has undergone plastic deformation is left as a deformed portion 511 on each convex portion 51.

Here, FIG. 7 schematically shows a state before each convex portion 51 is plastically deformed, and FIG. 8 schematically shows a state after each convex portion 51 is plastically deformed. Each figure is a figure which shows typically the state by which the deformation | transformation part 511 is formed in each convex part 51 for description, and shows the convex part 51 exaggeratingly.

Each convex part 51 in the electric heater 1 may be formed in any shape as long as the deformation part 511 is formed at the tip part. The shape of the convex portion 51 before the deformation portion 511 is formed is, for example, a cone, a triangular pyramid, a quadrangular pyramid such as a quadrilateral guess, a curved projection such as a hemisphere, etc., in order to facilitate the formation of the deformation portion 511. can do. Moreover, the shape of the convex part 51 before the deformation | transformation part 511 is formed can also be made into the cylinder or prism which has a flat shape or a curved-shaped front-end | tip part, the cone shape or column shape which has several front-end | tip parts, etc. The shape of the convex portion 51 before the deformation portion 511 is formed is the case where the convex portion 51 is plastically deformed even when the surface of the convex portion contact member 12 is plastically deformed as shown in the second embodiment described later. It can be made the same shape as.

The plastic deformation of the convex portion 51 is performed by applying a load to the convex portion 51 beyond the elastic limit for elastic deformation. The size of the convex portion 51 can be made small in order to facilitate plastic deformation. The size of the convex portion 51 can be, for example, in the range of 0.5 to 5 mm as the maximum outer shape when the convex portion 51 in the resin plate 5 is viewed in plan. The height of the convex portion 51 on which the deformable portion 511 is formed can be set to 0.05 to 1 mm, for example.

The convex portion 51 can also be provided on the surface 501 of the resin plate 5 facing the frame 6B. Also in this case, since the hardness of the resin plate 5 is lower than the hardness of the frame 6B, a deformed portion 511 crushed by plastic deformation is formed at the tip of each convex portion 51 in the resin plate 5 by the frame 6B. Is done.

Moreover, the convex part 51 can also be provided in the surface 501 of the both sides in the resin plate 5. FIG. In this case, the convex portion 51 on one side has a deformed portion 511 caused by plastic deformation by contacting with the electrode plate 3, and the deformation caused by plastic deformation by contacting the convex portion 51 on the other side with the frame 6B. A portion 511 may be included.

Next, a method for manufacturing the electric heater 1 according to this embodiment will be described.
First, the PTC element 2, the electrode plate 3, the heat radiating fin 4, the resin plate 5, the frames 6A and 6B, and the pressing spring 7 are respectively processed by known methods. When the resin plate 5 is molded, a plurality of convex portions 51 are formed on the surface 501 of the resin plate 5. The plurality of convex portions 51 are formed so as to protrude from the surface 501 in each projection range R obtained by projecting the arrangement site of the plurality of PTC elements 2 in the stacking direction H on the surface 501 in the stacking direction H of the resin plate 5. To do.

Next, each PTC element 2 is arranged in each arrangement hole 211 of the positioning plate 21, and the positioning plate 21, the plurality of electrode plates 3, the plurality of radiating fins 4, and the resin plate 5 are stacked to form the stacked body 10. . At this time, each projection 51 in the resin plate 5 is disposed within the projection range R of each PTC element 2 on the surface 501 in the stacking direction H of the resin plate 5. Further, the frames 6A and 6B are stacked on both ends of the stacked body 10 in the stacking direction H.

Next, using a jig or the like, the pressing spring 7 is elastically deformed so as to widen the distance between the pair of sandwiching portions 72 of the two pressing springs 7. Further, the respective pressing springs 7 are arranged on both sides of the laminated body 10 in the lateral direction W, and the clamping portions 72 of the respective pressing springs 7 are inserted into the hollow holes 62 of the respective frames 6A and 6B. And when the state which elastically deforms the press spring 7 is cancelled | released, the space | interval between a pair of clamping parts 72 becomes narrow. Thereby, the laminated body 10 is pressed by the pair of holding portions 72 of the pressing spring 7 via the pair of frames 6A and 6B.

When the laminate 10 receives a pressing force from the pressing spring 7, each convex portion 51 of the resin plate 5 contacts the surface 301 of the electrode plate 3, and the hardness of each convex portion 51 is lower than the hardness of the electrode plate 3, and Since the strength of each convex portion 51 is low, plastic deformation occurs so that the tip portion of each convex portion 51 is crushed. And the deformation | transformation part 511 where the front-end | tip part was crushed is formed in the convex part 51 in all the projection ranges R. FIG. Thereafter, the cover 81 and the connector 82 are attached, and the electric heater 1 is manufactured.

Next, the effect of the electric heater 1 of this form is demonstrated.
When the laminated body 10 is pressed by the pair of pressing springs 7, the electrode plate 3 comes into contact with each convex portion 51 in the resin plate 5. At this time, the thickness in the stacking direction H of each part in the lateral direction W in the stacked body 10 is the production that has occurred in the constituent members of the PTC element 2, the electrode plate 3, the heat radiation fin 4, the resin plate 5, and the frames 6A and 6B. Variations are affected by the above dimensional errors and deformation. And when the laminated body 10 receives the pressing force by the pressing spring 7, each convex part 51 of the resin plate 5 whose strength is lower than that of the electrode plate 3 is plastically deformed and crushed. At this time, in the projection range R of each PTC element 2 on the surface 501 of the resin plate 5, the amount by which each convex portion 51 is plastically deformed varies depending on the difference in thickness of the laminate 10 in each projection range R.

7 and 8, in the projection range R of the plurality of PTC elements 2, the plurality of convex portions 51 of the convex portion forming member 11 are in contact with the convex portion contact member 12, and the plurality of convex portions 51 are plastically deformed. Indicates the state to be performed. The convex portions 51 in each projection range R have different amounts of plastic deformation due to variations in the thickness of the stacked body 10 in the stacking direction H. Specifically, the laminate 10 is disposed in the projection range R where the thickness of the laminate 10 in the stacking direction H is larger than the amount of plastic deformation of the projection 51a disposed in the projection range R where the thickness in the stacking direction H is small. The amount of plastic deformation of the projected portion 51b is increased. Then, the protrusion amount (height) of the latter convex portion 51b from the surface 501 is lower than the protrusion amount (height) of the former convex portion 51a from the surface 501. The difference in the protruding amount between the convex portions 51a and 51b can be understood by observing the deformed portion 511 formed at the tip portions of the convex portions 51a and 51b.

Thus, the plastic deformation of the plurality of convex portions 51 in the resin plate 5 reduces the difference in the thickness in the stacking direction H of the stacked body 10 in the projection range R of each PTC element 2. 10, the thickness in the stacking direction H of each portion in the horizontal direction W is changed to be uniform. In addition, when each convex part 51 plastically deforms, the deformation | transformation etc. which have arisen in each structural member 2,3,4,5,6A, 6B may be corrected.

Within the projection range R of all the PTC elements 2, each convex portion 51 of the resin plate 5 and the electrode plate 3 are in contact with each other, and all the convex portions 51 have a deformed portion 511 that is plastically deformed. The deformed portion 511 is formed as a trace or a mark in which the convex portion 51 is crushed so as to be reduced in height by plastic deformation. Since the deformed portion 511 is formed by plastic deformation, unlike the case formed by elastic deformation, the phenomenon that the reaction force generated in each convex portion 51 varies depending on the amount of deformation hardly occurs. Thereby, within the projection range R of each PTC element 2, the force with which each PTC element 2 is pressed by the electrode plate 3 and the radiation fin 4 becomes as uniform as possible.

Thus, in the electric heater 1 of the present embodiment, the following effects can be obtained by utilizing the plastic deformation of all the convex portions 51 of the resin plate 5. That is, the stacking direction H at each position in the lateral direction W where the PTC element 2 is arranged due to a manufacturing dimensional error, deformation, etc., generated in each of the PTC element 2, the electrode plate 3, the radiation fin 4, and the resin plate 5. Even when the thicknesses of the PTC elements are different from each other, it is possible to form a state in which all the PTC elements 2, the electrode plates 3, and the radiation fins 4 are pressed and contacted with each other as much as possible. Thereby, electricity supply from the electrode plate 3 to all the PTC elements 2 and heat conduction from all the PTC elements 2 to the radiation fins 4 can be performed more effectively. Therefore, according to the electric heater 1 of this embodiment, the heater performance can be further improved.

In FIGS. 9 and 10, as a comparative form, a state in which the plurality of elastic deformation portions 51 </ b> X are elastically deformed when the member 11 </ b> X formed with the elastic deformation portions 51 </ b> X is used instead of the convex portion forming member 11. Show. A contact member in contact with the elastically deforming portion 51X of the member 11X is indicated by reference numeral 12X. The elastic deformation portions 51X in each projection range R have different amounts of elastic deformation in response to variations in the thickness of the stacked body 10 in the stacking direction H. Specifically, the elastic deformation portion 51Xb disposed in the projection range R where the thickness of the stacked body 10 is larger than the elastic deformation amount of the elastic deformation portion 51Xa disposed in the projection range R where the thickness of the stacked body 10 is small. The amount of elastic deformation increases.

At this time, the reaction force generated in each of the elastic deformation portions 51Xa and 51Xb differs depending on the amount of deformation, and the elastic deformation portion 51Xb having a large elastic deformation amount has a larger reaction force than the elastic deformation portion 51Xa having a small elastic deformation amount. Will be added. Thereby, in the projection range R of each PTC element 2, the force with which each PTC element 2 is pressed by the electrode plate 3 and the radiation fin 4 becomes non-uniform | heterogenous. As a result, the contact state of each PTC element 2 with respect to the electrode plate 3 and the radiating fin 4 varies, and the current conduction from the electrode plate 3 to each PTC element 2 and the heat conduction from each PTC element 2 to the radiating fin 4 vary. Will occur.

Further, when neither the plastically deformed convex portion 51 nor the elastically deformable portion 51X is formed on the resin plate 5 or the like, the resin plate 5 or the like is subjected to dimensional variations occurring in the respective component parts 2, 3, 4, 5, 6A, 6B. In the projection range R of the PTC element 2, there is a case where the force for the PTC element 2 to contact the electrode plate 3 and the heat radiating fin 4 hardly acts.
Therefore, in order to improve the heater performance of the electric heater 1, it can be said that it is effective to have the convex portions 51 that are plastically deformed.

The electrode plate 3 and the radiating fins 4 are only required to have conductivity and heat transfer with the PTC element 2, and any of them may be disposed at a position in direct contact with the PTC element 2.
The electric heater 1 includes a plurality of PTC elements 2 in a stacked state in which the electrode plate 3 and the radiation fins 4 are respectively disposed on both sides in the stacking direction H of the plurality of PTC elements 2. The laminated body 10 having the PTC element 2 may be pressed by the pressing spring 7.

(Embodiment 2)
In this embodiment, as shown in FIGS. 11 and 12, the convex portion forming member 11 is the electrode plate 3 on which the convex portion 31 is formed, and the convex portion contact member 12 that is in contact with the convex portion 31 is the resin plate 5. Show about.
The convex portions 31 are respectively provided within the projection ranges R of the plurality of PTC elements 2 on the surface 301 in the stacking direction H of the electrode plate 3. The convex portion 31 is provided on the surface 301 of the electrode plate 3 facing the resin plate 5. The convex portion 31 is integrally provided on the electrode plate 3 with the same material as the electrode plate 3 by deforming a part of the electrode plate 3. The convex portion 31 may be a metal material provided separately on the surface 301 of the electrode plate 3.

The electrode plate 3 is made of a copper material, and the resin plate 5 is made of a resin material. Since the hardness of the electrode plate 3 is higher than the hardness of the resin plate 5, the resin plate 5 is plastically deformed by the convex portions 31 of the electrode plate 3, and the surface 501 of the resin plate 5 is recessed by the convex portions 31. A deformed portion 512 is formed. The deformed portion 512 is formed as a trace or a mark or the like in which the surface 501 of the resin plate 5 is recessed by plastic deformation.

The electrode plate 3 on which the convex portions 31 of this embodiment are formed is assumed to face the resin plate 5. The convex portion 31 can be provided on any electrode plate 3 in the electric heater 1. Although the structure is different from that of the electric heater 1 of the present embodiment, the convex portion 31 can be provided on the surface of the electrode plate 3 facing the frame 6A.

Further, as shown in FIG. 13, the convex contact member 12 may be the heat radiation fin 4, and the convex portion 31 may be provided on the surface 301 of the electrode plate 3 facing the heat radiation fin 4. In this case, since the hardness of the electrode plate 3 is higher than the hardness of the radiating fin 4, the surface 401 of the flat plate 42 of the radiating fin 4 is plastically deformed by the convex portions 31 of the electrode plate 3, and the flat plate 42 of the radiating fin 4. A deformed portion that is recessed by the convex portion 41 is formed on the surface 401.

As shown in FIGS. 14 and 15, when the laminate 10 of this embodiment is pressed by the pressing spring 7, each convex portion 31 of the electrode plate 3 comes into contact with the resin plate 5, and each part of the resin plate 5 The protrusion 31 is plastically deformed to be recessed. At this time, most of the material of the portion of the resin plate 5 with which the convex portions 31 come into contact flows from between the convex portions 31 and the resin plate 5 around the convex portions 31.

Here, FIG. 14 schematically shows a state before the resin plate 5 is plastically deformed, and FIG. 15 schematically shows a state after the resin plate 5 is plastically deformed. Each figure is a figure which shows typically the state in which the deformation | transformation part 512 is formed in the resin plate 5 for description, and shows the convex part 31 and the deformation | transformation part 512 exaggeratedly.

And the convexity arrange | positioned in the projection range R where the thickness of the laminated body 10 is large compared with the amount of plastic deformation of the site | part of the resin plate 5 which contacts the convex part 31a arrange | positioned in the projection range R where the thickness of the laminated body 10 is small. The amount of plastic deformation of the portion of the resin plate 5 that comes into contact with the portion 31b increases. Then, compared to the amount of depression (depth) from the surface 301 of the portion of the resin plate 5 that is recessed by the former convex portion 31a, the amount of depression from the surface 301 of the portion of the resin plate 5 that is recessed by the latter convex portion 31b. (Depth) becomes deeper. The difference in the amount of depression at each part of the resin plate 5 can be understood by observing the deformed portion 512 formed on the surface 501 of the resin plate 5.

Also in the electric heater 1 of this embodiment, each projection range R of the radiating fin 4 is plastically deformed by all the convex portions 31, so that each of the PTC element 2, the electrode plate 3, the radiating fin 4, and the resin plate 5 is used. Even if the thickness in the stacking direction H is different at each position in the lateral direction W where the PTC element 2 is disposed due to a dimensional error, deformation, etc. in manufacturing, all the PTC elements 2, the electrode plates 3 and the resin are different. It is possible to form a state in which the plate 5 is pressed and brought into contact with the plate 5 as much as possible. Thereby, electricity supply from the electrode plate 3 to all the PTC elements 2 and heat conduction from all the PTC elements 2 to the radiation fins 4 can be performed more effectively. Therefore, the heater performance can be further improved by the electric heater 1 of this embodiment.

Also in the electric heater 1 of this embodiment, the other configurations are the same as those in the first embodiment. Also in this embodiment, the electric heater 1 can be manufactured in the same manner as in the first embodiment. In addition, the constituent elements and the like indicated by the same reference numerals as those in the first embodiment are the same as the constituent elements and the like in the first embodiment. Also in this embodiment, the same effects as those of the first embodiment can be obtained.

(Embodiment 3)
In this embodiment, as shown in FIGS. 16 and 17, the convex forming member 11 is the heat radiation fin 4 on which the convex 41 is formed, and the convex contact member 12 that is in contact with the convex 41 is the electrode plate 3. Show about.
The convex portions 41 are respectively provided in the projection ranges R of the plurality of PTC elements 2 on the surface 401 in the stacking direction H of the radiating fins 4. The convex portion 41 is provided on the surface 401 of the radiating fin 4 that faces the electrode plate 3. The convex portion 41 is integrally provided on the heat radiation fin 4 with the same material as the heat radiation fin 4 by deforming a part of the flat plate 42 of the heat radiation fin 4. The convex portion 41 may be a metal material separately provided on the surface 401 of the flat plate 42 of the radiating fin 4.

The heat radiation fin 4 is made of an aluminum material, and the electrode plate 3 is made of a copper material. Since the hardness of the radiating fin 4 is lower than the hardness of the electrode plate 3, the convex portion 41 of the flat plate 42 of the radiating fin 4 is plastically deformed by the electrode plate 3. A deformed portion 411 crushed by 3 is formed. The deformed portion 411 is formed as a trace or a mark or the like in which the tip portion of the convex portion 41 of the radiating fin 4 is crushed by plastic deformation.

The heat dissipating fin 4 on which the convex portion 41 of this embodiment is formed is the closest to the frame 6B. The convex portion 41 can be provided on any of the radiating fins 4 in the electric heater 1. For example, the convex portion 41 is different from the configuration of the electric heater 1 of the present embodiment, but can be provided on the surface of the radiating fin 4 facing the frame 6A.

Also in the electric heater 1 of this embodiment, the other configurations are the same as those in the first embodiment. Also in this embodiment, the electric heater 1 can be manufactured in the same manner as in the first embodiment. In addition, the constituent elements and the like indicated by the same reference numerals as those in the first embodiment are the same as the constituent elements and the like in the first embodiment. Also in this embodiment, the same effects as those of the first embodiment can be obtained.

(Embodiment 4)
In this embodiment, as shown in FIGS. 18 and 19, the convex portion forming member 11 is a frame 6 </ b> B in which the convex portion 61 is formed, and the convex portion contact member 12 in contact with the convex portion 61 is a resin plate 5. Show about.
The convex portions 61 are respectively provided in the projection ranges R of the plurality of PTC elements 2 on the surface 601 in the stacking direction H of the frame 6B. The convex portion 61 is provided on the surface 601 of the frame 6B that faces the resin plate 5. The convex portion 61 is provided integrally with the frame 6B with the same material as the frame 6B by deforming a part of the frame 6B. The convex portion 61 may be a metal material provided separately on the surface 601 of the frame 6B.

The frame 6B is made of a metal material such as stainless steel, and the resin plate 5 is made of a resin material. Since the hardness of the frame 6B is higher than the hardness of the resin plate 5, the resin plate 5 is plastically deformed by the convex portions 61 of the frame 6B, and the surface 501 of the resin plate 5 is deformed by the convex portions 61. A portion 512 is formed. The deformed portion 512 is formed as a trace or a mark or the like in which the surface 501 of the resin plate 5 is recessed by plastic deformation.

In this embodiment, the frame 6B is the convex portion forming member 11 in which the convex portion 61 is formed. In addition, the frame 6A may be the convex portion forming member 11 in which the convex portion 61 is formed. In this case, as shown in FIG. 20, the convex contact member 12 is used as the heat radiation fin 4, and the convex portion 61 is provided on the surface 601 of the frame 6 </ b> A facing the heat radiation fin 4. In this case, since the hardness of the frame 6A is higher than the hardness of the radiating fin 4, the flat plate 42 of the radiating fin 4 is plastically deformed by the convex portion 61 of the frame 6A, and the surface 401 of the flat plate 42 of the radiating fin 4 is A deformed portion that is recessed by the convex portion 61 of the frame 6A is formed.

Further, although different from the structure of the electric heater 1 of this embodiment, the convex contact member 12 is the electrode plate 3, and the convex portions 61 of the frames 6A and 6B are the surfaces of the electrode plate 3 facing the frames 6A and 6B. Can also be contacted. In this case, since the hardness of the frames 6A and 6B is higher than the hardness of the electrode plate 3, the surface of the electrode plate 3 is plastically deformed by the convex portions 61 of the frames 6A and 6B, and the surface of the electrode plate 3 is convex. A deformed portion that is recessed by the portion 61 is formed.

Also in the electric heater 1 of this embodiment, the other configurations are the same as those in the first embodiment. Also in this embodiment, the electric heater 1 can be manufactured in the same manner as in the first embodiment. In addition, the constituent elements and the like indicated by the same reference numerals as those in the first embodiment are the same as the constituent elements and the like in the first embodiment. Also in this embodiment, the same effects as those of the first embodiment can be obtained.

(Embodiment 5)
This embodiment shows an electric heater 1Z having a structure different from that of the electric heater 1 of the first to fourth embodiments.
As shown in FIGS. 21 to 24, in the electric heater 1Z of this embodiment, the first laminated body 10A composed of a plurality of PTC elements 2, a plurality of electrode plates 3, a plurality of heat radiation fins 4, and resin plates 5A and 5B. The second stacked body 10 </ b> B is arranged in two layers in the stacking direction H. The electrode plates 3 in each of the stacked bodies 10A and 10B can be separately supplied with voltages from a positive power source and a negative power source. The electric heater 1Z can perform a half-heating operation in which heating is performed by the first stacked body 10A or the second stacked body 10B and a full heating operation in which heating is performed by both the stacked bodies 10A and 10B. In FIG. 24, the electrode plate 3 connected to the positive power source is indicated by (+), and the electrode plate 3 connected to the negative power source is indicated by (−).

The convex portion forming member 11 of this embodiment is a resin plate 5A on which convex portions 51 are formed, and the convex portion contact member 12 is the electrode plate 3. The convex part 51 of this form is provided in the surface 501 facing the electrode plate 3 of 10 A of 1st laminated bodies in the resin plate 5A arrange | positioned between 10 A of 1st laminated bodies, and the 2nd laminated body 10B. It has been. The convex portions 51 are respectively provided in four projection ranges R obtained by projecting the arrangement site of the four PTC elements 2 in the stacking direction H on the resin plate 5A.

Also in this embodiment, as in the case of the first embodiment, when the hardness of the resin plate 5A is lower than the hardness of the electrode plate 3, the tip portions of the convex portions 51 in the resin plate 5A are plastically deformed and crushed. Moreover, as shown in FIG. 25, the convex part 51 can also be provided in the surface 501 facing the radiation fin 4 of the 2nd laminated body 10B in the resin plate 5A. Also in this case, when the hardness of the resin plate 5A is lower than the hardness of the radiating fins 4, the tips of the convex portions 51 in the resin plate 5A are plastically deformed and crushed. Moreover, the convex part 51 is a surface in the resin plate 5B arrange | positioned between the 2nd laminated body 10B and the flame | frame 6B, the surface facing the electrode plate 3 of the 2nd laminated body 10B, or the frame in the resin plate 5B. It can also be provided on the surface facing 6B.

The arrangement site | part of the horizontal direction W and the depth direction D of each PTC element 2 in the two laminated bodies 10A and 10B of this form corresponds when it sees along the lamination direction H. The projection range R of each PTC element 2 is uniquely determined. On the other hand, the arrangement | positioning site | part of the horizontal direction W and the depth direction D of the some PTC element 2 in each laminated body 10A, 10B does not necessarily need to correspond. In this case, when the multi-layer stacks 10A and 10B are viewed along the stacking direction H, the projections 51 are formed at portions where the projection ranges R of the PTC elements 2 in the stacks 10A and 10B overlap each other. Can be formed.

As shown in FIG. 24, the electrode plates 3 in the electric heater 1Z having the two-layered laminates 10A and 10B are alternately arranged in the order of one side in the stacking direction H into the positive power source, the negative power source, the positive power source, and the negative power source. Connected to. The resin plates 5A and 5B are disposed between the first stacked body 10A and the second stacked body 10B, and between the second stacked body 10B and the frame 6B. The resin plate 5A disposed between the first laminated body 10A and the second laminated body 10B includes the electrode plate 3 and the radiation fins 4 connected to the negative power source of the first laminated body 10A, and the second The laminated body 10B is insulated from the electrode plate 3 and the radiation fin 4 connected to the plus power source. The resin plate 5B disposed between the second laminate 10B and the frame 6B is composed of the electrode plate 3 and the radiation fin 4 connected to the negative power source, the frames 6A and 6B, and the press of the second laminate 10B. The electrode plate 3 and the radiation fin 4 connected to the positive power source of the first stacked body 10A are prevented from being electrically connected to each other through the spring 7.

Also in the electric heater 1Z of the present embodiment, other configurations are the same as those in the first embodiment. Also in this embodiment, the electric heater 1Z can be manufactured in the same manner as in the first embodiment. In addition, the constituent elements and the like indicated by the same reference numerals as those in the first embodiment are the same as the constituent elements and the like in the first embodiment. Also in this embodiment, the same effects as those of the first embodiment can be obtained.

(Embodiment 6)
As shown in FIGS. 26 and 27, the present embodiment is a modification of the electric heater 1 </ b> Z according to the fifth embodiment, in which the convex portion forming member 11 is a heat radiating fin 4 having the convex portion 41 and the convex portion 41. A case where the convex contact member 12 in contact with the resin plate 5A is shown.
The convex portions 41 are respectively provided in the projection ranges R of the plurality of PTC elements 2 on the surface 401 in the stacking direction H of the radiating fins 4. The convex portion 41 is provided on the surface 401 of the radiating fin 4 facing the resin plate 5A. The convex portion 41 is integrally provided on the heat radiation fin 4 with the same material as the heat radiation fin 4 by deforming a part of the flat plate 42 of the heat radiation fin 4. The convex portion 41 may be a metal material separately provided on the surface 401 of the flat plate 42 of the radiating fin 4.

The heat radiating fins 4 are made of an aluminum material, and the resin plate 5A is made of a resin material. Since the hardness of the radiating fin 4 is higher than the hardness of the resin plate 5A, the resin plate 5A is plastically deformed by the convex portion 41 of the flat plate 42 of the radiating fin 4, and the convex portion is formed on the surface 501 of the resin plate 5A. A deformed portion 512 that is recessed by 41 is formed. The deformed portion 512 is formed as a trace or a mark or the like in which the surface 501 of the resin plate 5A is recessed by plastic deformation.

The heat dissipating fins 4 formed with the convex portions 41 of this embodiment are used for the second laminated body 10B. The convex part 41 can also be provided in any radiation fin 4 in the electric heater 1Z. The convex part 41 can also be provided, for example, on the surface of the radiating fin 4 facing the frame 6A.

Also in the electric heater 1Z of the present embodiment, the other configurations are the same as in the case of the fifth embodiment. Also in this embodiment, the electric heater 1Z can be manufactured in the same manner as in the first embodiment. In addition, the constituent elements and the like indicated by the same reference numerals as those in the first embodiment are the same as the constituent elements and the like in the first embodiment. Also in this embodiment, the same effects as those of the first embodiment can be obtained.

(Other)
As described above, the convex portion forming member 11 forming the convex portions 31, 41, 51, 61 may be any one of the electrode plate 3, the heat radiating fins 4, the resin plates 5, 5A, 5B, or the frames 6A, 6B. it can. Moreover, the convex part contact member 12 which contacts the convex parts 31, 41, 51, 61 can also be any of the electrode plate 3, the radiation fin 4, the resin plates 5, 5A, 5B, or the frames 6A, 6B. Which of the convex portions 31, 41, 51, 61 and the convex portion contact member 12 is plastically deformed is determined by the hardness of both, and the lower the hardness, the plastic deformation occurs. Therefore, when both hardness becomes equivalent, while deforming so that convex part 31,41,51,61 may be crushed, it may be plastically deformed so that convex part contact member 12 may be dented. Moreover, even if the hardness of the convex portions 31, 41, 51, 61 is higher than the hardness of the convex portion contact member 12, depending on the shape of the convex portions 31, 41, 51, 61, it is necessary for plastic deformation of the convex portion contact member 12. The convex portions 31, 41, 51, 61 may be plastically deformed with a load lower than a normal load.

Among the electrode plate 3, the radiating fin 4, the resin plates 5, 5A, 5B and the frames 6A, 6B, the resin plates 5, 5A, 5B have the lowest hardness. Therefore, by using the convex portion forming member 11 or the convex portion contact member 12 as the resin plates 5, 5A, 5B, the convex portion 51 or the convex portion contact member 12 can be easily plastically deformed by the pressing force of the pressing spring 7. Become. Further, since the resin plates 5, 5 </ b> A, 5 </ b> B are molded by an injection molding method or the like, it is easy to integrally form the convex portions 51. When the convex portions 31, 41, 61 are formed on the electrode plate 3, the flat plate 42 of the radiating fin 4, and the frames 6A, 6B, a part of the material is deformed when each member is formed by pressing. The convex portions 31, 41, 61 can be integrally formed.

It is preferable that the surface in the stacking direction H of the electrode plate 3 and the surface in the stacking direction H of the radiation fin 4 are in close contact with each other in order to ensure conductivity or heat transfer. Therefore, when the convex part forming member 11 is the electrode plate 3 and the convex part contact member 12 is the radiating fin 4, or the convex part forming member 11 is the radiating fin 4 and the convex part contact member 12 is the electrode plate 3. In this case, the formation height of the convex portions 31 and 41 is lowered, and at least one of the convex portions 31 and 41 and the convex portion contact member 12 is plastically deformed, and the surface of the electrode plate 3 in the stacking direction H and the radiation fin 4. It is also necessary to devise a method for forming a state in which the surface in the stacking direction H is in close contact.

On the other hand, the resin plates 5, 5A, 5B and the frames 6A, 6B are not required to have conductivity and heat conductivity. Therefore, by using at least one of the convex portion forming member 11 and the convex portion contact member 12 as the resin plates 5, 5 </ b> A, 5 </ b> B or the frames 6 </ b> A, 6 </ b> B, the surface in the stacking direction H is not necessarily closely adhered. It is possible to easily set the formation height, size, and the like of the convex portions 31, 41, 51, 61 of the forming member 11. However, fluid such as air for air conditioning is basically heated by heat conduction from the radiation fins 4. The gap formed between the convex portions 31, 41, 51, 61 of the convex portion forming member 11 and the convex portion contact member 12 may be a gap that allows fluid to pass through without being heated. Therefore, the formation height of the convex portions 31, 41, 51, 61 is lowered, and the surface of the convex portion forming member 11 in the stacking direction H excluding the formation portions of the convex portions 31, 41, 51, 61, and the convex portions It is preferable to prevent a gap from being formed as much as possible between the contact member 12 and the surface in the stacking direction H.

The present disclosure is not limited to each embodiment, and further different embodiments can be configured without departing from the scope of the disclosure. In addition, the present disclosure includes various modifications, modifications within an equivalent range, and the like.

Claims (13)

1. A plurality of PTC elements (2) that generate heat when energized and are arranged side by side in the lateral direction (W);
   A plurality of electrode plates (3) stacked on both sides of the stacking direction (H) perpendicular to the lateral direction of the PTC element, and for energizing the PTC element;
   A plurality of heat dissipating fins (4) laminated on both sides of the PTC element in the laminating direction and for radiating heat transmitted from the PTC element;
   One or a plurality of resin plates (5, 5A, 5B) laminated in the laminating direction of the electrode plates or the heat radiating fins and insulating between the electrode plates having different polarities;
   A pressing spring (7) that presses the laminated body (10, 10A, 10B) of the PTC element, the electrode plate, the radiation fin, and the resin plate from both sides in the laminating direction;
   The electrode plate, wherein any one of the electrode plate, the radiating fin, and the resin plate is a convex portion forming member (11) having a convex portion (31, 41, 51), and the convex portion forming member is excluded. When any one of the heat radiating fins and the resin plate is a convex contact member (12) that contacts the convex part,
   The convex portion is within a plurality of projection ranges (R) obtained by projecting the arrangement portions of the plurality of PTC elements in the stacking direction on the surface (301, 401, 501) of the convex portion forming member in the stacking direction. Each is provided,
   The electric heater (1), wherein at least one of the convex portion and the convex portion contact member in all the projection ranges has a deformed portion (511, 512) due to plastic deformation.
2. The electric heater according to claim 1, wherein the convex forming member is the resin plate.
3. The convex contact member is the electrode plate or the radiating fin,
   The electric heater according to claim 2, wherein the deformable portion is formed by plastic deformation of the convex portion within each projection range.
4. The electric heater according to claim 1, wherein the convex forming member is the electrode plate.
5. The convex contact member is the heat radiating fin or the resin plate,
   The electric heater according to claim 4, wherein the deforming portion is formed by plastic deformation of the convex portion contact member.
6. The electric heater according to claim 1, wherein the convex forming member is the heat radiating fin.
7. The convex contact member is the electrode plate or the resin plate,
   The electric heater according to claim 6, wherein the deformable portion is formed by plastic deformation of at least one of the convex portion and the convex portion contact member in each projection range.
8. A plurality of PTC elements (2) that generate heat when energized and are arranged side by side in the lateral direction (W);
   A plurality of electrode plates (3) stacked on both sides of the stacking direction (D) perpendicular to the lateral direction of the PTC element, and for energizing the PTC element;
   A plurality of heat dissipating fins (4) laminated on both sides of the PTC element in the laminating direction and for radiating heat transmitted from the PTC element;
   One or a plurality of resin plates (5, 5A, 5B) laminated in the laminating direction of the electrode plates or the heat radiating fins and insulating between the electrode plates having different polarities;
   A pair of frames (6A, 6B) laminated at both ends in the laminating direction of the laminated body (10, 10A, 10B) of the PTC element, the electrode plate, the radiation fin, and the resin plate;
   A pressing spring (7) for pressing the stacked body from both sides in the stacking direction via a pair of the frames;
   Any one of the electrode plate, the radiating fin, the resin plate, and the frame is a convex portion forming member (11) having convex portions (31, 41, 51, 61), and the convex portion forming member is When excluding the electrode plate, the heat radiating fin, the resin plate, and the other one of the frame, a convex contact member (12) that contacts the convex portion,
   The convex portion is a plurality of projection ranges (R) obtained by projecting arrangement portions of the plurality of PTC elements in the stacking direction on the surface (301, 401, 501, 601) in the stacking direction of the convex forming member. In each,
   The electric heater (1), wherein at least one of the convex portion and the convex portion contact member in all the projection ranges has a deformed portion (511, 512) due to plastic deformation.
9. The electric heater according to claim 8, wherein the convex forming member is the frame.
10. The convex contact member is the electrode plate, the radiation fin or the resin plate,
    The electric heater according to claim 9, wherein the deforming portion is formed by plastic deformation of the convex portion contact member.
11. The convex portion forming member is the electrode plate, the heat radiating fin, or the resin plate, and the convex portion contact member is the frame,
    The electric heater according to claim 8, wherein the deformable portion is formed by plastic deformation of the convex portion within each projection range.
12. The electric heater according to any one of claims 1 to 11, wherein the convex portion is provided integrally with the convex portion forming member using the same material as the convex portion forming member.
13. A plurality of PTC elements (2) that generate heat when energized and are arranged side by side in the lateral direction (W);
    A plurality of electrode plates (3) stacked on both sides of the stacking direction (D) perpendicular to the lateral direction of the PTC element, and for energizing the PTC element;
    A plurality of heat dissipating fins (4) laminated on both sides of the PTC element in the laminating direction and for radiating heat transmitted from the PTC element;
    One or a plurality of resin plates (5, 5A, 5B) laminated in the laminating direction of the electrode plates or the heat radiating fins and insulating between the electrode plates having different polarities;
    Manufacturing an electric heater, comprising: a pressing spring (7) that presses the PTC element, the electrode plate, the heat radiating fin, and the laminate (10, 10A, 10B) of the resin plate from both sides in the stacking direction. In the way to
    The electrode plate, wherein any one of the electrode plate, the radiating fin, and the resin plate is a convex portion forming member (11) having a convex portion (31, 41, 51), and the convex portion forming member is excluded. When any one of the heat radiating fins and the resin plate is a convex contact member (12) that contacts the convex part,
    The convex portion is within a plurality of projection ranges (R) obtained by projecting the arrangement portions of the plurality of PTC elements in the stacking direction on the surface (301, 401, 501) of the convex portion forming member in the stacking direction. Each provided,
    When the laminate is pressed from both sides in the stacking direction by the pressing spring, at least one of the convex portions and the convex portion contact members in all the projection ranges is plastically deformed, The manufacturing method of the electric heater (1) which forms a deformation | transformation part (511,512) in at least one of the said convex part and the said convex part contact member in a projection range.

Images