Vehicle cabin heating heater member, vehicle cabin heating heater unit, and vehicle cabin heating heater system

Abstract

The heater component (100) for heating the carriage includes: a honeycomb structure (10) having an outer peripheral wall (11) and a partition wall (12), the partition wall (12) being disposed on the inner side of the outer peripheral wall (11) and dividing it into multiple compartments (14), the multiple compartments (14) forming a flow path from a first end face (13a) to a second end face (13b), the outer peripheral wall (11) and the partition wall (12) being made of a material having PTC properties; and a pair of electrodes (20) disposed on the first end face (13a) and the second end face (13b). The first end face (13a) and the second end face (13b) of the honeycomb structure (10) are rectangular. The heater component (100) for heating the carriage also includes a pair of connectors (30) that are connected to the electrode (20) from one of the short sides (15) of the first end face (13a) and the second end face (13b).

Description

Technical Field

[0001] This invention relates to heater components, heater units, and heater systems for heating train carriages. Background Technology

[0002] In recent years, heating systems for electric vehicle cabin heating have adopted the following heating system: using a vapor compression heat pump as the main heater, and using a Joule heater as an auxiliary heater when rapid heating is needed during vehicle startup or when the outside air temperature is very low.

[0003] As a heater that utilizes Joule heat in the heater system, Patent Document 1 proposes a heater unit, which is obtained by stacking heater components formed by integrating PTC elements with aluminum fins.

[0004] However, in addition to the PTC element and aluminum fins, the heater component also has many other parts such as an insulating plate and a conductive plate. Therefore, it has the following problems: it has a complex structure and high assembly cost and price.

[0005] Therefore, Patent Document 2 proposes a heater component that is compact and utilizes a honeycomb structure that increases the heat transfer area per unit volume. Compared to the heater components described above, the heater component using this honeycomb structure has the advantage of a simpler structure.

[0006] Existing technical documents

[0007] Patent documents

[0008] Patent Document 1: Japanese Patent Application Publication No. 2007-157528

[0009] Patent Document 2: International Publication No. 2020 / 036067 Summary of the Invention

[0010] However, based on the research findings of the inventors of this invention, when using the heater component described in Patent Document 2 in an existing heater unit, design changes are required to the wiring, retaining components, and other parts of the existing heater unit. This results in a larger heater unit and compromises the advantage of a compact heater component; therefore, improvements are needed.

[0011] This invention was implemented to solve the problems described above, and its object is to provide a car heating heater component with a simpler structure than existing heater components, and capable of suppressing the increase in heater unit size due to design changes in wiring, retaining components, and other parts of existing heater units. Furthermore, this invention aims to provide a car heating heater unit and a car heating heater system using this car heating heater component.

[0012] The aforementioned problems are solved by the following invention, which is defined as follows.

[0013] That is, the present invention is a heater component for heating a train carriage, which comprises:

[0014] A honeycomb structure having an outer peripheral wall and partitions, the partitions being disposed on the inner side of the outer peripheral wall and dividing it into multiple compartments, the multiple compartments forming a flow path from a first end face to a second end face; the outer peripheral wall and the partitions being made of a material having PTC properties; and

[0015] A pair of electrodes, wherein the pair of electrodes are disposed on the first end face and the second end face.

[0016] The first and second end faces of the honeycomb structure are rectangular.

[0017] The heater component for heating the carriage also includes a pair of connectors, which are connected to the electrode from one short side of each of the first end face and the second end face.

[0018] In addition, the present invention is a heater unit for heating a train carriage, which includes two or more of the aforementioned heater components for heating a train carriage.

[0019] The heating components for the carriage heating are stacked in a manner in which the surfaces of the outer peripheral walls of the honeycomb structure, including the long sides of the first end face and the second end face, are opposite to each other.

[0020] Furthermore, the present invention is a heater system for heating a vehicle compartment, comprising:

[0021] The aforementioned heating unit for the carriages;

[0022] An inflow pipe connects the external atmosphere inlet or the carriage to the inlet of the heating unit for the carriage heating.

[0023] A storage battery, used to apply voltage to the heater unit for heating the passenger compartment; and

[0024] An outflow pipe connects the outlet of the heater unit for heating the carriage to the carriage.

[0025] Invention Effects

[0026] According to the present invention, a car heating heater component with a simpler structure than existing heater components can be provided, and a larger heater unit due to design changes in wiring, retaining components, and other parts of existing heater units can be prevented. Furthermore, according to the present invention, a car heating heater unit and a car heating heater system using the present invention can be provided. Attached Figure Description

[0027] Figure 1 This is a perspective view of the heater component according to an embodiment of the present invention.

[0028] Figure 2 From Figure 1 A side view of the heater component as seen from direction A.

[0029] Figure 3 It constitutes Figure 1 A three-dimensional schematic diagram of the honeycomb structure of the heater component.

[0030] Figure 4 This is a schematic end view of a cellular assembly with 5 cellular units.

[0031] Figure 5 This is a front view schematic diagram of the heater unit according to an embodiment of the present invention, viewed from the first end face side of the heater component.

[0032] Figure 6 This is a schematic diagram illustrating an example configuration of a heater system according to an embodiment of the present invention.

[0033] Figure 7 This is a top view of the heater component prepared in the comparative example.

[0034] Figure 8 This is a chart comparing the power-on test results of Example 1 and Comparative Example 1.

[0035] Figure 9 This is a chart comparing the power-on test results of Example 1 and Example 2. Detailed Implementation

[0036] Hereinafter, embodiments of the present invention will be specifically described with reference to the accompanying drawings. The present invention is not limited to the following embodiments, and it should be understood that solutions obtained by appropriate modifications or improvements to the following embodiments based on common knowledge of those skilled in the art without departing from the spirit of the present invention are also included within the scope of the present invention.

[0037] (1. Heater component)

[0038] The heater component according to embodiments of the present invention is preferably used as a heater component for heating the passenger compartment of a vehicle. The vehicle is not particularly limited, and examples include automobiles and trams. The automobile is not particularly limited, and examples include gasoline vehicles, diesel vehicles, gas-fueled vehicles using CNG (compressed natural gas) or LNG (liquefied natural gas), fuel cell vehicles, electric vehicles, and plug-in hybrid electric vehicles. The heater component according to embodiments of the present invention is particularly preferred for vehicles without an internal combustion engine, such as electric vehicles and trams.

[0039] Figure 1 This is a perspective view of the heater component according to an embodiment of the present invention. Figure 2 From Figure 1 A side view of the heater component as seen from direction A. Figure 3 It constitutes Figure 1 A three-dimensional schematic diagram of the honeycomb structure of the heater component.

[0040] The heater component 100 according to the embodiments of the present invention includes: a honeycomb structure 10 having an outer peripheral wall 11 and a partition wall 12, the partition wall 12 being disposed on the inner side of the outer peripheral wall 11 and dividing to form a plurality of compartments 14, the plurality of compartments 14 forming a flow path from a first end face 13a to a second end face 13b; and a pair of electrodes 20 disposed on the first end face 13a and the second end face 13b. Furthermore, the end faces (first end face 13a and second end face 13b) of the honeycomb structure 10 are rectangular. In addition, the heater component 100 also includes a pair of connectors 30, which are connected to the electrodes 20 from one short side 15 of each of the first end face 13a and the second end face 13b. Thus, the rectangular end faces of the honeycomb structure 10, and the pair of connectors 30 connected to the end faces of the honeycomb structure 10 as described above, can suppress the increase in size of the heater unit due to design changes to existing heater unit wiring, retaining members, and other components, thereby enabling a compact heater unit.

[0041] (1-1. Honeycomb structure 10)

[0042] The end faces (first end face 13a and second end face 13b) of the honeycomb structure 10 are rectangular. That is, the end faces of the honeycomb structure 10 are rectangles with a short side 15 and a long side 16.

[0043] The ratio of the length of the short side 15 to the length of the long side 16 is not particularly limited, but is preferably 1:2 to 1:10, and more preferably 1:3 to 1:8. By controlling the ratio to the above range, it can be adapted to the size of the heater components used in existing heater units.

[0044] The shape of compartment 14 in the cross-section orthogonal to the flow direction of compartment 14 is not particularly limited, but is preferably quadrilateral (rectangular, square), hexagonal, octagonal, or a combination of two or more thereof. Quadrilaterals and hexagons are preferred. By making the compartment 14 in this shape, the pressure loss when gas flows through the honeycomb structure 10 can be reduced. It should be noted that... Figure 1 The honeycomb structure 10 in the heater component 100 shown is an example where the shape of the compartment 14 in the cross section orthogonal to the flow path direction of the compartment 14 is square.

[0045] The honeycomb structure 10 can be a honeycomb joint having multiple honeycomb cells and bonding layers connecting the multiple honeycomb cells. By using the honeycomb joint, cracking can be suppressed, and the total cross-sectional area of ​​the compartment 14, which is important for ensuring gas flow, can be increased.

[0046] Here, as an example, a schematic end face of a honeycomb joint with 5 honeycomb units is shown in the figure. Figure 4 .

[0047] like Figure 4 As shown, the cellular connector 17 has: 5 cellular cells 18 and a bonding layer 19 that joins the cellular cells 18 together. Each cellular cell 18 has an outer peripheral wall 11 and a partition wall 12, the partition wall 12 being disposed on the inner side of the outer peripheral wall 11 and dividing to form a plurality of compartments 14, the plurality of compartments 14 forming a flow path from a first end face 13a to a second end face 13b.

[0048] The bonding layer 19 can be formed using a bonding material. There are no particular limitations on the bonding material; a paste-like substance made by adding a solvent such as water to a ceramic material can be used. The bonding material may contain ceramics with PTC properties, or it may contain the same ceramics as the outer peripheral wall 11 and the partition wall 12. In addition to serving to bond the honeycomb cells 18 together, the bonding material can also be used as a coating material for the outer periphery of the bonded honeycomb cells 18.

[0049] From the perspective of ensuring gas flow, the area of ​​each end face of the honeycomb structure 10 is preferably 20 cm². 2 The above, preferably 50cm 2 The above is further optimized to 70cm. 2 That's all. From the viewpoint of making the heater component 100 compact, the area of ​​each end face of the honeycomb structure 10 is preferably 500 cm². 2 Below, 300cm is preferred. 2 The following is a further preferred size: 200cm 2 The area of ​​each end face of the honeycomb structure 10 can be, for example, 20 to 500 cm². 2 .

[0050] From the viewpoint of making the heater component 100 compact, the length of the honeycomb structure 10 (the flow path length of each compartment 14) is preferably 40 mm or less, more preferably 30 mm or less, further preferably 20 mm or less, and even more preferably 10 mm or less. From the viewpoint of ensuring heating performance and strength, the length of the honeycomb structure 10 (the flow path length of each compartment 14) is preferably 3 mm or more. The length of the honeycomb structure 10 (the flow path length of each compartment 14) can be, for example, 3 to 40 mm.

[0051] (1-1-1. Material of honeycomb structure 10)

[0052] The outer peripheral wall 11 and partition wall 12 of the honeycomb structure 10 are formed of a material that can generate heat when electricity is applied. Therefore, during the period from when a gas such as external atmosphere or cabin air flows in from the first end face 13a until it flows out from the second end face 13b through the multiple compartments 14, the gas can be heated by heat conducted from the heated outer peripheral wall 11 and partition wall 12.

[0053] Furthermore, the outer peripheral wall 11 and the partition wall 12 are made of a material with PTC (Positive Temperature Coefficient) characteristics. That is, the outer peripheral wall 11 and the partition wall 12 have the following characteristics: when the temperature rises above the Curie point, the resistance value increases sharply, making it difficult for current to flow. Because the outer peripheral wall 11 and the partition wall 12 have PTC characteristics, the current flowing in them is restricted when the heater component 100 is at a high temperature, thus suppressing overheating of the heater component 100.

[0054] From the viewpoint of being able to generate heat through electricity and possessing PTC characteristics, the outer peripheral wall 11 and the partition wall 12 are preferably ceramics made of a material with barium titanate as the main component, more preferably ceramics made of a material containing 70% by mass or more of barium titanate, and even more preferably ceramics made of a material containing 90% by mass or more of barium titanate. It should be noted that in this specification, "main component" refers to a component that occupies more than 50% by mass in the total composition. For example, the content of barium titanate can be determined by fluorescence X-ray analysis, EDAX (energy dispersive X-ray) analysis, etc.

[0055] From the perspective of obtaining the desired PTC properties, the ceramic preferably contains one or more additives such as rare earth elements. Examples of additives include: semiconductor agents such as Y, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Sc, and Lu; low-temperature displacement agents such as Sr, Sn, and Zr; high-temperature displacement agents such as (Bi-Na) and (Bi-K); property improvers such as Mn; metal oxides such as vanadium oxide and yttrium oxide (especially oxides of rare earth elements); and conductive powders such as carbon black and nickel. Other PTC materials include composite materials using cristobalite phase SiO2 as a base material and containing conductive fillers. Tridymite phase SiO2, cristobalite phase AlPO4, or tridymite phase AlPO4 can also be used instead of the cristobalite phase SiO2 base material.

[0056] Furthermore, from the viewpoint of the environmental impact of exhaust gases, the outer peripheral wall 11 and the partition wall 12 are preferably ceramics made of a material that is substantially lead-free, and more preferably ceramics made of a material with a lead content of 0.001% by mass or less. It should be noted that "substantially lead-free" in this specification means that the lead content in the overall composition is 0.01% by mass or less. For example, the lead content can be determined by fluorescence X-ray analysis, ICP-MS (inductively coupled plasma mass analysis), etc.

[0057] From the viewpoint of efficiently heating air for heating purposes, the Curie point of the materials constituting the outer peripheral wall 11 and the partition wall 12 is preferably 100°C or higher, more preferably 110°C or higher, and even more preferably 125°C or higher. Furthermore, from the viewpoint of ensuring the safety of components placed in or near the vehicle compartment, the upper limit of the Curie point is preferably 250°C or lower, more preferably 225°C or lower, even more preferably 200°C or lower, and even more preferably 150°C or lower.

[0058] The Curie point of the materials constituting the outer peripheral wall 11 and the partition wall 12 can be adjusted according to the type and amount of displacement agent. For example, the Curie point of barium titanate (BaTiO3) is about 120°C, and the Curie point can be shifted to the low-temperature side by replacing a portion of Ba and Ti with one or more of Sr, Sn and Zr.

[0059] In this invention, the Curie point is determined using the following method. The sample is mounted in a sample holder and assembled in a measuring chamber (e.g., a MINI-SUBZERO MC-810P manufactured by Tabai Espec). A DC resistance meter (e.g., a YHP 3478A multimeter) is used to measure the change in resistance of the sample relative to temperature as the temperature increases from 10°C. Based on the resulting resistance-temperature diagram, the temperature at which the resistance value becomes twice the resistance value at room temperature (20°C) is defined as the Curie point.

[0060] (1-1-2. Thickness of the partition wall 12 of the honeycomb structure 10)

[0061] From the viewpoint of suppressing initial current, it is advantageous to reduce the current path and increase the resistance. Therefore, the thickness of the partition 12 in the honeycomb structure is preferably 0.125 mm or less, more preferably 0.075 mm or less. However, from the viewpoint of ensuring the strength of the honeycomb structure 10, the thickness of the partition 12 is preferably 0.020 mm or more, more preferably 0.040 mm or more, and even more preferably 0.060 mm or more. The thickness of the partition 12 refers to the length of the line segment that crosses the partition 12 when the centroids of adjacent compartments 14 are connected to each other in a cross section orthogonal to the flow direction of the compartment 14. The thickness of the partition 12 refers to the average thickness of all partitions 12.

[0062] From the viewpoint of reinforcing the honeycomb structure 10, the thickness of the outer peripheral wall 11 is preferably 0.05 mm or more, more preferably 0.06 mm or more, and even more preferably 0.08 mm or more. However, from the viewpoint of increasing resistance to suppress initial current and reducing pressure loss during gas passage, the thickness of the outer peripheral wall 11 is preferably 1.0 mm or less, more preferably 0.5 mm or less, even more preferably 0.4 mm or less, and even more preferably 0.3 mm or less. The thickness of the outer peripheral wall 11 refers to the length in the normal direction of the side surface from the boundary between the outer peripheral wall 11 and the outermost peripheral compartment 14 or partition 12 to the side surface of the honeycomb structure in a cross section orthogonal to the flow path of the compartment 14.

[0063] (1-1-3. Cell density and cell spacing of honeycomb structure 10)

[0064] The preferred cell density of the honeycomb structure 10 is 93 cells / cm³. 2 The following is more preferably 62 compartments / cm 2 Furthermore, the cell spacing of the honeycomb structure 10 is preferably 1.0 mm or more, and more preferably 1.3 mm or more. By controlling the cell density or cell spacing within the above range, ventilation resistance can be suppressed, thereby suppressing the output power of the blower.

[0065] It should be noted that the lower limit of the cell density of the honeycomb structure 10 is not particularly limited, but is preferably 10 cells / cm². 2 The above is more preferably 20 compartments / cm. 2That's all. Furthermore, the upper limit of the cell spacing in the honeycomb structure 10 is not particularly limited, but is preferably 3.0 mm or less, more preferably 2.0 mm or less. The cell density of the honeycomb structure 10 is the value obtained by dividing the number of cells by the area of ​​each end face of the honeycomb structure 10. Additionally, the cell spacing in the honeycomb structure 10 refers to the length of the line segment connecting the centroids of two adjacent cells 14 on each end face of the honeycomb structure 10.

[0066] (1-2. Electrode 20)

[0067] The heater component 100 according to the embodiments of the present invention has a pair of electrodes 20 on a first end face 13a and a second end face 13b. By applying voltage to the pair of electrodes 20, electricity can be passed through and Joule heating can be used to heat the honeycomb structure 10.

[0068] The electrode 20 is not particularly limited, but preferably has an extension that extends outward in the same direction from one of the short sides 15 of the first end face 13a and the second end face 13b, and the extension is connected to the connector 30. By providing the extension, connection with the connector 30 is made easier.

[0069] Electrode 20 can be composed of a single component or multiple components.

[0070] When the electrode 20 is composed of a single component, for example, the electrode 20 may be provided as an electrode layer 21 disposed on the first end face 13a and the second end face 13b. In this case, the electrode layer 21 is disposed on the surface of the outer peripheral wall 11 and the partition wall 12 at the first end face 13a and the second end face 13b, and has an extension extending outward in the same direction from one of the short sides 15 of the first end face 13a and the second end face 13b respectively.

[0071] When electrode 20 is composed of multiple components, for example, such as Figure 1 and Figure 2 As shown, the electrode 20 may include an electrode layer 21 disposed on a first end face 13a and a second end face 13b, and an electrode plate 22 disposed on the electrode layer 21. In this case, the electrode layer 21 is disposed on the surface of the outer peripheral wall 11 and the partition wall 12 at the first end face 13a and the second end face 13b, and the electrode plate 22 is disposed on the outer peripheral wall 11 on which the electrode layer 21 is disposed, with respect to the electrode layer 21. The electrode plate 22 is formed with an opening in a manner that does not block the portion other than the outer peripheral wall 11 on which the electrode layer 21 is disposed (the surface of the partition wall 12 on which the electrode layer 21 is disposed, the compartment 14). In addition, the electrode plate 22 has an extension portion extending outward in the same direction from one short side 15 side of each of the first end face 13a and the second end face 13b.

[0072] There are no particular limitations on the connection method between the electrode layer 21 and the electrode plate 22; diffusion bonding, mechanical pressure mechanism, welding, etc., can be used.

[0073] From the viewpoint of improving the contact between the two, a carbon sheet can be provided between the electrode layer 21 and the electrode plate 22 as needed.

[0074] The electrode layer 21 is not particularly limited, and for example, a metal or alloy containing at least one selected from Cu, Ag, Al, Ni, and Si can be used. Alternatively, an ohmic electrode layer capable of making ohmic contact with the peripheral wall 11 and / or partition wall 12 having PTC characteristics can also be used. The ohmic electrode layer can, for example, contain at least one selected from Au, Ag, and In as the base metal and at least one selected from Ni, Si, Ge, Sn, Se, and Te for n-type semiconductors as the dopant. Furthermore, the electrode layer 21 can be one layer or two or more layers. When the electrode layer 21 has two or more layers, the materials of each layer can be the same or different types.

[0075] The electrode plate 22 is not particularly limited and can be formed of a plate-shaped material with excellent conductivity. The electrode plate 22 can be a metal plate such as a copper plate or a stainless steel plate.

[0076] (1-3. Connector 30)

[0077] The heater component 100 according to the embodiments of the present invention includes a pair of connectors 30, which are connected to the electrode 20 from a short side 15 of the first end face 13a and the second end face 13b of the honeycomb structure 10. The connectors 30 are terminals that can be electrically connected to a power source. By providing a pair of connectors 30 at the above-mentioned locations, it is possible to replace existing heater components, and the increase in size of the heater unit due to design changes in wiring and other components of existing heater units is suppressed.

[0078] The connector 30 is preferably connected to the surface of the honeycomb structure 10 side of the extension of the electrode 20. By adopting the above configuration, the heater component 100 can be made compact, and therefore it can be easily applied to existing heater units.

[0079] Regarding the connection method between electrode 20 and connector 30, electrical connection is sufficient and there are no particular limitations. For example, the connection can be made through diffusion bonding, mechanical pressure mechanism, welding, etc.

[0080] The material of connector 30 is not particularly limited, and can be, for example, metal. As metal, it can be an elemental metal, an alloy, etc. However, from the viewpoint of corrosion resistance, resistivity and linear expansion rate, it is preferable to use an alloy containing at least one selected from the group consisting of Cr, Fe, Co, Ni, Cu and Ti, and more preferably stainless steel, Fe-Ni alloy, or phosphor bronze.

[0081] The shape and size of connector 30 are not particularly limited; they can be adjusted appropriately according to the existing structure of the heater unit.

[0082] (1-4. Manufacturing method of heater component 100)

[0083] Next, an example will be given of a method for manufacturing the heater component 100 according to an embodiment of the present invention. First, a raw material composition containing a dispersion medium and a binder is mixed with ceramic raw materials, and the mixture is kneaded to prepare a blank. Then, the blank is extruded to produce a honeycomb molded body. Additives such as dispersants, plasticizers, semiconductor agents, displacement agents, metal oxides, property improvers, and conductive powders may be added to the raw material composition as needed. During extrusion molding, a die having the desired overall shape, compartment shape, compartment wall thickness, compartment density, etc., can be used.

[0084] For example, ceramic raw materials can be provided in powder form. As ceramic raw materials, oxides and carbonates such as TiO2 and BaCO3, which are the main components of barium titanate, can be used. Additionally, oxides, carbonates, or oxalates that become oxides after firing can be used as semiconductor agents such as Y, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Sc, and Lu; low-temperature displacement agents such as Sr, Sn, and Zr; high-temperature displacement agents such as (Bi-Na) and (Bi-K); and property improvers such as Mn. To control conductivity, conductive powders such as carbon black and nickel can be added. For the addition of alkali metal elements such as Na and K, they can also be used in the form of binders containing alkali metal elements.

[0085] Alternatively, for example, by adding La(NO3)3·6H2O to raw material powders such as TiO2 and BaCO3, and then further adding dispersants and binders, and combining them in a manner that results in BaO (50.3 mol%), TiO2 (49.6 mol%), La2O3 (0.05 mol%), K2O (0.033 mol%), and Na2O (0.002 mol%) in the sintered body, a substantially lead-free (i.e., lead-free) honeycomb structure can be obtained. However, it is not limited to this composition; by combining it in a manner where ceramics constitute more than 90% by mass according to the following formula, a honeycomb structure containing rare earth elements and alkali metal elements but without the use of lead can be produced.

[0086] (Ba 1-x-y A1 x A2 y TiO3

[0087] In the formula, A1 represents one or more rare earth elements, A2 represents one or more alkali metal elements, 0.001≤x≤0.01, 0.001≤y≤0.01, and 0.002≤x+y≤0.02.

[0088] Examples of suitable dispersion media include water or mixtures of water and organic solvents such as alcohols, with water being particularly preferred.

[0089] Examples of adhesives include organic adhesives such as methylcellulose, hydroxypropoxycellulose, hydroxyethylcellulose, carboxymethylcellulose, and polyvinyl alcohol. It is particularly preferred to use methylcellulose and hydroxypropoxycellulose together. Furthermore, from the viewpoint of improving the strength of the honeycomb molded body and suppressing gaps caused by abnormal heating during the firing process, the adhesive content is preferably 4 to 9 parts by weight relative to 100 parts by weight of ceramic raw material. One type of adhesive can be used alone, or two or more types can be used in combination.

[0090] Dispersants can be surfactants such as ethylene glycol, dextrin, fatty acid soaps, polyols, and organophosphorus compounds. A single dispersant can be used, or two or more can be used in combination. The preferred content of the dispersant is 0 to 2 parts by mass relative to 100 parts by mass of the ceramic raw material.

[0091] Next, the obtained honeycomb molded body is dried. In the drying process, conventionally known drying methods such as hot air drying, microwave drying, induction drying, reduced pressure drying, vacuum drying, and freeze drying can be used. Among these, a drying method combining hot air drying with microwave drying or induction drying is preferred.

[0092] Next, the dried honeycomb molded body is fired to produce a columnar honeycomb structure. A degreasing process to remove the binder can be performed before firing. For example, if the honeycomb molded body is mainly composed of barium titanate, the firing temperature is preferably 1100–1400°C. Furthermore, the firing time is preferably set to approximately 1–4 hours.

[0093] The atmosphere used during the degreasing process can be, for example, atmospheric atmosphere, inactive atmosphere, or reduced pressure atmosphere. An inactive atmosphere and a reduced pressure atmosphere are preferred. The firing furnace is not particularly limited and can be an electric furnace, a gas furnace, etc.

[0094] Electrodes 20 are formed on the first end face 13a and the second end face 13b of the honeycomb structure obtained above. For example, the electrode layer 21 of the electrode 20 can be formed by metal deposition methods such as sputtering, vapor deposition, electrolytic deposition, and chemical deposition. Alternatively, the electrode layer 21 can be formed by sintering after coating an electrode paste. Furthermore, the electrode layer 21 can also be formed by fusion deposition. The electrode layer 21 can be a single layer or a multilayer with different compositions. When forming the electrode layer 21 using the above methods, the thickness of the electrode layer 21 is set so as not to be too large, so as not to block the compartment 14. For example, regarding the thickness of the electrode layer 21, it is preferably set to about 5 to 30 μm for sintering of paste, about 100 to 1000 nm for dry deposition such as sputtering and vapor deposition, about 10 to 100 μm for fusion deposition, and about 5 to 30 μm for wet deposition such as electrolytic deposition and chemical deposition.

[0095] When an electrode plate 22 is provided on the electrode layer 21, the electrode plate 22 is disposed on the electrode layer 21 and connected. The method described above can be used as a method for connecting the electrode layer 21 and the electrode plate 22.

[0096] Next, the connector 30 is connected to the electrode 20. The method described above can be used as the method for connecting the electrode 20 and the connector 30.

[0097] (1-5. How to use heater component 100)

[0098] For the heater component 100 according to the embodiments of the present invention, for example, a voltage can be applied from the connector 30 via a pair of electrodes 20 to heat the honeycomb structure 10. As the applied voltage, from the viewpoint of rapid heating, a voltage of 200V or more is preferred, and a voltage of 250V or more is more preferred.

[0099] When the heater component 100 heats up due to the applied voltage, the gas can be heated by allowing gas to flow in the compartment 14. The temperature of the gas flowing into the compartment 14 can be set, for example, from -60°C to 20°C, and typically from -10°C to 20°C.

[0100] The heater assembly 100 according to the embodiments of the present invention has a simpler structure than existing heater assemblies that integrate the PTC element with aluminum fins, and can suppress the increase in heater unit size due to design changes in components such as wiring or retaining parts of existing heater units. Furthermore, in existing heater assemblies, the gas heating rate (heating time) is insufficient because the PTC element does not directly contact the gas. However, in the heater assembly 100 according to the embodiments of the present invention, since the outer peripheral wall 11 and partition wall 12 are made of a honeycomb structure 10 of a material with PTC properties and directly contact the gas, the gas heating rate can be improved. In addition, the heater assembly 100 according to the embodiments of the present invention consumes less power than existing heater assemblies.

[0101] (2. Heater Unit)

[0102] The heater unit according to the embodiments of the present invention can be preferably used as a heater unit for heating the passenger compartment of a vehicle. In particular, the heater unit according to the embodiments of the present invention can prevent the heater unit from becoming larger due to design changes to components such as wiring or retainers of existing heater units. Therefore, the heater component 100 described above can be used to replace existing heater components.

[0103] Figure 5 This is a front view schematic diagram of the heater unit according to an embodiment of the present invention, viewed from the first end face side of the heater component.

[0104] like Figure 5 As shown, the heater unit 200 according to the embodiment of the present invention includes two or more heater components 100. Furthermore, in this heater unit 200, the heater components 100 are stacked and arranged with the surfaces of the outer peripheral wall 11 of the honeycomb structure 10, including the long sides of the first end face 13a and the second end face 13b, facing each other. By adopting the above configuration, the heater unit 200 can be manufactured without significantly changing the design of existing heater unit components such as wiring or retainers.

[0105] The heater unit 200 according to the embodiments of the present invention may further include a housing (outer shell component) 110.

[0106] The material of the housing 110 is not particularly limited, and examples include metal and resin. However, resin is preferred as the material for the housing 110. By using a resin housing, electric shock can be suppressed even when the housing is not grounded.

[0107] The shape and size of the housing 110 are not particularly limited and can be the same as existing heater units.

[0108] The heater unit 200 according to the embodiments of the present invention may further include an insulating material 120 disposed between the stacked heater components 100. By adopting the above configuration, electrical short circuits between the plurality of heater components 100 can be suppressed.

[0109] As the insulating material 120, plates, gaskets, cloths, etc., formed from insulating materials such as alumina and ceramics can be used.

[0110] (3. Heater System)

[0111] The heater system according to the embodiments of the present invention can be preferably used as a heater system for heating the passenger compartment of a vehicle. In particular, the heater system according to the embodiments of the present invention can prevent the heater unit from becoming larger due to design changes to components such as wiring or retaining parts of existing heater units.

[0112] Figure 6 This is a schematic diagram illustrating an example configuration of a heater system according to an embodiment of the present invention.

[0113] like Figure 6 As shown, the heater system 300 according to an embodiment of the present invention includes: a heater unit 200 according to an embodiment of the present invention; inflow pipes 320a and 320b that connect an external atmosphere inlet or carriage 310 to an inlet 301 of the heater unit 200; a battery 330 for applying voltage to the heater unit 200; and an outlet pipe 325 that connects an outlet 302 of the heater unit 200 to the carriage 310.

[0114] The heater unit 200 can be configured such that, for example, it is connected to the battery 330 via a wire 340, and the heater unit 200 is powered on and heated by turning the power switch of the battery 330 to ON.

[0115] A vapor compression heat pump 350 can be installed upstream of the heater unit 200. In the heater system 300, the vapor compression heat pump 350 constitutes the main heating device, and the heater unit 200 constitutes an auxiliary heater. The vapor compression heat pump 350 may include a heat exchanger comprising: an evaporator 351 that absorbs heat from the outside and evaporates the refrigerant during cooling, and a condenser 352 that liquefies the refrigerant gas and releases heat to the outside during heating. It should be noted that the vapor compression heat pump 350 is not particularly limited, and a vapor compression heat pump known in the art can be used.

[0116] A blower 360 may be installed upstream and / or downstream of the heater unit 200. From the viewpoint of ensuring safety by positioning high-voltage components as far away as possible from the passenger compartment 310, the blower 360 is preferably located upstream of the heater unit 200. When the blower 360 is driven, air flows from inside or outside the passenger compartment 310 into the heater unit 200 via inflow pipes 320a and 320b. The air is heated while passing through the heating unit 200. The heated air exits the heater unit 200 and is delivered into the passenger compartment 310 via outflow pipe 325. The outlet of the outflow pipe 325 may be located near the feet of the occupants to ensure particularly good heating even inside the passenger compartment 310; it may also be located inside the seats to heat the seats from the inside; or it may be located near the windows to help suppress window fogging.

[0117] Inflow pipes 320a and 320b merge midway. Valves 321a and 321b can be installed on inflow pipes 320a and 320b, respectively, upstream of the merging point. By controlling the opening and closing of valves 321a and 321b, it is possible to switch between a mode that introduces outside air into the heater unit 200 and a mode that introduces air from inside the carriage 310 into the heater unit 200. For example, when valve 321a is opened and valve 321b is closed, the mode switches to introducing outside air into the heater unit 200. Alternatively, both valves 321a and 321b can be opened, thereby simultaneously introducing outside air and air from inside the carriage 310 into the heater unit 200.

[0118] Example

[0119] The present invention will be further described in detail below through embodiments; however, the present invention is not limited to these embodiments in any way.

[0120] (Example 1)

[0121] A binder, dispersant, plasticizer, and water are added to ceramic raw materials, and the mixture is stirred and kneaded to prepare a green body. As the ceramic raw material, a substance obtained by mixing BaCO3 powder, TiO2 powder, and La(NO3)3·6H2O powder in a manner where 0.1% of the Ba produced after firing is replaced with La is used. As the binder, methylcellulose is used, with 6 parts by mass relative to 100 parts by mass of the ceramic raw material. As the dispersant, a potassium-containing alkyl phosphate is used, with 0.5 parts by mass relative to 100 parts by mass of the ceramic raw material. As the plasticizer, an ether ester compound and an alkanediol are used, with the ether ester compound used at 0.5 parts by mass relative to 100 parts by mass of the ceramic raw material and the alkanediol used at 1 part by mass relative to 100 parts by mass of the ceramic raw material.

[0122] Next, the fired mixture will have a wall thickness of 0.100 mm and a compartment density of 62 compartments / cm³. 2 The honeycomb structure is obtained by extrusion molding of prismatic honeycomb units with a cell spacing of 1.27 mm, a cross section of 30 mm × 34 mm orthogonal to the direction of cell extension, and a length of 14 mm in the direction of cell extension.

[0123] Next, the honeycomb molded body is dried, degreased, and then fired in the atmosphere at 1400°C for 2 hours to obtain the honeycomb unit.

[0124] Next, five of the above-mentioned honeycomb cells are prepared, and bonding material is applied to the sides of the honeycomb cells for bonding, thereby obtaining... Figure 4 The honeycomb joint shown is a rectangular cross-section of 30mm × 175mm orthogonal to the direction of cell extension, with a length of 14mm in the direction of cell extension. A paste-like substance, formed by adding a solvent such as water to a ceramic material, is used as the bonding material. The end face area of ​​this honeycomb joint is 52.5cm². 2 .

[0125] Next, after applying Al-Ni electrode paste to the first and second end faces of the honeycomb composite, a silver electrode paste is applied, and sintering is carried out at 700°C to form an Al-Ni electrode layer and a silver electrode layer.

[0126] Next, carbon sheets and copper electrode plates are sequentially disposed on the silver electrode layer formed on the outer peripheral wall surface of the honeycomb composite, and then bonded together. The copper electrode plate and... Figure 1 and Figure 2The structure shown similarly forms an opening that does not block the portion other than the outer peripheral wall where each electrode layer is provided (the surface and compartment of the partition wall where each electrode layer is provided), and provides an extension that extends outward in the same direction from one short side of the first end face and the second end face of the honeycomb joint. In addition, a carbon sheet is disposed between the silver electrode layer and the copper electrode plate.

[0127] Next, with Figure 1 and Figure 2 Similarly, in the structure shown, a connector made of phosphor bronze is connected to the extension of the copper electrode plate to obtain the heater component.

[0128] Next, with Figure 5 Similarly, the structure shown involves stacking four of the aforementioned heater components and housing them within a casing to obtain a heater unit. Alumina fiber gaskets (insulating material) are placed between the stacked heater components.

[0129] The aforementioned heater unit was assembled into a commercially available automotive HVAC (Heating Ventilation and Air Conditioning) system. A constant voltage of 200V was used to control the current, which was limited to less than 30A. The heater unit was tested under power-on heating conditions at a gas flow rate of 6m / s.

[0130] Results: The gas temperature at the HVAC outlet reached 50°C in 6 seconds after being heated by electricity, and rose to 88°C after 60 seconds. The power consumption at this point was 2.8kW. Additionally, the energy consumption 30 seconds after power-on was 90kJ.

[0131] (Example 2)

[0132] Using the same blank as in Example 1, the blank was fired to achieve a wall thickness of 0.125 mm and a compartment density of 62 compartments / cm³. 2 The honeycomb structure is obtained by extrusion molding in a rectangular shape with a cross-section of 30mm×175mm orthogonal to the direction of the cell extension and a length of 14mm in the direction of the cell extension.

[0133] Next, the honeycomb molded body is dried, degreased, and then fired at 1400°C for 2 hours in atmospheric conditions to obtain the honeycomb structure. The end face area of ​​this honeycomb structure is 52.5 cm². 2 .

[0134] Next, under the same conditions as in Example 1, after forming an Al-Ni electrode layer and a silver electrode layer on the first and second end faces of the honeycomb structure, carbon sheets and copper electrode plates are sequentially arranged on the silver electrode layer and joined together. A connector is then connected to the extension of the copper electrode plate to obtain a heater component.

[0135] Next, under the same conditions as in Example 1, the four heater components described above are stacked and arranged in a housing to obtain a heater unit.

[0136] The heater unit described above was assembled into a commercially available automotive HVAC system. The heater unit was tested under constant voltage of 250V and current limited to below 30A at a gas flow rate of 6m / s.

[0137] Results: The gas temperature at the HVAC outlet reached 60°C 8 seconds after power-on heating, and rose to 100°C after 60 seconds. The power consumption at this point was 3.4kW. Additionally, the energy consumed 30 seconds after power-on was applied was 108kJ.

[0138] (Comparative Example 1)

[0139] Prepare Figure 7 The diagram shows a conventional heater unit obtained by stacking and arranging an integrated heater assembly of PTC element 500 and aluminum fins 510. It should be noted that... Figure 7 This is a top view of the heater components.

[0140] The PTC element 500 measures 29mm × 8mm × 2mm. Six PTC elements 500 are arranged in a row and, together with components such as a frame, insulating plate, and conductive plate, are housed inside the heater body 520. A connector 30 is also provided in the heater body 520. Furthermore, the eight heater bodies 520 are configured such that they are housed within a housing 110, and aluminum fins 510 are arranged between each heater body 520.

[0141] It should be noted that the PTC element 500 is composed of a material containing 49 mol% TiO2, 32 mol% BaO, 9 mol% PbO, 8 mol% CaO, 1 mol% SrO and 1 mol% SiO2.

[0142] The aforementioned conventional heater unit was assembled into a commercially available automotive HVAC system. The heater unit was tested with a constant voltage of 300V, a current limited to below 30A, and a gas flow rate of 6m / s.

[0143] Results: The gas temperature at the HVAC outlet reached 50°C 11 seconds after power-on heating and rose to 88°C after 60 seconds. The power consumption at this point was 2.8kW. Additionally, the energy consumed 30 seconds after power-on was applied was 123kJ.

[0144] Here, a graph comparing the power-on test results of Example 1 and Comparative Example 1 is presented. Figure 8Furthermore, a graph comparing the power-on test results of Example 1 and Example 2 is shown in [the figure]. Figure 9 . Figure 8 and Figure 9 In the figure, L1 represents the gas temperature at the outlet of Example 1, L2 represents the power of Example 1, L3 represents the gas temperature at the outlet of Comparative Example 1, L4 represents the power of Comparative Example 1, L5 represents the gas temperature at the outlet of Example 2, and L6 represents the power of Example 2.

[0145] like Figure 8 As shown, the heater unit of Example 1, compared to the heater unit of Comparative Example 1, can shorten the gas temperature rise time (comparison of L1 and L3). For example, regarding the time required to reach a gas temperature of 50°C from the start of energization, Example 1 requires 6 seconds, while Comparative Example 1 requires 11 seconds, thus reducing the gas temperature rise time by 40%. Furthermore, compared to the heater unit of Comparative Example 1, the heater unit of Example 1 can reduce the maximum power during energization (comparison of L2 and L4). For example, regarding the maximum power during energization, Example 1 requires 5.8 kW, while Comparative Example 1 requires 7.6 kW, thus reducing the maximum power by 25%.

[0146] like Figure 9 As shown, compared with the heater unit of Example 1, the heater unit of Example 2 can further shorten the gas temperature rise time, and the gas temperature reaches a higher level after 60 seconds (comparison of L1 and L5). On the other hand, regarding the maximum power during energization, the heater unit of Example 1 is lower than that of the heater unit of Example 2 (comparison of L2 and L6).

[0147] As can be seen from the above results, according to the present invention, a car heating heater component with a simpler structure than existing heater components can be provided, and the increase in the size of the heater unit due to design changes in components such as wiring or retaining parts of existing heater units can be suppressed. Furthermore, according to the present invention, a car heating heater unit and a car heating heater system using the present invention can be provided.

[0148] Explanation of reference numerals in the attached figures

[0149] 10. Honeycomb structure

[0150] 11. Peripheral wall

[0151] 12 Next door

[0152] 13a First end face

[0153] 13b Second end face

[0154] 14 compartments

[0155] 15 Short side

[0156] 16 Long side

[0157] 17. Honeycomb junction

[0158] 18 Cellular Units

[0159] 19 Bonding Layer

[0160] 20 electrodes

[0161] 30 connectors

[0162] 100 Heater components

[0163] 110 Casing

[0164] 120 Insulation Material

[0165] 200 heater unit

[0166] 300 heater system

[0167] 301 Inlet

[0168] 302 Outlet

[0169] Carriage 310

[0170] 320a and 320b flow into the piping

[0171] 325 outflow piping

[0172] 330 storage battery

[0173] 340 wire

[0174] 350 vapor compression heat pump

[0175] 351 Evaporator

[0176] 352 Condenser

[0177] 360° air blower

[0178] 500 PTC components

[0179] 510 aluminum fins

[0180] 520 Heater Body

Claims

1. A heater component for heating a train carriage, comprising: A honeycomb structure having an outer peripheral wall and partitions, the partitions being disposed on the inner side of the outer peripheral wall and dividing it into multiple compartments, the multiple compartments forming a flow path from a first end face to a second end face; the outer peripheral wall and the partitions being made of a material having PTC properties; and A pair of electrodes, wherein the pair of electrodes are disposed on the first end face and the second end face. The first and second end faces of the honeycomb structure are rectangular. The pair of electrodes has an extension that extends outward in the same direction from one of the short sides of each of the first and second end faces. The heating component for heating the carriage also includes a pair of connectors that are connected to the surface of the honeycomb structure side of the extension.

2. The heater component for heating a train carriage according to claim 1, characterized in that, In the first end face and the second end face, the ratio of the length of the short side to the length of the long side is 1:2 to 1:

10.

3. The heater component for heating a train carriage according to claim 1 or 2, characterized in that, The cellular structure is a cellular assembly having multiple cellular cells and bonding layers that connect the multiple cellular cells.

4. The heater component for heating a train carriage according to claim 1 or 2, characterized in that, In the honeycomb structure, the thickness of the partition walls is less than 0.125 mm, and the cell density is 93 cells / cm³. 2 The following compartment spacing is 1.0 mm or more.

5. The heater component for heating a train carriage according to claim 1 or 2, characterized in that, The outer peripheral wall and the partition wall are made of a material mainly composed of barium titanate and substantially free of lead.

6. The heater component for heating a train carriage according to claim 1 or 2, characterized in that, The pair of electrodes includes: an electrode layer disposed on the first end face and the second end face, and an electrode plate disposed on the electrode layer.

7. The heater component for heating a train carriage according to claim 6, characterized in that, The electrode plate has an extension extending outward in the same direction from one short side of each of the first end face and the second end face, and the extension is connected to the connector.

8. A heater unit for heating a train carriage, comprising two or more heater components for heating a train carriage as described in any one of claims 1 to 7. The heating components for the carriage heating are stacked in a manner in which the surfaces of the outer peripheral walls of the honeycomb structure, including the long sides of the first end face and the second end face, are opposite to each other.

9. The heater unit for heating a train carriage according to claim 8, characterized in that, Insulating material is disposed between the stacked heating elements for the carriage.

10. A heater system for heating a train carriage, comprising: The heating unit for carriage heating as described in claim 8 or 9; An inflow pipe connects the external atmosphere inlet or the carriage to the inlet of the heating unit for the carriage heating. A storage battery, used to apply voltage to the heater unit for heating the passenger compartment; and An outflow pipe connects the outlet of the heater unit for heating the carriage to the carriage.

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