Heater component and carriage purification system

Abstract

The present invention provides a heater member and a cabin purification system, the heater member can reduce the stress acting on a honeycomb structure due to the thermal expansion difference between a metal terminal and the honeycomb structure, and can reduce the possibility of cracking in the honeycomb structure. A heater member (1) is provided with: a honeycomb structure (10) having an outer peripheral wall (100) and partition walls (101) disposed on the inner side of the outer peripheral wall and defining a plurality of cells (101a) extending from a first end surface (10a) to a second end surface (10b) to form a flow path, at least the partition walls (101) being made of a material having PTC characteristics; a first electrode (11) and a second electrode (12) provided on the first end surface and the second end surface; and a first metal terminal (13) and a second metal terminal (14) provided on the first electrode and the second electrode, at least one of the first metal terminal and the second metal terminal having a plurality of partial electrodes (15).

Description

Technical Field

[0001] This invention relates to a heater component and a vehicle cabin purification system. Background Technology

[0002] Patent Document 1 discloses a heater component comprising: a honeycomb structure having an outer peripheral wall and a partition wall disposed on the inner side of the outer peripheral wall and dividing to form a plurality of compartments forming a flow path extending from a first end face to a second end face, wherein at least the partition wall is made of a material having PTC properties; a pair of electrodes disposed on the first end face and the second end face; and a metal terminal (terminal) disposed on at least a portion of the pair of electrodes.

[0003] By allowing current from the metal terminals to flow through the honeycomb structure after the electrodes are expanded, the current distribution at the end face of the honeycomb structure can be made nearly uniform, thereby making the temperature distribution of the honeycomb structure nearly uniform. Patent Document 1 proposes the use of metal terminals integrally disposed around the entire end face of the honeycomb structure.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2024-101454 Summary of the Invention

[0007] If metal terminals are used integrally arranged around the end face of the honeycomb structure as in Patent Document 1, stress may sometimes be applied to the honeycomb structure due to the difference in thermal expansion between the metal terminals and the honeycomb structure, causing cracking. If cracking occurs, the current path may change, and the temperature distribution of the honeycomb structure may become uneven.

[0008] The present invention was implemented to solve the problems described above, and one of its objectives is to provide a heater component and a vehicle purification system that can reduce the stress acting on the honeycomb structure due to the difference in thermal expansion between the metal terminals and the honeycomb structure, thereby reducing the possibility of cracking in the honeycomb structure.

[0009] The inventors of this invention conducted in-depth research and discovered that by dividing the metal terminal into multiple partial electrodes, the above-mentioned problems could be solved, thus completing this invention.

[0010] [1] In one embodiment of the present invention, a heater component is provided, comprising: a honeycomb structure having an outer peripheral wall and a partition wall disposed on the inner side of the outer peripheral wall and dividing to form a plurality of compartments forming a flow path extending from a first end face to a second end face, wherein at least the partition wall is made of a material having PTC properties; a first electrode and a second electrode disposed on the first end face and the second end face; and a first metal terminal and a second metal terminal disposed on the first electrode and the second electrode, wherein at least one of the first metal terminal and the second metal terminal has a plurality of partial electrodes.

[0011] [2] Based on the heater component described in the first item, the present invention may be such that the first metal terminal and the second metal terminal both have the plurality of partial electrodes.

[0012] [3] Based on the heater component described in the first or second item, the present invention may be: the plurality of partial electrodes are arranged around the entire circumference of the honeycomb structure.

[0013] [4] Based on the heater component described in any one of the first to third items of the present invention, the plurality of partial electrodes may include a first partial electrode and a second partial electrode that are adjacent to each other in the circumferential direction of the honeycomb structure, and the ends of the first partial electrode and the second partial electrode have an interlocking shape that fits into each other.

[0014] [5] Based on the heater component described in the fourth item, the present invention may be as follows: the end of the first partial electrode has: a first protrusion that contacts the outer edge of the first partial electrode in the width direction of the honeycomb structure, and a first recess that contacts the extension line of the inner edge of the first partial electrode in the width direction of the honeycomb structure and is disposed adjacent to the first protrusion in the width direction of the honeycomb structure, wherein at least a portion of the end of the second partial electrode enters the first recess in the circumferential direction of the honeycomb structure.

[0015] [6] In one embodiment, the present invention relates to a vehicle compartment purification system comprising: at least one heater component as described in any one of the first to fifth claims; a power source for applying a voltage to the heater component; an inflow pipe connecting the vehicle compartment and a first end face of the heater component; an outflow pipe having a first path connecting a second end face of the heater component and the vehicle compartment; and a ventilator for causing air from the vehicle compartment to flow into the first end face of the heater component via the inflow pipe.

[0016] [7] Based on the vehicle purification system described in item 6, the present invention may be as follows: in addition to having the first path, the outflow pipe also has a second path connecting the second end face of the heater component to the outside of the vehicle; the outflow pipe has a switching valve capable of switching the airflow flowing through the outflow pipe between the first path and the second path; the vehicle purification system includes a control unit capable of switching between a first mode and a second mode; in the first mode, the external voltage from the power supply is disconnected so that the air flowing through the outflow pipe passes through the first path to switch the switching valve and the ventilator is turned on; in the second mode, the external voltage from the power supply is turned on so that the air flowing through the outflow pipe passes through the second path to switch the switching valve and the ventilator is turned on.

[0017] Invention Effects

[0018] According to one embodiment of the heater component and the vehicle purification system of the present invention, since at least one of the first metal terminal and the second metal terminal has multiple partial electrodes, the stress acting on the honeycomb structure due to the thermal expansion difference between the metal terminal and the honeycomb structure can be mitigated, thereby reducing the possibility of cracking in the honeycomb structure. Attached Figure Description

[0019] Figure 1 This is a front view showing the heater component according to an embodiment of the present invention.

[0020] Figure 2 It is shown Figure 1 Rear view of the heater component.

[0021] Figure 3 It is shown Figure 1 Right view of the heater component.

[0022] Figure 4 It is shown Figure 1 A magnified view of region IV.

[0023] Figure 5 It is shown Figure 1 The front view of the first modified example of the heater component.

[0024] Figure 6 It is shown Figure 5 A magnified view of region VI.

[0025] Figure 7 It is shown Figure 1 The main view of the main part of the second variant of the heater component.

[0026] Figure 8It is shown Figure 1 The main view of the main part of the third variant of the heater component.

[0027] Figure 9 It is shown Figure 1 The front view of the fourth variant of the heater component.

[0028] Figure 10 It is shown Figure 9 Rear view of the heater component.

[0029] Figure 11 It is shown Figure 9 Right view of the heater component.

[0030] Figure 12 It is shown Figure 1 The main view of the main part of the fifth variant of the heater component.

[0031] Figure 13 It is shown Figure 1 The main view of the main part of the sixth variant of the heater component.

[0032] Figure 14 It is shown Figure 1 The main view of the main part of the seventh variant of the heater component.

[0033] Figure 15 This is a schematic diagram illustrating the configuration of a vehicle cabin purification system according to an embodiment of the present invention.

[0034] Figure 16 This is an explanatory diagram showing the area where the temperature was measured in the embodiment.

[0035] Symbol Explanation

[0036] 1: Heater component; 10: Honeycomb structure; 10a: First end face; 10b: Second end face; 11: First electrode; 12: Second electrode; 13: First metal terminal; 14: Second metal terminal; 15: Partial electrode; 100: Outer peripheral wall; 101: Partial wall; 101a: Compartment; 151: First partial electrode; 151a: First protrusion; 151b: First recess; 152: Second partial electrode; 200: Power supply; 300: Switching valve; 400: Inflow piping; 500: Outflow piping; 500a: First path; 500b: Second path; 600: Ventilation fan; 900: Control unit; 1000: Carriage purification system; EL1: Extension line; EL2: Extension line. Detailed Implementation

[0037] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. The present invention is not limited to each embodiment, and its constituent elements can be modified to embody the invention without departing from its spirit. Furthermore, various inventions can be formed by appropriately combining the multiple constituent elements disclosed in each embodiment. For example, several constituent elements can be deleted from all the constituent elements given in the embodiments. In addition, constituent elements from different embodiments can be appropriately combined.

[0038] (1. Heater component)

[0039] Figure 1 This is a front view showing the heater component 1 according to an embodiment of the present invention. Figure 2 It is shown Figure 1 Rear view of heater component 1, Figure 3 It is shown Figure 1 Right view of heater component 1, Figure 4 It is shown Figure 1 A magnified view of region IV.

[0040] The heater component 1 according to embodiments of the present invention can preferably be used as a heater component 1 in the cabin air purification system of various vehicles such as automobiles. The vehicle is not particularly limited, and examples include automobiles and electric vehicles. The automobile is not particularly limited, and examples include: gasoline vehicles, diesel vehicles, gas fuel 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 1 according to embodiments of the present invention can preferably be used, particularly in vehicles without internal combustion engines, such as electric vehicles and electric vehicles.

[0041] like Figures 1-4 As shown, the heater component 1 has: a honeycomb structure 10, a first electrode 11, a second electrode 12, a first metal terminal 13, and a second metal terminal 14.

[0042] The honeycomb structure 10 has an outer peripheral wall 100 and a partition wall 101 disposed on the inner side of the outer peripheral wall 100 and dividing it into a plurality of compartments 101a. These compartments 101a form a flow path extending from a first end face 10a to a second end face 10b. At least the partition wall 101 of the honeycomb structure 10 is made of a material with PTC (Positive Temperature Coefficient) properties. Materials with PTC properties have the following characteristic: when the temperature rises above the Curie point, the resistance increases sharply, making it difficult for current to flow.

[0043] In particular, such as Figure 3As shown, the first electrode 11 is disposed on the first end face 10a of the honeycomb structure 10, and the second electrode 12 is disposed on the second end face 10b of the honeycomb structure 10. The first electrode 11 and the second electrode 12 are as follows... Figure 1 and Figure 2 As shown, it is disposed on the end face of the outer peripheral wall 100, and, as Figure 4 The first electrode 11 and the second electrode 12 are shown disposed on the end face of the partition 101. The first electrode 11 and the second electrode 12 do not enclose the compartment 101a. However, a portion of the compartment 101a can also be enclosed by the first electrode 11 and / or the second electrode 12.

[0044] like Figures 1-3 As shown, the first metal terminal 13 is disposed on the first electrode 11, and the second metal terminal 14 is disposed on the second electrode 12.

[0045] One of the first metal terminal 13 and the second metal terminal 14 is connected to the positive terminal of a power source (not shown), and the other of the first metal terminal 13 and the second metal terminal 14 is connected to the negative terminal of a power source. If the first metal terminal 13 is connected to the positive terminal and the second metal terminal 14 is connected to the negative terminal, the current from the first metal terminal 13 extends through the first electrode 11 on the first end face 10a, flows through the honeycomb structure 10 in the direction extending from the compartment 101a, and flows through the second electrode 12 on the second end face 10b to the second metal terminal 14. This flow of current causes the honeycomb structure 10 to be uniformly heated.

[0046] In the heater component 1 of this embodiment, at least one of the first metal terminal 13 and the second metal terminal 14 has a plurality of partial electrodes 15. In other words, at least one of the first metal terminal 13 and the second metal terminal 14 is not integrally disposed on the end face of the honeycomb structure 10, but is divided into a plurality of partial electrodes 15 (parts) in the circumferential direction of the honeycomb structure 10.

[0047] If the first metal terminal 13 and the second metal terminal 14 are integrally disposed on the end face of the honeycomb structure 10, stress may sometimes be applied to the honeycomb structure 10 due to the difference in thermal expansion between the first metal terminal 13 and the second metal terminal 14 and the honeycomb structure 10, causing cracking in the honeycomb structure 10. Sometimes, cracking may interrupt the flow of current, resulting in uneven temperature distribution in the honeycomb structure 10. However, by having at least one of the first metal terminal 13 and the second metal terminal 14 with multiple partial electrodes 15, as in this embodiment, the stress applied to the honeycomb structure 10 due to the difference in thermal expansion between the first metal terminal 13 and the second metal terminal 14 and the honeycomb structure 10 can be mitigated, thereby reducing the possibility of cracking in the honeycomb structure 10. This reduces the possibility of interrupting the flow of current due to cracking, and thus reduces the possibility of uneven temperature distribution in the honeycomb structure 10.

[0048] like Figure 1 and Figure 2 As shown, in the heater component 1 of this embodiment, both the first metal terminal 13 and the second metal terminal 14 have multiple partial electrodes 15. This more reliably reduces the possibility of cracking in the honeycomb structure 10. However, it is also possible for only one of the first metal terminal 13 and the second metal terminal 14 to have multiple partial electrodes 15, while the other is integrally formed around the end face of the honeycomb structure 10.

[0049] like Figure 1 and Figure 2 As shown, in the heater component 1 of this embodiment, a plurality of partial electrodes 15 are disposed around the entire circumference of the honeycomb structure 10. For example, when the total length (L1) of the outer edges of the partial electrodes 15 is 80% or more relative to the length (L0) of the entire circumference of the honeycomb structure 10 at the outer edges of the first end face 10a and / or the second end face 10b, it can be understood that a plurality of partial electrodes 15 are disposed around the entire circumference of the honeycomb structure 10. The outer edge refers to the outer edge in the width direction of the honeycomb structure 10. When the honeycomb structure 10 is circular as shown in the illustration, the width direction refers to the radial direction. By distributing a plurality of partial electrodes 15 around the entire circumference of the honeycomb structure 10, the current can be spread more evenly on the first end face 10a and the second end face 10b of the honeycomb structure 10.

[0050] Figures 1-4 In the illustrated scheme, an isolation region 16 extending linearly along the width direction of the honeycomb structure 10 is provided between the ends of the plurality of partial electrodes 15. The ends of the plurality of partial electrodes 15 are not interlocked but are separated in the circumferential direction of the honeycomb structure 10.

[0051] Next, Figure 5 It is shown Figure 1The front view of the first modified example of heater component 1, Figure 6 It is shown Figure 5 A magnified view of region VI. (See attached image.) Figure 5 and Figure 6 As shown, a plurality of partial electrodes 15 include a first partial electrode 151 and a second partial electrode 152 that are adjacent to each other in the circumferential direction of the honeycomb structure 10. The ends of the first partial electrode 151 and the second partial electrode 152 have an interlocking shape. An interlocking shape means that they fit together. In other words, the ends of the first partial electrode 151 and the second partial electrode 152 are configured to overlap each other in the circumferential direction of the honeycomb structure 10.

[0052] It should be explained that Figure 5 and Figure 6 As shown, the ends of the first partial electrode 151 and the second partial electrode 152 of the first metal terminal 13 disposed on the front side of the heater member 1 have an interlocking shape that fits into each other. However, the second metal terminal 14 disposed on the back side of the heater member 1 can also be configured in the same way. The terms first partial electrode 151 and second partial electrode 152 refer to any two partial electrodes 15 that are adjacent to each other in the circumferential direction of the honeycomb structure 10, and do not limit the number of partial electrodes 15.

[0053] As described above, in the heater component 1 of this embodiment, the possibility of cracking in the honeycomb structure 10 is reduced. However, like Figures 1-4 In the scheme shown where the ends of multiple partial electrodes 15 have a non-interlocking shape, if a crack occurs in a manner that traverses the straight isolation region 16, a portion of the honeycomb structure 10 may be electrically disconnected, causing the current toward a portion of the honeycomb structure 10 to be cut off.

[0054] On the other hand, in a scheme where the ends of the first electrode 151 and the second electrode 152, as in the first variation, have an interlocking shape, the shape of the isolation region 16 can be made more complex. Even like Figure 6 As shown in the straight line L1, a crack has occurred, which not only traverses the isolation region 16 but also the ends of the first partial electrode 151 and / or the second partial electrode 152. The ends of the first partial electrode 151 and / or the second partial electrode 152 are not divided by the crack; for example, current flowing through the first partial electrode 151 can flow into the first electrode 11 beyond the cracked location. Therefore, in the embodiment where the ends of the first partial electrode 151 and the second partial electrode 152 have an interlocking shape, as in the first variation, the possibility of electrical separation of a portion of the honeycomb structure 10 can be reduced, thereby reducing the possibility of current being cut off to a portion of the honeycomb structure 10.

[0055] Figure 5 and Figure 6 In the first modified example shown, the end of the first partial electrode 151 has: a first protrusion 151a that contacts the outer edge of the first partial electrode 151 in the width direction of the honeycomb structure 10, and a first recess 151b that contacts the extension line EL1 of the inner edge of the first partial electrode 151 in the width direction of the honeycomb structure 10 and is disposed adjacent to the first protrusion 151a in the width direction of the honeycomb structure 10. In the circumferential direction of the honeycomb structure 10, at least a portion of the end of the second partial electrode 152 enters the first recess 151b.

[0056] Figure 5 and Figure 6 In the first modified example shown, the end of the second partial electrode 152 has: a second protrusion 152a that contacts the inner edge of the second partial electrode 152 in the width direction of the honeycomb structure 10, and a second recess 152b that contacts the extension line EL2 of the outer edge of the second partial electrode 152 in the width direction of the honeycomb structure 10 and is disposed adjacent to the second protrusion 152a in the width direction of the honeycomb structure 10. In the circumferential direction of the honeycomb structure 10, the first protrusion 151a enters into the second recess 152b, and the second protrusion 152a enters into the first recess 151b.

[0057] The following will sometimes be Figure 5 and Figure 6 The interlocking shape shown is called a "Z-shaped" interlocking shape.

[0058] Next, Figure 7 It is shown Figure 1 A front view of the main part of the second modified example of heater component 1. Figure 8 It is shown Figure 1 A front view of the main part of the third modified example of the heater component 1. The fitting shape of the ends of the first electrode 151 and the second electrode 152 is not limited to... Figure 5 and Figure 6 The "Z-shaped" interlocking shape shown can be any other shape.

[0059] For example, like Figure 7As shown in the second variation, the fitting shape can be "U-shaped". In the second variation, the end of the first electrode 151 has: a third protrusion 151c located at the middle position of the first electrode 151 in the width direction of the honeycomb structure 10, and third recesses 151d located on both sides of the third protrusion 151c in the width direction of the honeycomb structure 10. The end of the second electrode 152 has: a fourth recess 152c located at the middle position of the second electrode 152 in the width direction of the honeycomb structure 10, and fourth protrusions 152d located on both sides of the fourth recess 152c in the width direction of the honeycomb structure 10. In the circumferential direction of the honeycomb structure 10, the third protrusion 151c enters the fourth recess 152c, and the fourth protrusion 152d enters the third recess 151d.

[0060] In addition, like Figure 8 As shown in the third variation, the fitting shape can be "circular". In the third variation, the end of the first electrode 151 has a circular fifth protrusion 151e, and the end of the second electrode 152 has a circular fifth recess 152e. In the circumferential direction of the honeycomb structure 10, the fifth protrusion 151e enters the fifth recess 152e.

[0061] Next, Figure 9 It is shown Figure 1 The front view of the fourth modified example of heater component 1. Figure 10 It is shown Figure 9 Rear view of heater component 1, Figure 11 It is shown Figure 9 Right view of heater component 1. Figures 1 to 8 The heater component 1 is shown to be circular in shape; however, the shape of the heater component 1 can be arbitrarily changed. For example, like... Figures 9-11 As shown in the fourth variation, the heater component 1 can be quadrilateral in shape. In the fourth variation, the ends of the plurality of partial electrodes 15 are not interlocked with each other, but are spaced apart in the circumferential direction of the honeycomb structure 10.

[0062] Next, Figure 12 It is shown Figure 1 The main view of the main part of the fifth modified example of heater component 1. Figure 13 It is shown Figure 1 The main view of the main part of the sixth modified example of heater component 1. Figure 14 It is shown Figure 1 The image shows a front view of the main part of the seventh modified example of the heater component 1. When the heater component 1 is quadrilateral in shape, the ends of the first electrode 151 and the second electrode 152 can also have an interlocking shape. The interlocking shape can be like... Figure 12It can be "Z-shaped" like the fifth variation shown, or like... Figure 13 As shown in the sixth variation, it is "U-shaped", and can also be like... Figure 14 The seventh variation shown is "circular in shape". These fitted shapes are similar to the reference. Figures 5-8 The shapes described correspond to each other. However, Figure 12 As shown, the end of the second partial electrode 152 does not have a second protrusion 152a and a second recess 152b, and the entire end of the second partial electrode 152 enters the fitting shape of the first recess 151b. Such fitting shapes are also included in the "Z-shape". Furthermore, Figure 13 The diagram shows a fitting shape in which a fourth protrusion 152d is integrally formed with the other parts of the second electrode 152. Such fitting shapes are also included in the “U-shape”.

[0063] The components of heater assembly 1 will be described in detail below.

[0064] (1-1. Honeycomb structure)

[0065] The shape of the honeycomb structure 10 is not particularly limited. For example, the cross-section of the honeycomb structure 10 orthogonal to the flow path direction (the direction in which the compartment 101a extends) can be a polygon such as a quadrilateral (rectangle, square), pentagon, hexagon, heptagon, or octagon, or a circle or a near-elliptical shape (oval, elliptical, oblong, rounded rectangle, etc.). It should be noted that the end faces (first end face 10a and second end face 10b) have the same shape as the cross-section. In addition, when the cross-section and end faces are polygonal, the corners can be chamfered.

[0066] The shape of compartment 101a is not particularly limited. In the cross-section of the honeycomb structure 10 perpendicular to the flow direction, it can be a polygon, circle, or ellipse-like shape, such as a quadrilateral, pentagon, hexagon, heptagon, or octagon. These shapes can be singular or a combination of two or more. Among these shapes, a quadrilateral or hexagonal shape is preferred. By providing compartment 101a with such a shape, the pressure loss during airflow can be reduced. It should be noted that... Figures 1 to 14 The diagram shows a honeycomb structure 10 with a quadrilateral shape, in which the cross-section orthogonal to the flow path direction and the compartment 101a are shown as an example.

[0067] The honeycomb structure 10 can be a honeycomb joint having multiple honeycomb cells and a bonding layer that interlocks the outer peripheral surfaces of the multiple honeycomb cells. By using the honeycomb joint, it is possible to suppress the occurrence of cracking and increase the total cross-sectional area of ​​the compartment 101a, which is very important for ensuring airflow.

[0068] It should be noted that a bonding material can be used to form the bonding layer. There are no particular limitations on the bonding material; a paste-like material made by adding a solvent such as water to a ceramic material can be used. The bonding material may contain a material with PTC properties, or it may contain the same material as the outer peripheral wall 100 and the partition wall 101. In addition to its function of bonding the cell units together, the bonding material can also be used as a coating material for the outer periphery of the bonded cell units.

[0069] From the viewpoints of ensuring the strength of the honeycomb structure 10, reducing the pressure loss when air passes through the compartment 101a, ensuring the load-bearing capacity of functional materials, and ensuring the contact area with the air flowing in the compartment 101a, it is preferable to combine the thickness of the partition wall 101, the compartment density, and the compartment spacing (or the compartment opening ratio) well.

[0070] In this specification, the compartment density is the number of compartments divided by the area of ​​one end face (first end face 10a or second end face 10b) of the honeycomb structure 10 (the total area of ​​the partition walls 101 and compartments 101a excluding the peripheral wall 100).

[0071] In this specification, the compartment spacing refers to the value obtained through the following calculations. First, the area of ​​one end face (first end face 10a or second end face 10b) of the honeycomb structure 10 (the total area of ​​the partition walls 101 and compartments 101a excluding the peripheral wall 100) is divided by the number of compartments to calculate the area of ​​each compartment. Next, the square root of the area of ​​each compartment is calculated and set as the compartment spacing.

[0072] In this specification, the aperture ratio of compartment 101a refers to the value obtained by dividing the total area of ​​compartments 101a divided by partition walls 101 in a cross section of the honeycomb structure 10 orthogonal to the flow direction by the area of ​​one end face (first end face 10a or second end face 10b) (the total area of ​​partition walls 101 and compartments 101a excluding the peripheral wall 100). It should be noted that the first electrode 11, the second electrode 12, and the functional material layer 17 described later are not considered when calculating the aperture ratio of compartment 101a.

[0073] In an advantageous embodiment from the viewpoint of carrying a sufficient amount of functional material, the thickness of the partition wall 101 is 0.300 mm or less, and the compartment density is 100 compartments / cm³. 2 The compartment spacing is 1.0 mm or more. In a preferred embodiment, the thickness of the partition wall 101 is 0.200 mm or less, and the compartment density is 70 compartments / cm². 2 The following conditions apply, and the spacing between compartments is 1.2 mm or more. In a more preferred embodiment, the thickness of the partition wall is 0.130 mm or less, and the compartment density is 65 compartments / cm². 2The following applies, and the spacing between compartments is 1.3mm or more.

[0074] In the above embodiments, from the viewpoint of ensuring the strength of the honeycomb structure 10 and keeping the resistance at a low level, the lower limit of the thickness of the partition 101 is preferably 0.010 mm or more, more preferably 0.020 mm or more, and even more preferably 0.030 mm or more.

[0075] In the above embodiments, from the viewpoints of ensuring the strength of the honeycomb structure 10, maintaining a low resistance level, and increasing the surface area to promote reaction, adsorption, and detachment, the lower limit of the cell density is preferably 30 cells / cm². 2 The above is preferred to be 35 compartments / cm. 2 The above is further preferred to be 40 compartments / cm. 2 above.

[0076] In the above embodiments, from the viewpoints of ensuring the strength of the honeycomb structure 10, keeping the resistance at a low level, and increasing the surface area to promote reaction, adsorption, and detachment, the upper limit of the cell spacing is preferably 2.0 mm or less, more preferably 1.8 mm or less, and even more preferably 1.6 mm or less.

[0077] In an advantageous embodiment from the viewpoint of reducing pressure loss while maintaining strength, the thickness of the partition wall 101 is 0.08 to 0.36 mm, and the compartment density is 2.54 to 140 compartments / cm³. 2 The opening ratio of compartment 101a is 0.70 or higher. In a preferred embodiment, the thickness of the partition wall 101 is 0.09 to 0.35 mm, and the compartment density is 15 to 100 compartments / cm³. 2 The opening ratio of compartment 101a is 0.80 or higher. In a more preferred embodiment, the thickness of the partition wall 101 is 0.14 to 0.30 mm, and the compartment density is 20 to 90 compartments / cm³. 2 The opening ratio of compartment 101a is 0.85 or higher.

[0078] In the above embodiments, from the viewpoint of ensuring the strength of the honeycomb structure 10, the upper limit of the opening ratio of the compartment 101a is preferably 0.94 or less, more preferably 0.92 or less, and even more preferably 0.90 or less.

[0079] The thickness of the outer peripheral wall 100 is not particularly limited, but is preferably determined based on the following viewpoints. First, from the viewpoint of reinforcing the honeycomb structure 10, the thickness of the outer peripheral wall 100 is preferably 0.05 mm or more, more preferably 0.06 mm or more, and even more preferably 0.08 mm or more. On the other hand, from the viewpoint of increasing resistance to suppress initial current and reducing pressure loss during airflow, the thickness of the outer peripheral wall 100 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.

[0080] In this specification, the thickness of the outer peripheral wall 100 refers to the length in the normal direction of the side surface of the honeycomb structure 10, from the boundary between the outer peripheral wall 100 and the outermost compartment 101a or partition 101 to the side surface of the honeycomb structure 10 in a cross section orthogonal to the flow path direction.

[0081] The length of the honeycomb structure 10 in the flow path direction and the cross-sectional area orthogonal to the flow path direction can be adjusted according to the required size of the heater component 1, without any particular limitation. For example, in the case of a compact heater component 1 that ensures the specified function, the length in the flow path direction of the honeycomb structure 10 can be set to 2 to 20 mm, and the cross-sectional area orthogonal to the flow path direction can be set to 10 cm². 2 That's all. It should be noted that there is no specific upper limit to the cross-sectional area orthogonal to the flow direction, for example, 300 cm². 2 .

[0082] The partitions 101 constituting the honeycomb structure 10 are made of a material capable of generating heat through electrical conduction, specifically, a material with PTC properties. If necessary, the outer peripheral wall 100 may also be made of a material with PTC properties, similar to the partitions 101. By employing such a configuration, the functional material layer 17 can be heated by heat transfer from the heated partitions 101 (and, if necessary, the outer peripheral wall 100). Furthermore, the material with PTC properties exhibits a characteristic where, when the temperature rises above the Curie point, the resistance increases sharply, making it difficult for current to flow. Therefore, when the heater components 1 reach high temperatures, the current flowing through the partitions 101 (and, if necessary, the outer peripheral wall 100) is limited, thus suppressing overheating of the heater components 1. Consequently, thermal degradation of the functional material layer 17 caused by overheating can also be suppressed.

[0083] From the viewpoint of achieving moderate heat generation, the lower limit of the volume resistivity of the material with PTC characteristics at 25°C is preferably 0.5 Ω·cm or more, more preferably 1 Ω·cm or more, and even more preferably 5 Ω·cm or more. From the viewpoint of generating heat with a low driving voltage, the upper limit of the volume resistivity of the material with PTC characteristics at 25°C is preferably 30 Ω·cm or less, more preferably 18 Ω·cm or less, and even more preferably 16 Ω·cm or less. In this specification, the volume resistivity of the material with PTC characteristics at 25°C is measured according to JIS K6271:2008.

[0084] From the viewpoint of being able to generate heat through electricity and possessing PTC characteristics, the outer peripheral wall 100 and the partition wall 101 are preferably made of a material with barium titanate (BaTiO3) as the main component. Furthermore, this material is more preferably a ceramic made of a material whose main component is barium titanate (BaTiO3) crystalline particles, with a portion of Ba replaced by rare earth elements. 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. The content of BaTiO3 crystalline particles can be determined using fluorescence X-ray analysis. Other crystalline particles can also be determined using the same method.

[0085] The composition of BaTiO3-based crystal particles, which utilize rare earth element substitution to partially replace Ba, can be expressed as (Ba 1-x A x TiO3 represents the rare earth element. In the composition formula, A represents one or more rare earth elements, and 0.0001≤x≤0.010.

[0086] A can be any rare earth element, without particular limitation, but preferably selected from one or more elements in the group consisting of La, Ce, Pr, Nd, Eu, Gd, Dy, Ho, Er, Y, and Yb, and more preferably La. From the viewpoint of suppressing excessively high resistance at room temperature, x is preferably 0.001 or more, and more preferably 0.0015 or more. On the other hand, from the viewpoint of suppressing excessively high resistance at room temperature due to insufficient sintering, x is preferably 0.009 or less.

[0087] The content of BaTiO3-based crystalline particles, which are a portion of Ba replaced by rare earth elements, in the ceramic is not particularly limited as long as it is an amount that constitutes a major component. Preferably, it is 90% by mass or more, more preferably 92% by mass or more, and even more preferably 94% by mass or more. It should be noted that the upper limit of the content of BaTiO3-based crystalline particles is not particularly limited, but is typically 99% by mass, preferably 98% by mass.

[0088] The content of BaTiO3 crystalline particles can be determined using fluorescence X-ray analysis. Other crystalline particles can also be determined using the same method.

[0089] From the viewpoint of reducing environmental impact, the materials used for the outer peripheral wall 100 and the partition wall 101 are preferably substantially lead-free (Pb). Specifically, the Pb content in the outer peripheral wall 100 and the partition wall 101 is preferably 0.01% by mass or less, more preferably 0.001% by mass or less, and even more preferably 0% by mass. With a low Pb content, it is possible to safely blow heated air, for example, into living organisms such as humans, through contact with the heated partition wall 101. It should be noted that the Pb content in the outer peripheral wall 100 and the partition wall 101, converted to PbO, is preferably less than 0.03% by mass, more preferably less than 0.01% by mass, and even more preferably 0% by mass. The lead content can be determined using ICP-MS (Inductively Coupled Plasma Mass Analysis).

[0090] From the viewpoint of efficiently heating air, the lower limit of the Curie point of the material constituting the outer peripheral wall 100 and the partition wall 101 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.

[0091] The Curie point of the materials constituting the outer peripheral wall 100 and the partition wall 101 can be adjusted by the type and amount of displacement agent. For example, barium titanate (BaTiO3) has a Curie point of about 120°C. By replacing a portion of Ba and Ti with one or more of Sr, Sn and Zr, the Curie point can be shifted to the low-temperature side.

[0092] In this specification, the Curie point is determined using the following method. The sample is mounted in a sample holder for measurement and fitted into a measuring chamber (e.g., MINI-SUBZERO MC-810P, Espec Co., Ltd.). Using a DC resistance meter (e.g., multimeter 3478A, YOKOGAWA HEWLETT PACKARD, LTD.), the change in resistance of the sample relative to temperature is measured as the temperature increases from 10°C. Based on the obtained 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.

[0093] (1-2. First electrode and second electrode)

[0094] The first electrode 11 and the second electrode 12 are disposed on the first end face 10a and the second end face 10b, respectively. By applying an external voltage between the first electrode 11 and the second electrode 12, the honeycomb structure 10 can be heated by utilizing Joule heating.

[0095] The first electrode 11 and the second electrode 12 are 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 capable of ohmic contact with the outer peripheral wall 100 and / or partition wall 101 having PTC characteristics can also be used. The ohmic electrode can be, for example, an ohmic electrode containing at least one selected from Al, Au, Ag, and In as the base metal, and at least one selected from Ni, Si, Zn, Ge, Sn, Se, and Te for n-type semiconductors as the dopant. Furthermore, the first electrode 11 and the second electrode 12 can be a single-layer structure or a stacked structure of two or more layers. When the first electrode 11 and the second electrode 12 have a stacked structure of two or more layers, the materials of each layer can be the same type or different types.

[0096] The thicknesses of the first electrode 11 and the second electrode 12 can be appropriately set according to the method of forming the first electrode 11 and the second electrode 12. Examples of methods for forming the first electrode 11 and the second electrode 12 include metal deposition methods such as sputtering, vapor deposition, electrolytic deposition, and chemical deposition. Alternatively, the first electrode 11 and the second electrode 12 can be formed by sintering after coating with electrode paste, or by fusion deposition. Furthermore, the first electrode 11 and the second electrode 12 can also be formed by bonding metal plates or alloy plates.

[0097] Regarding the thickness of the first electrode 11 and the second electrode 12, for example, it is preferably about 5 to 30 μm in the sintering of electrode paste, about 100 to 1000 nm in dry plating such as sputtering and evaporation, about 10 to 100 μm in fusion plating, and about 5 to 30 μm in wet plating such as electrolytic deposition and chemical deposition. Furthermore, in the bonding of metal plates or alloy plates, it is preferable to set their thickness to about 5 to 100 μm.

[0098] (1-3. First metal terminal and second metal terminal)

[0099] By providing the first metal terminal 13 and the second metal terminal 14, connection to an external power source is facilitated. The first metal terminal 13 and the second metal terminal 14 are connected to the wires connected to the external power source.

[0100] The metals constituting the first metal terminal 13 and the second metal terminal 14 can be elemental metals or alloys. However, from the viewpoint of corrosion resistance, resistivity, and linear expansion rate, alloys containing at least one selected from the group consisting of Cr, Fe, Co, Ni, Cu, Al, and Ti are preferred, and stainless steel, Fe-Ni alloys, and phosphor bronze are more preferred. The thickness of the first metal terminal 13 and the second metal terminal 14 is not particularly limited, and is, for example, 0.01 to 10 mm, typically 0.05 to 5 mm.

[0101] Regarding the connection method between the first metal terminal 13 and the second metal terminal 14 and the first electrode 11 and the second electrode 12, electrical connection is sufficient and there are no particular limitations. For example, the connection can be made by diffusion bonding, mechanical pressure mechanism, welding, etc.

[0102] (1-4. Intermediate Materials)

[0103] An intermediate material can be provided between the first electrode 11 and the second electrode 12 and the first metal terminal 13 and the second metal terminal 14. By providing an intermediate material, the structural freedom of the connection between the first electrode 11 and the second electrode 12 and the first metal terminal 13 and the second metal terminal 14 is increased. The material of the intermediate material is not particularly limited and can be the same as the material of the first metal terminal 13 and the second metal terminal 14. Alternatively, the intermediate material can be different from the material of the first metal terminal 13 and the second metal terminal 14. In this case, the intermediate material can be formed from solder, brazing filler metal, conductive adhesive, etc. Regarding the connection method between the intermediate material and the first metal terminal 13 and the second metal terminal 14, and the first electrode 11 and the second electrode 12, an electrical connection is sufficient and is not particularly limited. For example, the connection can be performed through diffusion bonding, mechanical pressure mechanisms, welding, etc.

[0104] (1-5. Including functional material layers)

[0105] like Figure 4 As shown, the heater component 1 may include a functional material layer 17, which is disposed on the surface of the partition wall 101. The functional material layer 17 may be disposed on the surface of the partition wall 101 (in the case of the outermost compartment 101a, dividing the partition wall 101 that forms the outermost compartment 101a and the outer peripheral wall 100). By disposing the functional material layer 17 in this way, the functional material contained in the functional material layer 17 can be easily heated, thus enabling it to perform the desired function provided by the functional material.

[0106] The functional material contained in the functional material layer 17 can be any material that enables it to perform the desired function; there are no particular limitations, and adsorbent materials, catalysts, etc., can be used. The adsorbent material preferably has the function of adsorbing one or more of the target components in the air, such as water vapor, carbon dioxide, and volatile components. Furthermore, by using a catalyst, the target components can be purified. In addition, for purposes such as improving the capture function of the target components by the adsorbent material, the adsorbent material and the catalyst can be used in combination.

[0107] The preferred adsorbent material possesses the ability to adsorb target components, such as water vapor, carbon dioxide, and volatile components, at temperatures ranging from -20°C to 40°C and to desorb them at temperatures above 60°C. Examples of adsorbent materials with this function include zeolite, silica gel, activated carbon, alumina, silica, low-crystallinity clay, and amorphous aluminosilicate composites. The type of adsorbent material is selected appropriately based on the type of target component to be removed. One type of adsorbent material can be used alone, or two or more can be used in combination.

[0108] As a catalyst, it is preferable to have the function of promoting redox reactions. Examples of catalysts with such function include metal catalysts such as Pt, Pd, and Ag, and oxide catalysts such as CeO2 and ZrO2. A catalyst can be used alone or in combination of two or more.

[0109] The volatile components in the air inside the train car include volatile organic compounds (VOCs) and odor components other than VOCs. Specific examples of volatile components include: ammonia, acetic acid, isovaleric acid, nonenal, formaldehyde, toluene, xylene, p-dichlorobenzene, ethylbenzene, styrene, chlorpyrifos, di-n-butyl phthalate, tetradecane, di-2-ethylhexyl phthalate, diazinon, acetaldehyde, and N-methylcarbamate-2-(1-methylpropyl)phenyl ester.

[0110] The thickness of the functional material layer 17 can be determined according to the size of the compartment 101a and is not particularly limited. For example, from the viewpoint of ensuring sufficient contact with air, the thickness of the functional material layer 17 is preferably 20 μm or more, more preferably 25 μm or more, and even more preferably 30 μm or more. On the other hand, from the viewpoint of suppressing the peeling of the functional material layer 17 from the partition wall 101 and the outer peripheral wall 100, the thickness of the functional material layer 17 is preferably 400 μm or less, more preferably 380 μm or less, and even more preferably 350 μm or less.

[0111] The thickness of the functional material layer 17 is measured according to the following steps: An arbitrary cross-section of the honeycomb structure 10 parallel to the flow path direction is cut out, and a cross-sectional image at approximately 50x magnification is obtained using a scanning electron microscope or the like. Furthermore, this cross-section is positioned through the centroid of a cross-section of the honeycomb structure 10 orthogonal to the flow path. For each functional material layer 17 visible from the cross-sectional image, the thickness is calculated by dividing the cross-sectional area by the length of the compartment 101a in the flow path direction. This calculation is performed for all functional material layers 17 visible from the cross-sectional image, and the overall average value is taken as the thickness of the functional material layer 17.

[0112] From the viewpoint that the functional material performs its desired function within the heater component 1, the amount of the functional material layer 17 is preferably 50 to 500 g / L relative to the volume of the honeycomb structure 10, more preferably 100 to 400 g / L, and even more preferably 150 to 350 g / L. It should be noted that the volume of the honeycomb structure 10 is a value determined based on the external dimensions of the honeycomb structure 10.

[0113] (2. Manufacturing method of heater components)

[0114] The method for manufacturing the heater component according to the embodiments of the present invention can be any method having the above-described features, and is not particularly limited, and can be carried out according to known methods. Hereinafter, the method for manufacturing the heater component according to the embodiments of the present invention will be described illustratively.

[0115] The manufacturing method of the honeycomb structure constituting the heater component includes a molding process and a firing process.

[0116] In the molding process, a blank containing ceramic raw materials including BaCO3 powder, TiO2 powder and rare earth nitrates or hydroxides is molded to produce a honeycomb molded body with a relative density of more than 60%.

[0117] Ceramic raw materials can be obtained by dry mixing of various powders according to the desired composition.

[0118] A green body can be obtained by adding a dispersion medium, binder, plasticizer, and dispersant to ceramic raw materials and then mixing them. The green body may contain additives such as displacement agents, metal oxides, property improvers, and conductive powders, as needed.

[0119] The amount of components other than ceramic raw materials can be such that the relative density of the honeycomb molded body reaches more than 60%, without any special limitation.

[0120] Here, the "relative density of the honeycomb molded body" in this specification refers to the ratio of the density of the honeycomb molded body to the true density of the entire ceramic raw material. Specifically, it can be calculated using the following formula.

[0121] Relative density (%) of honeycomb molded material = Density of honeycomb molded material (g / cm³) 3 True density of the ceramic raw material (g / cm³) 3 )×100

[0122] The density of the honeycomb molded body can be determined using Archimedes' method with pure water as the medium. Alternatively, the true density of the entire ceramic raw material can be calculated by dividing the total mass (g) of all raw materials by the total actual volume (cm³) of all raw materials. 3 To find the solution.

[0123] Examples of dispersion media include water, or a mixture of water and organic solvents such as alcohols, with water being particularly preferred.

[0124] Examples of adhesives include organic adhesives such as methylcellulose, hydroxypropoxycellulose, hydroxyethylcellulose, carboxymethylcellulose, and polyvinyl alcohol. The combination of methylcellulose and hydroxypropoxycellulose is particularly preferred. One type of adhesive may be used alone, or two or more may be used in combination; however, it is preferable that the adhesive does not contain alkali metal elements.

[0125] Examples of plasticizers include: polyoxyethylene alkyl ethers, polycarboxylic acid polymers, and alkyl phosphates.

[0126] Dispersants can be surfactants such as polyoxyethylene alkyl ethers, ethylene glycol, dextrin, fatty acid soaps, and polyols. A single dispersant can be used, or two or more can be used in combination.

[0127] Honeycomb structures can be made by extruding preforms. During extrusion molding, a die with the desired overall shape, cell shape, cell wall thickness, cell density, etc., can be used.

[0128] The relative density of the honeycomb molded body obtained by extrusion molding is 60% or more, preferably 65% ​​or more. By controlling the relative density of the honeycomb molded body within such a range, the honeycomb molded body can be densified, thereby reducing its electrical resistance at room temperature. It should be noted that there is no particular upper limit to the relative density of the honeycomb molded body, which is typically 80%, preferably 75%.

[0129] The honeycomb molded body can be dried before the firing process. There are no particular limitations on the drying method; for example, conventionally known drying methods such as hot air drying, microwave drying, dielectric drying, reduced pressure drying, vacuum drying, and freeze drying can be used. However, a drying method combining hot air drying and microwave drying or dielectric drying is preferred in terms of achieving rapid and uniform drying of the entire molded body.

[0130] The firing process includes: holding at 1150-1250℃, then heating it to a maximum temperature of 1360-1430℃ at a heating rate of 20-600℃ / hour, and holding it for 0.5-10 hours.

[0131] By holding the honeycomb molded body at a maximum temperature of 1360–1430°C for 0.5–10 hours, a honeycomb structure 10 with BaTiO3 crystalline particles, in which a portion of Ba is replaced by rare earth elements, as the main component can be obtained.

[0132] In addition, by holding the temperature at 1150–1250°C, the Ba2TiO4 crystal particles generated during the firing process can be easily removed, thus enabling the honeycomb structure 10 to be densified.

[0133] Furthermore, by setting the heating rate of the maximum temperature from 1150 to 1250°C to 1360 to 1430°C to 20 to 600°C / hour, it is possible to generate 1.0 to 10.0% by mass of Ba6Ti in the honeycomb structure 10. 17 O 40 Crystalline particles.

[0134] The holding time at 1150–1250°C is not particularly limited, but is preferably 0.5–10 hours. By setting the holding time to this level, the Ba2TiO4 crystal particles generated during the firing process can be easily and stably removed.

[0135] The firing process preferably includes maintaining the temperature at 900–950°C for 0.5–5 hours during heating. By maintaining the temperature at 900–950°C for 0.5–5 hours, BaCO3 is efficiently decomposed, easily yielding a honeycomb structure 10 with a specified composition.

[0136] It should be noted that a degreasing process to remove the binder can be performed prior to the firing process. The atmosphere for the degreasing process is preferably atmospheric to ensure complete decomposition of the organic components.

[0137] Furthermore, from the perspective of controlling electrical characteristics and manufacturing costs, the atmosphere for the firing process is preferably an atmospheric atmosphere.

[0138] There are no particular restrictions on the type of furnace used for firing and degreasing processes; electric furnaces, gas furnaces, etc., can be used.

[0139] By forming the first electrode 11 and the second electrode 12 into the honeycomb structure 10 obtained in this way, the heater component 1 can be manufactured. Alternatively, the first electrode 11 and the second electrode 12 can be formed by metal deposition methods such as sputtering, vapor deposition, electrolytic deposition, or chemical deposition. Alternatively, the first electrode 11 and the second electrode 12 can be formed by sintering after coating with electrode paste. Furthermore, the first electrode 11 and the second electrode 12 can be formed by fusion deposition. The first electrode 11 and the second electrode 12 can be composed of a single layer or multiple electrode layers with different compositions. Hereinafter, representative methods for forming the first electrode 11 and the second electrode 12 will be described.

[0140] First, an electrode slurry comprising electrode material, organic binder, and dispersion medium is prepared and coated onto the first end face 10a or the second end face 10b of the honeycomb structure 10. The dispersion medium can be water, an organic solvent (e.g., toluene, xylene, ethanol, n-butanol, ethyl acetate, butyl acetate, terpineol, dihydroterpineol, Texanol, ethylene glycol monobutyl ether acetate, diethylene glycol monoethyl ether acetate, diethylene glycol monoethyl ether, diethylene glycol monobutyl ether acetate, diethylene glycol monobutyl ether) or a mixture thereof. Excess slurry on the outer periphery of the honeycomb structure 10 is removed by blowing and wiping. Then, by drying the slurry, a first electrode 11 and a second electrode 12 can be formed on the first end face 10a or the second end face 10b of the honeycomb structure 10. Drying can be performed while the heater component 1 is heated to a temperature of, for example, approximately 120–600°C. The series of processes of coating, slurry removal and drying can be performed once or repeatedly to set the desired thickness of the first electrode 11 and the second electrode 12.

[0141] Next, a first metal terminal 13 and a second metal terminal 14 are disposed at predetermined positions on the first electrode 11 and the second electrode 12, and the first electrode 11 and the second electrode 12 are connected to the first metal terminal 13 and the second metal terminal 14. The method described above can be used as a method for connecting the first electrode 11 and the second electrode 12 to the terminals. Alternatively, if an intermediate material is provided between the first electrode 11 and the second electrode 12 and the first metal terminal 13 and the second metal terminal 14, after connecting the first electrode 11 and the second electrode 12 at predetermined positions using the intermediate material, the first metal terminal 13 and the second metal terminal 14 can be disposed at predetermined positions using the intermediate material to connect them. The method described above can be used as one of these connection methods.

[0142] It should be noted that the first metal terminal 13 and the second metal terminal 14, as well as the intermediate material, can be set after the functional material layer 17 described below is formed.

[0143] Next, by forming a functional material layer 17 on the surface of the partition wall 101, etc., of the heater component 1 obtained above, a heater component with a functional material layer is obtained.

[0144] The method for forming the functional material layer 17 is not particularly limited, and for example, it can be formed using the following steps: The heater component 1 is immersed in a slurry containing the functional material, an organic binder, and a dispersion medium for a specified time, and excess slurry on the end faces and outer periphery of the honeycomb structure 10 is removed by blowing and wiping. The dispersion medium can be water, an organic solvent (e.g., toluene, xylene, ethanol, n-butanol, ethyl acetate, butyl acetate, terpineol, dihydroterpineol, Texanol, ethylene glycol monobutyl ether acetate, diethylene glycol monoethyl ether acetate, diethylene glycol monoethyl ether, diethylene glycol monobutyl ether acetate, diethylene glycol monobutyl ether) or a mixture thereof. Afterward, by drying the slurry, the functional material layer 17 can be formed on the surface of the partition wall 101. Drying can be performed while heating the heater component 1 to a temperature of, for example, approximately 120–600°C. The series of processes of impregnation, slurry removal and drying can be performed only once or repeatedly to create a functional material layer 17 of desired thickness on the surface of the partition 101, etc.

[0145] (3. Carriage purification system)

[0146] Figure 15 This is a schematic diagram illustrating the configuration of a vehicle cabin purification system 1000 according to an embodiment of the present invention. According to an embodiment of the present invention, a vehicle cabin purification system 1000 including the aforementioned heater component 1 is provided. This vehicle cabin purification system 1000 can preferably be used in various vehicles such as automobiles.

[0147] like Figure 15 As shown, the car body purification system 1000 includes: at least one heater component 1; a power source 200 such as a battery that applies voltage to the heater component 1; an inflow pipe 400 that connects the car body and a first end face 10a of the heater component 1; an outflow pipe 500 that has a first path 500a connecting a second end face 10b of the heater component 1 and the car body; and a fan 600 that allows air from the car body to flow into the first end face 10a of the heater component 1 via the inflow pipe 400.

[0148] In addition to the first path 500a, the outlet pipe 500 may also have a second path 500b that connects the second end face 10b of the heater component 1 to the outside of the vehicle. Furthermore, the outlet pipe 500 may have a switching valve 300 capable of switching the airflow flowing through the outlet pipe 500 between the first path 500a and the second path 500b.

[0149] The vehicle cabin purification system 1000 can have two operating modes: a first mode and a second mode. In the first mode, the external voltage from the power supply 200 is disconnected, so that the air flowing through the outlet pipe 500 passes through the first path 500a to switch the switching valve 300, and the ventilation fan 600 is turned on. In the second mode, the external voltage from the power supply 200 is turned on, so that the air flowing through the outlet pipe 500 passes through the second path 500b to switch the switching valve 300, and the ventilation fan 600 is turned on.

[0150] The vehicle compartment purification system 1000 may include a control unit 900 capable of switching between a first mode and a second mode. The control unit 900 may be configured to alternately execute the first mode and the second mode, for example. By repeatedly switching between the first mode and the second mode at a certain cycle, the target components inside the vehicle compartment can be stably discharged outside the vehicle.

[0151] In the first mode, air purification is performed in the carriage. Specifically, air from the carriage flows in through the inflow pipe 400 from the first end face 10a of the heater component 1, passes through the heater component 1, and flows out from the second end face 10b of the heater component 1. Target components of the air from the carriage are removed during passage through the heater component 1 by being captured by functional materials. The clean air flowing out from the second end face 10b of the heater component 1 returns to the carriage through the first path 500a of the outflow pipe 500.

[0152] In the second mode, the functional material is regenerated. Specifically, air from the carriage flows in through the inflow pipe 400 from the first end face 10a of the heater component 1, passes through the heater component 1, and flows out from the second end face 10b of the heater component 1. The heater component 1 heats up when energized, thereby heating the functional material carried on the heater component 1. As a result, the components to be removed, such as those captured by the functional material, are removed from or react with the functional material.

[0153] To facilitate the removal of the target components captured by the functional material, it is preferable to heat the functional material to a temperature above the removal temperature, depending on the type of functional material. For example, when using an adsorbent as the functional material, it is preferable to heat at least a portion, ideally all of the functional material, to 70–150°C, more preferably to 80–140°C, and even more preferably to 90–130°C. Furthermore, in the second mode, it is preferable to allow the functional material to be fully regenerated for a certain period. Although this also depends on the type of functional material, in the second mode, for example, when using an adsorbent as the functional material, it is preferable to heat the functional material within the above temperature range for 1–10 minutes, more preferably 2–8 minutes, and even more preferably 3–6 minutes.

[0154] Air from the carriage flows out from the second end face 10b of the heater component 1 in a state containing the removed target components that have detached from the functional material during passage through the heater component 1. The air containing the removed target components flowing out from the second end face 10b of the heater component 1 is discharged outside the carriage through the second path 500b of the outlet pipe 500.

[0155] The switching of the applied voltage to the heater component 1 can be achieved, for example, by electrically connecting the power supply 200 and the first electrode 11 and the second electrode 12 of the heater component 1 via a wire 810, and operating a power switch 910 located along the wire 810. The control unit 900 is capable of operating the power switch 910.

[0156] Regarding the switching on and off of the ventilation fan 600, for example, the control unit 900 and the ventilation fan 600 can be electrically connected via wire 820 or wirelessly, and the control unit 900 can be used to operate the switch (not shown) of the ventilation fan 600. The ventilation fan 600 can also be configured to change the ventilation volume via the control unit 900.

[0157] Regarding the switching of the switching valve 300, for example, the control unit 900 and the switching valve 300 can be electrically connected by a wire 830 or wirelessly, and the control unit 900 can be used to operate the switching valve 300 (not shown) to achieve this.

[0158] As the switching valve 300, any electrically driven valve with the function of switching flow paths is acceptable; there are no particular limitations, and examples include solenoid valves and electric valves. In one embodiment, the switching valve 300 includes: an opening / closing gate 312 supported on a rotation shaft 310, and an actuator 314, such as a motor, for rotating the rotation shaft 310. The actuator 314 is configured to be controllable by a control unit 900.

[0159] From the viewpoint of reliably ensuring the above-mentioned functions, the car body purification system 1000 preferably positions the heater component 1 close to the car body. Therefore, from the viewpoint of preventing electric shock, the driving voltage is preferably 60V or less. The honeycomb structure 10 used for the heater component 1 has low resistance at room temperature, so heating of the honeycomb structure 10 can be achieved with this low driving voltage. It should be noted that the lower limit of the driving voltage is not particularly limited, but is preferably 10V or more. If the driving voltage is less than 10V, the current when heating the honeycomb structure 10 increases, therefore, the wire 810 needs to be thicker.

[0160] exist Figure 15In the illustrated embodiment, the ventilator 600 is located upstream of the heater assembly 1. More specifically, the ventilator 600 is located along the inflow pipe 400 connecting the heater assembly 1 and the vehicle compartment, and air passing through the ventilator 600 flows in such a way that it is pushed in relative to the heater assembly 1. Alternatively, the ventilator 600 may be located downstream of the heater assembly 1. In this case, the ventilator 600 may be located, for example, along the outflow pipe 500, and air passing through the inflow pipe 400 flows in such a way that it is drawn into the heater assembly 1.

[0161] The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings; however, the present invention is not limited to these examples. Those skilled in the art to which this invention pertains will be able to conceive of various modifications or alterations within the scope of the technical concept set forth in the claims, and will understand that these examples also fall within the technical scope of the present invention.

[0162] Example

[0163] The present invention will now be described in more detail through embodiments. However, the present invention is not limited to these embodiments.

[0164] BaCO3 powder, TiO2 powder, and La(NH3)3·6H2O powder were prepared as ceramic raw materials. These powders were weighed according to the specified composition after firing and dry-mixed to obtain a mixed powder. Dry mixing was carried out for 30 minutes. Next, relative to 100 parts by weight of the obtained mixed powder, water, binder, plasticizer, and dispersant were added in appropriate amounts ranging from 3 to 30 parts by weight, respectively, to obtain a ceramic molded body with a relative density of 64.8% after extrusion molding, and the mixture was kneaded to obtain a green body. Methylcellulose was used as the binder. Polyoxyethylene alkyl ethers were used as the plasticizer and dispersant.

[0165] Next, the obtained preform is placed into an extrusion molding machine and extruded using a specified die in the manner that it will become a honeycomb structure as shown below after firing.

[0166] The shape of the cross-section and end face of the honeycomb structure orthogonal to the flow direction: circular or quadrilateral.

[0167] The dimensions of the circular honeycomb structure are: diameter 120mm and length 10mm.

[0168] The dimensions of the quadrilateral honeycomb structure are: width 89mm, length 68mm, and length 10mm.

[0169] The cross-sectional shape of the compartment orthogonal to the flow path direction: quadrilateral

[0170] The thickness of the partition wall: 0.127mm

[0171] Thickness of the outer peripheral wall: 0.127mm

[0172] Compartment density: 85.3 compartments / cm³ 2

[0173] Compartment spacing: 1.08mm

[0174] Compartment opening ratio: 0.55~0.80

[0175] The cross-sectional area of ​​the honeycomb structure orthogonal to the direction of flow path extension: (circular) 11310 mm² 2 (Quadrilateral) 6052mm 2

[0176] Length of the flow path in the honeycomb structure: 10mm

[0177] The volume resistivity of the material constituting the partition (and outer peripheral wall) at 25°C is 12 Ω·cm.

[0178] Curie point of the material constituting the partition (and outer perimeter): 120°C

[0179] It should be noted that the volume resistivity of the adjacent wall is controlled by adjusting the proportion of raw materials and firing conditions.

[0180] Next, the obtained honeycomb molded body was subjected to dielectric drying and hot air drying. Then, it was degreased in a firing furnace under atmospheric atmosphere (450℃ × 4 hours). Following this, it was fired under atmospheric atmosphere to obtain the honeycomb structure. The firing process was as follows: after holding at 950℃ for 1 hour, the temperature was increased to 1200℃ and held at 1200℃ for 1 hour. Then, the temperature was increased to 1400℃ (maximum temperature) at a rate of 200℃ / hour and held at 1400℃ for 2 hours.

[0181] Next, a first electrode and a second electrode with a thickness of 0.05 mm are formed on the two end faces (first end face and second end face) of the obtained honeycomb structure. The first electrode and the second electrode are formed as follows. First, an electrode paste containing aluminum (electrode material), ethyl cellulose, and diethylene glycol monobutyl ether (organic binder) is prepared and coated onto one end face. Next, excess electrode paste on the outer periphery of the honeycomb structure is removed by blowing and wiping, and the electrode paste is dried, thereby forming an electrode on one end face. Similarly, an electrode is formed on the other end face.

[0182] Next, a first metal terminal is joined to the first electrode, and a second metal terminal is joined to the second electrode. The first metal terminal and the second metal terminal are joined as follows. As the first metal terminal and the second metal terminal, a component made of a strip-shaped metal body of SUS430 with a width of 3.5 mm and a thickness of 0.7 mm is used. Regarding the overall outer shape of the first metal terminal and the second metal terminal, it is a quadrilateral frame shape with respect to the quadrilateral honeycomb structure, and a circular frame shape with respect to the circular honeycomb structure. The outer edges of the first metal terminal and the second metal terminal are aligned with the outer edges of the two end faces of the honeycomb structure, and the first metal terminal and the second metal terminal are joined to the first electrode and the second electrode using solder.

[0183] As shown in the following table, as the first metal terminal and the second metal terminal, a component that is integral around the entire circumference of the honeycomb structure and a component divided into multiple partial electrodes as shown in Figures 1 to 15 are used. When using the first metal terminal and the second metal terminal divided into multiple partial electrodes, the number of divisions of the first metal terminal and the second metal terminal is 2 or 4.

[0184] In addition, when using the first metal terminal and the second metal terminal divided into multiple partial electrodes, the shape of the ends of the partial electrodes is changed. In the table, "Z-shaped" represents the end shapes shown in Figure 5 , Figure 6 and Figure 12 , "U-shaped" represents the end shapes shown in Figure 7 and Figure 13 , "round shape" represents the end shapes shown in Figure 8 and Figure 14 , and "no fitting" represents the shapes shown in Figures 1-3 and Figures 9-11 .

[0185] The following evaluations are performed on various samples of the heater member obtained as described above.

[0186] <Thermal stress>

[0187] A voltage of 13.5 V is applied to each sample for 3 minutes, and it is confirmed whether cracking occurs in the honeycomb structure. The case where no visible cracking occurs is evaluated as qualified, and the case where visible cracking exists is evaluated as unqualified.

[0188] <Power-on heating characteristics>

[0189] A voltage of 13.5 V is applied to each sample for 3 minutes, and the temperature of each part of each sample is measured.

[0190] In No. 1 using the first metal terminal and the second metal terminal that are integral around the entire circumference of the honeycomb structure, the temperature (TC1) at the axial center position of the honeycomb structure is measured.

[0191] Using Nos. 2 to 13, which are divided into multiple partial electrodes, a scenario simulating cracking between the ends of the partial electrodes was simulated. Figure 16 The temperatures at the center positions (TC1-TC4) of each region R1-R4 and the temperature between the ends of some electrodes (TC5) were measured. A simulation of a cracked condition was performed as follows: The honeycomb structure was divided into the same number of segments as the first and second metal terminals, and then the first and second metal terminals were joined to the honeycomb structure. At this time, the first and second metal terminals were arranged such that the segmented surfaces of the honeycomb structure were located between the ends of some electrodes.

[0192] The case where the temperature (TC1 to TC4) at the center of the shaft or in each region R1 to R4 is above 80°C and below 150°C is evaluated as A; the case where the temperature is above 150°C and below 200°C is evaluated as B; the case where the temperature is above 200°C is evaluated as C; and the case where the temperature is below 80°C is evaluated as D.

[0193] In addition, the case where the maximum temperature difference (the difference between the highest temperature and the lowest temperature) of the temperature at the center of the shaft or in each region R1 to R4 is less than 20°C is evaluated as A, the case where the maximum temperature difference is 20°C or more but less than 50°C is evaluated as B, the case where the maximum temperature difference is 50°C or more but less than 100°C is evaluated as C, and the case where the maximum temperature difference is 100°C or more is evaluated as D.

[0194] Furthermore, cases where the temperature between the ends of some electrodes (TC5) is less than 150°C are evaluated as A, and cases where the temperature is 150°C or higher are evaluated as B.

[0195] The evaluation results are shown in the table below.

[0196] Table 1

[0197]

[0198] In Option No. 1, where the first and second metal terminals are integrally formed around the entire circumference of the honeycomb structure, cracking occurred in the honeycomb structure. On the other hand, in Options No. 2 to 13, where the first and second metal terminals are divided into multiple partial electrodes, no cracking occurred in the honeycomb structure. This result confirms that by having multiple partial electrodes in the first and second metal terminals, the stress acting on the honeycomb structure due to the thermal expansion difference between the metal terminals and the honeycomb structure can be mitigated, thereby reducing the likelihood of cracking in the honeycomb structure.

[0199] Furthermore, among Nos. 2 to 13, which use first and second metal terminals divided into multiple partial electrodes, Nos. 2 to 4, 6 to 8, and 10 to 12, which employ an interlocking shape, received an evaluation of temperature (TC1 to TC4) for regions R1 to R4. However, in Nos. 5, 9, and 13, which do not employ interlocking, the evaluation of temperature (TC1 to TC4) for regions R1 to R4 is D. This is believed to be because, in the case of "no interlocking," the segmented parts of the honeycomb structure undergo electrical separation and are not heated; however, by employing an interlocking shape, electrical separation of the segmented parts can be avoided. This result confirms the advantage of employing an interlocking shape.

[0200] Furthermore, among the Nos. 2-4, 6-8, and 10-12 that employ a mating shape, the temperature (TC5) between the ends of some electrodes in Nos. 2, 6, and 10, which have a "Z-shaped" mating shape, is rated A. However, in Nos. 3, 4, 7, 8, 11, and 12 that employ other mating shapes, the temperature (TC5) between the ends of some electrodes is rated B. This is believed to be because the "Z-shaped" shape ensures a relatively large width of the first protrusion, thereby preventing an increase in resistance at the ends. This result confirms the advantage of using a "Z-shaped" mating shape, where at least a portion of the end of the second portion electrode in the circumferential direction of the honeycomb structure enters the first recess of the first portion electrode.

Claims

1. A heater component comprising: A honeycomb structure having an outer peripheral wall and a partition wall disposed on the inner side of the outer peripheral wall and divided into multiple compartments forming a flow path extending from a first end face to a second end face, wherein at least the partition wall is made of a material having PTC properties. A first electrode and a second electrode, the first electrode and the second electrode being disposed on the first end face and the second end face, respectively; and A first metal terminal and a second metal terminal are disposed on the first electrode and the second electrode, respectively. At least one of the first metal terminal and the second metal terminal has a plurality of partial electrodes.

2. The heater component according to claim 1, wherein, Both the first metal terminal and the second metal terminal have the plurality of partial electrodes.

3. The heater component according to claim 1, wherein, The plurality of partial electrodes are arranged around the entire circumference of the honeycomb structure.

4. The heater component according to any one of claims 1 to 3, wherein, The plurality of partial electrodes includes a first partial electrode and a second partial electrode that are adjacent to each other in the circumferential direction of the honeycomb structure. The ends of the first part electrode and the second part electrode have an interlocking shape that fits into each other.

5. The heater component according to claim 4, wherein, The end of the first electrode portion has: a first protrusion that contacts the outer edge of the first electrode portion in the width direction of the honeycomb structure, and a first recess that contacts the extension line of the inner edge of the first electrode portion in the width direction of the honeycomb structure and is disposed adjacent to the first protrusion in the width direction of the honeycomb structure. In the circumferential direction of the honeycomb structure, at least a portion of the end of the second electrode enters the first recess.

6. A vehicle cabin purification system, comprising: At least one heater component as described in any one of claims 1 to 3; A power source for applying external voltage to the heater component; An inflow pipe connects the carriage and the first end face of the heater assembly; Outflow piping having a first path connecting the second end face of the heater component and the carriage; as well as A ventilator for directing air from the carriage through the inflow pipe to the first end face of the heater assembly.

7. The carriage purification system according to claim 6, wherein, In addition to the first path, the outflow piping also has a second path connecting the second end face of the heater component to the outside of the vehicle. The outflow piping has a switching valve capable of switching the airflow flowing through the outflow piping between the first path and the second path. The vehicle cabin purification system includes a control unit capable of switching between a first mode and a second mode. In this first mode, the external voltage from the power source is disconnected, allowing the air flowing through the outlet pipe to pass through the first path to switch the switching valve, and the ventilation fan is turned on. In this second mode, an external voltage from the power source is applied to switch the switching valve so that the air flowing through the outlet pipe passes through the second path, and the ventilation fan is turned on.

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