Heater case, heater device, and vehicle-mounted heater unit

Abstract

To provide a heater case capable of improving transfer efficiency of heat by bringing a heater and a housing into sufficient adhesion and proximity to each other without exerting adverse influences upon the heater, a heater device and an on-vehicle heater unit.SOLUTION: The present invention relates to a heater case in which a heater including a heating element is stored. The heater case comprises: a case main body including a passage in which a medium flows and having a contour of a rectangular column shape extending in a first direction; and a cylinder part provided along an outer surface of the case main body, extending in the first direction and including a space in which the heater is stored. The cylinder part includes: a sheath part provided substantially in parallel with an outer surface of the case main body while being spaced apart from the outer surface at a predetermined interval in a second direction orthogonal to the first direction; and a plurality of support parts, with a direction orthogonal to the first direction and the second direction as a third direction, provided between both ends of the sheath part and the outer surface in the third direction. Each of the plurality of support parts includes a narrowed portion extending in the first direction.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a heater case, a heater device, and an in-vehicle heater unit, and more particularly to a heater case, a heater device, and an in-vehicle heater unit that are applied to an insulated and waterproof heater that uses a heating element that generates heat when a voltage is applied. [Background technology]

[0002] Vehicle heaters that use a heating element that generates heat when voltage is applied are used as an auxiliary heater when engine heat cannot be used to heat the interior of the vehicle, such as immediately after the engine is started. A PTC (Positive Temperature Coefficient) element, for example, is used as the heating element for vehicle heaters. PTC elements have a positive temperature coefficient, which allows for easy temperature control and reduced power consumption.

[0003] The present inventors have proposed an insulated and waterproof heater as a heater with excellent insulating and waterproof properties, as disclosed in Patent Document 1. This insulated and waterproof heater includes a pair of electrode members sandwiching a heating element, an insulating sheet enclosing the heating element and the pair of electrode members, a cylindrical body that houses these, caps that close both ends of the cylindrical body, and a sealant that closes both ends of the hollow part of the cylindrical body.

[0004] Furthermore, the inventors of the present application have proposed an in-vehicle heater disclosed in Patent Document 2. This in-vehicle heater includes a pair of electrode members sandwiching a heating element, an insulating sheet enclosing the heating element and the pair of electrode members, a cylindrical body accommodating these, and a heat dissipation unit including at least fins. In this in-vehicle heater, the insulating sheet is sandwiched between the electrode surface of the heating element and the back side of the heat dissipation surface of the cylindrical body, and both edge portions of the insulating sheet overlap substantially parallel to the side surfaces of the heating element. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent No. 4388519 [Patent Document 2] Patent No. 4455473 Summary of the Invention [Problem to be solved by the invention]

[0006] In a heater device in which a heater is housed in a hollow portion of a cylindrical body, the heater housed in the hollow portion is sandwiched between the cylindrical bodies, bringing the heater and the cylindrical body into close contact. The closer the heater is to the housing, the more efficiently the heater's heat can be transferred to the housing. However, if the clamping force is too strong when the heater is sandwiched between the housing, the heater may be scratched or damaged. Therefore, a structure that allows the heater and the housing to be sufficiently close and in close contact without adversely affecting the heater is desired.

[0007] The present invention aims to provide a heater case, a heater device, and an in-vehicle heater unit that are inexpensive, easy to mass-produce, and capable of improving heat transfer efficiency by bringing the heater and the housing into sufficient close contact and proximity without adversely affecting the heater. [Means for solving the problem]

[0008] One aspect of the present invention is a heater case that houses a heater including a heat-generating element, and includes a case body having a flow path inside through which a medium flows and a prismatic outer shape extending in a first direction, and a tubular portion that is arranged along the outer surface of the case body, extends in the first direction, and has a space for accommodating the heater, and the tubular portion has an exterior portion that is arranged approximately parallel to the outer surface of the case body and at a predetermined interval in a second direction that is perpendicular to the first direction, and a direction perpendicular to the first and second directions is defined as a third direction, and a plurality of support portions that are arranged between each of the two ends of the exterior portion in the third direction and the outer surface, and each of the plurality of support portions has a narrowed portion that extends in the first direction from each of the inner and outer surfaces of the support portion.

[0009] According to this configuration, in the cylindrical portion that houses the heater in its internal space, each of the multiple support parts that make up the cylindrical portion has a narrowed portion. Therefore, when the heater is clamped by the cylindrical portion, even if each of the multiple support parts is pressed in the second direction, the support part does not protrude toward the heater, and contact between the support part and the heater can be avoided.

[0010] In the heater case, the constricted portions are preferably provided at intermediate portions in the second direction of each of the plurality of support portions. When the heater is clamped between the cylindrical portions, the support portions pressed in the second direction tend to bend at their intermediate portions. By providing the constricted portions at their intermediate portions, bending at their intermediate portions can be prevented.

[0011] In the heater case, it is preferable that the constricted portion is provided over the entire area of ​​each of the plurality of support parts in the first direction, thereby making it possible to prevent contact between the support parts and the heater over the entire area of ​​the support parts in the first direction.

[0012] In the heater case, it is preferable that the outer shape of the case body is rectangular, and that a cylindrical portion is provided on each of at least two opposing outer surfaces of the case body. This allows the heater to be housed in the cylindrical portion provided on each of the two opposing outer surfaces of the case body, and by applying a pressing force to the two cylindrical portions in directions facing each other, the heater can be sandwiched between each cylindrical portion with a single pressing force.

[0013] Another aspect of the present invention is a heater device including the heater case described above and a heater including a heating element housed in the space of the cylindrical portion of the heater case. With this configuration, when the heater including the heating element is housed in the space of the cylindrical portion, contact between the heater and the support portion of the cylindrical portion can be avoided.

[0014] In the heater device, the heating element may have one PTC (Positive Temperature Coefficient) element extending in the longitudinal direction of the space in the cylindrical portion. With such a configuration having one PTC element extending in the longitudinal direction of the space in the cylindrical portion, the PTC element can be housed in the cylinder efficiently (with good workability).

[0015] Another aspect of the present invention is an in-vehicle heater unit including the above-described heater device and an exterior case for housing the heater device. With this configuration, contact between the heater and the support portion of the cylindrical portion is avoided, resulting in a compact in-vehicle heater unit with good heat generation efficiency. [Effects of the Invention]

[0016] According to the present invention, it is possible to provide a heater case, a heater device, and an in-vehicle heater unit that are inexpensive, easy to mass-produce, and can increase heat transfer efficiency by bringing the heater and the housing into sufficient close contact and proximity without adversely affecting the heater. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 2 is a perspective view illustrating the configuration of a heater case according to the present embodiment. [Figure 2] 10(a) and 10(b) are perspective views illustrating the configuration of a heater. [Figure 3] 2 is a schematic view of the heater case according to the present embodiment as viewed in a first direction. FIG. [Figure 4] FIG. 4 is an enlarged view of part A in FIG. [Figure 5] FIG. 10 is an enlarged view showing a comparative example. [Figure 6] 1(a) to 1(c) are diagrams illustrating the manufacturing process of the heater device. [Figure 7] 1(a) to 1(c) are diagrams illustrating the manufacturing process of the heater device. [Figure 8] FIG. 1 is a perspective view illustrating a heater device. [Figure 9]1 is a schematic cross-sectional view illustrating the configuration of an in-vehicle heater unit according to an embodiment of the present invention; [Figure 10] FIG. 1 is a schematic diagram showing an application example (part 1) of an in-vehicle heater unit. [Figure 11] FIG. 10 is a schematic diagram showing an application example (part 2) of the in-vehicle heater unit. [Figure 12] FIG. 10 is a schematic diagram showing an application example (part 3) of the in-vehicle heater unit. [Figure 13] FIG. 10 is a schematic diagram showing an application example (part 3) of the in-vehicle heater unit. DETAILED DESCRIPTION OF THE INVENTION

[0018] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In the following description, the same components will be designated by the same reference numerals, and the description of components that have already been described will be omitted as appropriate.

[0019] (Heater case configuration) FIG. 1 is a perspective view illustrating the configuration of a heater case according to this embodiment. 2(a) and (b) are perspective views illustrating the configuration of the heater. 1, 2(a) and 2(b), the heater case 1 according to this embodiment is a cylindrical body that houses a heater 100 including a heat generating element 110. Such a cylindrical heater case 1 is manufactured by extrusion molding using a metal material (e.g., aluminum).

[0020] Here, the direction in which the cylindrical body extends in the heater case 1 is referred to as the first direction, the direction perpendicular to the first direction is referred to as the second direction, and the direction perpendicular to the first and second directions is referred to as the third direction. In this embodiment, of the mutually perpendicular X, Y, and Z directions, the X direction is referred to as the first direction, one of the Y and Z directions is referred to as the second direction, and the other is referred to as the third direction.

[0021] The heater case 1 includes a case body 10 extending in the X direction and a tubular portion 11 provided along an outer surface 10a of the case body 10. The case body 10 has a flow path 15 therein through which a medium (liquid or gas) flows, and has a rectangular prism-like outer shape extending in the X direction. In this embodiment, the case body 10 has a rectangular prism-like outer shape and four outer surfaces 10a.

[0022] The cylindrical portion 11 is provided along the outer surface 10a of the case body 10 and extends in the X direction. The cylindrical portion 11 extends over the entire area of ​​the outer surface 10a of the case body 10 in the X direction. In this embodiment, the cylindrical portion 11 is provided on each of the four outer surfaces 10a of the case body 10.

[0023] The tubular portion 11 has an exterior portion 111 and a support portion 112. The exterior portion 111 is disposed substantially parallel to the outer surface 10a of the case body 10 at a predetermined interval in the second direction. A plurality of support portions 112 are disposed at both ends of the exterior portion 111 in the third direction. Here, on the outer surface 10a along the XY plane, the Z direction is the second direction and the Y direction is the third direction. On the outer surface 10a along the XZ plane, the Y direction is the second direction and the Z direction is the third direction. For convenience of explanation, the outer surface 10a along the XY plane and the tubular portion 11 disposed on this outer surface 10a will be described as an example. In this case, the Z direction is the second direction and the Y direction is the third direction.

[0024] The cylindrical portion 11, which is composed of an exterior portion 111 and support portions 112, is provided so as to surround the outer surface 10a of the case body 10. The two support portions 112 provided at both ends of the exterior portion 111 in the Y direction serve as pillars for providing a predetermined space between the exterior portion 111 and the outer surface 10a. In the heater case 1 according to this embodiment, each of the multiple support portions 112 is provided with a constricted portion 115 extending in the X direction. The constricted portion 115 will be described in detail later.

[0025] The support portion 112 defines a certain gap between the outer surface 10a and the exterior portion 111, and the heater 100 is accommodated in this gap. As shown in Fig. 2, the heater 100 includes a heating element 110, a pair of electrode portions 120 that sandwich the heating element 110 therebetween, and an insulating sheet 130.

[0026] The heating element 110 is an element that generates heat when a voltage is applied. For example, a PTC (Positive Temperature Coefficient) element 110P is used as the heating element 110. The heating element 110 is configured by forming electrode layers (conductive films that are electrically connected to the pair of electrode portions 120) (not shown) on the front and back surfaces of the PTC element 110P. The PTC element 110P has a positive temperature coefficient characteristic. That is, when the temperature rises above the Curie point, the resistance increases, limiting any further temperature rise. Using the PTC element 110P as the heating element 110 makes it possible to easily control the temperature and reduce power consumption.

[0027] The positive temperature coefficient of the PTC element 110P can be changed by adding a small amount of rare earth elements to barium titanate (BaTiO3). In this embodiment, as shown in Figure 2(b), a heating element 110 made of a thin plate-shaped PTC element 110P is used. As an example, one PTC element 110P is thin plate-shaped with a thickness of approximately 2.5 millimeters (mm), a width of approximately 25 mm, and a length of approximately 90 mm.

[0028] When a PTC element is used as the heating element 110, it is common for the PTC element to be a roughly rectangular parallelepiped (hereinafter referred to as a "rectangular parallelepiped type") element with a thickness of approximately 3 mm, a width of approximately 24 mm, and a length of approximately 15 mm. In order to obtain a predetermined output using a rectangular parallelepiped type PTC element, it is necessary to arrange multiple PTC elements side by side. Although it is possible to arrange multiple small rectangular parallelepiped type PTC elements in this way, if a heating element 110 is used that is a thin plate-shaped PTC element 110P (hereinafter referred to as a "thin plate type") as shown in Figure 2(b), it is possible to obtain a predetermined output with just one PTC element 110P.

[0029] When using a thin plate type PTC element 110P, only one PTC element 110P is needed, so there are no gaps between the PTC elements as there are when multiple rectangular parallelepiped type PTC elements are lined up.As a result, the installation area required to obtain the same output is smaller with one thin plate type than with multiple rectangular parallelepiped types, allowing for the device to be made more compact.

[0030] The dimensions of the thin plate type PTC element 110P are, for example, a thickness t of 1.5 mm to 3 mm, a width W of 20 mm to 30 mm, and a length L of 30 mm or more. Furthermore, in the thin plate type PTC element 110P, the ratio of the width W to the thickness t (W / t) is approximately 10 or more, and the ratio of the length L to the thickness t (L / t) is approximately 20 or more.

[0031] The thin-plate type PTC element 110P has fewer longitudinal gaps than the rectangular parallelepiped type PTC element, and the density of the material containing barium titanate (BaTiO3) is higher and more uniform than that of the rectangular parallelepiped type. Therefore, even if the thickness t is thin (for example, about 1.5 mm), a sufficient withstand voltage can be obtained. For example, the withstand voltage of a thin-plate type PTC element 110P with a thickness t of 2.5 mm is approximately 350 V or more and 500 V or less. On the other hand, to obtain the same withstand voltage by arranging multiple rectangular parallelepiped type PTC elements (for example, six), the thickness of the rectangular parallelepiped type PTC elements must be 3.5 mm or more.

[0032] An electrode layer (not shown) is provided on each of the front and back surfaces (front and back surfaces in the thickness direction) of the heating element 110. The electrode layer is made of a metal such as silver (Ag) or aluminum (Al). The electrode layer is formed by, for example, spraying these metals onto the front and back surfaces of the heating element 110. The electrode layer is in ohmic contact with the heating element 110.

[0033] The heating element 110 is sandwiched between a pair of electrode sections 120. The electrode sections 120 are made of, for example, stainless steel or aluminum (Al). The thickness of the portion (plate-shaped portion) of the electrode section 120 that contacts the heating element 110 is approximately 0.2 mm or more and 0.5 mm or less. The electrode section 120 and the electrode layer of the heating element 110 are bonded together with, for example, a silicone-based adhesive that has excellent electrical and thermal conductivity. A conductive cable 140 is connected to each of the pair of electrode sections 120.

[0034] The insulating sheet 130 is an insulating sheet material that covers the periphery of the pair of electrode units 120. That is, the insulating sheet 130 is provided so as to wrap the periphery of the pair of electrode units 120 that sandwich the plurality of heating elements 110 therebetween. The material of the insulating sheet 130 is preferably a polyimide film that is flexible, thermally conductive, and electrically insulating, and has a thickness of, for example, about 0.05 mm.

[0035] Next, the details of the constricted portion 115 provided in the support portion 112 will be described. FIG. 3 is a schematic view of the heater case according to this embodiment as viewed in a first direction. FIG. 4 is an enlarged view of part A in FIG. FIG. 5 is an enlarged view showing a comparative example. 3 and 4, the constricted portion 115 provided in the support portion 112 is a narrow portion provided in the middle portion of the support portion 112 in the Z direction (second direction). The constricted portion 115 is provided so as to be concave from both sides of the support portion 112 in the Y direction (third direction) toward the center of the support portion 112. In other words, the width of the support portion 112 is set so as to narrow from both sides of the inner and outer surfaces (inner surface 112a and outer surface 112b) in the Y direction (third direction) toward the inside of the support portion 112 at the constricted portion 115.

[0036] The heater 100 is inserted into the space of the cylindrical portion 11, and the heater 100 is sandwiched within the space by pressing the cylindrical portion 11. When sandwiching the heater 100 within the cylindrical portion 11, the exterior portion 111 of the cylindrical portion 11 is pressed in the Z direction (second direction) to crush the cylindrical portion 11. At this time, since the support portion 112 has the constricted portion 115, even if the support portion 112 is crushed, it does not protrude toward the heater 100. In other words, the support portion 112 shrinks (crushes) in the Z direction (second direction) without bending, and the heater 100 can be sandwiched within the space of the cylindrical portion 11. This makes it possible to avoid contact between the support portion 112 and the heater 100 within the space of the cylindrical portion 11, even if the cylindrical portion 11 is pressed.

[0037] In the heater case 1B according to the comparative example shown in FIG. 5, the support portion 112 does not have a constricted portion 115. When a pressing force is applied to this support portion 112 in the Z direction (second direction) and the support portion 112 is crushed, the support portion 112 will bend midway. If this bend in the support portion 112 protrudes toward the heater 100, there is a possibility that the support portion 112 will come into contact with the heater 100. If the support portion 112 comes into contact with the heater 100 when crushed, there is a risk that the insulating sheet 130 will be torn or the heating element 110 will be damaged. Because the support portions 112 are located on both sides of the heater 100, the possibility of the support portions 112 coming into contact with the heater 100 increases when each support portion 112 bends inward.

[0038] In the heater case 1B of the comparative example, in order to avoid such contact between the support portion 112 and the heater 100, it is possible to design the space in the tubular portion 11 to be wider so that the support portion 112 will not come into contact with the heater 100 even if it bends and protrudes toward the heater 100, and to provide sufficient clearance between the support portion 112 and the heater 100.

[0039] However, increasing the width of the cylindrical portion 11 increases the size of the cylindrical portion 11, which in turn increases the size of the heater case 1, hindering space saving. In addition, increasing the width of the cylindrical portion 11 increases the distance between the support portion 112 and the heater 100, making it impossible to efficiently transfer heat from the heater 100 to the support portion 112. In order to efficiently transfer heat from the heater 100 to the support portion 112, it is necessary to minimize the gap between the heater 100 and the cylindrical portion 11 within the space of the cylindrical portion 11. Because the exterior portion 111 and the heater 100 are in close contact with each other, it is desirable to minimize the gap between the support portion 112 and the heater 100.

[0040] As shown in FIG. 4, in the heater case 1 according to this embodiment, a constricted portion 115 is provided in the support portion 112. Therefore, even if a pressing force is applied to the support portion 112 in the Z direction (second direction) and the support portion 112 is crushed, the support portion 112 is crushed at the narrow constricted portion 115 without bending along the way, and does not protrude toward the heater 100.

[0041] In particular, if the constricted portions 115 are provided with approximately the same amount of constriction from both sides of the support portion 112 toward the center, the support portion 112 will be crushed in a balanced manner along the Z direction (second direction).

[0042] Furthermore, if the constricted portion 115 is provided over the entire area of ​​the support portion 112 in the X direction, the support portion 112 will be crushed in a balanced manner over the entire X direction, and will not protrude toward the heater 100 at any position in the X direction.

[0043] By providing such a constricted portion 115 in the support portion 112, the width of the tubular portion 11 (the internal dimension of the two support portions 112) can be made approximately equal to the width of the heater 100. This makes it possible to reduce the overall space required for the heater case 1. Furthermore, the gap between the heater 100 and the support portion 112 can be minimized, allowing heat to be transferred efficiently from the heater 100 to the support portion 112.

[0044] The support portions 112 extend in the X direction (the longitudinal direction of the heater 100) and are provided on both sides of the heater 100, so even a slight difference in the distance between the heater 100 and the support portions 112 has a significant impact on the transfer of heat from the heater 100 to the support portions 112.

[0045] For example, in the case of the heater case 1B according to the comparative example shown in FIG. 5, it is necessary to provide a gap between the heater 100 and the support portion 112, so the gap between the heater 100 and the support portion 112 is approximately 1 mm wider than in the heater case 1 according to the present embodiment shown in FIG. 4. In other words, in the heater case 1 according to the present embodiment, the gap between the heater 100 and the support portion 112 can be narrowed by approximately 1 mm (a total of approximately 1.5 mm to 2.5 mm on both sides of the heater 100) compared to the heater case 1B according to the comparative example. This difference improves the efficiency of heat transfer from the heater 100 to the heater case 1 by approximately 10% per heater 100. When four heaters 100 are provided, the efficiency of heat transfer from the heaters 100 to the heater case 1 improves by a total of approximately 40%.

[0046] (Configuration of heater device) Next, the heater device according to this embodiment will be described. 6(a) to 7(c) are diagrams illustrating the manufacturing process of the heater device. FIG. 7 is a perspective view illustrating the configuration of the heater device. To manufacture the heater device 300, first, a heater case 1 is prepared as shown in Fig. 6(a). Next, as shown in Fig. 6(b), a heater 100 is inserted into each of the spaces between the two opposing cylindrical portions 11 of the heater case 1. Before the cylindrical portions 11 are crushed, a gap for inserting the heater 100 is secured between the exterior portion 111 and the outer surface 10a. At this time, if one heater 100 using a thin-plate type PTC element 110P is assembled into one cylindrical portion 11, the workability of assembling the heater 100 is improved.

[0047] Next, as shown in FIG. 6( c), pressing forces in opposite directions are applied to each of the two opposing cylindrical portions 11 into which the heater 100 has been inserted. For example, one cylindrical portion 11 is placed face down on a surface plate, and pressing force is applied from above to the upper cylindrical portion 11. As a result, pressing force is applied from above to the upper cylindrical portion 11, and a resistance force to the pressing force is applied from the surface plate to the lower cylindrical portion 11. Therefore, both the upper and lower cylindrical portions 11 can be crushed with a single pressing force. As the cylindrical portions 11 are crushed, the heater 100 is sandwiched within the space of the cylindrical portions 11. At this time, because the constricted portion 115 is provided in the support portion 112, the support portion 112 is crushed straight without protruding toward the heater 100, and the support portion 112 and the heater 100 do not come into contact with each other.

[0048] Next, as shown in Fig. 7(a), the heater 100 is inserted into the space between the remaining two cylindrical portions 11, and as shown in Fig. 7(b), pressing forces are applied to each of the two cylindrical portions 11 in opposite directions in the same manner as before. As the two cylindrical portions 11 are crushed, the heater 100 is sandwiched within the space between the cylindrical portions 11. In this way, a heater device 300 is manufactured in which the heater 100 is incorporated into the heater case 1, as shown in Fig. 7(c).

[0049] FIG. 8 is a perspective view illustrating an example of a heater device. 8, in heater device 300, seals 310 and pipes 320 are attached to both ends of heater case 1. By sending the medium from pipe 320 to flow path 15, heat from heater 100 can be transferred from heater case 1 to the medium.

[0050] In addition, by incorporating one PTC element 110P (thin plate type) extending in the longitudinal direction (X direction) of the space of one cylindrical portion 11 into one cylindrical portion 11 of the heater case 1, an inexpensive, high-performance heater device 300 can be realized.

[0051] That is, in the heater case 1 according to this embodiment, the support portion 112 of the cylindrical portion 11 is provided with the constricted portion 115, so that the internal space of the cylindrical portion 11 can be effectively utilized and a wide PTC element 110P can be incorporated. This allows for the construction of a compact yet high-output heater device 300.

[0052] Furthermore, by using a thin-plate type PTC element 110P, it is only necessary to incorporate one PTC element 110P into one tubular portion 11, which greatly simplifies the manufacturing process compared to incorporating multiple PTC elements side by side, thereby improving mass productivity.

[0053] Furthermore, the thin-plate type PTC element 110P can be fired at a lower temperature than a rectangular parallelepiped type PTC element, thereby reducing firing costs (electricity costs, etc.). For these reasons, by incorporating the thin-plate type PTC element 110P into one cylindrical portion 11 of the heater case 1, it is possible to mass-produce inexpensive, high-performance heater devices 300.

[0054] In the heater device 300 shown in FIG. 8, a seal 310 and a pipe 320 are provided to send a medium mainly consisting of a liquid to the flow path 15, but in a heater device 300 that uses air (gas) as a medium, the seal 310 and the pipe 320 do not necessarily have to be provided.

[0055] (Configuration of an in-vehicle heater unit) Next, the vehicle heater unit according to this embodiment will be described. FIG. 9 is a schematic cross-sectional view illustrating the configuration of the in-vehicle heater unit according to this embodiment. As shown in FIG. 9, the in-vehicle heater unit 500 includes the heater device 300 configured using the heater case 1 according to this embodiment, and an exterior case 501 that houses the heater device 300.

[0056] Next, an application example of the in-vehicle heater unit 500 according to this embodiment will be described. FIG. 10 is a schematic diagram showing an application example (part 1) of an in-vehicle heater unit. FIG. 10 shows a specific example in which the above-described in-vehicle heater unit 500 is attached to a vehicle equipped with an engine 5 such as an automobile. An exterior case 501 of the vehicle-mounted heater unit 500 is connected to a circulation path 6. The circulation path 6 has pipes 6a to 6d. Pipe 6a connects the exterior case 501 and the heater core 2H. Pipe 6b connects the heater core 2H and the hydraulic pump 3. Pipe 6c connects the hydraulic pump 3 and the three-way valve 4. Pipe 6d connects the three-way valve 4 and the exterior case 501. Pipe 6d is connected to an inlet 5011 of the exterior case 501, and pipe 6a is connected to an outlet 5012 of the case.

[0057] Circulation path 6 and outer case 501 are also connected to engine 5 via pipes 7a and 7b. When three-way valve 4 blocks communication between pipes 6c and 7a and connects pipes 6c and 6d, if hydraulic pump 3 is driven, liquid circulates through outer case 501 and circulation path 6 in the direction indicated by arrow A11 in FIG.

[0058] At this time, power is supplied to the vehicle-mounted heater unit 500 from a battery mounted on the vehicle, causing the vehicle-mounted heater unit 500 to generate heat and overheat the liquid in the exterior case 501. The hot water generated by this overheating is supplied to the heater core 2H through the outlet 5012 and the pipe 6a.

[0059] The hot water supplied to the heater core 2H flows through pipes provided in the heater core 2H. Gas (air) is blown into the heater core 2H from the blower 8. The heat of the hot water flowing through the pipes of the heater core 2H is transferred to the gas blown from the blower 8 via heat transfer surfaces such as fins provided in the heater core 2H. This causes hot air to be blown into the vehicle interior. This mode is selected when the exhaust heat of the engine 5 cannot be used, for example, when the engine 5 is started.

[0060] After engine 5 starts, by switching three-way valve 4 to connect pipes 6c and 7a and block pipes 6c and 6d, the liquid is supplied to engine 5 and functions as coolant for engine 5. The flow of liquid at this time is shown by arrow A12 in FIG. 10. Hot water that passes through engine 5 and is heated by heat exchange with engine 5 is supplied to heater core 2H via pipes 7b and 6d, inlet 5011, inside exterior case 501, outlet 5012, and pipe 6a. Therefore, in this mode, hot water can be supplied to heater core 2H without energizing (generating heat) in-vehicle heater unit 500, and hot air can be sent into the vehicle interior by driving blower 8.

[0061] The vehicle-mounted heater unit 500 according to this embodiment can be directly incorporated into an existing vehicle-mounted hot water generating system that uses coolant heated by exhaust heat from the engine 5 and used.

[0062] FIG. 11 is a schematic diagram showing an application example (part 2) of the in-vehicle heater unit. FIG. 11 shows a specific example in which the above-described in-vehicle heater unit 500 is attached to a vehicle that does not have an engine 5, such as an electric vehicle. In a vehicle that does not have an engine 5, such as an electric vehicle, a motor M is used as a drive source instead of the engine 5. In this case, an exterior case 501 of the vehicle-mounted heater unit 500 is connected to a circulation path 6. The three-way valve 4 and the pipes 7a and 7b shown in FIG. 10 are not connected to the circulation path 6.

[0063] Because the exhaust heat of the motor M is not used, warm air is sent into the vehicle interior in the same manner as the mode selected when the exhaust heat of the engine 5 cannot be used, such as when starting the engine 5, as described above. That is, when the hydraulic pump 3 is driven, liquid circulates inside the exterior case 501 and through the circulation path 6 in the direction indicated by the arrow A13 in FIG.

[0064] At this time, power is supplied from a battery mounted on the vehicle to the vehicle-mounted heater unit 500 in the exterior case 501, causing the vehicle-mounted heater unit 500 to generate heat and overheat the liquid in the exterior case 501. The hot water generated by this overheating is supplied to the heater core 2H through the outlet 5012 and the pipe 6a. Then, the heat of the hot water flowing through the pipe of the heater core 2H is transferred to the gas blown by the blower 8, and hot air is blown into the vehicle interior.

[0065] The in-vehicle heater unit 500 according to this embodiment can be incorporated into a hot air generating system for a vehicle that does not use an engine 5, such as an electric vehicle.

[0066] 12 and 13 are schematic diagrams showing an application example (part 3) of the in-vehicle heater unit. 12 shows an example in which the above-described vehicle heater unit 500 is applied to a heat pump system. The heat pump system includes two heat exchangers 101 and 105, an expansion valve 103, a compressor 107, and the vehicle heater unit 500 of the above-described embodiment.

[0067] A refrigerant (a medium such as non-fluorocarbon gas) circulates within this system. The refrigerant is compressed by compressor 107 and sent in the form of a high-temperature, high-pressure gas through pipe 108 to heat exchanger 101. Then, in heat exchanger 101, the refrigerant is condensed by heat exchange with the medium (liquid, gas) to be heated, and sent in the form of a high-temperature, high-pressure liquid through pipe 102 to expansion valve 103.

[0068] The refrigerant expanded by the expansion valve is sent in a low-temperature, low-pressure liquid state through pipe 104 to heat exchanger 105. The refrigerant is evaporated by heat exchange with the atmosphere or the like in heat exchanger 105, and sent in a low-temperature, low-pressure gas state through pipe 106 to compressor 107, and the cycle described above is repeated.

[0069] The vehicle heater unit 500 according to this embodiment is connected to the pipe 106 between the heat exchanger 105 and the compressor 107, and heats the low-pressure gas sent from the heat exchanger 105 to the compressor 107. That is, the vehicle heater unit 500 assists in heating the refrigerant in the path between the heat exchanger 105 and the compressor 107.

[0070] In the vehicle heater unit 500, low-pressure gas flows through the flow path 15 described above, and the gas is heated by the heating element 110. That is, the vehicle heater unit 500 is effective not only for heating liquids but also for heating gases.

[0071] 13, the vehicle heater unit 500 may be connected to the pipe 108 between the compressor 107 and the heat exchanger 101 to heat the liquid flowing through the pipe 108. Although not shown, the vehicle heater unit 500 may also be connected to the pipe 102. In a heat pump system, two or more vehicle heater units 500 may be connected to appropriate pipes. The vehicle heater unit 500 may be connected to any of the pipes 102, 106, and 108 in the heat pump system, but is preferably connected to the low-pressure pipe 106.

[0072] As described above, according to this embodiment, it is possible to provide a heater case 1, a heater device 300, and an in-vehicle heater unit 500 that are inexpensive, easy to mass-produce, and can bring the heater 100 and the tubular portion 11 into sufficient close contact and proximity to each other, without adversely affecting the heater 100, thereby increasing the heat transfer efficiency.

[0073] Although the present embodiment and its application examples (variations and specific examples) have been described above, the present invention is not limited to these examples. For example, while the case body 10 has a rectangular prism-shaped outer shape, it may have a polygonal prism-shaped outer shape other than a rectangular prism-shaped outer shape. Furthermore, while the example has been described in which the tubular portion 11 is provided on all outer surfaces 10a of the case body 10, it is sufficient that the tubular portion 11 is provided on at least one outer surface 10a. Furthermore, while the example has been described in which one PTC element 110P (thin plate type) is incorporated into one tubular portion 11, multiple thin plate type PTC elements 110P may be incorporated into one tubular portion 11. For example, if two thin plate type PTC elements 110P are arranged along the longitudinal direction of the tubular portion 11, one PTC element 110P can be inserted into each opening of the tubular portion 11, thereby efficiently accommodating two PTC elements 110P in the tubular portion 11.

[0074] Furthermore, any combination of features of the above-described embodiments or their application examples (variations, specific examples) to which a person skilled in the art appropriately adds, deletes, or modifies components is also included within the scope of the present invention, as long as it includes the gist of the present invention. [Industrial Applicability]

[0075] The present invention can be suitably used as a voltage-driven heating device for automobiles (electric vehicles, hybrid vehicles, etc.), trains and other moving objects, heating of industrial equipment, heaters for water tanks, and the like. [Explanation of symbols]

[0076] 1,1B...Heater case 2H...Heater core 3...Hydraulic pump 4...Three-way valve 5...Engine 6...Circulation path 6a~6d…Pipe line 7a~7b…Pipe line 8...Ventilation device 10...Case body 10a…External surface 11...Cylinder part 15...Flow path 100...Heater 101...Heat exchanger 102...Piping 103...Expansion valve 104...Plumbing 105...Heat exchanger 106...Plumbing 107...Compressor 108...Plumbing 110...heating element 110P...PTC element 111...Exterior part 112...Support part 112a…Inner surface 112b…outer surface 115...waist 120...Electrode part 130...Insulating sheet 140...Conductive cable 300...Heater device 310...Sealing body 320...Pipe 500...In-vehicle heater unit 501...Outer case 5011...Inlet 5012…Outlet M...Motor t...thickness W…width L...length

Claims

1. A metal heater case that houses a heater including a heat generating element, a case body having a flow path therein through which a medium flows and having a rectangular column-shaped outer shape extending in a first direction; a cylindrical portion that is provided integrally with the case body along an outer surface of the case body, extends in the first direction, has a space that accommodates the heater, and is crushed by pressure to sandwich the heater within the space; Equipped with The cylindrical portion is an exterior portion provided substantially parallel to the outer surface of the case body at a predetermined interval in a second direction perpendicular to the first direction; a direction perpendicular to the first direction and the second direction is defined as a third direction, and a plurality of support portions are provided between the outer surface and both end portions of the exterior portion in the third direction, Each of the plurality of support portions has a constricted portion extending in the first direction, the constricted portion being recessed in an approximately V-shape from both sides of the inner and outer surfaces of the support portion toward the center, thereby narrowing the width.

2. The heater case according to claim 1 , wherein the constricted portions are provided at intermediate portions in the second direction of each of the plurality of support portions, with the constricted portions being of approximately equal magnitude on both sides.

3. The heater case according to claim 1 or 2, wherein the constricted portion is provided over the entire area of ​​each of the plurality of support portions in the first direction.

4. The outer shape of the case body is rectangular, The heater case according to claim 1 , wherein the cylindrical portion is provided on each of at least two opposing outer surfaces of the case body.

5. The heater case according to claim 1; a heater that is accommodated in the space of the cylindrical portion of the heater case and includes a heat generating element; A heater device comprising:

6. The heater device according to claim 5 , wherein the heat generating element includes one PTC (Positive Temperature Coefficient) element extending in the longitudinal direction of the space of the cylindrical portion.

7. The heater device according to claim 5 or 6, an exterior case that houses the heater device; An in-vehicle heater unit equipped with the above.

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