Automotive heater and automotive heating device

Abstract

An automotive heater according to an embodiment of the present invention is for heating a gas in the interior of a vehicle. The automotive heater comprises: a substrate exhibiting a board shape, with a first surface and a second surface opposite the first surface, and extending in one direction; a heating element provided on the first-surface side and extending in the direction in which the substrate extends; a first detection unit which is provided on the first-surface side and which detects the temperature of the substrate; and a first protective unit covering the first-surface side.

Description

Vehicle heater and vehicle heating device

[0001] FIELD An embodiment of the present invention relates to a vehicle heater and a vehicle heating device.

[0002] Conventionally, heat (exhaust heat) from engine coolant has been used as a heat source for heating the interior of a vehicle. However, in recent years, as engine efficiency has increased, the temperature of the coolant has decreased, making it difficult to use engine exhaust heat as a heat source for heating the interior of a vehicle. Therefore, heaters that utilize Joule heat have become increasingly popular, along with or instead of heaters that utilize engine exhaust heat. In this case, heaters that utilize Joule heat are powered by a battery installed in the vehicle. Therefore, using a heater that utilizes Joule heat has the problem of reducing the energy stored in the battery that can be allocated to driving, etc.

[0003] Furthermore, in recent years, engines have increasingly been replaced by motors as the power source for vehicles. For example, hybrid electric vehicles (HEVs) equipped with both engines and motors and electric vehicles (EVs) equipped with only motors are becoming increasingly popular. If such vehicles were to use heaters that utilize Joule heat, the amount of energy allocated to driving would be further reduced, making it even more difficult to extend the driving distance. For this reason, vehicle heaters are required to have improved heat generation efficiency.

[0004] Another problem is that vehicles must accommodate many components in a limited space, so vehicle heaters are required to be space-saving.

[0005] Therefore, there has been a demand for the development of a technology that can improve heat generation efficiency and also save space.

[0006] JP 2014-54934 A JP 2023-45947 A

[0007] The problem to be solved by the present invention is to provide a vehicle heater and a vehicle heating device that can improve heat generation efficiency and can save space.

[0008] A vehicle heater according to an embodiment is a vehicle heater for heating gas inside a vehicle, and includes: a plate-shaped substrate having a first surface and a second surface opposite the first surface and extending in one direction; a heating element provided on the first surface and extending in the same direction as the substrate; a first detector provided on the first surface and detecting the temperature of the substrate; and a first protector covering the first surface.

[0009] According to the embodiments of the present invention, it is possible to provide a vehicle heater and a vehicle heating device that can improve heat generation efficiency and achieve space saving.

[0010] 1 is a schematic diagram of a vehicle heater according to the present embodiment, as viewed from one side in the Z direction. It is a schematic diagram of a vehicle heater according to the present embodiment, as viewed from the other side in the Z direction. It is a schematic cross-sectional view of the vehicle heater in FIG. 1, taken along line A-A. It is a schematic cross-sectional view for illustrating a vehicle heater according to another embodiment. It is a schematic cross-sectional view for illustrating a vehicle heater according to another embodiment. It is a schematic cross-sectional view for illustrating a vehicle heater according to another embodiment. It is a schematic cross-sectional view for illustrating a vehicle heater according to another embodiment. It is a schematic cross-sectional view of the vehicle heater in FIG. 8, taken along line B-B, which is a schematic view for illustrating a vehicle heater according to another embodiment. It is a schematic cross-sectional view for illustrating a heating device according to the present embodiment. (a) and (b) are schematic cross-sectional views of the heating device in FIG. 10, taken along line C-C. It is a schematic cross-sectional view for illustrating a heating device according to another embodiment.

[0011] Hereinafter, embodiments will be illustrated with reference to the drawings. In each drawing, similar components are designated by the same reference numerals, and detailed descriptions thereof will be omitted where appropriate. In each drawing, arrows X, Y, and Z represent three mutually orthogonal directions. For example, the longitudinal direction of the substrate is the X direction, the lateral direction (width direction) of the substrate is the Y direction, and the direction perpendicular to the surface of the substrate (thickness direction) is the Z direction.

[0012] (Vehicle Heater) A vehicle heater 1 according to this embodiment is a vehicle heater that heats gas inside a vehicle. FIG. 1 is a schematic diagram of the vehicle heater 1 according to this embodiment, viewed from one side in the Z direction. FIG. 2 is a schematic diagram of the vehicle heater 1, viewed from the other side in the Z direction. FIG. 3 is a schematic cross-sectional view of the vehicle heater 1 (hereinafter simply referred to as heater 1) in FIG. 1, taken along line A-A. As shown in FIGS. 1 to 3, the heater 1 includes, for example, a substrate 10, an insulating portion 20 (corresponding to an example of a first insulating portion), a heat generating portion 30, a wiring portion 40, a protective portion 50 (corresponding to an example of a first protective portion), an insulating portion 60 (corresponding to an example of a second insulating portion), a detecting portion 70 (corresponding to an example of a first detecting portion), a wiring portion 80, and a protective portion 90 (corresponding to an example of a second protective portion).

[0013] The substrate 10 is plate-shaped and has a surface 10a (corresponding to an example of a first surface) and a surface 10b (corresponding to an example of a second surface) opposite to the surface 10a. The substrate 10 extends in one direction (e.g., the X direction). The planar shape of the substrate 10 is, for example, an elongated rectangle. The planar shape of the substrate 10 can be appropriately changed depending on the shape of the housing 101 of the vehicle heating device 101 in which the heater 1 is housed. For example, the planar shape of the substrate 10 may be a curved shape such as an L-shape, or a frame-like shape such as an annular shape. However, if the planar shape of the substrate 10 is rectangular, the manufacture of the substrate 10 and therefore the manufacture of the heater 1 will be easier.

[0014] The thickness of the substrate 10 is, for example, about 0.3 mm to 1.0 mm. The width dimension W (short-side dimension; dimension in the Y direction) of the substrate 10 is, for example, about 5 mm to 15 mm. The length L (long-side dimension; dimension in the X direction) of the substrate 10 can be changed as appropriate depending on the size of the housing 101 of the vehicle heating device 100 in which the heater 1 is housed, etc.

[0015] The substrate 10 is made of a heat-resistant material with high thermal conductivity, such as a metal such as stainless steel or an aluminum alloy, or an inorganic material such as ceramics.

[0016] In this case, the thermal conductivity of metal is higher than that of inorganic materials such as ceramics. Therefore, if the substrate 10 is made of metal, the time required for the heater 1 to heat up can be shortened. Furthermore, it is also possible to improve the rigidity of the substrate 10 and reduce manufacturing costs. Generally, inorganic materials such as ceramics have insulating properties, so if the substrate 10 is made of an inorganic material, the insulating portions 20 and 60, which will be described later, can be omitted. The heater 1 illustrated in FIGS. 1 to 3 includes a substrate 10 containing metal and an insulating portion 20.

[0017] As shown in FIGS. 1 and 3 , the insulating portion 20 has insulating properties and is provided on the surface 10 a of the substrate 10. The insulating portion 20 extends in the longitudinal direction (X direction) of the substrate 10. The insulating portion 20 is provided to insulate the conductive substrate 10 from the heat generating portion 30 and the wiring portion 40. Therefore, the insulating portion 20 covers at least the area of ​​the surface 10 a of the substrate 10 where the heat generating portion 30 and the wiring portion 40 are provided. The thickness of the insulating portion 20 is not particularly limited as long as insulation can be ensured. The insulating portion 20 is formed from a material that is heat resistant and insulating. The insulating portion 20 can be formed from, for example, ceramics or glass materials. The insulating portion 20 can be formed by, for example, thermal spraying or firing.

[0018] The heat generating section 30 converts the applied power into heat (Joule heat). The heat generating section 30 is provided, for example, on the surface 10a side of the substrate 10. When the substrate 10 is made of metal, the heat generating section 30 is provided on the insulating section 20 (the surface of the insulating section 20 opposite to the substrate 10 side). When the substrate 10 is made of insulating ceramics or the like, the heat generating section 30 is provided on the surface 10a of the substrate 10.

[0019] The heat generating unit 30 includes, for example, a heat generating element 31 and a heat generating element 32. While the example illustrates a case in which the heat generating element 31 and the heat generating element 32 are provided, the number and size of the heat generating elements can be changed as appropriate depending on the size of the substrate 10, the required heat generation amount, and the like. Furthermore, multiple types of heat generating elements with different lengths, widths, shapes, and the like can also be provided. That is, it is sufficient that at least one heat generating element is provided. Furthermore, the example illustrates a case in which the heat generating element 31 and the heat generating element 32 are connected in series, but multiple heat generating elements may be connected in parallel or in series-parallel. The method of connecting the multiple heat generating elements can be changed as appropriate depending on the size of the substrate 10, the required heat generation amount, and the like.

[0020] The heating elements 31 and 32 can be arranged, for example, in the Y direction (the short-side direction of the substrate 10) at a predetermined interval. The heating elements 31 and 32 extend, for example, in the X direction (the long-side direction of the substrate 10).

[0021] The dimensions (length dimensions) of the heating elements 31 and 32 in the X direction can be, for example, approximately the same or different. Furthermore, the electrical resistance values ​​per unit length of the heating elements 31 and 32 can be approximately uniform in the X direction or can be different. For example, the dimensions (width dimensions) of the heating elements 31 and 32 in the Y direction and the dimensions (thickness dimensions) of the heating elements 31 and 32 in the Z direction can be approximately constant. In this case, the shapes of the heating elements 31 and 32 when viewed from the Z direction can be, for example, approximately rectangular extending in the X direction.

[0022] The heating elements 31 and 32 are made of, for example, ruthenium oxide (RuO ２), a silver-palladium (Ag—Pd) alloy, a silver-platinum (Ag—Pt) alloy, or the like. Heating elements 31 and 32 can be formed, for example, by applying a paste-like material onto insulating portion 20 using a screen printing method or the like, and then curing the paste-like material using a baking method or the like. When substrate 10 is formed from an insulating material, heating elements 31 and 32 can be formed, for example, by applying a paste-like material onto surface 10 a of substrate 10 using a screen printing method or the like, and then curing the paste-like material using a baking method or the like.

[0023] The wiring portion 40 is provided on the surface 10a side of the substrate 10. When the substrate 10 is made of metal, the wiring portion 40 is provided on the insulating portion 20. When the substrate 10 is made of an insulating material, the wiring portion 40 is provided on the surface 10a of the substrate 10.

[0024] The wiring unit 40 has, for example, a terminal 41, a terminal 42, a wire 43, a wire 44, and a wire 45. The terminals 41 and 42 are provided, for example, near one end of the substrate 10 in the X direction. The terminals 41 and 42 are provided, for example, side by side in the X direction and the Y direction. The terminals 41 and 42 are electrically connected, for example, to a controller 103 of the vehicle heating device 100 (described later) via a connector, wire, or the like.

[0025] The wiring 43 is provided, for example, in the X direction, on the side of the substrate 10 where the terminal 41 is provided. The wiring 43 extends in the X direction. The wiring 43 is electrically connected to the terminal 41 and the end of the heating element 32 on the terminal 41 side.

[0026] The wiring 44 is provided, for example, in the X direction, near the end of the substrate 10 opposite to the side on which the terminals 41 and 42 are provided. The wiring 44 is electrically connected to the end of the heating element 31 opposite to the wiring 45 side and the end of the heating element 32 opposite to the wiring 43 side.

[0027] The wiring 45 is provided, for example, in the X direction, on the side of the substrate 10 where the terminal 42 is provided. The wiring 45 extends in the X direction. The wiring 45 is electrically connected to the terminal 42 and the end of the heating element 31 on the terminal 42 side.

[0028] The wiring portion 40 (terminals 41, 42, wiring 43, wiring 44, and wiring 45) are formed using a material containing, for example, silver or copper. For example, the terminals 41, 42, wiring 43, wiring 44, and wiring 45 can be formed by applying a paste-like material onto the insulating portion 20 using a screen printing method or the like and then curing the paste using a baking method or the like. Note that, when the substrate 10 is formed from an insulating material, the terminals 41, 42, wiring 43, wiring 44, and wiring 45 can be formed by applying a paste-like material onto the surface 10a of the substrate 10 using a screen printing method or the like and then curing the paste using a baking method or the like.

[0029] The protective portion 50 covers the surface 10a side of the substrate 10. For example, the protective portion 50 is provided on the insulating portion 20. When the substrate 10 is made of an insulating material, the protective portion 50 is provided on the surface 10a of the substrate 10. The protective portion 50 extends in the X direction. The protective portion 50 covers the heat generating portion 30 (heat generating elements 31 and 32) and part of the wiring portion 40 (wires 43, 44, and 45). In this case, the terminals 41 and 42 of the wiring portion 40 are exposed from the protective portion 50.

[0030] The protective section 50 has, for example, the function of insulating the heat generating section 30, wiring 43, wiring 44, and wiring 45, the function of transferring heat generated in the heat generating section 30 to the outside, and the function of protecting the heat generating section 30, wiring 43, wiring 44, and wiring 45 from external forces, corrosive gases, etc.

[0031] The protective part 50 is formed from a material that is heat-resistant and insulating, and has high chemical stability and thermal conductivity. The protective part 50 is formed from, for example, a glass material. In this case, the protective part 50 can also be formed using a glass material to which a filler containing a material with high thermal conductivity, such as aluminum oxide, has been added. The thermal conductivity of the glass material to which the filler has been added can be, for example, 2 [W / (m·K)] or more. The thickness of the protective part 50 can be, for example, approximately 10 μm to 60 μm.

[0032] Protective portion 50 can be formed, for example, by applying a paste-like material onto insulating portion 20, heat generating portion 30, wiring 43, wiring 44, and wiring 45 using a screen printing method or the like, and then hardening the paste using a baking method or the like. In this case, terminals 41 and 42 are exposed from protective portion 50.

[0033] As shown in Figures 2 and 3, the insulating portion 60 has insulating properties and is provided on the surface 10b of the substrate 10. The insulating portion 60 extends in the longitudinal direction (X direction) of the substrate 10. The insulating portion 60 is provided to insulate the conductive substrate 10 from the detection portion 70 and the wiring portion 80. Therefore, the insulating portion 60 covers at least the area of ​​the surface 10b of the substrate 10 where the detection portion 70 and the wiring portion 80 are provided. The insulating portion 60 is formed from a material that is heat-resistant and insulating. The material and forming method of the insulating portion 60 can be the same as the material and forming method of the insulating portion 20 described above.

[0034] The detection unit 70 detects the temperature of the substrate 10 and, therefore, the temperature of the heat-generating unit 30. The detection unit 70 can be, for example, a thermistor, a thermocouple, a resistance temperature detector, or the like. The detection unit 70 illustrated in FIGS. 2 and 3 is a thermistor. In this case, the thermistor can be formed by applying a paste material to a predetermined position on the wiring unit 80 using, for example, a screen printing method, and then curing it using a baking method. The thermistor material can contain, for example, manganese and cobalt, and at least one of copper and nickel. The thermistor's sheet resistance can be, for example, approximately 100 kΩ / sq to 10,000 kΩ / sq, and its B constant can be, for example, approximately 2,500 K to 4,000 K.

[0035] When the substrate 10 is made of metal, the detection unit 70 is provided on the insulating unit 60 (the surface of the insulating unit 60 opposite the substrate 10 side). When the substrate 10 is made of an insulating material, the detection unit 70 is provided on the surface 10a of the substrate 10. At least one detection unit 70 can be provided. The heater 1 illustrated in FIGS. 2 and 3 is provided with three detection units 70.

[0036] When multiple detection units 70 are provided, as shown in FIG. 2 , the multiple detection units 70 can be arranged at predetermined intervals in the longitudinal direction (X direction) of the substrate 10. Furthermore, the multiple detection units 70 can also be arranged at predetermined intervals in the longitudinal direction (X direction) of the substrate 10 and in the lateral direction (Y direction) of the substrate 10. In this manner, the in-plane temperature of the substrate 10, and ultimately the in-plane temperature of the heater 1, can be detected. The number, intervals, arrangement, etc. of the detection units 70 can be appropriately changed depending on, for example, the size of the heater 1 (substrate 10). The number, intervals, arrangement, etc. of the detection units 70 can be appropriately determined, for example, by conducting experiments or simulations.

[0037] The wiring portion 80 is provided on the surface 10b side of the substrate 10. When the substrate 10 is made of metal, the wiring portion 80 is provided on the insulating portion 60. When the substrate 10 is made of an insulating material, the wiring portion 80 is provided on the surface 10b of the substrate 10.

[0038] 2 , the wiring unit 80 includes, for example, a wiring 81, a wiring 82, a wiring 83, and a wiring 84. The wiring 81 is provided, for example, in the short-side direction (Y direction) of the substrate 10 near one peripheral edge of the surface 10b. The wiring 81 extends in the long-side direction (X direction) of the substrate 10 along one peripheral edge of the surface 10b. The wiring 81 is electrically connected to the two detection units 70. Ends on both sides of the wiring 81 are exposed from the protection unit 90.

[0039] The wiring 82 can be provided, for example, for each of the two detection units 70. In this case, one wiring 82 can be provided at one end of the substrate 10 in the longitudinal direction (X direction) of the substrate 10, and the other wiring 82 can be provided at the other end of the substrate 10. The wiring 82 is provided, for example, alongside the wiring 81 at a predetermined distance in the lateral direction (Y direction) of the substrate 10. The wiring 82 extends, for example, parallel to the wiring 81 in the longitudinal direction (X direction) of the substrate 10. One end of the wiring 82 is electrically connected to the detection unit 70. The other end of the wiring 82 is exposed from the protective unit 90.

[0040] The wiring 83 is provided, for example, near the other peripheral edge of the surface 10b in the short-side direction (Y direction) of the substrate 10. The wiring 83 extends in the longitudinal direction (X direction) of the substrate 10 along the other peripheral edge of the surface 10b. One end of the wiring 83 is electrically connected to the detection unit 70. The other end of the wiring 83 is exposed from the protection unit 90.

[0041] The wiring 84 is provided, for example, near the other peripheral edge of the surface 10b in the short-side direction (Y direction) of the substrate 10. The wiring 84 extends in the longitudinal direction (X direction) of the substrate 10 along the other peripheral edge of the surface 10b. One end of the wiring 84 is electrically connected to the detection unit 70. The other end of the wiring 84 is exposed from the protection unit 90. In the longitudinal direction (X direction) of the substrate 10, the wiring 84 can be provided on the opposite side of the wiring 83 from the detection unit 70.

[0042] The material and forming method of the wiring section 80 (the wirings 81, 82, 83, and 84) can be, for example, the same as the material and forming method of the above-described wiring section 40. The number, arrangement, and planar shape of the wirings 81, 82, 83, and 84 can be changed as appropriate depending on the number, arrangement, etc. of the detection sections 70.

[0043] 2 and 3 , the protective portion 90 covers the surface 10b side of the substrate 10. For example, the protective portion 90 is provided on the insulating portion 60. When the substrate 10 is made of an insulating material, the protective portion 90 is provided on the surface 10b of the substrate 10. The protective portion 90 extends in the X direction. The protective portion 90 covers the detection portion 70 and the wiring portion 80 (wires 81, 82, 83, and 84). In this case, the vicinity of the ends of the wires 81, 82, 83, and 84 are exposed from the protective portion 90.

[0044] The protective section 90 has, for example, a function of insulating the detection section 70 and the wiring section 80, and a function of protecting the detection section 70 and the wiring section 80 from external forces, corrosive gases, etc. The material of the protective section 90 can be the same as or different from the material of the protective section 50 described above. The method of forming the protective section 90 can be, for example, the same as the method of forming the protective section 50 described above. The thickness of the protective section 90 can be, for example, about 10 μm to 60 μm.

[0045] Here, when the heater 1 is used or when the heater 1 is manufactured (for example, when the protective parts 50 and 90 are baked), thermal stress occurs due to the difference in the thermal expansion coefficients of the materials. Therefore, the thermal stress may cause warping of the heater 1. If warping occurs in the heater 1, the heater 1 may be deformed or may become more susceptible to breakage.

[0046] 3, in the heater 1 according to the present embodiment, an insulating portion 20 and a protective portion 50 are provided on the surface 10a of the substrate 10. An insulating portion 60 and a protective portion 90 are provided on the surface 10b of the substrate 10. Therefore, thermal stress generated on the surface 10a of the substrate 10 due to the difference in thermal expansion coefficient between the material of the substrate 10 and the material of the insulating portion 20 and the protective portion 50 can be offset by thermal stress generated on the surface 10b of the substrate 10 due to the difference in thermal expansion coefficient between the material of the substrate 10 and the material of the insulating portion 60 and the protective portion 90. If the thermal stresses are offset, warping of the heater 1 can be suppressed.

[0047] In this case, if the insulating portion 20 and the insulating portion 60 are made of the same material and the protective portion 50 and the protective portion 90 are made of the same material, the thermal stress generated on the surface 10a side of the substrate 10 and the thermal stress generated on the surface 10b side of the substrate 10 will be approximately the same. This can further prevent warping of the heater 1. This also applies when the substrate 10 is made of an insulating material and the insulating portions 20 and 60 are omitted.

[0048] In the above, the case where the heating elements 31 and 32 are provided on the surface 10a side of the substrate 10 has been exemplified, but the heating elements 31 and 32 can also be provided on the surface 10b side of the substrate 10. In other words, the heating elements 31 and 32 can be provided on at least one of the surface 10a side of the substrate 10 and the surface 10b side of the substrate 10.

[0049] Furthermore, although the example has been given in which the detection unit 70 is provided on the surface 10b side of the substrate 10, the detection unit 70 can also be provided on the surface 10a side of the substrate 10. That is, the detection unit 70 can be provided on at least one of the surface 10a side of the substrate 10 and the surface 10b side of the substrate 10.

[0050] As will be described later, the heater 1 is provided inside the housing 101 of the vehicle heating device 100 and heats the gas (e.g., air) flowing inside the housing 101. Therefore, the surfaces of the protective part 50 and the protective part 90 come into contact with the gas flowing inside the housing 101. In this case, if the surface area of ​​at least one of the protective part 50 and the protective part 90 is increased, the amount of heat dissipated from the heater 1 to the gas can be increased.

[0051] For example, it is only necessary to increase the surface roughness of at least one of the surfaces of the protective portion 50 and the protective portion 90. For example, it is preferable that at least one of the maximum height roughness Rz of the surface of the protective portion 50 and the maximum height roughness Rz of the surface of the protective portion 90 is set to "0.3 μm≦Rz≦5 μm." In this way, the amount of heat dissipated from the heater 1 to the gas can be increased, thereby improving the heat generation efficiency.

[0052] In this case, at least one of the maximum height roughness Rz of the surface of the protective portion 50 and the maximum height roughness Rz of the surface of the protective portion 90 can be more preferably set to "2 μm≦Rz≦5 μm", and even more preferably "3 μm≦Rz≦5 μm". In this way, the amount of heat dissipated from the heater 1 to the gas can be further increased, thereby further improving the heat generation efficiency.

[0053] The above-mentioned surface roughness may be the surface roughness of at least the surface of the protective part 50 facing the surface 10a of the substrate 10. The surface roughness of the entire surface of the protective part 50 may be the above-mentioned surface roughness. The above-mentioned surface roughness may be the surface roughness of at least the surface of the protective part 90 facing the surface 10b of the substrate 10. The surface roughness of the entire surface of the protective part 90 may be the above-mentioned surface roughness.

[0054] As shown in FIGS. 1 to 3, the heater 1 according to this embodiment includes a plate-shaped substrate 10 and a film-shaped insulating portion 20, a heat generating portion 30, a wiring portion 40, a protective portion 50, an insulating portion 60, a detecting portion 70, a wiring portion 80, and a protective portion 90, which are provided on the surface of the substrate 10. This facilitates miniaturization of the heater 1. The planar shape of the plate-shaped substrate 10 can be arbitrarily changed to match, for example, the shape of the housing 101 of the vehicle heating device 100. This facilitates space saving. As described above, the heater 1 according to this embodiment can improve heat generation efficiency and achieve space saving.

[0055] FIG. 4 is a schematic cross-sectional view illustrating a heater 1a according to another embodiment. This view corresponds to FIG. 3 described above. As shown in FIG. 4, the protective portion 50a covers the heating elements 31, 32, and the wiring 43, 44, and 45, and does not cover the areas of the insulating portion 20 where the heating elements 31 and 32 are not provided, or the thickness of the protective portion 50a in these areas can be reduced. This can further increase the surface area of ​​the protective portion 50a, thereby further increasing the amount of heat dissipated from the heater 1a to the gas. This can further improve the heat generation efficiency.

[0056] Furthermore, the protective portion 90a can cover the detection portion 70 and the wiring portion 80 (wires 81, 82, 83, and 84) and not cover the area of ​​the insulating portion 60 where the wiring portion 80 is not provided, or the thickness of the protective portion 90a in this area can be made thinner. In this way, the surface area of ​​the protective portion 90a can be further increased, thereby further increasing the amount of heat dissipated from the heater 1a to the gas. As a result, the heat generation efficiency can be further improved.

[0057] Fig. 5 is a schematic cross-sectional view illustrating a heater 1b according to another embodiment. Fig. 5 corresponds to Fig. 3 described above. As shown in Fig. 5, the surface of the protective portion 50b facing the surface 10a of the substrate 10 can be a convexly curved surface or a concavely curved surface. This can further increase the surface area of ​​the protective portion 50b, thereby further increasing the amount of heat dissipated from the heater 1b to the gas. This can further improve the heat generation efficiency.

[0058] Furthermore, the surface of the protective portion 90b facing the surface 10b of the substrate 10 can be a convex curved surface or a concave curved surface. This can further increase the surface area of ​​the protective portion 90b, thereby further increasing the amount of heat dissipated from the heater 1b to the gas. This can further improve the heat generation efficiency.

[0059] Fig. 6 is a schematic cross-sectional view illustrating a heater 1c according to another embodiment. Fig. 6 corresponds to Fig. 3 described above. As shown in Fig. 6, the surface of the protective portion 50c facing the surface 10a of the substrate 10 can have at least one protrusion. This can further increase the surface area of ​​the protective portion 50c, thereby further increasing the amount of heat dissipated from the heater 1c to the gas. This can further improve the heat generation efficiency.

[0060] Furthermore, the surface of the protective portion 90c facing the surface 10b of the substrate 10 may have at least one protrusion. This can further increase the surface area of ​​the protective portion 90c, thereby further increasing the amount of heat dissipated from the heater 1c to the gas. This can further improve the heat generation efficiency.

[0061] However, as shown in Fig. 3, it is preferable to make the thickness of the protective portion 50 approximately uniform and to make the surface roughness of the protective portion 50 rough. It is also preferable to make the thickness of the protective portion 90 approximately uniform and to make the surface roughness of the protective portion 90 rough. If the thicknesses of the protective portion 50 and the protective portion 90 are approximately uniform, it is possible to prevent the heat capacity of the heater 1 from increasing, thereby improving the responsiveness of the heater 1. If the responsiveness of the heater 1 is high, it is possible to shorten the time it takes for the gas to reach a predetermined temperature.

[0062] Fig. 7 is a schematic diagram illustrating a heater 1d according to another embodiment. Fig. 7 is a diagram corresponding to Fig. 1 described above. As shown in Fig. 7, the wiring portion 40a is provided on the surface 10a side of the substrate 10. When the substrate 10 is made of metal, the wiring portion 40a is provided on the insulating portion 20. When the substrate 10 is made of an insulating material, the wiring portion 40a is provided on the surface 10a of the substrate 10.

[0063] The wiring portion 40a has, for example, a terminal 41a, a terminal 42a, a wiring 43a, a wiring 44a, a wiring 45a, and a terminal 46. The terminals 41a and 42a are provided, for example, near the ends of both sides of the substrate 10 in the X direction. The terminals 41a and 42a are provided, for example, side by side in the X direction. The terminal 41a is electrically connected to the wiring 45a. The terminal 42a is electrically connected to the wiring 43a and the wiring 44a.

[0064] The wiring 43a extends in the X direction along one peripheral edge in the Y direction of the substrate 10. The wiring 44a extends in the X direction along the other peripheral edge in the Y direction of the substrate 10. In the Y direction, the wiring 45a is provided between the wiring 43a and the wiring 44a and extends in the X direction.

[0065] In the Y direction, the heating element 32 extending in the X direction is provided between the wiring 43a and the wiring 45a. In the Y direction, the wiring 43a and the wiring 45a are electrically connected to the heating element 32. In the Y direction, the heating element 31 extending in the X direction is provided between the wiring 44a and the wiring 45a. In the Y direction, the wiring 44a and the wiring 45a are electrically connected to the heating element 31. A plurality of terminals 46 are electrically connected to the heating element 31, the heating element 32, and the wiring 45a. The plurality of terminals 46 are arranged in the X direction at predetermined intervals.

[0066] The terminals 41a, 42a, and the plurality of terminals 46 are electrically connected to, for example, a controller 103 of the vehicle heating device 100 (described later) via connectors, wiring, and the like.

[0067] In this way, the heat generating regions (heat generating areas) of the heating elements 31 and 32 can be changed. For example, by applying a voltage between the terminals 41a and 42a, the entire regions of the heating elements 31 and 32 can be heated. For example, by applying power between the terminal 42a and the selected terminal 46, the regions of the heating elements 31 and 32 between the terminal 42a and the selected terminal 46 can be heated. Changing the heat generating regions can change the amount of heat generated and, ultimately, the temperature of the heated gas. In this case, if the temperature of the heated gas can be controlled by changing the heat generating regions while keeping the applied power approximately constant, the heat generating efficiency can be improved compared to when the gas temperature is controlled by changing the applied power. Furthermore, the control circuit can be simplified.

[0068] Fig. 8 is a schematic diagram illustrating a heater 1e according to another embodiment. Fig. 9 is a schematic cross-sectional view of the heater 1e in the direction of line B-B in Fig. 8. As shown in Fig. 8, the heater 1e has, for example, a substrate 10, an insulating portion 20, a heat generating portion 30, a wiring portion 40, a protective portion 50, a detection portion 70, and wiring 85. Also, as shown in Fig. 9, the insulating portion 20, the heat generating portion 30, the wiring portion 40, the protective portion 50, the detection portion 70, and wiring 85 are provided on the surface 10a of the substrate 10, but not on the surface 10b of the substrate 10.

[0069] The detection unit 70 can be provided on the insulating unit 20. Wiring 85 is electrically connected to the detection unit 70. The detection unit 70 and the wiring 85 are covered by the protective unit 50. The vicinity of the end of the wiring 85 is exposed from the protective unit 50.

[0070] For example, the surface roughness of the surface of the protective portion 50 may be increased. For example, it is preferable that the maximum height roughness Rz of the surface of the protective portion 50 is set to "0.3 μm≦Rz≦5 μm." In this way, the amount of heat dissipated from the heater 1 e to the gas can be increased, thereby improving the heat generation efficiency.

[0071] In this case, the maximum height roughness Rz of the surface of the protective portion 50 can be more preferably set to "2 μm≦Rz≦5 μm", and even more preferably "3 μm≦Rz≦5 μm". In this way, the amount of heat dissipated from the heater 1 e to the gas can be further increased, thereby further improving the heat generation efficiency.

[0072] The number, spacing, and arrangement of the detection units 70 can be changed as appropriate depending on, for example, the size of the heater 1e (substrate 10). The number, spacing, and arrangement of the detection units 70 can be determined as appropriate by, for example, conducting experiments or simulations. The material and formation method of the wiring 85 can be the same as the material and formation method of the wiring unit 40 described above. The number, arrangement, and planar shape of the wiring 85 can be changed as appropriate depending on the number, arrangement, and other factors of the detection units 70.

[0073] Instead of the protective portion 50, the protective portion 50b having a convex curved surface or a concave curved surface as described above may be provided, or the protective portion 50c having at least one convex portion may be provided.

[0074] In the heater 1e, the insulating portion 20, the heat generating portion 30, the wiring portion 40, the protective portion 50, the detection portion 70, and the wiring 85 are provided on one surface 10a of the substrate 10, so that the dimensions of the heater 1e in the Z direction can be reduced. This makes it easy to install the heater 1e in a small space inside the vehicle cabin. This also allows for the vehicle heating device 100, which will be described later, to be miniaturized. Furthermore, the insulating portion 60 and the protective portion 90 can be omitted, or the wiring 85 and the wiring portion 40 can be formed in the same process. This reduces the manufacturing cost of the heater 1e.

[0075] (Vehicle Heating Device) In one embodiment of the present invention, a vehicle heating device 100 can be provided that includes the heater 1. The above description of the heater 1 and modified versions of the heater 1 (for example, heaters 1a to 1d, and heaters 1a to 1d that have been modified by a person skilled in the art to add, delete, or change components as appropriate, and that have the features of the present invention) can all be applied to the vehicle heating device 100.

[0076] The vehicle heating device 100 (hereinafter simply referred to as the heating device 100) can be installed, for example, in the interior of an automobile or a train. The heating device 100 can be, for example, a heater that heats gas G (e.g., air) inside the vehicle.

[0077] FIG. 10 is a schematic cross-sectional view illustrating a heating device 100 according to this embodiment. FIGS. 11(a) and 11(b) are schematic cross-sectional views of the heating device 100 in FIG. 10 taken along line CC. As shown in FIG. 10, the heating device 100 includes, for example, a heater 1, a housing 101, a blower 102, a controller 103, and a detector 104 (corresponding to an example of a second detector). The heater 1 is provided inside the housing 101. The heater 1 can be attached to the inner wall of the housing 101 via a bracket or the like. While FIGS. 10 and 11(a) and 11(b) illustrate an example in which one heater 1 is provided, the number of heaters 1 can be changed as appropriate depending on the processing flow rate of the gas G, etc. That is, at least one heater 1 is required. When multiple heaters 1 are provided, the heaters 1 can be arranged side by side at a predetermined interval in the direction of gas G flow. Furthermore, a plurality of heaters 1 may be arranged at predetermined intervals in a direction perpendicular to the flow direction of the gas G. When a plurality of heaters 1 are provided, the planar dimensions and planar shapes of the heaters 1 may be the same or different.

[0078] The housing 101 is, for example, box-shaped and has an air inlet 101a and an exhaust port 101b. For example, the air inlet 101a and the exhaust port 101b can be provided at positions facing each other. For example, the housing 101 may be cylindrical. Note that although the housing 101 extending in one direction is illustrated, the shape of the housing 101 is not limited to the illustrated one. The shape of the housing 101 can be changed as appropriate depending on the space inside the vehicle in which the heating device 100 is installed.

[0079] The air intake port 101a may be provided with a filter 101c. The filter 101c is breathable and captures, for example, visible dust. The air exhaust port 101b may be provided with a so-called finger guard 101d. The filter 101c may be provided instead of the finger guard 101d.

[0080] 11A, the outline of the housing 101 can be, for example, a circle in the direction perpendicular to the flow direction of the gas G. In this way, the flow path resistance of the gas G can be reduced, which makes the flow of the gas G smoother and thus makes it easier to increase the processing flow rate.

[0081] 11(b), the outline of the housing 101 in the direction perpendicular to the flow direction of the gas G can be, for example, a rectangle. In this way, the dimension between the inner wall of the housing 101 and the heater 1 can be made approximately constant, making it easy to heat the gas G flowing inside the housing 101 approximately uniformly.

[0082] The blower 102 forms an airflow flowing inside the housing 101 in which the heater 1 is provided. The blower 102 is provided, for example, inside the housing 101. The blower 102 can be provided, for example, in the area between the air inlet 101a and the heater 1. The blower 102 draws gas G from the vehicle interior into the housing 101 through the filter 101c and the air inlet 101a. The gas G drawn into the housing 101 is discharged to the outside of the heating device 100 through the exhaust port 101b of the housing 101. Therefore, a flow of gas G is formed inside the housing 101, flowing from the air inlet 101a to the exhaust port 101b. Note that while FIG. 10 illustrates an example in which the blower 102 is an axial flow blower, the type of blower 102 can be changed as appropriate. The blower 102 may be, for example, a centrifugal blower, a cross-flow blower, or the like. The location of the blower 102 may be changed as appropriate. For example, the blower 102 may be provided outside the housing 101.

[0083] The controller 103 is provided, for example, outside the housing 101. The controller 103 is electrically connected to the heater 1. The controller 103 is electrically connected, for example, to the heating elements 31 and 32 provided in the heater 1, and the detection unit 70. The controller 103 is also electrically connected to a detection unit 104 provided outside the housing 101. The controller 103 is also electrically connected to the blower unit 102. The detection unit 104 detects the temperature of the atmosphere outside the housing 101 (the temperature of the atmosphere inside the vehicle). The detection unit 104 can be, for example, a thermistor, a thermocouple, a resistance temperature detector, or the like.

[0084] Next, the operation of the heating device 100 will be illustrated. As shown in Fig. 10, when gas G is sucked into the housing 101 by the air blower 102 and reaches the heater 1, it flows along the surface of the heater 1. The gas G that has flowed along the surface of the heater 1 flows from the periphery of the heater 1 toward the exhaust port 101b of the housing 101. When the gas G flows along the surface of the heater 1, the temperature of the gas G increases due to the heat from the heater 1. The gas G with an increased temperature is released through the exhaust port 101b into, for example, the atmosphere in which the heating device 100 is provided.

[0085] In this case, when the temperature detected by the detection unit 104 is lower than the set temperature, the controller 103 applies power to the heating elements 31 and 32 to cause the heating elements 31 and 32 to generate heat. The set temperature is a temperature input to the controller 103 by the driver or the like. The controller 103 controls the heat generation by the heating elements 31 and 32 based on the difference between the temperature detected by the detection unit 104 and the set temperature. For example, the controller 103 performs PID control to control the heat generation by the heating elements 31 and 32 so that the temperature detected by the detection unit 104 (the temperature of the atmosphere inside the vehicle) approaches the set temperature.

[0086] Furthermore, the controller 103 can further control the heat generation by the heating elements 31 and 32 based on the temperature detected by the detection unit 70 provided in the heater 1. For example, if the temperatures of the heating elements 31 and 32 become too high, the heating elements 31 and 32 may break down. Therefore, the controller 103 can control the heat generation by the heating elements 31 and 32 so that the temperatures detected by the detection unit 70 fall within a predetermined range.

[0087] Furthermore, as illustrated in Figure 7, when multiple terminals 46 for applying power are provided, the controller 103 can appropriately select the terminal 46 for applying power to change the heat generating areas of the heating elements 31 and 32, thereby controlling the amount of heat generated and ultimately the temperature of the gas G being heated.

[0088] Furthermore, when controlling the heat generated by the heating elements 31 and 32, the controller 103 can control the amount of air sent by the blower 102. In this case, the controller 103 can control the rotation speed of the blower 102 to control the amount of air sent by the gas G. For example, if the rotation speed of the blower 102 is reduced, the amount of air sent is reduced, and therefore the temperature of the gas G discharged from the exhaust port 101b can be increased. If the rotation speed of the blower 102 is increased, the amount of air sent is increased, and therefore the temperature of the gas G discharged from the exhaust port 101b can be decreased.

[0089] Fig. 12 is a schematic cross-sectional view illustrating a heating device 100a according to another embodiment. In the heating device 100 illustrated in Fig. 10, the extension direction of the heater 1 is set to be approximately perpendicular to the flow direction of the gas G sucked into the housing 101. In contrast, in the heating device 100a, as shown in Fig. 12, the extension direction of the heater 1 is set to be inclined with respect to the flow direction of the gas G sucked into the housing 101. In this way, as shown in Fig. 12, the amount of gas G flowing along the surface of the heater 1 can be increased, thereby further improving heat generation efficiency.

[0090] FIG. 13 is a schematic cross-sectional view illustrating a heating device 100b according to another embodiment. As shown in FIG. 13, the extension direction of the heater 1 can be made substantially parallel to the flow direction of the gas G drawn into the housing 101. In this way, as shown in FIG. 13, the amount of gas G flowing along the surface of the heater 1 can be increased, thereby further improving heat generation efficiency. Furthermore, the number of heaters 1 that can be provided inside the housing 101 can be increased. The dimension of the housing 101 in a direction substantially perpendicular to the flow direction of the drawn gas G can be reduced. This also allows the heating device 100b to be made more compact.

[0091] Although several embodiments of the present invention have been described above, these embodiments are presented by way of example only and are not intended to limit the scope of the invention. These novel embodiments can be embodied in various other forms, and various omissions, substitutions, modifications, etc. can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, as well as within the scope of the invention and its equivalents as set forth in the claims. Furthermore, the above-described embodiments can be implemented in combination with each other.

[0092] REFERENCE SIGNS LIST 1 Vehicle heater 1a Vehicle heater 1b Vehicle heater 1c Vehicle heater 1d Vehicle heater 1e Vehicle heater 10 Substrate 10a Surface 10b Surface 20 Insulating section 30 Heat generating section 31 Heat generating element 32 Heat generating element 40 Wiring section 50 Protective section 50a Protective section 50b Protective section 50c Protective section 60 Insulating section 70 Detecting section 80 Wiring section 90 Protective section 90a Protective section 90b Protective section 90c Protective section 100 Vehicle heating device 100a Vehicle heating device 100b Vehicle heating device 101 Housing 102 Blower section 103 Controller 104 Detecting section G Gas

Claims

1. A vehicle heater for heating gas inside a vehicle, comprising: a plate-shaped substrate having a first surface and a second surface opposite the first surface and extending in one direction; a heating element provided on the first surface side and extending in the direction in which the substrate extends; a first detection unit provided on the first surface side for detecting the temperature of the substrate; and a first protection unit covering the first surface side.

2. The vehicle heater according to claim 1, wherein the first protective portion includes a glass material, and the maximum height roughness Rz of the surface of the first protective portion satisfies the following formula: 0.3 μm≦Rz≦5 μm.

3. A vehicle heater for heating gas inside a vehicle, comprising: a plate-shaped substrate having a first surface and a second surface opposite the first surface and extending in one direction; a heating element provided on at least one of the first surface side and the second surface side and extending in the direction in which the substrate extends; a first detection unit provided on at least one of the first surface side and the second surface side and detecting the temperature of the substrate; a first protective unit covering the first surface side; and a second protective unit covering the second surface side.

4. The vehicle heater according to claim 3, wherein the first protective portion includes a glass material, and the maximum height roughness Rz of the surface of the first protective portion satisfies the following formula: 0.3 μm≦Rz≦5 μm.

5. The vehicle heater according to claim 3 or 4, wherein the second protective portion includes a glass material, and the maximum height roughness Rz of the surface of the second protective portion satisfies the following formula: 0.3 μm≦Rz≦5 μm.

6. A vehicle heater as claimed in any one of claims 3 to 5, further comprising: a first insulating portion provided on the first surface; and a second insulating portion provided on the second surface; the substrate includes a metal; at least one of the heating element and the first detection portion, covered by the first protective portion, is provided on the first insulating portion; and at least one of the heating element and the first detection portion, covered by the second protective portion, is provided on the second insulating portion.

7. A vehicle heater as claimed in any one of claims 3 to 5, wherein the substrate includes ceramics, the first surface is provided with at least one of the heating element and the first detection portion covered by the first protective portion, and the second surface is provided with at least one of the heating element and the first detection portion covered by the second protective portion.

8. A vehicle heating device comprising: a housing; a vehicle heater according to any one of claims 1 to 7 provided inside the housing; a blower section that forms an air current that flows inside the housing in which the vehicle heater is provided; a second detection section that detects the temperature of the atmosphere outside the housing; and a controller electrically connected to the vehicle heater and the second detection section; wherein the controller controls heat generation by the heating element based on the difference between the temperature detected by the second detection section and a set temperature.

9. The vehicle heating device according to claim 8, wherein the controller further controls the heat generation by the heating element based on a temperature detected by a first detection section provided in the vehicle heater.

10. The vehicle heating device according to claim 8 or 9, wherein the controller is electrically connected to the air blowing section and controls the amount of air blown by the air blowing section when controlling heat generation by the heating element.

Images