JP2023074466A - Heater unit and its applied product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a heater unit that has a function of preventing an excessive rise in temperature to achieve uniform temperature and includes a heating element and the like appropriately fixed, and to provide a vehicle windshield device.

SOLUTION: A heater unit has a base material 15, a ceramic-based PTC heating element 11, a first electrode terminal 13a, a second electrode terminal 13b, a first lead wire 19a, and a second lead wire 19b. The base material 15 is formed with a recessed part 15c adapted to a shape of the PTC heating element 11. The PTC heating element 11 and the second electrode terminal 13b are arranged in the recessed part 15c. The first electrode terminal 13a covers a surface on which the recessed part 15c is formed, of the base material 15. The base material 15 is formed with a peripheral wall 15w so as to surround the recessed part 15c. A part of the peripheral wall 15w is cut off to form a lead wire insertion part 15r. The first lead wire 19a is held by being caught between the first electrode terminal 13a and the lead wire insertion part 15r.

SELECTED DRAWING: Figure 4

COPYRIGHT: (C)2023,JPO&INPIT

Description

The present invention provides, for example, a heater unit for removing dew condensation, ice, frost, and water droplets adhering to a camera unit, windshield, radar unit, etc. of a vehicle, and for preventing fogging, dew condensation, ice, and frost adhesion, and , to a windshield device provided with this heater unit.

A vehicle windshield device is attached to the cabin side of the windshield and used to detect the presence or absence of other vehicles or obstacles in front of the vehicle. A windshield device for a vehicle includes a bracket fixed to the windshield, a camera unit or radar unit supported by the bracket, and a light shielding hood that suppresses external light such as sunlight from entering the camera unit. Here, when the humidity inside the vehicle is high or the temperature outside the vehicle is low, cloudiness, condensation, frost, ice, etc. adhere to the windshield. A heater unit is provided on the back side of the light shielding hood. The heat emitted from this heater unit melts, evaporates, and removes fogging, dew condensation, frost, ice, etc. adhering to the windshield facing the shading hood. As a result, the image taken by the camera unit becomes clear. Moreover, accurate detection is possible without attenuation of the radar from the radar unit (see Patent Document 1, etc.).

As a heater unit, for example, in order to uniformly raise the temperature of a planar target region to be heated, a first linear heating element positioned at the periphery of the target region and a second linear heating element positioned inside the target region. There is known a device in which a heating element is provided separately (see Patent Document 2, etc.). Also, various linear heating elements are known (see Patent Document 3, etc.). Various types of heater units are also known (see Patent Documents 4 to 6, etc.).

Japanese Patent Application Laid-Open No. 2017-185893 Utility Model Registration No. 1801190 Patent No. 6320935 Japanese Patent Application Laid-Open No. 2019-93794 Japanese Patent Application Laid-Open No. 2019-104378 Japanese Patent Application Laid-Open No. 2021-153036

In conventional heater units, fuses are used to prevent excessive temperature rise. In the event of unintended high-temperature heat generation due to a short circuit or control system failure, the fuse cuts off the power supply to the heater unit. was supposed to be de-energized. However, when a fuse is installed, the number of parts increases, the thickness of the heater unit also increases, and the heater unit has fuse-shaped unevenness. As a means for preventing excessive temperature rise without using a fuse, it is possible to use a positive temperature coefficient thermistor element (PTC element) as a heater element. As PTC elements, there are ceramic-based ones and organic-based ones. At present, many organic PTC elements are mainly being studied for windshield devices for vehicles. This is because the range of objects to be heated is wide and there is no room for installation space for heater elements, so there is a background that organic PTC elements that can be easily processed into a thin planar shape like a film are preferred. However, due to its structure, organic PTC elements are accompanied by the problem of deterioration in high temperature environments and deterioration over time. Its use remains limited in fields where it is required. On the other hand, the ceramic PTC element is hard and has a certain thickness, and it is difficult to process it into a thin planar shape. . In addition, the properties of the ceramic-based PTC element, which is hard and has a certain thickness, also pose a problem when holding and fixing the PTC element. In particular, there has been a demand for a fixing method that ensures reliable fixing, including fixing to electrode terminals that feed power to the PTC element, and that suppresses the thickness.

SUMMARY OF THE INVENTION The present invention has been made to solve the problems of the prior art. To provide a heater unit in which a is properly fixed and a windshield device for a vehicle equipped with the heater unit.

In order to achieve the above object, the heater unit according to the present invention comprises a substrate, a PTC heating element comprising a ceramic PTC thermistor element having a pair of electrodes formed thereon, a first electrode terminal, and a second electrode terminal. , a heater unit having a first lead wire and a second lead wire, wherein the first electrode terminal and one electrode layer of the PTC heating element are electrically connected, and the second electrode terminal and The other electrode layer of the PTC heating element is electrically connected, the first electrode terminal and the first lead wire are electrically connected, and the second electrode terminal and the second lead wire are connected. The substrate is formed with a recess conforming to the shape of the PTC heating element, and the PTC heating element and the second electrode terminal are arranged in the recess. and the first electrode terminal covers the surface of the base material on which the recess is formed, and the base material has a peripheral wall formed so as to surround the recess, and a part of the peripheral wall is cut out. It is characterized in that a lead wire insertion portion is formed on the back, and the first lead wire is sandwiched and held between the first electrode terminal and the lead wire insertion portion.
Further, in the base material, a second lead groove for drawing out to the second electrode terminal second lead wire is formed continuously with the recess, and the second lead groove is separated from the partition wall, A first lead-out groove is formed for leading the first electrode terminal to the first lead wire, and the peripheral wall is cut away at a location where the first lead-out groove is located to form a lead wire insertion portion. In addition, it is conceivable that the peripheral wall at the location where the second lead-out groove is located is notched to form a lead wire insertion portion.
Further, it is conceivable that a filler is arranged in the second lead-out groove, and the second lead wire is sandwiched and held between the filler and the lead wire insertion portion. The width of the portion located on the boundary between the recess and the second extraction groove is equal to the width of the portion located on the recess and the second extraction groove. It is conceivable that it is narrower than the width.
A windshield device for a vehicle as an applied product according to the present invention includes the heater unit described above, a bracket attached to the windshield of the vehicle, and a sensor unit housed in the bracket.

According to the present invention, by using a PTC heating element as a heater element, it is possible to prevent excessive temperature rise. In addition, since the lead wire is sandwiched between the base material and the first electrode terminal, it is possible to suppress the force applied to the lead wire in the peeling direction, thereby preventing disconnection of the lead wire.

It is a perspective view showing composition of a heater unit by an embodiment of the invention. It is a perspective view showing composition of a heater unit by an embodiment of the invention. FIG. 2 is a cross-sectional view showing the configuration of the heater unit according to the embodiment of the present invention, and is a cross-sectional view taken along line III-III' in FIG. 1; 1 is an exploded perspective view showing each configuration of a heater unit according to an embodiment of the present invention; FIG. 1 is a cross-sectional view showing an overview of a vehicle windshield device using a heater unit according to the present invention; FIG. FIG. 5 is a plan view showing the configuration of a heater unit according to another embodiment of the present invention; FIG. 10 is a perspective view showing the configuration of a heater unit according to another embodiment of the present invention; FIG. 4 is an exploded perspective view showing each configuration of a heater unit according to another embodiment of the present invention;

An embodiment will be described with reference to FIGS. 1 to 5. FIG. This embodiment shows an example on the assumption that the heater unit according to the present invention is applied to a vehicle windshield device.

FIG. 4 is an exploded view showing each configuration of the heater unit 10. As shown in FIG. As shown in FIG. 4, the base material 15 is made of an engineering plastic such as PPS resin or PBT resin, and has a generally flat rectangular parallelepiped shape as a whole. A concave portion 15c is formed substantially in the center of one main surface of the base material 15. The shape of the concave portion 15c is such that a PTC heating element, which will be described later, can be arranged and held. 4 mm. Further, a second lead-out groove 15b is formed continuously with the recess 15c for drawing out a second electrode terminal 13b, which will be described later, to the second lead wire 19b. Further, next to the second lead-out groove 15b, a first lead-out groove 15a for drawing out a first electrode terminal 13a, which will be described later, to the first lead wire 19a is formed with a partition wall therebetween. In addition, four through holes 15h are formed in the peripheral portion of the base material 15 for inserting extension portions 15e of first electrode terminals 15a, which will be described later.

A peripheral wall 15w is formed in the base material 15 so as to surround the concave portion 15c, the second extraction groove 15b, and the first extraction groove 15a. A lead wire insertion portion 15r is formed by cutting out a portion of the peripheral wall 15w where the first extraction groove 15a is located. A lead wire insertion portion 15s is formed by cutting out a portion of the peripheral wall 15w where the second extraction groove 15b is located. Since the lead wire insertion portion 15r is to receive a first lead wire 19a, which will be described later, the lead wire insertion portion 15r has a shape compatible with the first lead wire 19a. Further, since the lead wire insertion portion 15s is to receive a second lead wire 19b, which will be described later, the lead wire insertion portion 15s has a shape compatible with the second lead wire 19b.

The PTC heating element 11 is a positive temperature coefficient thermistor element (PTC element) made of barium titanate-based ceramic and formed in a substantially rectangular plate shape of 6.6 mm long, 35.0 mm wide and 1.2 mm thick. As shown, an electrode layer made of a silver paste is formed on one main surface, and an electrode layer made of a silver paste is formed on the other main surface, which are referred to as an electrode layer 11a and an electrode layer 11b, respectively. , in FIG. 4, the electrode layer 11b is not shown because it is positioned on the back surface). One of the electrode layers 11a and 11b is a positive electrode, and the other is a negative electrode. Incidentally, the material of the PTC heating element 11 may be appropriately set according to the required heating characteristics (for example, Curie temperature, etc.).

In this embodiment, a first electrode terminal 13a made of a copper plate with a thickness of 0.5 mm and a second electrode terminal 13b made of a phosphor bronze plate with a thickness of 0.2 mm and excellent spring elasticity are used. The first electrode 13a and the second electrode 13b are shown in FIG. The first electrode terminal 13a has such a shape as to cover one main surface of the base material 15, and has a shape in which a lead wire lead-out portion and four extension portions 13e are continuously provided there. The second electrode 13b has substantially the same shape as the concave portion 15c and the second extraction groove 15b of the substrate 15, and the portion corresponding to the concave portion 15c has a rectangular shape of 14.0 mm long and 50.0 mm wide. , and a lead wire lead-out portion corresponding to the second lead-out groove 15b is continuously provided there. Moreover, a part of the second electrode 13b has a narrowed portion. In the present embodiment, the width of the portion located at the boundary between the recess 15c and the second extraction groove 15b is narrower than the width of the portion located in the recess 15c and the width of the portion located in the second extraction groove 15b. there is If for some reason a short circuit occurs at any point, this narrow portion becomes a current fuse and disconnects, so other devices and elements can be protected from overcurrent.

The assembly of these constituent materials is described below. 1 is the overall configuration of the heater unit 10, FIG. 2 is the overall configuration of the heater unit 10 viewed from the opposite direction to FIG. 1, FIG. 3 is a view showing the III-III′ cross section in FIG. 1, and FIG. 4 is the heater unit. 10 is an exploded view showing each configuration. First, the second electrode terminal 13b and the second lead wire 19b are connected by spot welding via a connection terminal (not shown). The second electrode terminal 13b to which the second lead wire 19b is connected is arranged on the bottom of the concave portion 15c of the substrate 15 and the second extraction groove 15b. At this time, the second electrode 13b is curved so that the central portion is convex in order to urge the PTC heating element 11 in the direction to hold it down. At the same time, the filling material 17 made of thermoplastic resin is filled in the second lead-out groove 15b to ensure that the connecting portion between the second lead wire 19b and the second electrode terminal 13b is insulated from the outside. Next, the PTC heating element 11 is arranged in the recess 15c of the base material 15 so that the electrode layer 11b faces the bottom of the recess 15c and the electrode layer 11a faces the opening of the recess 15c. Next, the first electrode terminal 13a and the first lead wire 19a are connected by spot welding via a connection terminal (not shown). At the same time, the root portion of the extension portion 15 of the first electrode terminal 13a is bent at right angles. The first electrode terminal 13a, to which the lead wire 19a is connected, is arranged on the PTC heating element 11 while allowing the extension 13e to communicate with the through hole 15h. Then, while applying pressure so that the first electrode terminal 13a and the PTC heating element 11 and the PTC heating element 11 and the second electrode terminal 13b are sufficiently closely attached, the tip of the extension part 13e is placed on the surface of the base material 15 that does not form the concave part 15c. , and the first electrode terminal 13a and the base material 15 are fixed. As a result, the PTC heating element 11 is sandwiched between the first electrode terminal 13a and the second electrode terminal 13b, and the first electrode terminal 13a and one electrode layer 11a of the PTC heating element 11 are electrically connected, The second electrode terminal 13b and the other electrode layer 11b of the PTC heating element 11 are electrically connected. In addition, since the first electrode terminal 13a presses the PTC heating element 11 and the second electrode terminal 13b against the bottom side of the concave portion 15b, the restoring force of the curved second electrode terminal 13b causes the PTC The heating element 11 will be held down. Thus, heater unit 10 according to the present embodiment is configured.

Also, in the lead wire insertion portion 15r, the first lead wire 19a is sandwiched and held between the substrate 15 and the first electrode terminal 13a. The second lead wire 19b is sandwiched and held between the base material 15 and the filler 17 at the lead wire insertion portion 15s. In general, welds such as spot welds tend to be strong against force in the shear direction but weak against force in the peeling direction. Since the first lead wire 19a is sandwiched between the base material 15 and the first electrode terminal 13a, it is possible to suppress the application of force in the peeling direction to the first lead wire 19a. You can prevent it from coming off. Similarly, the second lead wire 19b is sandwiched between the base material 15 and the filler 17, so that it is possible to suppress the force applied to the second lead wire 19b in the peeling direction. disconnection can be prevented.

In the heater unit 10 according to the embodiment obtained as described above, the connector ( not shown) are connected.

Such a heater unit 10 can be installed in a vehicle windshield device. An example of a vehicle windshield device will be described with reference to FIG. The right side in FIG. 5 is the front side of the vehicle. The bracket 51 is a bowl-shaped resin member, and accommodates the light shielding hood 53 and the sensor unit 55 . An adhesive is applied to the periphery of the bracket 51 and attached to the windshield 57 on the passenger compartment side. The windshield 57 is generally called a windshield, a side glass, or a rear glass. The sensor unit 55 is fixed and held by a resin member formed inside the bracket. Note that the sensor unit 55 may be a camera unit, a radar unit, or the like. At this time, the light receiving portion of the sensor unit 55 is directed toward the windshield 57 and no other member is interposed between the light receiving portion of the sensor unit 55 and the windshield 57 . In the vehicle windshield device, the light shielding hood 53 is used to define the range of light received by the light receiving portion of the sensor unit 55. The heater unit 10 in the present embodiment is attached to the light shielding hood 53. ing. Further, the heater unit 10 can be used as the light shielding hood 53 as it is by appropriately designing the shape of the base material 15 .

When the heater unit 10 is used as the light shielding hood 53 , it is preferable that a stray light prevention material is formed on the outermost surface of the side facing the windshield 57 . This makes it possible to suppress the incidence of external light from outside the light receiving range. The anti-stray light material is sometimes referred to as an anti-reflection material, and includes non-woven fabrics and sheets whose surfaces have undergone processing such as pear-finishing, texturing, delustering, and flocking. Also, as one measure for forming the anti-stray light material, it is conceivable to apply matte paint.

When the humidity inside the vehicle is high or the temperature outside the vehicle is low, fogging, dew condensation, frost, ice, etc. may adhere to the windshield 57 . Light is scattered by this cloudiness, dew condensation, frost, ice, etc., and there is a possibility that clear photographing by the sensor unit 55 may be hindered. This is the same when using a radar unit instead of a camera unit. Therefore, the heater units 10, 20 according to the present invention are used to heat the windshield 57 with the heat emitted from the heater units 10, thereby removing fog, condensation, frost and ice. In addition, the heat from the heater unit 10 heats the air in the bracket 51, thereby reducing the humidity in the bracket 51, thereby removing condensation.

It should be noted that the present invention is not limited to the above embodiments. For example, the number of PTC heating elements 11 is not one as in the above embodiment, but may be two, three, or more. When a plurality of PTC heating elements 11 are used, using elements with different Curie temperatures makes it possible to design the temperature by changing the heating temperature for each part or creating a temperature gradient. Moreover, the shape of the substrate 15 is not limited to a flat plate shape, and may be a completely different shape. The position of the recess 15c formed in the base material 15, that is, the position where the PTC heating element 11 is arranged can also be appropriately designed according to the desired heat generation characteristics and usage environment.

In the substrate 15, the first electrode terminal 13a is arranged in the effective heating portion. An effective heating portion is a portion designed to generate heat. In the embodiment, it is the portion where the first electrode terminal 13a is arranged. Considering fixing of the PTC heating element 11 and electrical connection between the PTC heating element 11, the first electrode terminal 13a and the second electrode terminal 13b, the area of the effective heating portion is preferably larger than the area of the recess 15c.

In particular, it is preferable that the first electrode terminal 13a substantially covers the entire area of one surface of the substrate. Here, the term “substantially covered the entire area” does not necessarily mean that the entire area is completely covered. For example, if 80% of the area of one side of the substrate is covered, then the entire area is considered substantially covered. In addition, since the portion where the first electrode terminal 13a is arranged becomes a heat generating portion, it is conceivable to appropriately design the shape of the first electrode terminal 13a according to the required heat generating portion. In addition, by changing the thickness of the first electrode terminal for each portion, it is possible to design the temperature by changing the heat generation temperature for each portion or creating a temperature gradient.

Also, the surface of the base material 15 forming the recess 15c is preferably flat, but does not have to be completely flat. It may have unevenness or may have a curved surface. When the surface of the substrate 15 on which the concave portions 15c are formed is flat, for example, when the square root of the area of one surface of the substrate is L, and the maximum value of the normal direction of the unevenness or curved portion is H, H/L. >0.1, it is considered to be substantially flat.

The number of lead wires connected to the first electrode terminal 13a or the second electrode terminal 13b does not have to be one, and a plurality of lead wires can be connected. For example, when two heater units 10 are prepared and connected in parallel as shown in FIG. In addition, in FIG. 6, a part is shown transparently, and the transparent part is shown by a broken line. More specifically, in one heater unit 10, a first lead wire 19a and a third lead wire 19c are connected to the first electrode terminal 13a, and a second lead wire 19b is connected to the second electrode terminal 13b. Connecting. In one heater unit 10', the first electrode terminal 13a' is connected to the second lead wire 19b and the fourth lead wire 19d, and the second electrode terminal 13b is connected to the third lead wire 19c. . The other ends of the first lead wire 19 a and the fourth lead wire 19 d are connected to the connector 41 . As a result, a parallel circuit of the heater units 10 and 10' can be configured without using a connection terminal for connecting lead wires. Each structure of the heater unit in this case is shown in FIGS. 7 and 8. FIG. The PTC heating element 11 is sandwiched between and electrically connected to the first electrode terminal 13a and the second electrode terminal 13b. A recess 15c is formed substantially in the center of one main surface of the base material 15, and the PTC heating element 11 is arranged and held in this recess 15c. Further, a second lead groove 15b for leading the second electrode terminal 13b to the second lead wire 19b is formed continuously with the recess 15c. Further, next to the second lead-out groove 15b, a first lead-out groove 15a for drawing the first electrode terminal 13a to the first lead wire 19a and the third lead wire 19c is formed with a partition therebetween. A portion of the peripheral wall 15w of the base material 15 where the first lead-out groove 15a is positioned is notched to form a lead wire insertion portion 15r and a lead wire insertion portion 15t. In addition, a lead wire insertion portion 15s is formed by notching a portion of the peripheral wall 15w where the second extraction groove 15b is located. Of course, it is conceivable to form four or more lead wire insertion portions in order to connect more lead wires.

It is also conceivable to connect not only two heater units 10 but also three or more. If the PTC heating element used in each heater unit has a different Curie temperature, it is possible to design the temperature by changing the heating temperature for each part or creating a temperature gradient.

It is also conceivable to attach a heat insulating material to the heater unit 10 so that the heat generated by the PTC heating element 11 is not released to the outside. It is also conceivable to attach a cushioning material to protect against impact from the outside. Since it is preferable that both the heat insulating material and the cushioning material are made of various foamed resins or foamed rubbers, a member that serves both as the heat insulating material and the cushioning material can be used. It is also possible to use a combination of a plurality of heat insulating materials and cushioning materials having different properties such as heat insulating properties, heat resistance, shock absorption, and appearance. Moreover, it is conceivable to appropriately use an adhesive tape or the like in order to attach the heater unit 10 to another member.

As described in detail above, according to the present invention, it is possible to obtain a heater unit having a function of preventing an excessive rise in temperature, uniformizing the temperature, and in which a heating element and the like are appropriately fixed. Such a heater unit can be suitably used as various heat sources, such as household heaters, automobile interior heaters, industrial heaters, various snow and ice removal devices, anti-fogging devices, and cooking appliances. .

10 heater unit 11 PTC heating element 11a, 11b electrode layer 13a first electrode terminal 13b second electrode terminal 13e extension part 15 base material 15a first extraction groove 15b second extraction groove 15c recess 15h through holes 15r, 15s, 15t lead wire Insertion portion 15w Peripheral wall 19a First lead wire 19b Second lead wire

Claims (5)

A base material, a PTC heating element consisting of a ceramic PTC thermistor element having a pair of electrodes formed thereon, a first electrode terminal, a second electrode terminal, a first lead wire, and a second lead wire, In a heater unit having
The first electrode terminal and one electrode layer of the PTC heating element are electrically connected, and the second electrode terminal and the other electrode layer of the PTC heating element are electrically connected. ,
The first electrode terminal and the first lead wire are electrically connected, the second electrode terminal and the second lead wire are electrically connected,
The base material is formed with a concave portion conforming to the shape of the PTC heating element,
The PTC heating element and the second electrode terminal are arranged in the recess,
The first electrode terminal covers the surface of the substrate on which the recess is formed,
A peripheral wall is formed in the base material so as to surround the recess, and a lead wire insertion portion is formed by cutting out a part of the peripheral wall,
A heater unit in which the first lead wire is sandwiched and held between the first electrode terminal and the lead wire insertion portion. In the base material, a second lead-out groove for drawing out to the second electrode terminal second lead wire is formed continuously with the recess, and the second lead-out groove is separated from the second lead-out groove by a partition wall. A first lead-out groove is formed for leading the one electrode terminal to the first lead wire,
The peripheral wall is notched at a location where the first extraction groove is located to form a lead wire insertion portion, and the peripheral wall is notched at a location where the second extraction groove is located to allow the lead wire to be inserted. 2. The heater unit according to claim 1, wherein a portion is formed. 3. The heater unit according to claim 2, wherein a filler is arranged in the second lead-out groove, and the second lead wire is sandwiched and held between the filler and the lead wire insertion portion. The second electrode terminal is arranged so as to be continuous with the recess and the second lead-out groove, and the width of the portion located at the boundary between the recess and the second lead-out groove is equal to the width of the recess and the second lead-out groove. 3. The heater unit according to claim 2, wherein the width is narrower than the width of the portion located in the lead-out groove. A windshield device for a vehicle, comprising: the heater unit according to any one of claims 1 to 4; a bracket attached to a windshield of a vehicle; and a sensor unit housed in the bracket.

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