Positive temperature coefficient heater assembly

Abstract

This invention relates to a positive temperature coefficient (PTC) heater assembly, characterized by comprising: a housing having an internal storage space; a PTC frame housed within the storage space, having a plurality of hollow retainer portions spaced along its length, and a terminal fastening portion at one end along the length; a plurality of PTC elements inserted into the retainer portions of the PTC frame; a terminal plate forming surface contact with one and another side of the PTC elements and extending along its length; and an insulating film attached to the outside of the terminal plate. The terminal plate includes: a pair of first terminal plates grouping and energizing a portion of the plurality of PTC elements and arranged facing each other; and a pair of second terminal plates separated from the first terminal plates, energizing the remaining portions of the PTC elements and arranged facing each other. Therefore, even if either the first or second terminal plate heats up due to energization, current can be prevented from flowing into the other or heat from being conducted to the other, thus enabling more precise and fine temperature control and blocking the flow of excess current.

Description

Technical Field

[0001] This invention relates to a positive temperature coefficient (PTC) heater assembly, and more specifically, to a PTC heater assembly that, by improving the structure and assembly structure of the heater assembly, not only can the independent heating efficiency be maximized, but the assembly defect rate can also be significantly reduced. Background Technology

[0002] Typically, vehicles are equipped with heating systems for heating the passenger compartment and for dehumidifying or defrosting the windshield.

[0003] The working principle of this heating system is as follows: after the engine starts, the coolant flowing around the engine enters the heater. Therefore, the cabin can only be heated after the coolant has heated up, which takes a relatively long time. As a result, the interior of the vehicle remains cold for a period of time after starting.

[0004] In recent years, electric vehicles have become a research and development trend. Since electric vehicles do not have independent engines and coolant structures, they mostly use electric heaters that utilize resistive elements.

[0005] The electric heater uses a PTC heater assembly with a built-in PTC element.

[0006] The following is for reference Figure 1 This paper describes the existing PTC heater assembly.

[0007] As shown in the figure, the PTC heater assembly in the prior art includes: a (+) terminal plate 50, a (-) terminal plate 52, a PTC element 40 between the two, a PTC frame 30 that houses the PTC element 40, an insulating film 20 bonded to the outer surfaces of the (+) and (-) terminal plates 50 and 52 and the PTC frame 30, and a housing 10 that houses the PTC frame 30 bonded to the insulating film 20 on the inner side.

[0008] However, in the existing PTC heater assembly, when current flows into the (+) and (-) terminal plates 50 and 52, the multiple PTC elements 40 between them will heat up, making it difficult to adjust the heating temperature intensity, that is, it is difficult to finely adjust the temperature setting and maintain the temperature.

[0009] like Figure 2 As shown, in recent years, in order to solve the aforementioned problem, Korean Patent Publication No. 1913121 (October 24, 2018) discloses an "independently controlled PTC heater and device" that can independently control PTC elements to maximize energy and heating efficiency.

[0010] However, for the "independently controlled PTC heater and device" in the prior art, when the first opening 121-1 and the second opening 121-2 formed by the guide frame 120 into which PTC elements 110-1 and 110-2 are inserted are offset from each other (direction of offset), due to the offset structure of the first opening 121-1 and the second opening 121-2, the overall width of the guide frame 120 needs to be made wider, which leads to an increase in volume and weight, and thus increases manufacturing costs.

[0011] Furthermore, since the common electrode plate 150 is in full contact with one side of the PTC elements 110-1 and 110-2 inserted into the first opening 121-1 and the second opening 121-2, current always flows through the other PTC element 110-2, which does not need to generate heat. This not only causes unnecessary current loss, but also the heat from the heated PTC element 110-1 is conducted to the other PTC element 110-2 through the common electrode plate 150, thereby reducing the efficiency of independent heating.

[0012] Existing technical documents

[0013] Patent documents

[0014] Patent Document 1: Korean Patent Publication No. 1096286 (December 13, 2011)

[0015] Patent Document 2: Korean Patent Publication No. 1913121 (October 24, 2018) Summary of the Invention

[0016] Technical issues

[0017] This invention is proposed to solve the aforementioned problems. The purpose of this invention is to provide a PTC heater assembly, that is, by improving the structure and assembly structure of the heater assembly, not only can the independent heating efficiency be maximized, but the assembly defect rate can also be significantly reduced, thereby significantly improving the reliability of product quality.

[0018] Technical solution

[0019] To achieve the aforementioned objective, the PTC heater assembly of the present invention includes: a housing having an internal storage space; a PTC frame housed within the storage space, having a plurality of hollow retainer portions spaced along its length and a terminal fastening portion at one end along its length; a plurality of PTC elements inserted into the retainer portions of the PTC frame; a terminal plate forming surface contact with one and another side of the PTC elements and extending along its length; and an insulating film attached to the outside of the terminal plate, the terminal plate including: a pair of first terminal plates grouping and energizing a portion of the plurality of PTC elements and arranged facing each other; and a pair of second terminal plates separated from the first terminal plates, energizing the remaining portions of the PTC elements and arranged facing each other.

[0020] The first terminal plate includes: a first energized plate that contacts the PTC element surface; and a terminal portion that extends from the outer side of one end of the first energized plate toward the terminal fastening portion and is coupled to the terminal fastening portion. The second terminal plate includes: a second energized plate that contacts the PTC element surface; and a terminal portion that protrudes from one end of the second energized plate, the protruding end of which extends in a direction through the terminal fastening portion.

[0021] When viewed from the side, the terminal portion of the first terminal board bends from the end of the first power-conducting board toward the PTC element and intersects with one side of the PTC element.

[0022] The PTC frame has a first insertion slot and a second insertion slot for accommodating and inserting the terminal portions of the first terminal board and the second terminal board, respectively. The depth of the first insertion slot is greater than the depth of the second insertion slot.

[0023] The first terminal plate and the second terminal plate have fastening bends formed on opposite sides of the ends where the terminals are respectively provided. The PTC frame has a third fastening hole and a fourth fastening hole for fastening the fastening bends of the first terminal plate and the second terminal plate.

[0024] Each of the terminal portions is bent at its end to form an overlapping portion of a double-layer structure.

[0025] The effects of the invention

[0026] According to the present invention with the described structure, by setting a pair of first terminal boards and second terminal boards that can independently group multiple PTC elements, even if either the first terminal board or the second terminal board heats up due to power-on, current can be prevented from flowing into the other or heat can be conducted to the other. Therefore, the temperature can be adjusted more precisely and finely, and excess current can be blocked.

[0027] Furthermore, the first terminal plate includes a terminal portion, which bends from the end of the first power-conducting plate toward the PTC element and intersects with one side of the PTC element. A first insertion groove corresponding to the terminal portion is formed in the PTC frame. By contacting the inner wall surfaces on both sides of the first insertion groove, the coefficient of friction can be greatly improved, which can not only maintain a more robust and stable connection state, but also minimize the increase in the overall width or weight of the PTC frame.

[0028] Furthermore, by forming overlapping double-layer structures, the thickness of each terminal increases the fastening rigidity, which not only improves the warping phenomenon when assembling the PTC frame, but also significantly increases the current carrying capacity, thereby ensuring a stable current. Attached Figure Description

[0029] Figure 1 An exploded perspective view showing the structure of a PTC heater assembly in the prior art.

[0030] Figure 2 An exploded perspective view showing the structure of a PTC heater assembly in another prior art.

[0031] Figure 3 This is a perspective view of a PTC heater assembly according to an embodiment of the present invention.

[0032] Figure 4 for Figure 2 An exploded 3D diagram.

[0033] Figure 5 for Figure 3 Side sectional view.

[0034] Figure 6 To show Figure 4 An enlarged view of the terminal block structure.

[0035] Figure 7 for Figure 4 A top view of the PTC frame.

[0036] Figure 8 To show the formation in Figure 4 Side view of another embodiment of the overlapping portion of the terminal block Detailed Implementation

[0037] Hereinafter, preferred embodiments of the PTC heater assembly of the present invention will be described in detail with reference to the accompanying drawings.

[0038] For reference, the terms and vocabulary used in this specification and the scope of protection of the invention should not be limited to their usual meanings or dictionary definitions. Based on the principle that inventors can best express their inventions by appropriately defining terms and concepts, they should be interpreted as meanings and concepts that conform to the technical ideas of the invention.

[0039] Furthermore, the embodiments and structures shown in the accompanying drawings described in this specification are merely preferred embodiments of the present invention and do not represent all the technical ideas of the present invention. It should be understood that, at the time of this application and thereafter, there may be various alternative equivalent schemes and modified embodiments.

[0040] The following will refer to Figures 3 to 8 The preferred embodiments of the present invention will be described in detail below.

[0041] As shown in the figure, the PTC heater assembly of the present invention includes: a housing 100 having a storage space 101 formed inside; a PTC frame 200 housed in the storage space 101, having a plurality of hollow retainer portions 201 spaced apart along the length direction, and having a terminal fastening portion 210 at one end along the length direction; a plurality of PTC elements 300 inserted into the retainer portions 201 of the PTC frame 200; a terminal plate 400 having surface contact with one side and the other side of the PTC elements 300 and extending along the length direction; and an insulating film 500 attached to the outside of the terminal plate 400.

[0042] In particular, the terminal block 400 includes: a pair of first terminal blocks 410 that group and energize a portion of the plurality of PTC elements 300 and are arranged facing each other; and a pair of second terminal blocks 420 that are separate from the first terminal blocks 410, energize the remaining portions of the PTC elements 300 and are arranged facing each other.

[0043] In this configuration, the first terminal block 410 includes: a first energized plate 411 that is in surface contact with the PTC element 300; and a terminal portion 412 that extends from the outer side of one end of the first energized plate 411 toward the terminal fastening portion 210 and is coupled to the terminal fastening portion 210.

[0044] The second terminal block 420 includes: a second energized plate 421 that is in contact with the PTC element 300; and a terminal portion 422 that protrudes from one end of the second energized plate 421, the protruding end of which extends in a direction through the terminal fastening portion 210.

[0045] The housing 100, as an external component extending to a predetermined length and having a storage space 101 inside, serves to provide safety protection for the PTC frame 200, PTC element 300, terminal board 400, and insulating film 500, and to prevent external moisture or foreign objects from intruding.

[0046] Preferably, the housing 100 is made of a metal material such as aluminum with excellent thermal conductivity.

[0047] The terminal plate 400, which is in surface contact with one side and the other side of the PTC element 300, has opposite polarities ((+) pole, (-) pole).

[0048] The PTC frame 200 extends along its length and has a plurality of hollow retainer portions 201 formed along its length for inserting a plurality of the PTC elements 300.

[0049] That is, through the retainer section 201, the PTC element 300 can stably achieve power-on heating without shaking.

[0050] Preferably, the PTC frame 200 is made of synthetic resin to ensure that the terminal plates 400 disposed on one side and the other side of the plurality of PTC elements 300 maintain an insulated state that does not come into contact with each other.

[0051] In addition, a terminal fastening part 210 is provided on one side end of the PTC frame 200. A pair of first fastening holes 211 and second fastening holes 212 are formed in the terminal fastening part 210 for the end of the terminal part 412 of the first terminal plate 410 and the terminal part 422 of the second terminal plate 420 to be inserted through.

[0052] The PTC frame 200 of the present invention has a first insertion slot 220 and a second insertion slot 230, and the first insertion slot 220 and the second insertion slot 230 are respectively inserted into the terminal portion 412 of the first terminal plate 410 and the terminal portion 422 of the second terminal plate 420.

[0053] When viewed from above, the widths of the first insertion slot 220 and the second insertion slot 230 are different; the width of the first insertion slot 220 is smaller than the width of the second insertion slot 230, and the depth of the first insertion slot 220 is greater than the depth of the second insertion slot 230.

[0054] The reason is that, when viewed along the length direction, the terminal portion 412 constituting the first terminal plate 410 bends toward the PTC element 300 and intersects with one side of the PTC element 300, so its terminal portion 412 can be formed to be narrower and higher than the terminal portion 422 of the second terminal plate 420.

[0055] That is, the terminal portion 412 of the first terminal plate 410 inserted into the first insertion slot 220 is vertically arranged, and the first insertion slot 220 accommodates the terminal portion 412 on one side along the longitudinal direction, thereby achieving a more stable fixation.

[0056] Furthermore, when viewed from above, the two sides of the terminal portion 412 of the first terminal plate 410 are in overall contact with the inner walls of the two sides of the first insertion groove 220, which can greatly improve the coefficient of friction. Even when assembling the "PTC heater assembly", if the PTC frame 200 is lifted and reversed, erected, or shaken, the first terminal plate 410 connected to the terminal portion 412 will not detach, but will remain stably and firmly fixed.

[0057] Furthermore, due to this structural characteristic, the width of the space used to accommodate the terminal portion 412 on one side of the first insertion slot 220 is greatly reduced, thereby minimizing the overall width of the PTC frame 200 and suppressing the increase in volume to the greatest extent.

[0058] Therefore, preferably, the width and height of the first fastening hole 211 and the second fastening hole 212 into which the ends of the terminal portion 412 of the first terminal plate 410 and the terminal portion 422 of the second terminal plate 420 are inserted are different.

[0059] As shown in the figure, the width of the first fastening hole 211 is smaller than the width of the second fastening hole, and the height is greater than the height of the second fastening hole.

[0060] Furthermore, a third fastening hole 240 and a fourth fastening hole 250 are formed in the PTC frame 200. The third fastening hole 240 and the fourth fastening hole 250 are used to fasten the first terminal plate 410 and the second terminal plate 420 of the terminal plate 400 at a position different from that of the terminal fastening part 210.

[0061] That is, the third fastening hole 240 and the fourth fastening hole 250 are hollow holes used to perform additional fastening at the opposite ends of the terminals 412, 422 of the first terminal plate 410 and the second terminal plate 420.

[0062] As described above, preferably, when viewed from the length direction, the terminal portion 412 of the first terminal plate 410 bends from the end of the first energized plate 411 toward the PTC element 300 and intersects with one side of the PTC element 300.

[0063] Specifically, the terminal portion 412 has the same thickness as the first power-conducting plate 411 and a relatively narrow width, and extends toward the terminal fastening portion 210, bending 90° relative to the first power-conducting plate 411 so that its edge portion faces the PTC element 300.

[0064] On the other hand, the PTC element 300, as a plurality of structural elements inserted into the retainer portion 201 of the PTC frame 200, can be made into a quadrilateral plate structure.

[0065] However, its shape is not specifically limited.

[0066] One side and the other side of the PTC element 300 inserted into the retainer portion 201 of the PTC frame 200 can contact a pair of first terminal plates 410 and second terminal plates 420 respectively, and heat is generated by the incoming current.

[0067] The first terminal board 410 and the second terminal board 420 divide the PTC element 300 into two groups along the length direction and supply power to each group independently. Even if either the first terminal board 410 or the second terminal board 420 heats up due to power-on, it can prevent current from flowing into the other or heat from being conducted to the other. Therefore, it is possible to adjust the temperature more precisely and finely and block the flow of excess current.

[0068] The first terminal plate 410 and the second terminal plate 420 have fastening bends 413 and 423 formed on opposite sides of the ends where the terminal portions 412 and 422 are respectively provided, for fastening to the third fastening hole 240 and the fourth fastening hole 250.

[0069] Meanwhile, in order to increase the fastening rigidity, each of the terminal portions 412 and 422 is bent to form overlapping portions 412a and 422a of a double-layer structure.

[0070] That is, by forming overlapping portions 412a and 422a of a double-layer structure, the thickness is increased several times, which improves the fastening strength. This not only improves the warping phenomenon when assembling the PTC frame, but also greatly increases the current carrying capacity, thereby ensuring a stable current.

[0071] That is, such as Figure 8 As shown, the overlapping portion 412a of the terminal portion can be bent into a "V" shape and is elastically installed or attached to the inner wall surface of the first insertion groove 220.

[0072] The overlapping portions 412a and 422a with the double-layer structure can be formed by additionally stacking individual terminal plates corresponding to each terminal portion 412 and 422 through a welding operation.

[0073] On the other hand, the insulating film 500 is attached to the upper and lower outer surfaces of the first terminal plate 410 and the second terminal plate 420 respectively, and plays an insulating role, blocking the current flowing into the first terminal plate 410 and the second terminal plate 420 from flowing into the housing 100.

[0074] Preferably, an elastic synthetic resin material is additionally coated or attached to the upper end of the insulating film 500 to maximize the internal residual stress when the housing is pressed.

[0075] Preferably, the insulating film 500 is composed of an insulator with excellent insulation and heat dissipation properties and an elastic synthetic resin material, but it is not limited to this. A variety of excellent materials with good insulation, adhesion and the ability to maximize the internal residual stress when pressing the shell 100 can be used.

[0076] The present invention is not limited to the embodiments and drawings described herein. It is obvious that those skilled in the art can make various substitutions, modifications and alterations without departing from the technical concept of the present invention.

Claims

1. A positive temperature coefficient heater assembly, characterized in that, include: The shell has an internal storage space. A positive temperature coefficient frame is housed in the storage space and has multiple hollow retainer portions spaced along its length. It has a terminal fastening portion at one end along its length. Multiple positive temperature coefficient elements are inserted into the retainer portion of the positive temperature coefficient frame; Terminal plate, forming surface contact with one and another side of the positive temperature coefficient element and extending along its length; and An insulating film is attached to the outer side of the terminal block. The terminal block includes: A pair of first terminal blocks group and energize a portion of a plurality of positive temperature coefficient elements, and are positioned facing each other; and A pair of second terminal boards, separate from the first terminal board, energize the rest of the PTC element and are positioned opposite each other.

2. The positive temperature coefficient heater assembly according to claim 1, characterized in that, The first terminal board includes: The first energized plate is in contact with the surface of the positive temperature coefficient element; and The terminal portion extends from the outer side of one end of the first energized plate toward the terminal fastening portion and is coupled to the terminal fastening portion. The second terminal board includes: The second energized plate is in contact with the surface of the positive temperature coefficient element; and The terminal portion extends elongatedly from the outer side of one end of the second power board toward the terminal fastening portion and is attached to the terminal fastening portion.

3. The positive temperature coefficient heater assembly according to claim 2, characterized in that, The terminal portion of the first terminal board bends from the end of the first energized board toward the positive temperature coefficient element and intersects with one side of the positive temperature coefficient element.

4. The positive temperature coefficient heater assembly according to claim 3, characterized in that, The positive temperature coefficient frame has a first insertion groove and a second insertion groove for accommodating and inserting the terminal portions of the first terminal board and the second terminal board, respectively. The depth of the first insertion groove is greater than the depth of the second insertion groove.

5. The positive temperature coefficient heater assembly according to any one of claims 2 to 4, characterized in that, The first terminal plate and the second terminal plate have fastening bends formed on opposite sides of the ends where the terminals are respectively provided. The positive temperature coefficient frame has a third fastening hole and a fourth fastening hole for fastening the first terminal plate and the second terminal plate with a bending portion.

6. The positive temperature coefficient heater assembly according to claim 4, characterized in that, Each of the terminal portions is bent at its end to form an overlapping portion of a double-layer structure.

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