Temperature control device, in particular for heating the interior of a vehicle and / or the power pack of a vehicle

Abstract

The invention relates to a temperature control device (10) for heating an interior space (33) of a vehicle (32) and / or a temperature control device for a unit of a vehicle (32), comprising a plurality of electrically driven heating elements (12), electric conductors (16) used for connecting the heating elements (12) to an electrical power supply (20) of the vehicle (32), and at least one heat transfer section (22) which can be flowed through or encircled by a fluid and which transfers heat generated by the heating elements (12) to the fluid, wherein the at least one heat transfer section (22) comprises a first material (24) which is thermally conductive, and the heating elements (12) and the electric conductors (16) are surrounded by a second material (26) which is electrically non-conductive and thermally conductive. Furthermore, the invention relates to a method for manufacturing the temperature control device (10) and to a vehicle (32) comprising the temperature control device (10), in particular a motor vehicle.

Description

Technical Field

[0001] The present invention relates to a temperature control device specifically for heating the interior space of a vehicle and / or the engine compartment of a vehicle. Background Technology

[0002] Due to the increasing efficiency of modern internal combustion engines in vehicles, they provide less and less waste heat, which can be used to heat the vehicle's interior and / or its components (e.g., the vehicle battery). Since the electric motors in electric vehicles produce almost no waste heat, they cannot function as a heat source at all. Therefore, in both cases, a temperature control device (sometimes called an auxiliary heater) is used, which has an electrically driven heating element to provide the necessary heat. Known temperature control devices have at least one heat transfer section through which a fluid can flow or circulate, and this heat transfer section transfers the heat generated by the heating element to the fluid. The heat transfer section is connected to the heating element to achieve thermal conduction. The heat transfer section has, for example, fins that are circulated by air. The fins are made of a material with high thermal conductivity, typically a metal such as aluminum. To power the heating element, electrical wires must be provided, through which the heating element is connected to the vehicle's power source. In temperature control devices, separation is required between the heat transfer section and the conductive components such as electrical wires. However, because aluminum is not only thermally conductive but also electrically conductive, known temperature control devices, such as those described in US 7399948 B2, have a plastic frame for separation. Other such temperature control devices are known from EP 1407907A1, EP 1839920 A1, EP 1933598 A1, US5206476 A, and US 2017 / 0113511 A1. Due to the large number of different materials and complex structures, the manufacture and assembly of such known temperature control devices are time-consuming and expensive. Automation is virtually impossible; therefore, manufacturing is carried out entirely or partially manually. Summary of the Invention

[0003] The objective of one embodiment of the present invention is to develop a temperature control device of the type described above, thereby simplifying manufacturing and assembly and making it cheaper.

[0004] This objective is achieved by the features described in claims 1, 7, and 8. Advantageous embodiments are the subject of the dependent claims.

[0005] One embodiment of the present invention relates to a temperature control device for heating the interior space of a vehicle and / or a unit of the vehicle, comprising a plurality of electrically driven heating elements, electrical wires for connecting the heating elements to the vehicle’s power supply, and at least one heat transfer portion through which a fluid can flow and transfer the heat generated by the heating elements to the fluid, wherein the at least one heat transfer portion comprises a thermally conductive first material, and the heating elements and electrical wires are surrounded by a non-conductive and thermally conductive second material.

[0006] In the following description, thermally conductive materials should be understood as materials having a thermal conductivity in the range of approximately 15 to 500 W / mK. For example, aluminum (Al) has a thermal conductivity of 235 W / mK, and iron (Fe) has a thermal conductivity of 80.2 W / mK.

[0007] Non-conductive materials should be understood as having <10 -1 Materials with a conductivity of S / m. For example, glass has a conductivity of 0.01 S / m, and ceramics have a conductivity of 0.001 S / m.

[0008] The use of a thermally conductive first material in the heat transfer section ensures that the heat generated by the heating element can be effectively transferred to the circulating fluid or fluid flowing through the heat transfer section. The use of a thermally conductive but non-conductive second material ensures electrical insulation between the conductors and the heating element, thus eliminating the risk of short circuits. Simultaneously, due to its thermal conductivity, the second material does not impede heat transfer from the heating element to the heat transfer section compared to materials used in known temperature control devices. The heat transfer section can be, for example, made of aluminum or at least comprise aluminum. Because of the electrical insulation effect of the second material, no further measures are needed to separate the heat transfer section from the conductors, simplifying the structure of the temperature control device, thereby simplifying manufacturing and assembly and reducing associated costs.

[0009] In another embodiment, the first and second materials can be the same non-conductive and thermally conductive material. As mentioned above, the heat transfer section is designed to ensure that the heat provided by the heating element is efficiently transferred to the fluid. In this case, this depends on high thermal conductivity. Therefore, only the first material can be conductive because the second material is electrically insulating. However, the second material is not only electrically insulating but also has high thermal conductivity, so it can also be used in the heat transfer section. Therefore, the amount of material used in the temperature control device can be reduced, which further simplifies manufacturing and assembly. In particular, the interaction between the first and second materials in this embodiment does not need to be considered in the design of the temperature control device.

[0010] In a further developed embodiment, the temperature control device may include a non-thermally conductive third material. As mentioned above, the temperature control device is particularly used for heating the interior space of a vehicle and / or for heating components (e.g., a vehicle battery). Therefore, the temperature control device must be securely fastened to the vehicle. For example, a third material is used at the contact points between the temperature control device and adjacent components of the vehicle for fastening. Because the third material is non-thermally conductive, heat transfer is prevented to components that do not require heating and / or may be damaged by heating.

[0011] In another embodiment, the first, second, and / or third materials can be injection-moldable plastics. Injection-moldable plastics can be thermoplastics, such as PA (polyamide), PBT (polybutylene terephthalate), or PPS (polyphenylene sulfide). These plastics (e.g., polymers and these thermoplastics) are non-conductive and non-thermal in their initial state. However, to impart the desired thermal conductivity, additives such as graphite, carbon fiber, or suitable ceramics can be provided. The use of injection-moldable plastics allows the temperature control device to be manufactured entirely through an injection molding process. In this case, the heating element and electrical wires can be pre-positioned in the injection mold using corresponding cores and pins, and then pressure-injected encapsulated. This allows for the easy injection of not just one material, but multiple materials, during the injection molding process. Even when the temperature control device comprises multiple materials, it can be manufactured using a so-called "one-shot molding process," meaning that the temperature control device can be manufactured entirely by opening and closing the injection mold only once. Therefore, manufacturing time and manufacturing costs remain low.

[0012] One embodiment is characterized in that the heating element is a positive thermistor. A positive thermistor, also known as a positive temperature coefficient thermistor (PTC thermistor), has a positive temperature coefficient, therefore it conducts current better at low temperatures than at high temperatures. If the PTC thermistor is driven with a constant voltage, it will automatically adjust. If the PTC thermistor is driven to dissipate a large amount of heat, it will heat up accordingly. However, as the temperature rises, the heat it generates decreases, and it will cool down again. This prevents overheating.

[0013] PTC thermistors can be used not only for heating interior spaces or other units, but also for cooling. The application areas of the proposed temperature control device, particularly according to the embodiment with the PTC thermistor, are not limited to temperature control of vehicle interior spaces or vehicle units. Moreover, the temperature control device can be used for, for example, cooling of computers and servers. In this respect, the invention relates not only to the use of temperature control devices for heating vehicle interior spaces and vehicle units, but also to their use for cooling heat-generating and heat-hazardous IT components (especially servers and computers). In this case, heat is drawn from the fluid, causing heat to transfer from the fluid to the heat transfer section.

[0014] In another embodiment, the temperature control device includes a connection portion through which it can be connected to the vehicle's power supply. The connection portion can be designed to connect to a universal plug found in the vehicle body. Therefore, the temperature control device can be effortlessly integrated into the vehicle's power electronics.

[0015] One embodiment of the present invention relates to a method for manufacturing a temperature control device according to one of the foregoing embodiments, wherein the temperature control device is manufactured using a "one-shot injection molding process".

[0016] One embodiment of the present invention relates to a vehicle (particularly a motor vehicle) that includes a temperature control device according to one of the foregoing embodiments and / or a temperature control device manufactured by the method according to the above embodiments.

[0017] The technical effects and advantages achievable using the proposed method and the proposed vehicle correspond to what has already been discussed regarding the previously presented temperature control devices. In summary, it should be noted that the structure of the temperature control devices can be designed so that they can be manufactured using an injection molding process. Furthermore, the injection molding process can be configured as a "one-step injection molding process," where the injection mold only needs to be closed and opened once to manufacture the temperature control device. Therefore, low manufacturing costs and manufacturing time for the temperature control devices can be maintained. Vehicles equipped with temperature control devices can be manufactured correspondingly at a lower cost. Attached Figure Description

[0018] Exemplary embodiments of the invention will now be explained in more detail with reference to the accompanying drawings. In the drawings:

[0019] Figure 1a A schematic view of an embodiment of the temperature control device according to the present invention is shown;

[0020] Figure 1b It shows Figure 1a A magnified view of the area marked X; and

[0021] Figure 2This is a schematic plan view of a vehicle equipped with a temperature control device according to the present invention. Detailed Implementation

[0022] Figure 1a A schematic view of an embodiment of the temperature control device 10 according to the present invention is shown. Figure 1b It shows Figure 1a A magnified view of the region X marked in the middle. Therefore, the following description also refers to... Figure 1a and 1b .

[0023] The temperature control device 10 has multiple electrically driven heating elements 12, which are designed as positive thermistors 14 in the illustrated embodiment. The heating elements 12 are connected to a connection portion 17 via electrical wires 16, through which the temperature control device 10 can be connected to the vehicle's onboard electronics 32, particularly the control unit 18 and the power supply 20 (see...). Figure 2 Additionally, the connection portion 17 can accommodate the heating element 12, and particularly the power electronic device, the positive thermistor 14. Figure 1b As can be seen, heating elements 12 are connected in parallel.

[0024] Furthermore, the temperature control device 10 has multiple heat transfer sections 22 through which fluid (particularly air) can flow. In this example, the heat transfer sections 22 are made of a thermally conductive first material 24, such as aluminum.

[0025] Furthermore, the heating element 12 and the electrical wire 16 are surrounded by a second material 26, which is thermally conductive, electrically insulating, and provides support. The second material 26 is in contact with the first material 24, allowing the heat generated by the heating element 12 to be conducted to the heat transfer portion 22 and transferred to the fluid thereon.

[0026] In an embodiment not shown, the power electronics of the heating element 12 (particularly the power electronics of the positive thermistor 14) are also surrounded by the second material 26. The heat generated during operation by the power electronics can be conducted through the second material 26 to the heat transfer portion 22 and transferred to the fluid there, thereby reducing power loss.

[0027] Furthermore, the temperature control device 10 includes a frame 28 made of a non-thermally conductive third material 30. The temperature control device 10 is fastened to the connecting portion 17 by means of the frame 28. Not shown, the temperature control device 10 can be fastened to adjacent components of the vehicle 32 by means of the frame 28.

[0028] For the first, second, and third materials 30, injection-moldable plastics can be used, which allows the temperature control device 10 to be manufactured by injection molding, thereby enabling the mass production of temperature control devices at low cost. The heating element 12 and the electrical wire 16 can be positioned in the injection mold using a core and pin, and then pressure-injected encapsulated by the second material 26. Subsequently, the heat transfer portion 22 is injection molded, followed by the frame 28. Other manufacturing sequences are also conceivable. All injection molding steps can be performed without opening the injection tool, thus allowing the temperature control device 10 to be produced in a "one-shot injection molding process". Manufacturing can be further simplified by replacing at least the first material 24 with the second material 26 and thus reducing the amount of material used. However, it is meaningful to manufacture the frame 28 from the non-thermally conductive third material 30. This prevents the heat generated by the heating element 12 from being dissipated to adjacent parts, and therefore no longer needs to be used for heating fluids.

[0029] Figure 2 A vehicle 32 based on a schematic plan view is shown, equipped with a temperature control device 10 according to the invention and having an interior space 33. The temperature control device 10 is connected to the vehicle's on-board electronics via electrical wires 16, the on-board electronics including a control unit 18. The control unit 18 is connected to a temperature measuring sensor 34, which measures the temperature in the vehicle's interior space 33. Furthermore, the control unit 18 is connected to an interface 36, which the driver can use to set a desired interior space temperature. The interior space temperature in the vehicle 32 can be controlled by a corresponding algorithm stored on the control unit 18. It should be noted that the use of a positive thermistor 14 (also known as a PTC thermistor) can both increase and decrease the interior space temperature.

[0030] In addition, the temperature control device 10 is connected to the power supply 20 via the electrical wire 16, and the power supply 20 provides electrical energy for driving the temperature control device 10. Figure 2The vehicle 32 shown is electrically driven and therefore has a vehicle battery 38 for driving an electric motor (not shown). The temperature control device 10 can also be used to control the temperature of the vehicle battery 38 or other units of the vehicle (not shown). It is also conceivable that the temperature control device 10 is powered by the vehicle battery 38, thus making the power source 20 unnecessary. However, the separation of the power source 20 from the vehicle battery 38 is meaningful because, especially at low external temperatures, the vehicle battery 38 discharges faster compared to moderate external temperatures. By separating the power source 20 from the vehicle battery 38, a warming strategy can be implemented, for example, after a specified time, if the specified temperature is not reached, the temperature control device 10 is activated by the control unit 18. Therefore, when the driver wants to start driving, the vehicle battery 38 is preheated during the preheating phase even if not requested. Thus, it is possible to prevent the vehicle battery 38 from discharging faster due to low external temperatures.

[0031] When vehicle 32 is driven by an internal combustion engine (not shown), and although it provides waste heat, it is not always sufficient, a temperature control device 10 can also be used to heat the interior space 33 of vehicle 32 to the required temperature within a certain time. In this case, the temperature control device 10 is not the sole heat source, but works in conjunction with the internal combustion engine; this is why the temperature control device 10 is also referred to as an auxiliary heater. A preheating strategy can also be implemented here, with a design very similar to that described for vehicle battery 38. Since the internal combustion engine operates optimally only at its operating temperature, especially at low external temperatures, the temperature control device 10 can be used to preheat the internal combustion engine and / or engine oil and / or other components of the transmission system, thereby reaching operating temperature more quickly and thus reducing wear and tear on the internal combustion engine and / or transmission system.

[0032] List of reference numerals in the attached diagram:

[0033] 10 Temperature control device

[0034] 12 Heating elements

[0035] 14 Positive thermistor

[0036] 16 Electrical wires

[0037] 17. Connection Part

[0038] 18 Control Unit

[0039] 20 power supply

[0040] 22 Heat Transfer Section

[0041] 24 First Material

[0042] 26 Second Material

[0043] 28 Frames

[0044] 30 Third Material

[0045] 32 vehicles

[0046] 33 Interior Space

[0047] 34 Temperature Measurement Sensor

[0048] 36 Interfaces

[0049] 38 Vehicle batteries

Claims

1. A temperature control device (10) for heating the interior space (33) of a vehicle (32) and / or the unit of the vehicle (32), the temperature control device comprising: - Multiple electrically driven heating elements (12); - Electrical wire (16), through which the heating element (12) is connected to the power supply (20) of the vehicle (32); and - At least one heat transfer section (22), through which fluid flows or circulates and the heat transfer section transfers the heat generated by the heating element (12) to the fluid. in, - The at least one heat transfer portion (22) includes a thermally conductive first material (24), and - The heating element (12) and the electrical wire (16) are surrounded by a non-conductive and thermally conductive second material (26), which provides support; The first material (24) and the second material (26) are injection-molded plastics, which enable the temperature control device (10) to be manufactured by injection molding.

2. The temperature control device according to claim 1, Its features are: The first material (24) and the second material (26) are the same material, which is non-conductive and thermally conductive.

3. The temperature control device according to claim 1, Its features are: The temperature control device (10) includes a third material (30) that is non-thermal conductive.

4. The temperature control device according to claim 3, Its features are: The third material (30) is an injection-molded plastic.

5. The temperature control device according to claim 1, multi-lead multi-lead Its features are: The heating element (12) is a positive thermistor (14).

6. The temperature control device according to any one of the preceding claims, Its features are: The temperature control device (10) includes a connection portion (17) by means of which the temperature control device (10) can be connected to the power source (20) of the vehicle (32).

7. A method for manufacturing a temperature control device (10) according to any one of the preceding claims, Its features are: The temperature control device (10) is manufactured using a "one-time injection molding process".

8. A vehicle comprising a temperature control device (10) as described in any one of claims 1 to 6 or a temperature control device (10) manufactured according to the method described in claim 7.

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