Electric heating device and its manufacturing method

Abstract

The present invention relates to an electric heating device (98) having a housing (100) forming a receiving cavity (102) in which at least one PTC heating assembly (2) is received. The PTC heating assembly has at least one PTC element (4) housed in a positioning frame (10) and a strip conductor (6) electrically connected to the PTC element (4) to energize the PTC element (4) using different polarities. In order to compensate for manufacturing tolerances in an improved manner without significantly affecting the heat dissipation of the PTC element, and to make the electric heating device economically manufactured, the present invention proposes to connect at least one contour member (26) to the PTC element (4) on opposite main side surfaces in a thermally conductive manner. In each case, the outer main side surface of the contour member (26) opposite to the PTC element (4) is thermally connected to the inner surface (136) of the receiving cavity (102). The contour member (26) is connected to the positioning frame (10).

Description

Technical Field

[0001] This invention relates to an electric heating device having a housing forming a receiving cavity for receiving at least one PTC heating element. The PTC heating element has a positioning frame for receiving at least one PTC element. Furthermore, a strip conductor electrically connected to the PTC element and a heater housing are provided. Background Technology

[0002] In the prior art, a positioning frame is used to hold the PTC element and to arrange the strip conductor. EP2637474A1 or EP2233425A1 respectively disclose PTC elements inserted into corresponding receiving cavities. An electric heating device for this purpose has a housing with a partition wall separating a connection chamber from a heating chamber for emitting heat, and at least one heating rib protrudes from the heating chamber along the direction of the heating chamber, thereby forming a receiving cavity for receiving the PTC heating assembly.

[0003] This configuration can also be used in this invention. EP2637474A1, representing prior art, discloses a PTC heating assembly that engages a wedge-shaped element with a structural unit disposed on the main side surface of at least one PTC element. After the PTC heating assembly is inserted into the receiving cavity, the wedge-shaped element is displaced to connect the PTC element to the inner surface of the receiving cavity in a thermally conductive manner.

[0004] In the previously described solution, the receiving cavity tapers towards its lower closed end. Therefore, the insertion opening towards the connection chamber is wider than the lower closed end of the receiving cavity. The PCT element and the adjacent contact pad are typically clamped together by inserting at least one insulating layer between the strip conductor and the opposing inner surfaces of the receiving cavity with wedge-shaped pressure elements. The wedge-shaped element ensures that the layers in the layer structure abut against each other in a clamping manner. These layers consist at least of the PTC element and the strip conductor (typically the contact pad) extending in a direction perpendicular to the direction of force application of the wedge-shaped element, and at least one insulating layer.

[0005] Although the cross-sectional shape of the receiving cavity tapers downwards due to the manufacturing process, the wedge-shaped element is designed to enable good heat transfer between the two opposing heat extraction surfaces of the PCT element and the respective inner surfaces of the receiving cavity where the wedge-shaped element is inserted. Due to the established pressure, the opposing heat extraction surfaces of the PCT element can also directly abut against or, with an insulating layer inserted, against the opposing inner surfaces of the receiving cavity.

[0006] Therefore, good thermal extraction properties are ensured. However, the problem is that, due to manufacturing tolerances, the receiving cavity cannot always correspond to a specific shape.

[0007] In addition, due to manufacturing tolerances, PTC elements will have some dimensional fluctuations. This makes it impossible to always ensure that the heat extraction surface of the PTC element is perfectly straight and flat.

[0008] Pressing a wedge into the housing as a pressure element can lead to stress peaks, potentially causing the PTC element or ceramic insulation within the receiving cavity to fracture. Due to tolerances, wedge elements used as pressure elements in the prior art may not be thick enough for certain applications, rendering them essentially ineffective at the lower end of the receiving cavity. Conversely, if the free space before insertion of the wedge element is too small, the heat extraction surface of the PTC element does not adequately cover the height of the receiving cavity (i.e., between the lower end and the insertion opening). Consequently, the PTC element heats up intensely, hindering further absorption of power current. Therefore, the efficiency of the PTC element is poor. Summary of the Invention

[0009] The present invention aims to provide an electric heating device of the above type, which can compensate for manufacturing tolerances in an improved manner without significantly affecting the heat dissipation of the PTC element, and which can be manufactured economically.

[0010] To address this problem, the present invention proposes an electric heating device having a housing forming a receiving cavity, wherein at least one PTC heating assembly is received. The at least one PTC heating assembly has at least one PTC element housed in a positioning frame and a strip conductor electrically connected to the PTC element to energize the PTC element using different polarities. The device is characterized in that at least one contour member is thermally connected to the PTC element on each of the opposing main side surfaces of the PTC element; the outer main side surfaces of the contour member opposite the PTC element are thermally connected to the inner surface of the receiving cavity; and the contour member is connected to the positioning frame.

[0011] The electric heating device is preferably an electric heating device for motor vehicles. The housing is typically suitable for heating a fluid medium, and for this purpose, the housing has an inlet nozzle and an outlet nozzle, but otherwise seals the heating chamber. A partition wall preferably separates the connecting chamber from the heating chamber in a fluid-tight manner. The upper end of the PTC heating assembly protrudes from the partition wall. Typically, several PTC heating assemblies are provided, protruding into the heating chamber as heating ribs. The protruding ends of the PTC heating assemblies into the connecting chamber typically include contact tongues that make electrical contact with the connecting chamber. For this purpose, the contact device is preferably configured to combine different PTC heating assemblies by grouping the contact tongues to a heating circuit, and the contact device is preferably provided with contact tongues that protrude to a printed circuit board equipped with contact tongues aligned with the contact tongues of the PTC heating assemblies. This equipped printed circuit board controls the power current used to heat the PTC heating assemblies and typically forms a control device; see EP2440004A1 and EP1128986A1 respectively.

[0012] However, the housing can also be formed from an extruded profile with receiving cavity openings on both sides, wherein the inner surface of the receiving cavity is formed by partition walls, which forms a heating chamber extending parallel to the receiving cavity, guiding the fluid to be heated. As is known, for example, from the principles in EP0 899985A1, several profiles can be arranged adjacent to each other in such a way that a parallel flow of the fluid to be heated is guided through the various receiving cavities. The receiving cavity can be formed between two joined profiles. However, the receiving cavity can also be formed within the same extruded profile.

[0013] According to the invention, in each case, a contoured member is provided inside the receiving cavity and between the PTC heating assemblies. This contoured member is used to compensate for stress peaks in the PTC element within the receiving cavity during thermally conductive tensioning. Preferably, the configuration of the contoured member for this purpose will be explained in more detail below.

[0014] According to the invention, in any case, the contoured component is connected to the positioning frame. The positioning frame at least engages the PTC element, wherein the PTC element is housed in a receptacle formed by the positioning frame in a known manner. The positioning frame also positions a strip conductor (typically in the form of a contact tab), which protrudes beyond the positioning frame on one side to form a contact tongue. The strip conductor can be connected to the positioning frame by material bonding or form-fit connection. As a rule, the contoured component is mechanically directly coupled to the positioning frame and / or securely connected to the positioning frame in a regular, restrained, and / or immovable manner.

[0015] An insulating layer (preferably in the form of a ceramic plate) is typically disposed on the outside of the strip conductor, such that the heating unit, including the PTC element and two contact surfaces, is electrically insulated between the two insulating layers. A contour member is typically located on the outside of the insulating layer. According to the invention, the contour member is connected to a positioning frame. The connection between the contour member and the positioning frame typically also enables the positioning of the insulating layer. For example, one of the insulating layers can be held between the contour member and the associated strip conductor by force engagement (e.g., clamping). Alternatively, a fastener of the positioning frame that mates with the contour member can also hold the strip conductor and / or the insulating layer in place. Connecting the contour member to the positioning frame provides a PTC heating assembly that can be treated as a structural unit, and after pre-assembly, such a PTC heating assembly can be inserted into a receiving cavity.

[0016] The contoured component can be clamped to the positioning frame. For this purpose, the positioning frame typically has engaging claws that engage with the rear of the corresponding contoured component. Preferably, the positioning frame has an upper transverse beam and a lower transverse beam, a contact tongue extending over one side of the upper transverse beam, and the lower transverse beam is disposed opposite to the upper transverse beam. According to a further development of this preferred embodiment, form-fitting portions each protrude from each of the transverse beams and overlap with the associated contoured component. Typically, at least the form-fitting portions associated with the transverse beams are configured as engaging claws, such that the contoured component can be connected to the positioning frame by clamping (and thus in a simple manner).

[0017] It should be understood that the positioning frame is typically made of a non-conductive material, such as plastic, and is preferably injection molded. The contour members are typically extruded profiles and made of metal, preferably aluminum. Each contour member is preferably connected to the receiving cavity via a tongue-and-groove connection. The tongue-and-groove connection extends along the insertion direction of the receiving cavity.

[0018] This means that in a cross-sectional view transverse to the insertion direction, at least one slot protrudes from the interior of the receiving cavity, or a tongue is provided inside the receiving cavity and engages with a tongue protruding from the contour member. In the first example mentioned, the contour member has a slot that engages with the tongue associated with the heating rib. The slot or tongue extends in the insertion direction. When the contour member is inserted, typically along with the PTC heating assembly, the associated tongue is forced into the slot. The tongue and slot slide past each other in the insertion direction and their longitudinal directions. The slot and / or tongue may have elastic properties. This allows for certain tolerance compensation. Heat is extracted from the PTC element to the outer surface of the heating rib exposed in the heating chamber via the tongue-and-slot connection.

[0019] Therefore, preferably, a plurality of tongue-and-groove connections are provided between at least one of the main side surfaces of the PTC element and the opposing inner surface of the receiving cavity. In this context, the main side surface of the PTC element is considered to be the maximum extending surface of the PTC element in a cross-sectional view transverse to the insertion direction. The PTC element is typically cubic in shape. The main side surface spans the width of the PTC element. In the cross-sectional view, the thickness of the PTC element is perpendicular to the width. The direction perpendicular to the plane spanned by the width and thickness and substantially along the insertion direction is the longitudinal extension direction of the PTC element or PTC heating assembly. This longitudinal direction corresponds to the insertion direction of the PTC heating assembly into the receiving cavity.

[0020] As mentioned earlier, the tongue-and-groove connection can compensate for certain manufacturing tolerances through deformation in the area of ​​the tongue-and-groove connection. Typically, the numerous tongue-and-groove connections between the main side surface of the PTC element and the opposing inner surface of the receiving cavity maintain good heat extraction from the PTC element.

[0021] Therefore, the solution according to the present invention can compensate for manufacturing tolerances without affecting the thermal extraction of the PTC element.

[0022] According to a preferred further improvement of the invention, the groove-defined protrusion and / or the tongue protrusion that at least partially forms the tongue is pivotable about an axis extending substantially in the insertion direction. This pivoting capability is achieved by at least one separate groove-defined protrusion or a separate tongue protrusion. The respective protrusions can be connected to the receiving cavity or contour member via relatively thin bridging portions. The alignment / arrangement and shape of the bridging portions allow the pivoting axis and the pivoting capability of the protrusions to be set in a defined manner. This pivoting capability is generally elastic, and may also be plastic if possible.

[0023] According to a preferred further improvement of the invention, the contoured component has a U-shaped receiving portion for the PTC heating assembly. This receiving portion typically houses the PTC element, the strip conductor, and any provided insulating layer, which in particular directly or indirectly covers the main side surface of the PTC element.

[0024] The profile component can be an extruded profile component. It is preferably made of aluminum. This necessitates the provision of at least one insulating layer between the PTC element and the inner surface of the profile component, wherein the PTC heating assembly is thermally abutting against the inner surface of the profile component.

[0025] To achieve the most symmetrical heat extraction and uniform tolerance compensation, a preferred aspect of the invention proposes a tongue-and-groove connection between each main side surface of the PTC element and the opposite inner side of the receiving cavity. Therefore, it is preferable to form corresponding tongue-and-groove connections near the two main side surfaces of the PTC element.

[0026] For good heat transfer between the contoured component and the inner side of the receiving cavity, a preferred further improvement according to the invention proposes that at least one groove-defining protrusion for defining the groove and / or at least one tongue protrusion for forming the tongue be at least partially configured as a wedge shape that tapers gradually toward their free ends. The surfaces of the tongue protrusion and the groove-defining protrusion that mates with the tongue protrusion are formed such that there is planar contact between the tongue protrusion and the groove-defining protrusion. The wedge shape facilitates an elastic pivoting movement of one of the protrusions during engagement. In this case, the invention also assumes that the receiving cavity is preferably a wedge shape that tapers gradually toward its lower closed end. Correspondingly, the tongue-and-groove connection can also be wedge-shaped in the insertion direction, such that the area of ​​the tongue-and-groove connection has substantially the same coverage in each cross-sectional plane transverse to the insertion direction of the PTC heating assembly into the receiving cavity.

[0027] Preferably, at least one groove defining protrusion for defining the slot and / or at least one tongue protrusion for forming the tongue are integrally formed on the receiving cavity. Preferably, this arrangement can also be applied to profiled parts that are preferably formed as extruded profiles and may have membrane hinges on their underside, such that the opposing legs of the profiled parts are connected to each other relative to the connecting chamber. This reduces the number of parts to be processed.

[0028] According to a preferred further improvement of the invention, at least one compression element is disposed between the contour member and the main side surface of the PTC element. In the case of a U-shaped contour member, the compression element is disposed inside the contour member. Preferably, the compression element is disposed between each of the two main side surfaces of the PTC element and the inner surface of the contour member. The compression element may be formed of a tongue made of metal. In a cross-sectional view transverse to the insertion direction, the tongue typically extends across the entire surface of the main side surface. Preferably, the compression element is disposed between the inner surface of the contour member and an insulating layer covering the outer side of the PTC heating assembly.

[0029] According to preferred further modifications, a curing adhesive is applied to the receiving cavity. The curing adhesive is at least partially received in the tongue-and-groove connection and cures there. Thus, the PTC heating element and the contoured component are secured in the receiving cavity by the adhesive. The adhesive can be a plastic / plastic adhesive with good thermal conductivity. For example, the adhesive can be a siloxane adhesive with added thermally conductive particles (e.g., alumina particles). Therefore, the adhesive also improves heat dissipation of the PTC element. It should be understood that the entire receiving cavity can be filled with the adhesive. Preferably, the adhesive is an electrically insulating adhesive.

[0030] This invention proposes a parallel aspect to a method for manufacturing a PTC heating assembly of the type described above. In this method, initially, an insulating layer applied against the outside of a strip conductor is held by a positioning frame. Thus, the positioning frame forms an assembly aid for pre-positioning the insulating layer. These insulating layers typically have inherent rigidity and generally comprise at least one ceramic layer, with other layers (e.g., layers in the form of plastic films) on one or both sides of the ceramic layer. Contour members abut against the outside of the insulating layer such that at least one of the insulating layers is located between each contour member and the strip conductor, which is typically covered by the insulating layer. In the method according to the invention, the contour members are engaged to the positioning frame in the manner described above. Therefore, at the end of the assembly of the contour members, the contour members are held to the positioning frame. The contour members also hold the insulating layer. Therefore, the method according to the invention provides a structural unit that can be processed separately during the assembly of an electric heating device, and this structural unit includes a positioning frame, at least one PTC element, a strip conductor conductively connected to at least one PTC element, an insulating layer, and contour members. At least one insulating layer and one contour member are located on both sides of the PTC element.

[0031] In this context, the positioning frame can also be connected to the strip conductor in a form-fitting manner, especially when the strip conductor is configured as a contact piece. Attached Figure Description

[0032] Other details of the invention will now be apparent from the following description of embodiments taken in conjunction with the accompanying drawings. Wherein:

[0033] Figure 1 An exploded perspective view of an embodiment of the PTC heating assembly is shown;

[0034] Figure 2 It shows according to Figure 1 An exploded perspective view of the PTC heating assembly and the housing of the electric heating device shown in cross section;

[0035] Figure 3 A cross-sectional view of a portion of the electric heating device is shown;

[0036] Figure 4 It shows along Figure 3 The cross-sectional view of line III-III shown; and

[0037] Figure 5 A variant is shown as follows Figure 4 Cross-sectional view. Detailed Implementation

[0038] Figure 1A PTC heating assembly 2 with a PTC element 4 is shown. Strip conductors 6 in the form of (metal) strips are respectively disposed on the main side surface of the PTC element 4. An insulating layer 8, in this case composed of a ceramic plate, covers the outer surface of the strip conductors 6 opposite to the PTC element 4. Reference numeral 10 indicates an injection-molded positioning frame made of plastic, forming a receiving portion 18 for the PTC element 4 between two transverse beams. The upper transverse beam is indicated by reference numeral 12, and the lower transverse beam by reference numeral 14. Two longitudinal beams 16 extend in a direction perpendicular to the upper and lower transverse beams 12 and 14. Contact pieces for forming the strip conductors 6 have contact tongues 20, which are integrally formed on the strip conductors 6 by stamping. The contact tongues 20 are disposed at the opposite ends of the positioning frame 10 in the longitudinal direction of the upper transverse beam 12 and are received by guide holes in the upper transverse beam 12.

[0039] Shape-fitting portions 22 with engaging claws 24 protrude from the upper transverse beam 12 relative to each other at the outer end of the upper transverse beam 12. These specific shape-fitting portions 22 protrude beyond the upper transverse beam 12 in the width direction.

[0040] The form-fitting portion 22 or the engaging claw 24 is located at the outer edge of the positioning frame 10 in the extending direction of the longitudinal beam 16, thus the form-fitting portion 22 or the engaging claw 24 is located outside the main side surface of the PTC element 4. The main side surface of the PTC element 4 is formed by the largest surfaces of the cuboid PTC element 4. Other surfaces extending between the two main side surfaces can serve as outer peripheral edges.

[0041] Engaging claw 24 overlaps with a contour member indicated by reference numeral 26, which is formed from an extruded aluminum element. The contour member 26 is securely connected to the positioning frame 10 via a form-fitting portion 22 or the engaging claw 24. Typically, the engaging claw 24 has a front slope surface that extends when the contour member 26 is pressed against it and springs back to engage with the rear of the contour member 26 after the contour member 26 has been placed against the outer surface of the insulating layer 8. In this way, the contour member 26 is connected to the positioning frame 10. The insulating layer 8 is sized such that it is also mounted between the form-fitting portions 22, and is latched as described above if necessary; however, in any case, the insulating layer 8 is clamped between the contour members 26, which are held in a form-fitting manner.

[0042] Therefore, during assembly, a contact piece constituting the strip conductor 6 is typically attached to one side of the positioning frame 10. Here, the contact piece constituting the strip conductor 6 is attached to one side of the positioning frame 10 by inserting the contact tongue of the contact piece into the guide through hole of the upper transverse beam 12. Then, the form-fitting portion 22 surrounds the strip conductor 6. The receiving portion 18 is thus closed on one side. The PTC element 4 is then inserted into this receiving portion.

[0043] Then, for example, on the side where the strip conductor 6 is provided, the associated insulating layer 8 is placed against the corresponding strip conductor 6. Thus, the insulating layer is arranged between the engaging claws 24 or the form-fitting portions 22, which ensures the pre-positioning and retention of the insulating layer 8, which, according to this embodiment, is formed of a ceramic plate. Then, from the same side, the contour member 26 is placed against the positioning frame 10 and connected to the positioning frame 10 via the form-fitting portions 22 or the engaging claws 24.

[0044] On the opposite side, another strip conductor 6, the insulating layer 8 associated with the strip conductor 6, and the finally provided contour member 26 can then be installed in the manner described above. Here, as is the case here, the positioning frame 10 has already held the insulating layer 8 or the strip conductor 6 in a position conducive to assembly before finally locking the contour member 26 into the positioning frame.

[0045] It is possible Figure 2 The PTC heating assembly 2, prepared in this manner, is seen in its assembled state. In this embodiment, it is evident that the shape-fitting portion 22 associated only with the upper transverse beam 12 is designed as an engagement claw. The shape-fitting portion 22 provided on the lower transverse beam 14 overlaps only with the contour member 26.

[0046] exist Figure 2 In the figure below, on the right side of the PTC heating element 2, the housing 100 of the electric heating device, indicated by reference numeral 98, can be seen. The housing 100 forms receiving cavities 102. Each receiving cavity 102 houses a single PTC heating element 2. Each receiving cavity 102 is configured at its end in a hammer-like shape, thus forming a space for inserting the shaped fitting 22 or engaging claw 24. Between the ends, the structure of the receiving cavities 102 (explained in detail below) matches the structure provided on the outer surface of the contour members 26, so that, on the one hand, the PTC heating elements are arranged in the receiving cavities 102 with a certain prestress, thereby achieving good thermal conductivity, and on the other hand, excessive stress is prevented on the elements of the PTC heating elements 2 disposed between the contour members 26. The insulating layer 8 and the PTC element 4 are ceramic components, and therefore can only compensate for point / point compressive stress or bending stress to a limited extent through elastic deformation.

[0047] Figure 3The basic components of an electric heating device 98 with a housing 100 made of a material with good thermal conductivity (in this example, die-cast aluminum) are shown. The housing 100 forms a wall 105 circumferentially surrounding the heating chamber 104. Since the bottom of the housing 100 is not enclosed from below... Figure 3 As shown, therefore in Figure 2 In this configuration, the bottom of the heating chamber 104 is also open. The control housing cover is similarly open, attached to the housing 100 on the opposite side to cover and surround the connecting chamber, indicated by reference numeral 106. The housing 100 has a partition wall 108 located between the heating chamber 104 and the connecting chamber 106. Heating ribs 110 protrude from the partition wall 108 into the heating chamber 104. The protrusions of the heating ribs 110 into the lower end of the heating chamber 104 are closed. Figure 3 As shown by the shaded lines, the heating rib 110, together with the partition wall 108 and the wall 105, forms a one-piece die-cast aluminum housing 100.

[0048] Heating ribs 110 form a wedge-shaped, downwardly tapering receiving cavity 102. The PTC heating assembly, as indicated by reference numeral 2, is received within this receiving cavity 102. As per... Figure 4 As shown in the cross-sectional view, the PTC heating assembly 114 includes a PTC element 116 whose main side surface is adjacent to a strip conductor 118. In this example, the strip conductor 118 includes a wire mesh made of a conductive material. The opposite side of the strip conductor 118 to the PTC element 116 is an insulating layer 120, which may be formed of a ceramic layer and / or an insulating plastic film. The gap between the insulating layer 120 and the PTC element 116 is generally filled by the strip conductor 118. For this purpose, the space between the wire meshes is filled with a thermally conductive adhesive, which is also provided in the plane of the strip conductor 118 and can be understood as belonging to the strip conductor 118. The wire mesh extending beyond the PTC element forms contact tongues 122, which... Figure 3 As shown in the diagram. Elsewhere, the various layers of the multilayer structure between the PTC element 116 and the contour member 126 have been combined into a corresponding layer that is cut between the contour member 126 and the PTC element 116 to clearly reveal the details. Figure 3 middle.

[0049] Contact tongue 122 is exposed in connection chamber 106. PTC element 116 and insulating layer 120 are bonded together as a single unit by strip conductor 118. On the outside of the PTC heating assembly 114, a compression element 124 in the form of a corrugated spring plate is provided (which can be used to compress the PTC heating assembly 114). Figure 4 (See in the middle).

[0050] Figure 4Details of the various contoured components 126, which are configured identically in this example, are shown. Compression elements 124 are abuttingly adjacent to the inside of these contoured components 126.

[0051] The groove-defining protrusion 132 protrudes from the outside of the contour member 126, and a groove 134 surrounds the pair of groove-defining protrusions 132. For example... Figure 4 As specifically shown, multiple identically configured slots 134 are recessed in this manner on the outer side of the main side surface of the contour member 126. The slots 134 are along the insertion direction of the receiving cavity 102 ( Figure 3 (The middle part is represented by E)

[0052] The inner surface 136 of the receiving cavity 102 includes protruding tongue-like projections 138. These tongue-like projections 138 are integrally formed on the molded housing 100. Figure 4 As shown in the cross-sectional view, the tongue protrusions 138 taper gradually towards their free ends to form a wedge shape. Correspondingly, the groove-defining protrusions 132 are also configured to taper gradually towards their free ends to form a wedge shape. It should be understood that only the surfaces of the groove-defining protrusions 132 that define the grooves 134 have this configuration. To illustrate this, in Figure 4 The right side of the tongue protrusion 138 is omitted.

[0053] exist Figure 4 In the illustrated embodiment, during assembly, the PTC element 116, strip conductor 118, insulating layer 120, compression element 124, and contour member 126 are first mounted onto the positioning frame 10. Then, the PTC heating assembly 114, pre-assembled in this manner, is inserted into the receiving cavity 102. During this process, the tongue protrusion 138 is engaged into the groove 134 associated with the tongue protrusion 138. This causes deformation of the area defining the protrusion 132, which can be achieved according to... Figure 4 A comparison of the right and left sides reveals this. This results in a certain tolerance compensation. Additionally, the compression element 124 is deformed for tolerance compensation. Ideally, after assembly, on the one hand, the entire surface of the compression element 124 is substantially abutting against the inner surface of the contour member 26, and on the other hand, the entire surface of the compression element 124 is substantially abutting against the outer surface of the insulating layer 120.

[0054] The compression element 124 may be made of aluminum, copper, beryllium copper, or other materials with good thermal conductivity and which apply permanent elastic pretension.

[0055] Any remaining cavity in the receiving cavity 102 may be filled with a compound with good thermal conductivity, such as a cured plastic compound filled with thermally conductive particles.

[0056] exist Figure 5In the variant shown, the slot-defining protrusion 132 is connected to the remaining contour member 26 via a relatively thin bridging portion 140. The bridging portion 140 provides a pivot axis extending substantially along the insertion direction E. In this embodiment, the compression element can be omitted. The slot-defining protrusions 132 adjacent to different slots 134 are spaced far enough apart that when the wedge-shaped tongue protrusion 138 is inserted, the slot-defining protrusions 132 can each pivot about their pivot axis without colliding with each other. This allows for considerable tolerance compensation. The layer of the PTC heating assembly 2 inside the contour member 126 is thus subjected to good elastic tension against the inner surfaces of the two contour members 126, which improves heat extraction.

[0057] Figure 5 The bending of the inner surface of the contour member 126 is also shown in the cross-sectional view, such that, in the transverse section, the contour member is applied to the insulating layer 120 substantially point-like and linearly along the longitudinal direction. The corresponding deformation of the contour member 126 also causes additional elastic tension in the layers of the PTC heating assembly 114 in the receiving cavity 102.

[0058] List of reference symbols

[0059] 2 PTC heating components

[0060] 4 PTC components

[0061] 6. Strip conductor (Leiterbahn)

[0062] 8 Insulation layer

[0063] 10. Positioning Frame

[0064] 12 Upper transverse beam

[0065] 14 Lower transverse beams

[0066] 16 Longitudinal beams

[0067] 18. Accommodation Department

[0068] 20 tongue contact

[0069] 22 Shape-fitting parts

[0070] 24 Engaging claws

[0071] 26. Profile part

[0072] 98 Electric heating device

[0073] 100 housing

[0074] 102 Receiving cavity

[0075] 104 Heating Chamber

[0076] 105 wall

[0077] 106 Connecting Room

[0078] 108 partition wall

[0079] 110 Heating Ribs

[0080] 114 PTC heating element

[0081] 116 PTC components

[0082] 118 strip conductor

[0083] 120 insulation layer

[0084] 122 tongue contact

[0085] 124 Compression element

[0086] 126 Contour Components

[0087] 128 Filmscharnier

[0088] 132 slot limit protrusion

[0089] 134 slots

[0090] 136 Inner Surface

[0091] 138. Tongue protrusion

[0092] 140 Bridging section

[0093] E Insertion direction

Claims

1. An electric heating device (98) having a housing (100) which forms a receiving cavity (102) in which at least one PTC heating assembly (2) is received, the at least one PTC heating assembly having at least one PTC element (4) accommodated in a positioning frame (10) and a strip conductor (6) which is electrically connected to the PTC element (4) for energizing the PTC element (4) with different polarity, characterized in that, On each of the opposite main side surfaces of the PTC element (4), at least one profiled part (26) is connected to the PTC element (4) in a thermally conductive manner; the outer main side surfaces of the profiled parts (26) opposite the PTC element (4) are each connected to the inner surface (136) of the receiving cavity (102) in a thermally conductive manner; and the profiled parts (26) are connected to the positioning frame (10) such that the profiled parts (26) cannot move vertically relative to the positioning frame (10), wherein the profiled parts (26) are connected to the receiving cavity (102) via a tongue-and-groove connection, which extends in the insertion direction of the receiving cavity (102).

2. The electric heating device according to claim 1, characterized in that The profiled parts (26) are clamped to the positioning frame (10).

3. The electric heating device according to claim 1, characterized in that The positioning frame (10) has an upper cross beam (12) and a lower cross beam (14) arranged opposite it, one side of the upper cross beam (12) is bridged by a contact tongue (20), and form-fit portions (22) each extend from the upper cross beam and the lower cross beam and engage with the associated profiled part (26).

4. The electric heating device according to claim 3, characterized in that At least one of the cross beams has a form-fit portion (22) formed in the manner of an engagement claw (24).

5. The electric heating device of claim 1, wherein, The profiled parts (26) are each formed from a metal extruded profile.

6. The electric heating device of claim 1, wherein, An electrically insulating layer (8) is arranged between each of the profiled parts (26) and the strip conductor (6).

7. The electric heating device of claim 1, wherein, The tongue-and-groove connection has at least one groove-defining protrusion (132) for defining a groove (134) and at least one tongue portion protrusion (138) forming at least partially a tongue, wherein the tongue portion protrusion (138) is received in the groove (134) to form the tongue-and-groove connection, wherein at least one of the groove-defining protrusion (132) and the tongue portion protrusion is pivotable about an axis extending in the insertion direction (E).

8. The electric heating device of claim 1, wherein, The housing (100) comprises a partition wall (108) separating a connection chamber (106) from a heating chamber (104) for discharging heat, and at least one heating rib protrudes from the partition wall (108) to the heating chamber (104) to form the receiving cavity (102).

9. The electric heating device according to claim 5, wherein The metal is aluminum.

10. A method of manufacturing a PTC heating assembly (2) for an electric heating device (98) having a housing (100) forming a receiving cavity (102) in which the PTC heating assembly (2) is received, the PTC heating assembly having at least one PTC element (4) accommodated in a positioning frame (10) and strip conductors (6) conductively connected to the PTC element (4) for energizing the PTC element (4) with different polarity, and at least one insulating layer (8) covering an outer side of each of the strip conductors (6), characterized in that, The externally applied insulating layer (8) against the strip conductor (6) is held by the positioning frame (10), and after the profiled part (26) is arranged against the insulating layer (8), the insulating layer is held on the outer side of the respective insulating layer (8) facing away from the PTC element (4), and the structure unit comprising at least one PTC element (4) is formed by the positioning frame (10), the strip conductor (6), the insulating layer (8), and the profiled part (26), The profile part (26) is connected to the receiving cavity (102) via a tongue and groove connection, which extends in the insertion direction of the receiving cavity (102). The profile part (26) is connected to the receiving cavity (102) via a tongue and groove connection, which extends in the insertion direction of the receiving cavity (102). The profile part (26) is connected to the receiving cavity (102) via a tongue and groove connection, which extends in the insertion direction of the receiving cavity (102). The profile part (26) is

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