Heating device

Abstract

The heating device comprises: a heating chamber; a resistor located inside the heating chamber for heating the coolant, the resistor including a terminal passing through a wall (402A) of the heating chamber, the wall (402A) being provided with a positioning pin (902) protruding outside the heating chamber; a printed circuit board; a lead frame connected to the printed circuit board and a terminal of the resistor; an overmold (714A) surrounding the lead frame, the overmold (714A) having a through hole (906) into which the positioning pin (902) is inserted; the sleeve (914) is inserted into the through hole (906) and is close to the positioning pin (902); and a securing element (604) comprising a stem (916) and a head (918), the stem (916) being sequentially inserted into the bore (904) of the sleeve (914) and the dowel pin (902) such that the sleeve (914) is clamped between the dowel pin (902) and the head (918).

Description

Technical Field

[0001] The present invention relates to a heating device for heating a coolant. The heating device is particularly intended for use in a vehicle, such as a motor vehicle, for example for heating the air in the vehicle's passenger compartment. The vehicle may be an electric or hybrid vehicle. The vehicle may be autonomous. Background Art

[0002] Passenger compartment air is typically heated by transferring heat between the airflow and a coolant (e.g., a liquid) using a heat exchanger. In hybrid or electric vehicles, the coolant is heated by a heating device in which an electric current is circulated through at least one resistor placed in contact with the coolant, causing the resistor's temperature to rise, thereby heating the coolant.

[0003] In this case, it is known to use a heating device comprising:

[0004] - a heating chamber provided with a coolant inlet for the entry of a coolant and a coolant outlet for the exit of the coolant;

[0005] - a resistor located inside the heating chamber for heating the coolant, the resistor comprising terminals passing through the wall of the heating chamber; and

[0006] - a printed circuit board, located outside the heating chamber, for controlling the resistor.

[0007] The terminals need to be connected to a printed circuit board (PCB) so that the resistor can be controlled by the electronics present on the PCB. The connections must be precisely positioned to reach the correct location on the PCB. However, due to space constraints, the use of locating pins is often not possible.

[0008] It would therefore be desirable to provide an object that would allow at least some of the above-mentioned problems and constraints to be overcome. Summary of the Invention

[0009] Therefore, a heating device is proposed, comprising:

[0010] - a heating chamber provided with a coolant inlet for the entry of a coolant and a coolant outlet for the exit of the coolant;

[0011] - a resistor located inside the heating chamber for heating the coolant, the resistor comprising terminals passing through the wall of the heating chamber; and

[0012] - a printed circuit board, located outside the heating chamber, for controlling the resistor.

[0013] Characterized in that the wall is provided with a positioning pin, the positioning pin protruding outside the heating chamber and having a hole, and characterized in that the wall further comprises:

[0014] - Connection module, including:

[0015] • a lead frame comprising connection pins connected to the printed circuit board and connectors connected to the terminals of the resistor,

[0016] • an overmold surrounding the lead frame, the overmold having through-holes into which the locating pins are inserted, and

[0017] • a sleeve inserted into the through hole beside the locating pin; and

[0018] - a fixing element comprising a rod and a head, the rod being inserted in turn into the holes of the sleeve and the dowel pin, so that the sleeve is clamped between the dowel pin and the head.

[0019] Thanks to the invention, the positioning and fixing functions are performed by the same elements, namely the perforated positioning pins of the wall and the receiving through-holes of the overmolding of the connection module, which saves space.

[0020] The invention may also include one or more of the following optional features in any technically possible combination.

[0021] Optionally, the wall is a removable cover covering an opening through which the resistor can be inserted into the heating chamber.

[0022] Likewise optionally, the fastening element is a screw or a rivet or a bolt.

[0023] Also optionally, the sleeve is made of steel.

[0024] Also optionally, within the through-hole of the overmolding, the locating pin extends less than 0.2 mm from the overmolding in at least one direction transverse to the longitudinal direction of the locating pin.

[0025] Still optionally, one of the locating pin and the through-hole of the overmold has a frustoconical shape, while the other has a cylindrical shape.

[0026] Optionally, the heating device further comprises a housing, the housing comprising the heating chamber and defining an interior space, wherein the heating chamber extends in the interior space.

[0027] Also optionally, a printed circuit board extends in the interior space.

[0028] A vehicle is also proposed, comprising a heating device according to the invention, in particular in an installation of a vehicle for heating the air of a passenger compartment of the vehicle.

[0029] A method for connecting terminals of a resistor located in a heating chamber to a printed circuit board located outside the heating chamber for controlling the resistor in a heating device is also proposed, the heating chamber being provided with a coolant inlet for allowing coolant to enter and a coolant outlet for allowing coolant to exit, the terminals passing through a wall of the heating chamber, characterized in that the wall is provided with a positioning pin protruding to the outside of the heating chamber and having a hole, and the method comprising:

[0030] - while connecting the terminals to the connectors of the lead frame, fixing the connection module to the wall by inserting positioning pins protruding to the wall outside the heating chamber into through-holes provided in the overmoulding around the lead frame of the connection module;

[0031] - inserting the rod of the fixing element successively into the sleeve located in the through hole and into the hole of the locating pin, so that the sleeve is clamped between the locating pin and the head of the fixing element located at the end of the rod; and

[0032] - securing the printed circuit board to the heating chamber while connecting the pins of the lead frame to the printed circuit board. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The invention will be better understood using the following description, which is given by way of example only and with reference to the accompanying drawings, in which:

[0034] - Figure 1 is a three-dimensional view of a heating device according to the present invention,

[0035] - Figure 2 is a 3D view of the heating unit with the top cover removed to reveal the printed circuit board.

[0036] - Figure 3 is a 3D view of the heating unit with the printed circuit board removed to reveal the heating chamber.

[0037] - Figure 4 is a three-dimensional cross-sectional view of the heating device showing the resistors in the heating chamber,

[0038] - Figure 5 is a three-dimensional view of the heating device with the front cover removed to reveal the terminals of the resistor passing through the heating chamber,

[0039] - Figure 6 is a three-dimensional view of a portion of a heating device showing a connection module for connecting the terminals of a resistor to a printed circuit board,

[0040] - Figure 7is a 3D view of one of the connected modules, with the overmold shown as transparent.

[0041] - Figure 8 is a 3D view of a connection module within another connection module, with the overmold shown as transparent.

[0042] - Figure 9 is a cross-sectional view of a fixing mechanism for fixing the connection module to the front cover, and

[0043] - Figure 10 is a block diagram illustrating steps of a method for connecting terminals of a resistor to a printed circuit board. DETAILED DESCRIPTION

[0044] refer to Figures 1 to 9 , an example of a heating device 100 according to the present invention will now be described.

[0045] In the following description, elements of the heating device 100 will be described with respect to an arbitrary orthogonal set of axes X, Y, Z.

[0046] refer to Figure 1 The heating device 100 includes a housing 102 having a main body 104 , an upper cover 106 and a front cover 108 .

[0047] refer to Figure 2 The heating device 100 further includes a printed circuit board 202 extending into an interior space 204 defined by the housing 102 .

[0048] refer to Figure 3 The heating device 100 further comprises a heating chamber 302 extending in the interior space 204 of the housing 102 and fixed to the housing 102, for example to its body 104. For example, the heating chamber 302 comprises two compartments 304A, 304B.

[0049] refer to Figure 4 The heating chamber 302 includes, for example, front covers 402A, 402B for closing openings 403A, 403B of the compartments 304A, 304B, respectively, and a connector 404 for passing a coolant between the compartments 304A, 304B.

[0050] The heating chamber 302 is also provided with a coolant inlet 406 for coolant to enter and a coolant outlet 408 for coolant to exit. For example, the coolant inlet 406 is provided in the compartment 304A, while the coolant outlet is provided in the compartment 304B. With this configuration, the coolant enters the compartment 304A through the coolant inlet 406, passes to the compartment 304B through the connector 404, and exits the compartment 304B through the coolant outlet 408.

[0051] Heating device 100 further includes at least one resistor 410A, 410B located within heating chamber 302 for heating the coolant. For example, one resistor 410A, 410B is provided in each compartment 304A, 304B. For example, openings 403A, 403B are sized to allow passage of resistors 410A, 410B, respectively.

[0052] refer to Figure 5 Each resistor 410A, 410B includes two terminals 502A, 504A, 502B, 504B for receiving power. At least one of the two terminals 502A, 504A, 502B, 504B passes through the wall of the heating chamber 302. For example, both terminals 502, 504 pass through the cover 402A, 402B of the compartment 304A, 304B in which the resistor 410A, 410B is located.

[0053] refer to Figure 6 For each resistor 410A, 410B, the heating device 100 comprises a connection module 602A, 602B for connecting at least one of the two terminals 502A, 504A, 502B, 504B of the resistor 410A, 410B to the printed circuit board 202. Each connection module 602A, 602B is fixed to the housing, for example to the associated cover 402A, 402B, by at least one fixing element such as a screw 604.

[0054] refer to Figure 7 For each of the two terminals 502A, 504A, the connection module 602A includes a lead frame 702A, 704A. Each lead frame 702A, 704A includes a connection pin 706A, 708A connected to the printed circuit board 202, for example, through a corresponding hole provided in the printed circuit board 202. Each lead frame 702A, 704A also includes a connector 710A, 712A connected to the terminal 502A, 504A. For example, each connector 710A, 712A includes a clamp for clamping the associated terminal 502A, 504A. The connection module 602A also includes an overmold 714A surrounding the lead frames 702A, 704A.

[0055] Similarly, reference Figure 8For each of the two terminals 502B and 504B, the connection module 602B includes a lead frame 802B and 804B. Each lead frame 802B and 804B includes a connection pin 806B and 808B connected to the printed circuit board 202. The connection pin 806B and 808B, for example, passes through a corresponding hole provided in the printed circuit board 202. Each lead frame 802B and 804B also includes a connector 810B and 812B connected to the terminal 502B and 504B. For example, each connector 810B and 812B includes a fixture for clamping the associated terminal 502B and 504B. The connection module 602B also includes an overmold 814B surrounding the lead frames 802B and 804B.

[0056] refer to Figure 9 , the securing of the cover 402A by the securing element 604 will now be described in more detail. The securing of the cover 402B by the securing element 604 is similar.

[0057] A positioning pin 902 is provided on the cover 402A, the positioning pin 902 protruding to the outside of the heating chamber 302 and having a hole 904. More specifically, the positioning pin 902 extends along the longitudinal direction, which is the X direction in the example shown.

[0058] The overmold 714A has a locating through-hole 906 into which the locating pin 902 is inserted. For example, the locating through-hole 906 includes a first section 908 and a second section 910 connected to each other by an internal shoulder 912, such that the diameter of the first section 908 is larger than the diameter of the second section 910. The locating pin 902 can then be inserted into the first section 908, with the internal shoulder 912 forming a stop for the locating pin 902.

[0059] Inside the through hole 906 of the overmold 714A, the locating pin 902 preferably extends less than 0.2 mm from the overmold 714A, 814B in at least one direction, preferably in all transverse directions, transverse to the longitudinal direction Z of the locating pin 902. In the example shown, the transverse direction is in the plane defined by the directions Y and Z.

[0060] It is also preferred that one of the locating pin 902 and the through hole 906 of the overmold 714A has a frustoconical shape, while the other has a cylindrical shape. In the example shown, the locating pin 902 has a frustoconical shape, and the first section 908 of the through hole 906 of the overmold has a cylindrical shape. This helps guide the locating pin 902 into the through hole 906.

[0061] The connection module 602A further includes a sleeve 914 that is inserted (e.g., pressed) into the positioning through-hole 906, adjacent to the positioning pin 902. For example, the sleeve 914 is inserted into the second section 912. For example, the sleeve 914 is made of steel so as to be more rigid than the overmold 714A.

[0062] The fixing element (i.e., screw 604 in the depicted example) includes a rod 916 and a head 918 fixed to the end of the rod 916. The rod 916 is inserted into the sleeve 914 and the hole 904 of the dowel pin 902 in turn, so that the sleeve 914 is clamped between the dowel pin 902 and the head 918.

[0063] refer to Figure 10 , a method 1000 for connecting a terminal to a circuit board will now be described.

[0064] At step 1002 , the housing 102 having the heating chamber 302 is obtained, with the covers 402A, 402B and the printed circuit board 202 separated.

[0065] At step 1004 , each resistor 410A, 410B is inserted into its respective compartment 304A, 304B through a respective opening 403A, 403B.

[0066] At step 1006 , each cover 402A, 402B is secured to the heating chamber 302 to close the associated opening 403A, 403B while passing the terminals 502A, 504A, 502B, 504B through the covers 402A, 402B.

[0067] At step 1008, each connection module 602A, 602B is temporarily secured to the associated cover 402A, 402B by inserting the locating pins 902 of the cover 402A, 402B into the through holes 906 of the connection module 602A, 602B, in the depicted example, into the first section 908 thereof. Simultaneously, the terminals 502A, 504A, 502B, 504B are respectively retained by the connectors 502A, 504A, 502B, 504B.

[0068] At step 1010, fixing elements, namely screws 604, are installed to fix the connection modules 602A, 602B to the covers 402A, 402B, respectively.

[0069] At step 1012 , the printed circuit board 202 is secured to the housing 102 , such as by screwing, eg, to the heating chamber 302 , while the pins 706A, 708B, 806B, 808B of the connection modules 602A, 602B are connected to the printed circuit board 202 .

[0070] In summary, it will be noted that the present invention is not limited to the above-described embodiments. For those skilled in the art, various modifications can be made to the above-described embodiments based on the teachings just disclosed to them.

[0071] In the foregoing detailed description of the invention, the terms used should not be construed to limit the invention to the embodiments set forth in this specification, but should be construed to include all equivalents that can be attained by those skilled in the art by applying their common knowledge to the practice of the teachings just disclosed to them.

Claims

1. A heating device (100), comprising: - a heating chamber (302), said heating chamber (302) being provided with a coolant inlet (406) for the entry of a coolant and a coolant outlet (408) for the exit of said coolant; - a resistor (410A, 410B) located inside the heating chamber (302) for heating the coolant, the resistor (410A, 410B) comprising terminals (502A, 504A, 502B, 504B) passing through a wall (402A, 402B) of the heating chamber (302); and - a printed circuit board (202), the printed circuit board (202) being located outside the heating chamber (302) and being used to control the resistors (410A, 410B); Characterized in that the walls (402A, 402B) are provided with positioning pins (902), the positioning pins (902) protrude outside the heating chamber (302) and have holes (904), and characterized in that the walls (402A, 402B) further include: - Connection module (602A, 602B), including: • a lead frame (702A, 704A, 802B, 804B) comprising connection pins (706A, 708A, 806A, 808A) connected to the printed circuit board (202) and connectors (710A, 712A, 810B, 812B) connected to the terminals (502A, 504A, 502B, 504B) of the resistor (410A, 410B), • an overmold (714A, 814B) surrounding the lead frame (702A, 704A, 802B, 804B), the overmold (714A, 814B) having a through hole (906) into which the locating pin (902) is inserted, and • a sleeve (914) inserted into the through hole (906) proximate to the locating pin (902); and - a fixing element (604), said fixing element (604) comprising a rod (916) and a head (918), said rod (916) being inserted in turn into said sleeve (914) and said hole (904) of said locating pin (902), so that said sleeve (914) is clamped between said locating pin (902) and said head (918).

2. The heating device (100) according to claim 1, wherein: The walls (402A, 402B) are removable covers that cover openings (403A, 403B) through which the resistors (410A, 410B) can be inserted into the heating chamber (302).

3. The heating device (100) according to claim 1 or 2, wherein: The fixing element (604) is a screw, a rivet or a bolt.

4. The heating device (100) according to any one of claims 1 to 3, wherein: The sleeve (914) is made of steel.

5. The heating device (100) according to any one of claims 1 to 4, wherein: Inside the through hole (906) of the overmold (714A, 814B), the locating pin (902) extends less than 0.2 mm from the overmold (714A, 814B) in at least one direction (X, Y) transverse to the longitudinal direction (Z) of the locating pin (902).

6. The heating device (100) according to any one of claims 1 to 5, wherein: One of the locating pin (902) and the through hole (906) of the overmold (714A, 814B) has a frustoconical shape, while the other has a cylindrical shape.

7. The heating device (100) according to any one of claims 1 to 6, further comprising a housing (102), the housing (102) comprising the heating chamber (302) and defining an interior space (204), the heating chamber (302) extending in the interior space (204).

8. The heating device (100) according to claim 7, wherein: The printed circuit board (202) extends in the interior space (204).

9. A vehicle comprising a heating device (100) according to any one of claims 1 to 8, in particular in an installation of the vehicle for heating the air of a passenger compartment of the vehicle.

10. A method (1000) for connecting terminals (502A, 504A, 502B, 504B) of a resistor (410A, 410B) located in a heating chamber (302) in a heating device (100) to a printed circuit board (202) for controlling the resistor (410A, 410B) located outside the heating chamber (302), the heating chamber (302) being provided with a coolant inlet (406) for allowing a coolant to enter and a coolant outlet (408) for allowing the coolant to leave, the terminals (502A, 504A, 502B, 504B) passing through a wall (402A, 402B) of the heating chamber (302), It is characterized in that The walls (402A, 402B) are provided with positioning pins (902) protruding outside the heating chamber (302) and having holes (904), and are characterized in that the method comprises: - fixing (1008) the connection module (602A, 602B) to the wall (402A, 402B) by inserting positioning pins (902) of the wall (402A, 402B) protruding outside the heating chamber (302) into through holes (906) in an overmold (714A, 814B) provided around the lead frame (702A, 704A, 802B, 804B) of the connection module, while connecting the terminals (502A, 504A, 502B, 504B) to the connectors (502A, 504A, 502B, 504B) of the lead frame (702A, 704A, 802B, 804B); - inserting (1010) the rod (916) of the fixing element (604) successively into the sleeve (914) located in the through hole (906) and the hole (904) of the positioning pin (902), so that the sleeve (914) is clamped between the positioning pin (902) and the head (918) of the fixing element (604) located at the end of the rod (916); and - fixing (1012) the printed circuit board (202) to the heating chamber (302) while connecting the pins (706A, 708B, 806B, 808B) of the lead frame (702A, 704A, 802B, 804B) to the printed circuit board (202).

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