Electric heating device

Abstract

The invention relates to an electric heating device having a heating block (2) and a control unit (3), the heating block (2) being connected to the control unit (3) on one side thereof, the heating block (2) having at least one heating element (4), the heating element (4) having at least one PTC element (7), the PTC element being in electrical contact with a contact plate (8) on each side and having an electrical insulation (9), the PTC element (7) being electrically insulated from the contact plate (8). The PTC element (7) and the two contact plates (8) are electrically insulated from each other by means of an electrical insulation (9), an assembly consisting of the at least one PTC element (7), the two contact plates (8) and the insulation (9) being arranged in the tube (11), at least one of the contact plates (8) having a contact tongue (12) at an end, the contact tongue protruding beyond a first tube end (23) for electrically contacting the contact plate (8), and wherein the PTC element (7) and the two contact plates (8) are electrically insulated from each other by means of the electrical insulation (9). The control unit (3) has a circuit board (13) and the at least one contact tongue (12) is electrically connected to the circuit board (13), a wall (15) having a through-opening (16) is arranged between the heating block (2) and the circuit board (13), a first tube end (23) of a tube (11) of the heating element (4) or a contact plate (8) of the heating element (4) rests on the wall (15) and at least one contact tongue (12) of the heating element (4) protrudes through the through-opening (16).

Description

Technical Field

[0001] This invention relates to electric heating equipment, and more particularly to PTC heating equipment for electric operation of motor vehicles. Background Technology

[0002] Electric heating devices, such as electrically operated PTC heating devices, are known in various forms in the prior art. These heating devices, for example, have a PTC heating element with contact plates on both sides, surrounded by an electrically insulating portion, all arranged within a tube. A connection area is provided at one of the contact plates, configured to be electrically connected to a circuit board of a controller unit. Here, the connection area is configured, for example, as a male plug that is inserted into a female plug receiver on the circuit board. Alternatively, the connection area can also be directly brazed to the circuit board, for example, by cooperating with and brazing the solder receiver thereto.

[0003] EP 1 338 451 A2 discloses a PTC heating device in which the contact tongue of a PTC heating tube, acting as a male plug, is pressed into a plug receiver of a circuit board of a controller unit. Because the components of the heating device undergo thermal expansion, the plug contact portion of the male plug moves within the plug receiver and rubs. Therefore, especially under frequent thermal changes, length fluctuations due to thermal expansion occur, leading to frictional corrosion, which deteriorates electrical contact and is therefore undesirable.

[0004] The danger in heating devices with brazed connections between the contact plate and the circuit board is that the brazed connections can break due to thermal expansion and the associated mechanical stresses acting on them. This severely compromises the electrical connection and can result in high contact resistance, which can significantly impair the functionality of the heating device. Summary of the Invention

[0005] The objective of this invention is to create an electric heating device that improves upon existing technologies and makes the electrical connection between the contact tongue and the circuit board less susceptible to thermal expansion.

[0006] This task is solved using the features of claim 1.

[0007] One embodiment of the present invention relates to an electric heating device having a heating block and a controller unit, wherein the heating block is connected to the controller unit at one side, wherein the heating block has at least one heating element, wherein the heating element has at least one PTC element, the PTC element being electrically contacted with contact plates on both sides and having an electrically insulating portion, the electrically insulating portion insulating the PTC element and the two contact plates, wherein an assembly consisting of at least one PTC element, two contact plates and an insulating portion is arranged in a tube, wherein at least one of the contact plates has a contact tongue at its end, the contact tongue extending beyond the end of a first tube for electrical contact with the contact plate, wherein the controller unit has a circuit board and at least one contact tongue is electrically connected to the circuit board, wherein a wall is arranged between the heating block and the circuit board, the wall having a through opening, wherein the first tube end of the tube of the heating element or the contact plate of the heating element abuts against the wall and at least one contact tongue of the heating element extends through the through opening. The heating element or contact plate with contact tongue can be supported against the wall in such a way that the heating element or contact plate with contact tongue is arranged relative to the circuit board at a defined spacing, and thermal expansion is prohibited at the tube end. This prevents unwanted forces from acting on the electrical connection between the contact tongue and the circuit board, as the thermal expansion of the heating element causes movement of the tube end at the opposite end. Therefore, the durability of the electrical connection is significantly improved by reducing or avoiding unwanted loads.

[0008] In one embodiment, it is advantageous to provide a plurality of heating elements and for each heating element at least one contact tongue, preferably two contact tongues, extending beyond the first tube end of the respective heating element from its respective tube probe. Thus, each heating element can be electrically connected to the circuit board with one or two contact tongues, wherein the electrical connection is achieved without axial displacement of the contact tongues relative to the circuit board and is therefore constructed to be mechanically and, consequently, electrically stable.

[0009] Advantageously, each contact tongue is electrically connected to the circuit board of the controller unit. Therefore, it is advantageous to achieve electrical connections without axial displacement of the contact tongue relative to the circuit board, and thus to be constructed to be mechanically and consequently electrically stable.

[0010] It is also suitable that the conductive connection between one or all of the contact tongues and the circuit board is implemented as a plug connection or a material locking connection, such as a brazing connection or an adhesive connection. This achieves a safe and durable electrical connection.

[0011] In another embodiment, it is also suitable that the heating block has heating elements and air guiding elements, such as finned elements, arranged in a layered structure. This achieves good heat dissipation of air flowing through the air guiding elements or finned elements.

[0012] It is also suitable to arrange two finned elements adjacent to the heating element, such that the two finned elements are in contact with opposite sides of the heating element. Therefore, heat dissipation is improved by allowing the heating element to expel heat to the air flowing past on both sides.

[0013] Alternatively, it is also suitable to have a frame surrounding the heating block, wherein the walls are part of the frame. The frame provides a structurally stable shape for the electric heating device and is used to protect the heating block. The frame also serves to define the boundary relative to the controller unit.

[0014] Advantageously, the frame houses the respective heating elements, wherein the tubes of the heating elements are arranged adjacent to the wall with their first tube ends and the tubes have second tube ends arranged opposite to the first tube ends, wherein the second tube ends are arranged in the frame with an air gap. Therefore, possible thermal expansion can cause displacement or movement at the second tube ends, where displacement or movement is not a problem.

[0015] It is also suitable that the end of the second tube is accommodated in the frame in a manner that allows for axial displacement, while maintaining an air gap. Therefore, possible thermal expansion can cause displacement or movement at the end of the second tube, where displacement or movement is not a problem.

[0016] Another advantage is that the controller unit is housed within a controller housing, which is configured to connect to the frame. This protects the controller unit and its circuit board. Attached Figure Description

[0017] The invention will now be explained in more detail with reference to the accompanying drawings and embodiments.

[0018] In the picture:

[0019] Figure 1 A schematic diagram of the components of an electric heating element in one embodiment of an electric heating device is shown;

[0020] Figure 2 A schematic detail diagram of one embodiment of the electric heating device is shown;

[0021] Figure 3 A schematic detailed diagram of an embodiment of the electric heating device is shown;

[0022] Figure 4 A schematic detail diagram of another embodiment of the electric heating device is shown; and

[0023] Figure 5 A schematic detail diagram of another embodiment of the electric heating device is shown. Detailed Implementation

[0024] This invention relates to an electric heating device 1 having a heating block 2 and a controller unit 3, such as in Figure 2 , Figure 3 as well as Figure 4 , Figure 5 As shown in the respective sections.

[0025] The heating block 2 is configured to be connected to the controller unit 3 on one side, so that the heating block 2 and the controller unit 3 constitute a structural unit that is connected to each other.

[0026] The heating block 2 has at least one heating element 4, wherein typically multiple such heating elements are provided.

[0027] Figure 1 A schematic example of heating element 4 is shown in the exploded view to identify which components can be mounted as heating element 4, wherein finned elements 5 are provided as air guiding elements 6, and these finned elements are laterally attached to heating element 4.

[0028] The electric heating element 4 has at least one PTC element 7, and more particularly multiple PTC elements 7, such as in Figure 1 As shown in the diagram.

[0029] Contact plates 8 are attached to both sides of one or more PTC elements 7 for electrical contact with the PTC elements 7. At least one or more PTC elements 7 are thus in electrical contact with the contact plates 8 on both sides respectively.

[0030] In addition, an electrical insulation section 9 is provided, which insulates at least one PTC element 7 and two contact plates 8. Two insulating elements 10, such as ceramic sheets, are provided as the electrical insulation section 9. The insulating elements can also be one or more electrical insulating elements in other arrangements or configurations, such as thin films.

[0031] An assembly consisting of at least one PTC element 7, two contact plates 8, and an insulating portion 9 is disposed in the tube 11, wherein at least one of the contact plates 8 has a contact tongue 12 at its end, which extends beyond the first tube end 23 of the tube 11 for electrical contact of the contact plate 8, for example by means of a controller unit 3. The electric heating element 4 thus formed is mounted in the heating block 2 together with the finned element 5 or the air guiding element 6.

[0032] The heating block 2 has heating elements 4 and air guiding elements 6, such as finned elements 5, which are arranged in a layered structure. Therefore, the heating elements 4 can be arranged alternately with the finned elements 5 or with the air guiding elements 6, for example. Other arrangements or repetition rates can also be set. Advantageously, two finned elements 5 or air guiding elements 6 can be optionally arranged adjacent to the heating element 4, such that the two finned elements 5 or air guiding elements 6 abut against opposite sides of the heating element 4.

[0033] Furthermore, the controller unit 3 is constructed and arranged such that it has a circuit board 13. The circuit board 13 is used for making electrical contact with the contact tongue 12 of the contact plate 8 and for arranging and connecting electronic components.

[0034] Here, at least one or more contact tongues 12 are arranged in a conductive connection to the circuit board 13. Figure 2 and Figure 3 or Figure 4 and Figure 5 In one embodiment, the electrical connection is achieved by inserting the contact tongue 12 into the plug receiving portion 14 in the circuit board 13.

[0035] The conductive connection between one or all of the contact tongues 12 and the circuit board 13 may be achieved as a plug connection or alternatively as a material locking connection, such as a brazing connection or an adhesive connection.

[0036] exist Figure 2 As can be seen, a wall 15 with a through opening 16 is arranged between the heating block 2 and the circuit board 13. This wall 15 separates the heating block 2 and the controller unit 3 and allows the first tube end 23 of the heating element 4's tube 11 to rest against the wall 15, and allows at least one contact tongue 12 of the heating element 4 to extend through the through opening 16. Therefore, the tube end 23 is supported at the wall 15 and maintains a defined distance from the circuit board 13 on the other side of the wall 15, so that thermal expansion substantially does not affect the connection between the circuit board 13 and the contact tongue 12. The support at the wall 15 acts as a stop.

[0037] Alternatively, the contact plate 8 of the heating element 4 can also be attached to the wall 15, such as... Figure 4 As shown.

[0038] Advantageously, a plurality of heating elements 4 are provided in the heating block 2, wherein each heating element 4 has at least one contact tongue 12, preferably two contact tongues 12, extending from their respective tubes 11 beyond the first tube end 23 of the heating element 4.

[0039] Preferably, each of the contact tongues 12 is electrically connected to the circuit board 13 of the controller unit 3.

[0040] exist Figure 2 and Figure 3 Or in Figure 4 and Figure 5 As also shown, a frame 17 is provided, which surrounds the heating block 2, wherein the wall 15 is part of the frame 17.

[0041] The frame 17 is designed to accommodate the heating element 4 and the contact plate 8, wherein the tube 11 of the heating element 4 is arranged adjacent to the wall 15 with its first tube end 23 and the tube 11 has a second tube end 24 arranged opposite to the first tube end 23, wherein the second tube end 24 is arranged in the frame 17 with an air gap 18. Therefore, the air gap 18 allows the second tube end 24 and / or the contact plate 8 to move relative to the frame 17 due to thermal expansion. Thus, the second tube end 24 and the contact plate 8 are accommodated in the frame 17 in a manner that allows for axial displacement with the air gap 18.

[0042] The controller unit 3 is arranged in the controller housing, which is connected to the frame 17.

Claims

1. An electric heating device (1), wherein the electric heating device has a heating block (2) and a controller unit (3), wherein, The heating block (2) is connected to the controller unit (3) on one side, wherein the heating block (2) has at least one heating element (4), wherein the heating element (4) has at least one PTC element (7), the PTC element is electrically in contact with the contact plate (8) on both sides and has an electrical insulation portion (9), the electrical insulation portion insulates the PTC element (7) and the two contact plates (8), wherein the assembly consisting of the at least one PTC element (7), the two contact plates (8) and the insulation portion (9) is arranged in the tube (11), wherein at least one of the contact plates (8) has a contact tongue (12) at its end. The contact tongue extends beyond the first tube end (23) for electrical contact with the contact plate (8), wherein the controller unit (3) has a circuit board (13) and the at least one contact tongue (12) is electrically connected to the circuit board (13), characterized in that a wall (15) is arranged between the heating block (2) and the circuit board (13), the wall having a through opening (16), wherein the first tube end (23) of the tube (11) of the heating element (4) or the contact plate (8) of the heating element (4) abuts against the wall (15) and at least one contact tongue (12) of the heating element (4) extends through the through opening (16).

2. The electric heating device (1) according to claim 1, characterized in that, The heating element (4) is provided with a plurality of heating elements (4) and for each heating element (4) there is at least one contact tongue (12), preferably two contact tongues (12) extending from their respective tubes (11) beyond the first tube end (23) of the heating element (4).

3. The electric heating device (1) according to claim 1 or 2, characterized in that, Each of the contact tongues (12) is electrically connected to the circuit board (13) of the controller unit (3).

4. The electric heating device (1) according to claim 1, 2 or 3, characterized in that, The conductive connection between one or all of the contact tongues (12) and the circuit board (13) is implemented as a plug connection or a material locking connection, such as a brazing connection or an adhesive connection.

5. The electric heating device (1) according to any one of the preceding claims, characterized in that, The heating block (2) has the heating element (4) and the air guiding element (5), such as the fin element (5), and the heating element and the air guiding element are arranged in a layered manner.

6. The electric heating device (1) according to claim 5, characterized in that, Two finned elements (5) are arranged adjacent to the heating element (4) such that the two finned elements (5) are attached to opposite sides of the heating element (4).

7. The electric heating device (1) according to any one of the preceding claims, characterized in that, A frame (17) is provided surrounding the heating block (2), wherein the wall (15) is part of the frame (17).

8. The electric heating device (1) according to claim 7, characterized in that, The frame (17) houses the respective heating elements (4), wherein the tube (11) of the heating element (4) is arranged adjacent to the wall (15) with its first tube end (23) and the tube (11) has a second tube end (24) arranged opposite to the first tube end (23), wherein the second tube end (24) is arranged in the frame (17) with an air gap (18) provided.

9. The electric heating device (1) according to claim 8, characterized in that, The second tube end (24) is accommodated in the frame (17) in a manner that allows for axial displacement while leaving the air gap (18).

10. The electric heating device (1) according to any one of the preceding claims, characterized in that, The controller unit (3) is arranged in a controller housing, which is configured to be connected to the frame (17).

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