Heater

Abstract

The disclosure relates to a heater (2; 1002; 2002) having a fluid chamber housing (38; 1038; 2038), which has an outer wall designed to enclose in a fluid-tight manner a fluid chamber (64; 1064; 2064) except for at least one fluid port (22, 24; 2022, 2024) of the fluid chamber housing (38; 1038; 2038), and having at least one first heating element (40) and at least one second heating element (42), which are arranged on two opposite sides of the fluid chamber (64; 1064; 2064) and designed to be able to heat a fluid that flows through the fluid chamber (64; 1064; 2064) or is held therein. The first heating element (40) has an output region (108; 1108) in which the first heating element (40) delivers heat and which has individually controllable heating zones (110, 112, 114). The second heating element (42) has an output region (122) in which the second heating element (42) delivers heat. The output region (122) of the second heating element (42) has individually controllable heating zones (124, 126, 128) that are each located opposite a corresponding heating zone (110, 112, 114) of the first heating element (40).

Description

[0001] heater

[0002] Description

[0003] Technical area

[0004] The present disclosure relates to a heater for heating a fluid, in particular a liquid, preferably in a motor vehicle, having a fluid chamber housing which has an outer wall which is designed to enclose a fluid chamber in a fluid-tight manner apart from at least one fluid connection of the fluid chamber housing, and at least two heating elements arranged on two opposite sides of the fluid chamber, which are designed to be able to heat a fluid flowing through the fluid chamber or accommodated in the latter.

[0005] State of the art

[0006] A heater of this type is known, for example, from DE 10 2019 133 043 A1. The heater according to this prior art comprises a fluid chamber housing that encloses a fluid chamber. The heater has a plurality of heating elements that are designed to heat a fluid flowing through the fluid chamber or contained therein, and which at least partially form side walls of the fluid chamber housing. One of the heating elements has two heating zones formed by heating strands.

[0007] The problem with the known heater is that if a heating line or heating zone fails, a corresponding area of ​​the fluid space is not heated or is only heated insufficiently.

[0008] Summary of Revelation

[0009] The object of the present invention is therefore to provide a heater in which the adverse consequences of a heating zone failure can be reduced. This object is achieved by the features of claim 1. Advantageous further developments are the subject of the dependent claims.

[0010] A heater according to the disclosure comprises a fluid chamber housing and at least one first heating element and at least one second heating element.

[0011] The fluid chamber housing has an outer wall designed to fluid-tightly enclose a fluid chamber, apart from at least one fluid connection of the fluid chamber housing. If a separate temperature sensor is to be provided in the heater for monitoring the temperature prevailing in the fluid chamber, the temperature sensor forms part of the outer wall.

[0012] The at least one first heating element and the at least one second heating element are arranged on two opposite sides of the fluid chamber, in particular on two opposite sides of the fluid chamber housing, and are designed to heat a fluid flowing through the fluid chamber or contained therein, in particular a liquid flowing through the fluid chamber or contained therein. The at least one first heating element and / or the at least one second heating element are / is designed in particular as IMS circuit boards or as one IMS circuit board. Alternatively, other types of heating elements, e.g., based on thick films or PTC, can also be used.

[0013] The first heating element has a power range in which the first heating element emits heat. The second heating element has a power range in which the second heating element emits heat. The power range of the first heating element has individually controllable heating zones. The power range of the second heating element has individually controllable heating zones, each of which is opposite a corresponding heating zone of the first heating element.

[0014] A coordinated arrangement of the heating zones advantageously makes it possible to at least partially compensate for the failure of a heating zone of one heating element by the corresponding heating zone of the other heating element. According to one aspect of the invention, the first heating element can have a control circuit area in which control elements are arranged that serve to control the power range of the first heating element and / or the power range of the second heating element.

[0015] If the control circuit section is provided on the first heating element, the assembly of the heater can be simplified.

[0016] According to one aspect of the disclosure, the heating zones of the first heating element can be arranged in a row, and the heating zones of the second heating element can be arranged in a row, correspondingly. The control circuit region of the first heating element can be arranged along the heating zones of the first heating element. In particular, the control circuit region can be configured such that its longitudinal axis extends parallel to a flow direction of a fluid flowing through the turbulator.

[0017] By arranging the control circuit area in this way, it is possible to arrange fluid connections and electrical connections on one side of the heater.

[0018] According to one aspect of the disclosure, the fluid chamber housing, the first heating element, and the second heating element can each be plate-shaped. The first heating element can be attached to the outer wall of the fluid chamber housing such that the control circuit region is arranged away from the fluid chamber in a longitudinal direction of the fluid chamber housing and / or a width direction of the fluid chamber housing. In other words, the heater can be configured such that the fluid chamber extends only along the power range of the first heating element and / or only along the power range of the second heating element.

[0019] By arranging the control circuit area away from the fluid space, the effectiveness of the heater can be improved. According to one aspect of the invention, the control circuit area of ​​the first heating element and the heating zones of the first heating element can be arranged in a row, and the control circuit area of ​​the first heating element can be arranged closer to the at least one fluid connection than the heating zones of the first heating element and / or than the heating zones of the second heating element.

[0020] If the control circuit area is arranged upstream of the heating zones, fluid that has not yet been heated can be used to cool the control circuit area or waste heat from the control circuit area can be used to heat the fluid, thus improving the efficiency of the heater.

[0021] According to one aspect of the invention, the heating zones of the second heating element may be larger than the heating zones of the first heating element.

[0022] If the heating zones of one heating element are designed to be larger than the heating zones of the other heating element, additional components can be provided on the heating element with the smaller heating zones without giving up the one-to-one assignment of the heating zones.

[0023] According to one aspect of the invention, the heating zones of the first heating element can be of equal size and / or the heating zones of the second heating element can be of equal size. In particular, all heating zones of the heater (ie, the first and second heating elements) can be of equal size.

[0024] By dimensioning the heating zones equally, the production of the heater can be simplified.

[0025] The fluid chamber housing can have a turbulator arranged within the outer wall, which is designed to be in contact with a fluid to be heated and which connects two opposing sections of the outer wall to one another in a materially bonded manner. In particular, the turbulator can be designed to be able to induce turbulent flows in a fluid to be heated. In particular, a first side of the turbulator can be materially bonded to a first section of the outer wall, and a second side of the turbulator opposite the first side can be materially bonded to a second section of the outer wall opposite the first section of the outer wall.

[0026] "Material bonded" specifically means that the turbulator is soldered, glued, and / or welded to the opposing sections of the outer walls. This can also advantageously optimize heat transfer between the outer walls and the turbulator.

[0027] By providing a turbulator that is firmly connected to two opposite sections of the outer wall, it is advantageously possible to increase the operational reliability and effectiveness of the heater

[0028] The outer wall can have a first shell and a second shell, and the turbulator can connect the first shell and the second shell to one another in a materially bonded manner. In particular, one of the two opposing sections bonded by the turbulator can be arranged on the first shell, and the other of the two opposing sections bonded by the turbulator can be arranged on the second shell.

[0029] If two shells of the outer wall are connected using the turbulator, the installation of the heater can be made easier.

[0030] The first shell and the second shell can be integrally connected to one another away from the turbulator. In particular, the first shell and the second shell can be integrally connected to one another along a circumference of the first shell and / or along a circumference of the second shell, in particular over their entire circumference. Preferably, the first shell and the second shell can be integrally connected to one another using the same method used to integrally connect the turbulator to the first shell and the second shell. Preferably, the turbulator, the first shell, and the second shell can be soldered to one another.

[0031] If the two shells are also connected to each other away from the turbulator, the stability of the fluid chamber housing can be improved.

[0032] The fluid chamber housing can have at least one collecting tube with a closed end, and the closed end of the collecting tube can be at least partially, preferably completely, part of the outer wall. The open end of the collecting tube can preferably be formed by the at least one fluid connection. Preferably, the fluid chamber housing can have two collecting tubes, each with a closed end, and the two closed ends of the two collecting tubes can be at least partially, preferably completely, part of the outer wall. The open ends of the two collecting tubes can preferably be formed by fluid connections.The at least one collecting pipe can preferably be configured to collect fluid flowing into the fluid chamber toward the turbulator and to distribute it evenly over an inflow surface of the turbulator upstream of the turbulator (the collecting pipe whose open end is used as a fluid inlet can also be referred to as a distribution pipe). The at least one collecting pipe can preferably be configured to collect fluid flowing from an outflow surface of the turbulator and to collect it and to direct it out of the fluid chamber.

[0033] If a closed end of at least one manifold is used to form part of the outer wall, the heater can be manufactured in an efficient manner.

[0034] The at least one manifold can be formed, at least in sections, by at least one linear bulge in the outer wall. Preferably, the fluid chamber housing can have two manifolds, each formed by at least one linear bulge. If the at least one manifold is formed integrally with the outer wall, the weight of the heater can be advantageously reduced.

[0035] The outer wall can have at least one fluid guide element in the form of an indentation in the outer wall adjacent to the at least one collecting tube. The fluid guide element can, in particular, be in the form of a linear indentation in the outer wall, and the indentation can preferably be arranged parallel to the indentation.

[0036] By providing at least one fluid guide element, a flow along the at least one collecting pipe can be made uniform.

[0037] The at least one first heating element and / or the at least one second heating element can be attached to the outer wall of the fluid chamber housing, in particular to an outer side of the outer wall of the fluid chamber housing, in such a way that they are separated or fluidically separated from the fluid chamber. In particular, the at least one first heating element and / or the at least one second heating element can be attached to the outer wall or to the outer side of the outer wall of the fluid chamber housing by means of gluing, soldering (soft soldering), and / or welding.

[0038] By separating the at least one first heating element and / or the at least one second heating element from the fluid space, the dimensions of the at least one first heating element and / or the at least one second heating element can be flexibly selected.

[0039] The heater can have a positioning block designed to positively engage with the fluid chamber housing and at least one of the heating elements, in particular with the at least one first heating element, in at least two directions extending transversely to one another, in order to hold the at least one (first) heating element in a predetermined position relative to the fluid chamber housing. The positive engagement can be achieved, in particular, by means of at least two recesses provided on the positioning block, one of which recesses can positively engage with a corresponding projection on the fluid chamber housing, and one of which recesses can positively engage with a corresponding projection on the at least one (first) heating element.

[0040] By providing a positioning block, installation of the heater can be simplified.

[0041] The heater may comprise two heating elements separated from the fluid chamber and mounted on two opposite sides of the outer wall of the fluid chamber housing.

[0042] By providing two heating elements, the effectiveness of the heater can be improved.

[0043] The heating element that interacts positively with the positioning block can be a first heating element of the two heating elements, and the positioning block can be designed to also interact positively with a second heating element of the two heating elements in at least two directions extending transversely to one another in order to also hold the second heating element in a predetermined position relative to the fluid chamber housing.

[0044] The heater may comprise a circuit board connector which is designed to encompass the fluid chamber housing and to electrically connect the two heating elements to one another.

[0045] By providing a circuit board connector, the heating elements can be made more efficient, for example by making control elements of one of the two heating elements usable for controlling the other heating element.

[0046] The heater may comprise a protective housing that accommodates the fluid chamber housing, the at least one first heating element, and the at least one second heating element in such a way that it extends along all six sides of the fluid chamber housing and / or the at least two heating elements. In particular, the protective housing may be configured to enclose a single interior space.

[0047] The circuit board connector can be designed to be elastically pre-stressed and supported against an inner side of the protective housing.

[0048] By providing a protective housing, the electromagnetic compatibility and user safety of the heater can be improved.

[0049] The protective housing can have a first protective housing shell and a second protective housing shell. The first protective housing shell can extend along two opposite sides and along a side connecting the two opposite sides of the fluid chamber housing and / or the at least two heating elements, and the second protective housing shell can extend along the remaining sides of the fluid chamber housing and / or the at least two heating elements. In other words, the first protective housing shell and the second protective housing shell can each have the shape of a U-profile.

[0050] Due to the U-profile shape of the first protective housing shell and the second protective housing shell, it is possible to manufacture the protective housing shells easily (by bending).

[0051] The circuit board connector can be designed to be elastically prestressed and supported only against an inner side of the first protective housing shell or the second protective housing shell.

[0052] If the board connector is supported on only one of the two protective housing shells, the preload of the board connector can be easily adjusted by positioning the corresponding protective housing shell.

[0053] The heater according to the disclosure is preferably designed to be mounted in a motor vehicle. In particular for this purpose, the heater can be equipped, for example, with at least one holder which has a fastening means (for example a thread or a bolt) and / or a counterpart to a fastening means (for example a nut or an opening). Alternatively, the heater can also be designed for domestic applications or the sanitary sector. Here, the heater can have at least one holder of the type just described. Alternatively or additionally, the at least one fluid connection can be designed with a union nut or a thread such that the heater can be attached to a sanitary system solely via the at least one fluid connection.

[0054] Brief description of the drawings

[0055] The present invention will be described in more detail below using preferred embodiments with reference to the accompanying drawings. They show:

[0056] Fig. 1 is a perspective view of a heater according to the disclosure according to a first embodiment;

[0057] Fig. 2 is an exploded view of the heater according to the first embodiment;

[0058] Fig. 3 is an exploded view of a fluid chamber housing according to the disclosure;

[0059] Fig. 4 is a perspective view of a first shell and a turbulator of the fluid chamber housing arranged on the first shell;

[0060] Fig. 5 is a perspective view of a second shell of the fluid chamber housing;

[0061] Fig. 6 is a perspective view of the fluid chamber housing with manifolds and a cutout in the second shell through which the turbulator is visible;

[0062] Fig. 7 is an exploded view of a core assembly including the fluid chamber housing, two heating elements, and a positioning block; Fig. 8 is a perspective view of the core assembly shown in Fig. 7 in a state in which the heating elements are in contact with the fluid chamber housing and in which the positioning block is not yet attached to the fluid chamber housing and the two heating elements;

[0063] Fig. 9 is a perspective view of the core assembly shown in Fig. 7 in a state in which a predetermined positioning of the heating elements relative to the fluid housing is established by means of the positioning block;

[0064] Fig. 10 is a perspective view of the core assembly shown in Fig. 7 and a first protective housing shell in a disassembled state;

[0065] Fig. 11 is a perspective view of the core assembly shown in Fig. 10 and the first protective housing shell shown in Fig. 10 in an assembled state together with a low-voltage plug and a high-voltage plug;

[0066] Fig. 12 and Fig. 13 are perspective views of the core assembly provided with the first protective housing shell, the low-voltage connector and the high-voltage connector together with a circuit board connector;

[0067] Fig. 14 is a perspective view of the core assembly provided with the first protective housing shell, the low-voltage plug, the high-voltage plug and the circuit board connector together with a second protective housing shell;

[0068] Fig. 15 is a perspective view of the core assembly provided with the first protective housing shell, the low-voltage connector, the high-voltage connector, the circuit board connector and the second protective housing shell together with four holders;

[0069] Fig. 16 is a perspective view of the heater according to the disclosure in accordance with the first embodiment with section planes I and ii;

[0070] Fig. 17 is a sectional view of the heater according to the sectional plane I shown in Fig. 16; Fig. 18 is a sectional view of the heater according to the sectional plane ii shown in Fig. 16;

[0071] Fig. 19 is a sectional view corresponding to Fig. 18 of a heater according to a second embodiment;

[0072] Fig. 20 is an exploded view of the circuit board connector according to the disclosure;

[0073] Fig. 21 is a perspective view of a back side of the board connector;

[0074] Fig. 22 is a perspective view of a front side of the board connector;

[0075] Fig. 23 is an exploded view of a heater according to a third embodiment;

[0076] Fig. 24 is a perspective view of a fluid chamber housing of the heater according to the third embodiment, corresponding to Fig. 6; and

[0077] Fig. 25 is a sectional view of the heater according to the third embodiment, corresponding to Fig. 17.

[0078] Detailed description of preferred embodiments

[0079] Fig. 1 shows a perspective view of a heater 2 according to the disclosure according to a first embodiment.

[0080] The heater 2 has a protective housing 4 with a first protective housing shell 6 and a second protective housing shell 8. The first protective housing shell 6 and the second protective housing shell 8 each have the shape of a U-profile, preferably a U-profile whose free corners are rounded, and are dimensioned such that the course of free edges or edges of the first protective housing shell 6 or of all free edges or edges of the first protective housing shell 6 is identical to the course of free edges or edges of the second protective housing shell 8 or of all free edges or edges of the second protective housing shell 8. In the assembled state of the first and second protective housing shells 6 and 8 shown in Fig. 1, the free edges or edges of the first protective housing shell 6 lie flush against the free edges or edges of the second protective housing shell 8.In other words, the first and second U-profile-shaped protective housing shells 6 and 8 are dimensioned such that they complement or can complement each other when arranged flush with each other to form the protective housing 4.

[0081] The protective housing 4 (in the assembled state of the first and second protective housing shells 6 and 8) essentially has the shape of a cuboid, in particular with an aspect ratio of a book. This means that the first protective housing shell 6 is band-shaped and has two leg sections 10 and 12 extending parallel to one another and a central section 14 extending perpendicular to the leg sections 10 and 12. The leg sections 10 and 12 and the central section 14 each have an essentially rectangular outline. The central section 14 connects the two leg sections 10 and 12 flush with one another. The leg sections 10 and 12 preferably each transition into the central section 14 via a curve. The second protective housing shell 8 is also band-shaped and has two leg sections 16 and 18 extending parallel to one another and a central section 20 extending perpendicular to the leg sections 16 and 18.The leg sections 16 and 18 and the central section 20 each have a substantially rectangular outline. The central section 20 connects the two leg sections 16 and 18 flush with each other. The leg sections 16 and 18 preferably each transition into the central section 20 via a curve.

[0082] The heater 2 has two fluid connections 22 and 24 (or a first fluid connection 22 and a second fluid connection 24), a low-voltage plug 26, a high-voltage plug 28 and four holders 30, 32, 34 and 36.

[0083] The fluid connections 22 and 24 as well as the low-voltage connector 26 and the high-voltage connector 28 are formed on the central section 14 of the first protective housing shell 6 and extend substantially perpendicular to the central section 14. The fluid connection 22 is arranged closest to the leg section 10, and the fluid connection 24 is arranged closest to the leg section 12. The low-voltage connector is arranged between a center of the central section 14 and the fluid connection 24, and the high-voltage connector 28 is arranged between the center of the central section 14 and the fluid connection 22. Alternatively, it would also be possible for the low-voltage connector 24 and the high-voltage connector 28 to be arranged interchangeably.

[0084] The fluid connections 22 and 24 are designed, in particular, as liquid connections. The (first) fluid connection 22 is intended, in particular, to serve as a fluid inlet, and the (second) fluid connection 24 is intended, in particular, to serve as a fluid outlet. In the present embodiment, the two fluid connections 22 and 24 are arranged on the same side of the heater 2. Alternatively, it would also be possible for the two fluid connections 22 and 24 to be arranged on sides extending transversely to one another or on opposite sides of the heater 2.

[0085] The low-voltage connector 26 is designed to supply signals and / or electrical power to control electronics or a control circuit of the heater 2. The term or prefix "low-voltage" refers, in the context of the present disclosure, to components or systems designed to operate with voltages up to and including 60 V.

[0086] The high-voltage connector 28 is designed to supply electrical power to a power electronics system or a power circuit designed to generate heat. In the context of the present disclosure, the term or prefix "high-voltage" refers to components or systems designed to operate at voltages above 60 V to 1.5 kV.

[0087] The holders 30 to 36 are identical to one another and have the shape of an L-profile. Each of the holders 30 to 36 has a long leg section and a short leg section. Each of the long leg sections has two longitudinal grooves, which increase the flexural rigidity of the long leg section. Each of the short leg sections has a recess or hole in the center. The holders 30 to 36 are fastened with their long leg sections to the leg sections 10 and 12 of the first protective housing shell 6 in such a way that the short leg sections of the holders 30 to 36 extend in one plane and protrude outwards (relative to a center of the first protective housing shell 6). In the assembled state of the first and second protective housing shells 6 and 8, the short leg sections of the holders 30 to 36 protrude beyond the leg section 18 of the second protective housing shell 8.The holders 30 and 32 on the leg portion 10 of the first protective housing shell 6 and the holders 34 and 36 on the leg portion 12 of the first protective housing shell 6 are arranged symmetrically to one another.

[0088] Fig. 2 shows an exploded view of the heater 2 according to the first embodiment, in which individual components and assemblies of the heater 2 are shown.

[0089] The fluid connections 22 and 24, also shown in Fig. 1, belong to a fluid chamber housing 38, which is designed to conduct fluid, preferably liquid, from one of the two fluid connections 22 and 24, preferably from the (first) fluid connection 22, in a fluid-tight manner with respect to the other components of the heater 2 to the other of the two fluid connections 22 and 24, preferably to the (second) fluid connection 24. The fluid chamber housing 38 is plate-shaped in such a way that plate-shaped heating elements 40 and 42, or a plate-shaped first heating element 40 and a plate-shaped second heating element 42, can be attached flatly to the fluid chamber housing 38. In order for the heating elements 40 and 42 to be mounted in a predetermined position on the fluid chamber housing 38, a positioning block 44 is provided which is designed to interact positively with the first heating element 40, the fluid chamber housing 38 and / or the second heating element 42.Furthermore, the positioning block 44 is preferably designed such that it can interact in a form-fitting manner with the first protective housing shell 6 or its central section 14 and / or the low-voltage connector 26. The positioning block 44 is preferably, at least largely, made of plastic. If the heating elements 40 and 42 are soldered to the fluid chamber housing 38, a positioning block made of a heat-resistant material can be used, which is replaced by the positioning block 44, which is preferably, at least largely, made of plastic, after the heating elements 40 and 42 have been soldered to the fluid chamber housing 38.

[0090] The fluid chamber housing 38, the heating elements 40 and 42, and the positioning block 44 are components of a core assembly 46. After the heating elements 40 and 42 are arranged on the fluid chamber housing 38 (see arrows A and B) and positioned by attaching the positioning block 44 (see arrow C), the core assembly 46 is inserted into the first protective housing shell 6 (see arrow D). Subsequently, the low-voltage connector 26 is connected to the positioning block 44 and / or to the first heating element 40 (see arrow E), before the high-voltage connector 28 is connected to the first heating element 40 (see arrow F). Alternatively, it would also be possible to first mount, solder, glue, or weld the fluid chamber housing 38 to the first protective housing shell 6 before the heating elements 40 and 42 and / or the positioning block 44 are mounted, glued, or soldered to the fluid chamber housing 38.

[0091] The electrical or electronic connection of the second heating element 42 to the low-voltage connector 26 and / or the high-voltage connector 28 is established indirectly via the first heating element 40. For this purpose, a circuit board connector 48 is provided, which is designed to be able to be attached or to be attached (see arrow G) to the core assembly 46 or to the sandwich formed by the first heating element 40, the fluid chamber housing 38, and the second heating element 42 in such a way that the first heating element 40 is electrically conductively connected to the second heating element 42. In the assembled state, the circuit board connector 48 is arranged on a side of the core assembly 46 facing away from the fluid connections 22 and 24 or on a side facing away from the low-voltage connector 26 and / or the high-voltage connector 28, or on the rear side.

[0092] Alternatively, the circuit board connector 48 can also be attached to the core assembly 46 before the first protective housing shell 6 is connected to the core assembly 46. The circuit board connector 48 can then advantageously serve as a further positioning aid for the heating elements 40 and 42. Apart from the electrical elements, the circuit board connector 48 is preferably made, at least largely, of plastic. If the heating elements 40 and 42 are soldered to the fluid chamber housing 38, a circuit board connector made of a heat-resistant material can be used. After the heating elements 40 and 42 have been soldered to the fluid chamber housing 38, this can be replaced by the circuit board connector 48, which, apart from the electrical elements, is preferably made, at least largely, of plastic.

[0093] After attaching the circuit board connector 48, the second protective housing shell 8 is connected to the first protective housing shell 6 (see arrow H).

[0094] Finally, the holders 30 to 36 are attached to the first protective housing shell 6 or its leg sections 10 and 12 (see arrow I).

[0095] Fig. 3 shows an exploded view of the fluid chamber housing 38. The fluid chamber housing 38 has a first shell 50 or lower shell, a turbulator 52, a second shell 54 or upper shell, a first collecting tube 56 with a closure 58 or lid or plug, and a second collecting tube 60 with a closure 62 or lid or plug. The fluid chamber housing 38 is designed to enclose a fluid chamber 64 (see Fig. 6), which exchanges or can exchange fluid with its surroundings exclusively via the fluid connections 22 and 24.

[0096] The first shell 50 is a plate with a substantially rectangular outline, with rounded corners. Two recesses 66 are provided on a front portion of the edge of the first shell 50 facing the fluid connections 22 and 24 when the heater 2 is in the assembled state. These recesses are designed to be able to interact or to interact with the positioning block 44 in a form-fitting manner.

[0097] The turbulator 52 is a trapezoidally or rectangularly folded profiled sheet whose ribs are serrated (see also Fig. 6). The ribs are aligned such that, when the fluid chamber housing 38 is assembled, they extend from the first collecting tube 56 to the second collecting tube 60 or from the second collecting tube 60 to the first collecting tube 56. Alternatively or additionally, the ribs can also be perforated in order to generate turbulence for improved heat transfer between the ribs and a fluid or liquid. The turbulator 52 essentially has the shape of a cuboid or a plate (a cuboid whose thickness is very small compared to its other geometric dimensions). The turbulator 52 can alternatively also be designed as a metal foam, knitted fabric, knitted fabric and / or as a spiral.

[0098] The second shell 54 has the shape of a trough with a substantially rectangular outline. The outline of the second shell 54 substantially corresponds to the outline of the first shell 50. This means that, like the first shell 50, the second shell 54 also has two recesses 68 on a front portion of the edge facing the fluid connections 22 and 24 when the heater 2 is in the assembled state. In addition, a (first) projection 70 is provided on each side of the two recesses 68 on the front portion of the edge of the second shell 54. The recesses 68 and the first projections 70 are designed to be able to interact or to interact with the positioning block 44 in a form-fitting manner. In addition, two (second) projections 72 are provided on the second shell 54 on a rear portion of the edge facing away from the fluid connections 22 and 24 when the heater 2 is in the assembled state.The second projections 72 are designed to be able to interact or to interact with the board connector 48 in a form-fitting manner.

[0099] The edge of the second shell 54 is flange-shaped in such a way that a contact surface 74 of an inner side 76 of the second shell 54 extending around the entire circumference of the second shell 54 can be brought into contact with a contact surface 78 (see Fig. 4) of an inner side 80 of the first shell 50 extending around the entire circumference of the first shell 50.

[0100] The interior space spanned by the trough-shaped second shell 54 and the first shell 50 as well as the turbulator 52 are dimensioned or matched to one another in such a way that the turbulator 52 can be accommodated between the first shell 50 and the second shell 54 with simultaneous surface contact of the two contact surfaces 74 and 78, and the plate-shaped turbulator 52 or its toothed and / or perforated ribs is or are in surface contact with both the first shell 50 or its inner side 80 and the second shell 54 or its inner side 76.

[0101] The fluid chamber housing 38 is preferably manufactured by soldering the first shell 50, the turbulator 52, the second shell 54, the header tubes 56 and 60, and the closures 58 and 62 of the header tubes 56 and 60 together. This allows for good heat conduction between the first and second shells 50 and 54, respectively, and the turbulator 52. Alternatively, the header tubes 56 and 60 can also be glued to the second shell 54.

[0102] On an outer side 82 of the second shell 54 opposite the inner side 76 (see Fig. 5), a linear or groove-shaped recess 84 or 86 with a preferably circular segment-shaped cross-section is provided along two opposite edges. Along the respective recess 84 or 86, two short elongated holes 88 and two long elongated holes 90 are provided next to one another, the longitudinal direction of which is parallel to the longitudinal direction of the respective recess 84 or 86. The two long elongated holes 90 are each arranged between the short elongated holes 88. Between the elongated holes 88 and 90, round holes 92 are provided in the respective recess 84 or 86, the diameter of which is smaller than the small diameter of the elongated holes 88 or 90.

[0103] The recesses 84 and 86 are provided to accommodate the collecting tubes 56 and 60. Accordingly, the outer diameter of the collecting tube 56 or 60 and the inner diameter of the corresponding recess 84 or 86 are coordinated such that the collecting tube 56 or 60, when assembled, rests flat against the recess 84 or 86. Corresponding to the recesses 84 and 86, the collecting tubes 56 and 60 are also provided with holes which, when the collecting tubes 56 and 60 are assembled, are at least partially aligned with the holes in the corresponding recess 84 or 86. Both collecting tubes 56 and 60 therefore each have two short elongated holes 94 and two long elongated holes 96 between them. The longitudinal direction of the elongated holes 94 and 96 is parallel to the longitudinal direction of the respective collecting pipe 56 or 60. Between the elongated holes 94 and 96, in the respective collecting pipe 56 or 60,60 round holes 98 are provided, the diameter of which is smaller than the small diameter of the elongated holes 94 and 96, respectively. The dimensions and diameters of the holes 94, 96 and / or 98 preferably correspond to the dimensions and diameters of the corresponding holes 88, 90 and / or 92. The shape, size and number of the holes in the collecting tubes 56 and 60 and, accordingly, the holes in the recesses 84 and 86 are only exemplary.

[0104] The round holes 92 of the recesses 84 and 86 and the corresponding round holes 98 of the manifolds 56 and 60 are provided to enable pre-fixing when soldering the manifolds 56 and 60 to the second shell 54. For this purpose, the manifolds 56 and 60 are first riveted to the second shell 54 via the round holes 92 and 98, creating a suitable soldering gap. The manifolds 56 and 60 are then soldered to the second shell 54.

[0105] The elongated holes 88 and 90 of the recesses 84 and 86 and the associated elongated holes 94 and 96 of the collecting tubes 56 and 60 are provided to effect or enable a homogenization of a fluid flow flowing laterally out of the collecting tube 56 or 60 or a liquid flow flowing laterally out of the collecting tube 56 or 60 over the length of the respective collecting tube 56 or 60, in particular in the case of the collecting tube 56 or 60 which serves as an inlet collecting tube.

[0106] Open ends of the manifolds 56 and 60 form the fluid connections 22 and 24 of the heater 2. At the other end, the manifolds 56 and 60 are closed by means of the closures 58 and 62.

[0107] The first shell 50, the turbulator 52, the second shell 54, the first manifold 56 with the associated closure 58 and the second manifold 60 with the associated closure 62, which together form the fluid chamber housing 38, are made in particular of an aluminum alloy, preferably the alloy EN-AW 3003.

[0108] The fluid chamber housing 38 is manufactured in particular by means of brazing, preferably by means of dip brazing or vacuum brazing.

[0109] Fig. 6 shows a perspective view of the assembled fluid chamber housing 38, in which the turbulator 52 is visible via a cutout in the second shell 54.

[0110] If fluid is introduced into the first manifold 65 via the fluid connection 22 (see arrow J), the fluid flows through the holes 94, 96 and (as far as the corresponding rivets allow) 98 of the first manifold 56 and the corresponding holes 88, 90 and (as far as the corresponding rivets allow) 92 of the first recess 84 of the second shell 54 to the turbulator 52. In the turbulator 52, its serrated ribs guide the fluid to the second manifold 60 (see arrow K). At the second manifold 60, the fluid first flows through the holes 88, 90 and (as far as the corresponding rivets allow) 92 of the second recess 86 of the second shell 54 before flowing via the holes 94, 96 and (as far as the corresponding rivets allow) 98 of the second manifold 60 into the interior of the second manifold 60. From there, the fluid flows to the fluid connection 24 and leaves the second collecting pipe 60 (see arrow L).The fluid chamber housing 38 according to the first embodiment is designed symmetrically such that fluid can also be guided through the fluid chamber housing 38 opposite to the flow path described above (in particular with the same flow resistance).

[0111] Fig. 7 shows an exploded view of the core assembly 46 with the assembled fluid chamber housing 38, the first heating element 40, the second heating element 42 and the positioning block 44.

[0112] The first heating element 40 is plate-shaped and has a heat side 100 and a cold side 102. The heat side 100 is designed to dissipate heat and, in particular, has an outer metal layer, preferably made of an aluminum alloy. The cold side 102 is designed to connect or be able to connect the first heating element 40 to an external power supply and / or to external signaling technology and to generate the heat to be dissipated by the heat side 100. On the cold side 102, in a front section facing the low-voltage plug 26 or the high-voltage plug 28 when the heater 2 is in the assembled state, a control circuit area 104 is provided in which a control circuit or control electronics is formed. For connecting the control circuit orIn order to connect the control electronics to an external (low-voltage) power supply and / or external signaling technology, a heating element plug 106 is provided in the control circuit area 104, which is designed to be connected or to be able to be connected to an inner side of the low-voltage plug 26.

[0113] Adjacent to the control circuit area 104, in a rear section of the cold side 102 facing away from the low-voltage connector 26 or the high-voltage connector 28 when the heater 2 is mounted, a power area 108 is provided, in which a power circuit or power electronics is formed. The power supply and the control of the power circuit or line electronics are carried out via the control circuit or control electronics in the control circuit area 104. Several (preferably three) heating zones 110, 112, and 114 or heating circuits are arranged in a row in the power area 108. Each of the heating zones 110, 112, and 114 extends from the control circuit area 104 to a rear portion of the cold side 102. Contacts 116 are provided in the rear portion of the cold side 102, which are electrically connected to the heating zones 110, 112, and 114 and the control circuit area 104.

[0114] The second heating element 42 is plate-shaped and has a heat side 118 and a cold side 120. The heat side 118 is designed to dissipate heat and, in particular, has an outer metal layer, preferably made of an aluminum alloy. The cold side 120 (see Fig. 13) is designed to connect or be able to connect the second heating element 42 to an external power supply and / or to external signaling technology, as well as to generate the heat to be dissipated by the heat side 118. Preferably, no separate control circuit is provided on the cold side 120 of the second heating element 42. The cold side 120 of the second heating element 42 has a power region 122 in which a power circuit or power electronics is formed. In the power region 122, several (preferably three) heating zones 124, 126, and 128, or heating circuits, are arranged in a row.Each of the heating zones 124, 126, and 128 extends from a rear portion of the cold side 120 to a front portion of the cold side 120. Contacts 130 are provided in the rear portion of the cold side 120 and are electrically connected to the heating zones 124, 126, and 128 and the control circuit area 104 on the first heating element 40.

[0115] The power supply and the control of the power circuit or line electronics of the second heating element 42 are carried out via the contacts 130. In the assembled state of the heater 2, the contacts 130 of the second heating element 42 are electrically connected to the contacts 116 of the first heating element 40 by means of the circuit board connector 48.

[0116] The heating zones 110, 112, and 114 on the first heating element 40 and the heating zones 124, 126, and 128 on the second heating element 42 are designed and / or arranged such that the individual heating zones 110, 112, and 114 of the first heating element 40 are each assigned to one of the heating zones 124, 126, and 128 of the second heating element 42. In the assembled state of the heater 2, the pairs of assigned heating zones are functionally connected to one another such that when one of the heating zones 110, 112, and 114 of the first heating element 40 is activated, the corresponding heating zone 124, 126, or 128 of the second heating element 42 exhibits a similar reaction to the initially activated heating zone 110, 112, or 114. In other words, the heating zones 110, 112 and 114 of the first heating element 40 are suitably connected in series with the heating zones 124, 126 and 128 of the second heating element 42.

[0117] The first heating element 40 and / or the second heating element 42 are / are preferably designed as IMS boards (“insulated metal substrate”). The heat side 100 or 118 of the first heating element 40 or second heating element 42 is preferably realized in the form of a plate made of aluminum or an aluminum alloy, for example, EN-AW 6061.

[0118] Alternatively, the heating elements could be designed as thick film, as wire elements or as PTC elements (“positive temperature coefficient” element).

[0119] The heating elements 40 and 42 are attached to the fluid chamber housing 38 by gluing, soldering, soft soldering (sintering soldering, diffusion soldering), bonding, or pressing (see arrows A and B). If the heating elements 40 and 42 are soldered to the fluid chamber housing 38, the solderability of the heating elements 40 and 42 or the fluid chamber housing 38 can be previously created or improved by galvanic coating (e.g., tinning, nickel plating, copper plating, or gold plating), friction tin plating, or ultrasonic tin plating.

[0120] If the heating elements 40 and 42 are bonded to the fluid chamber housing 38, the adhesive is preferably applied by screen printing to the fluid chamber housing 38 and / or to the hot sides 100 and 118 of the heating elements 40 and 42. To ensure good thermal conductivity of the adhesive, it is preferably enriched with one or more thermally conductive additives.

[0121] Fig. 8 shows a perspective view of the core assembly 46 shown in Fig. 7 in a state in which the heating elements 40 and 42 are in contact with the fluid chamber housing 38 and in which the positioning block 44 is not yet attached to the fluid chamber housing 38 and the two heating elements 40 and 42. In the state shown in Fig. 8, the positions of the heating elements 40 and 42 relative to the fluid chamber housing 38 can still be changed. If the heating elements 40 and 42 are glued to the fluid chamber housing 38, Fig. 8 shows a state in which the adhesion of the adhesive has not yet progressed to the point where relative movement of the heating elements 40 and 42 with respect to the fluid chamber housing 38 is still possible. If the heating elements 40 and 42 are welded or soldered to the fluid chamber housing 38, Fig. 8 shows a state in which the material bond between the heating elements 40 and 42 and the fluid chamber housing 38 has not yet been established.In order to enable predetermined positioning of the heating elements 40 and 42 relative to the fluid chamber housing 38, the positioning block 44 is placed against the fluid chamber housing 38 (see arrow C) in such a way that projections 132 on the positioning block 44 engage positively with the recesses 66 and 68 of the fluid chamber housing 38 and / or recesses on the positioning block 44 engage positively with the first projections 70 of the fluid chamber housing 38. By inserting the heating element plug 106 into a corresponding recess 134 on the positioning block 44, a predetermined position of the heating elements 40 and 42 relative to the fluid chamber housing is established.

[0122] Fig. 9 shows a perspective view of the core assembly 46 shown in Fig. 7 in an assembled state in which a predetermined positioning of the heating elements 40 and 42 relative to the fluid housing 38 is established by means of the positioning block 44.

[0123] Fig. 10 shows a perspective view of the core assembly 46 shown in Fig. 7 and the first protective housing shell 6 in a disassembled state.

[0124] As shown in Fig. 10, the central portion 14 of the first protective housing shell 6 has a first fluid connection recess 136 and a second fluid connection recess 138, which are arranged in edge regions of the central portion 14 and which are designed to receive the free ends of the collecting tubes 56 and 60 serving as fluid connections 22 and 24.

[0125] Between the first fluid connection recess 136 and the second fluid connection recess 138, a high-voltage connector recess 140 for receiving the high-voltage connector 28 and a low-voltage connector recess 142 for receiving the low-voltage connector 26 are provided.

[0126] Along its edge, the first protective housing shell 6 has an inwardly projecting standing seam 144. The first protective housing shell 6 is designed such that its two leg sections 10 and 12 must be (elastically) spread apart (see arrows M) so that the core assembly 46 can be inserted between them (see arrow D).

[0127] Fig. 11 shows a perspective view of the core assembly 46 shown in Fig. 10 and the first protective housing shell 6 shown in Fig. 10 in an assembled state together with the low-voltage plug 26 and a high-voltage plug 28.

[0128] The low-voltage plug 26 has a pressure equalization element 146, which enables pressure equalization of the otherwise fluid-tight protective housing 4. The pressure equalization element 146 is gas-permeable and liquid-impermeable.

[0129] The low-voltage connector 26 is mounted in the low-voltage connector recess 142 (see arrow E). The inside of the low-voltage connector 26 is connected to the heating element connector 106.

[0130] The high-voltage connector 28 is mounted in the high-voltage connector recess 140 (see arrow F). An inner side of the high-voltage connector 28 is connected to the control circuit area 104 of the first heating element 40 by means of a cable and / or plug connection (not shown).

[0131] The low-voltage connector 26 and the high-voltage connector 28 are preferably connected to the first protective housing shell 6 by means of a fluid-tight rivet. The high-voltage connector 28 seals the high-voltage connector recess 140 in a fluid-tight manner. The low-voltage connector 26 seals the low-voltage connector recess 142 in a liquid-tight manner, except for the pressure compensation element 146, which is gas-permeable.

[0132] Fig. 12 and Fig. 13 show perspective views of the core assembly 46 provided with the first protective housing shell 6, the low-voltage connector 26 and the high-voltage connector 28 together with the circuit board connector 48.

[0133] The circuit board connector 48 is designed to electrically connect the contacts 116 of the first heating element 40 to the contacts 130 of the second heating element 42. For this purpose, the circuit board connector 28 has spring tongues 148. The circuit board connector 48 further has spring elements 150, by means of which the circuit board connector 48 can be or is supported against the protective housing 4. In order to be able to attach the circuit board connector 48 in a predetermined position on the core assembly 46 in a simplified manner (see arrow G), the circuit board connector 48 has guide elements 152, which are designed to be or are able to interact positively with the second projections 72.

[0134] Fig. 14 shows a perspective view of the core assembly 46 provided with the first protective housing shell 6, the low-voltage plug 26, the high-voltage plug 28 and the circuit board connector 48 together with the second protective housing shell 8. In order to protect the core assembly 46 from external influences and to protect the environment from electrical and electromagnetic effects caused by the core assembly 46, the core assembly 46 is encapsulated by attaching the second protective housing shell 8 to the first protective housing shell 6 (see arrow H).

[0135] Fig. 15 shows a perspective view of the core assembly 46 provided with the first protective housing shell 6, the low-voltage connector 26, the high-voltage connector 28, the circuit board connector 48 and the second protective housing shell 8 together with the four holders 30, 32, 34 and 36.

[0136] The first protective housing shell 6 and the second protective housing shell 8 are connected to one another in particular by welding, preferably by laser welding. Because the first protective housing shell 6 and the second protective housing shell 8 are each U-shaped in such a way that they can be completed to form the protective housing 4 by contacting along a single edge, it is possible to weld the two protective housing shells 6 and 8 without offsetting in a single process or by means of a single weld seam 154 (see dashed line in Fig. 15).

[0137] Alternatively, it would be possible to glue or solder the two protective housing shells 6 and 8 together. The fluid chamber housing 38 is connected to the protective housing 4 via the manifolds 56 and 60 or their fluid connections 22 and 24. For this purpose, a circumferential weld seam 156 or 158 is provided on each fluid connection 56 or 60 in the area of ​​the respective fluid connection recess 136 or 138 (see dotted line in Fig. 15), which connects the fluid connection 22 or 24 to the protective housing 4 in a materially bonded manner. The circumferential weld seams 154 and 156 are preferably produced by laser welding. Alternatively, it would be possible to glue or solder the two fluid connections 22 and 24 to the protective housing 4.

[0138] To mount the heater 2 in an environment (e.g., in a vehicle), the holders 30 to 36 are attached to the first protective housing shell 6 (see arrows I). Preferably, the holders 30 to 36 are each connected to the first protective housing shell 6 by welding, preferably by laser welding. Alternatively, it would be possible to glue or solder the holders 30 to 36 to the first protective housing shell 6.

[0139] Fig. 16 shows a perspective view of the disclosed heater 2 according to the first embodiment with sectional planes I and ii.

[0140] Fig. 17 shows a cross-sectional view of the heater 2 corresponding to the sectional plane I shown in Fig. 16. The possible flow directions J, K and L shown in Fig. 17 correspond to the flow directions J, K and L shown in Fig. 6. Fig. 17 shows that the shells 50 and 54 of the fluid chamber housing 50 are connected to one another via the contact surfaces 74 and 78, respectively, that the turbulator 52 is connected to the inner sides 76 and 80 of the two shells 50 and 54, and that the collecting tubes 56 and 60 are connected to the recesses 84 and 86. Furthermore, it can be seen that the second protective housing shell 8 has a folded shoulder 160 on the edge to accommodate the standing seam 144. The folded shoulder 160 extends along the entire edge of the second protective housing shell 8.

[0141] Fig. 18 shows a longitudinal sectional view of the heater 2 corresponding to the sectional plane ii shown in Fig. 16. There may be a need for highly projecting components (not shown), particularly in the control circuit area 104 of the first heating element 40. For example, line filters with inductors and / or capacitors may be required. In order to be able to offer installation space 162 for highly projecting components, the heater 2 is designed such that the core assembly 46, the fluid chamber housing 38 and / or the collecting tubes 56 and 60 are set at an angle α relative to the protective housing 4, the second protective housing shell 8 and / or the leg section 16 or 18 of the second protective housing shell 8, so that a distance between the fluid chamber housing 38 and an inner side of the protective housing 4 is greater in one area within the protective housing 4 than in other areas within the protective housing 4.In particular, the core assembly 46, the fluid chamber housing 38 and / or the collecting tubes 56 and 60 are / are positioned such that a distance between the fluid chamber housing 38 and the inside of the protective housing 4 is greater in a front region or in a region adjacent to the low-voltage connector 26 and / or the high-voltage connector 28 than in a rear region or in a region spaced apart from the low-voltage connector 26 and / or the high-voltage connector 28.

[0142] Fig. 18 illustrates that the fluid chamber housing 38 and the first heating element 40 according to the first embodiment of the heater 2 are dimensioned such that the fluid chamber 64 extends both along or below the control circuit area 104 and along or below the power area 108 of the first heating element 40. With such a configuration, the waste heat from the control electronics of the first heating element 40 can also be used to heat a fluid flowing through the fluid chamber 64, or the fluid can be used to cool the control electronics of the first heating element 40.

[0143] Fig. 19 shows a longitudinal sectional view of a heater 1002 according to a second embodiment, corresponding to Fig. 18. The heater 1002 according to the second embodiment differs from the heater 2 according to the first embodiment in that a core assembly 1064 of the second embodiment is not positioned relative to a corresponding protective housing 1004 or a second protective housing shell 1008, and that a fluid chamber housing 1038 is designed such that a fluid chamber 1064 extends only along or below a power region 1108 and not along or below a control circuit region 1104. In other words, the heater 1002 is designed such that the control circuit region 1104 according to the second embodiment cannot be underflown. Apart from the differences described, the heater 1002 according to the second embodiment corresponds to the heater 2 according to the first embodiment.

[0144] Fig. 20 shows an exploded view of the circuit board connector 48 according to the disclosure. Fig. 21 shows a perspective view of a rear side of the assembled circuit board connector 48. Fig. 22 shows a perspective view of a front side of the assembled circuit board connector 48.

[0145] The circuit board connector 48 has a connector plate 164, which is designed to be connected to the spring tongues 148. The connector plate 164 has a substantially rectangular outline. One side of the connector plate 164, which faces the circuit boards to be connected or the heating elements 40 and 42 when the circuit board connector 48 is in use, represents a front side 166 (see Fig. 22), which is directed forward with respect to the circuit board connector 48. The side of the connector plate 164 opposite the front side 166, which faces away from the circuit boards to be connected or the heating elements 40 and 42 when the circuit board connector 48 is in use, represents a rear side 168, which is directed rearward with respect to the circuit board connector 48.

[0146] On the rear side 168, connecting pins 170 are arranged next to one another, corresponding to the number of similarly designed spring tongues 148 (four in the present embodiment). The connecting pins 170 are preferably circular-cylindrical in shape and extend rearwardly relative to the board connector 48.

[0147] The individual spring tongues 148 are each formed by a substantially flat-shaped bent metal strip or are metal strips that have an outline substantially in the shape of a large omega. This means that, starting from a substantially flat central section 172, two substantially S-shaped, corrugated leg sections 174 extend, which are symmetrical to one another with respect to a plane perpendicular to the central section 172. The S-shape of the leg sections 174 is each configured such that free ends 176 of the leg sections 174 point away from one another and that bends 178 of the leg sections 174 arranged at the free ends 176 form a constriction 180. The space delimited by the leg sections 174 between the central section 172 and the constriction 180 is dimensioned such that the spring tongues 148 can encompass the connector plate 164.The constriction 180 is dimensioned such that the leg sections 174 are spread apart when the corresponding spring tongue 148 is clipped around the connector plate 164.

[0148] The free ends 176 of the leg sections 174 are each split.

[0149] The central portion 172 of the respective spring tongue 148 is wider than the two leg portions 174 and has an opening 182 in the center. Two opposing fixing elements 184 are formed at the edge of the opening 182 (in the present embodiment).

[0150] To connect the spring tongues 148 to the connector plate 164, the respective spring tongue 148 is clipped around the connector plate 164 from the rear side 168 with the free ends 176 facing forward, and the corresponding connecting pin 170 is inserted into the opening 182. The fixing elements 184 are designed to be elastically deformed by the connecting pin 170 in the direction of insertion when the connecting pin 170 is inserted into the opening 182 such that the fixing elements 184 press against the connecting pin 170 when the central section 172 is in contact with the connector plate 164 or with the rear side 168 of the connector plate 164. Free ends of the essentially strip-shaped fixing elements 184 are adapted to the outer surface of the connecting pin 170 in order to achieve the largest possible contact area between the fixing element 184 and the connecting pin 170.In the present embodiment, the free ends of the fixing elements 184 are formed by concave edges corresponding to the circular cylindrical shape of the connecting pins 170. Figure 21 shows the circuit board connector 48 in a state in which the spring tongues 148 are connected to the connector plate 164.

[0151] The board connector 48 has rear partition walls 186, which are arranged on the rear side 168 of the connector plate 164 between the connecting pins 170, between the attached spring tongues 148, and between the center sections 172 of the attached spring tongues 148, respectively. The rear partition walls 186 extend rearwardly parallel to the center sections 172 of the attached spring tongues 148.

[0152] The board connector 48 has front-side partition walls 188 extending from those edges of the connector plate 164 encompassed by the attached spring tongues 148. The front-side partition walls 188 are provided on both sides of each leg section 174 of each attached spring tongue 148 and extend forward along the corresponding leg section 174. The front-side partition walls 188 each have a substantially rectangular outline. Facing edges of the front-side partition walls 188 form a gap 190 into which the arches 178 of the attached spring tongues 148 extend when the leg sections 174 are not spread out. The gap 190 is dimensioned such that it connects edge regions of circuit boards or heating elements 40 and 42 to be connected by means of the circuit board connector 48, if necessary with edge regions of further plates such as in the present case the fluid chamber housing 38 orwhose first and / or second shell 50 or 54 is received within it and preferably clamped. If the board connector 48 is attached to boards or to the core assembly 46, the arches 178 are pressed onto the boards or the contacts 116 or 130 of the core assembly 46.

[0153] Edges of those front-side partition walls 188 facing away from the gap 190 and extending on the same side with respect to the gap 190 are connected to one another in front regions via connector strips 192. The two connector strips 192 of the board connector 48 are each reinforced by a rib 194. Those front-side partition walls 188 that extend on the same side with respect to the gap 190 and between adjacent attached spring tongues 148 are also connected to one another in rear regions of the edges facing away from the gap 190 and at rear edges in the region of the rear-side partition walls 186.

[0154] Two of the guide elements 152 are provided on each end face of the gap 190 on the connector plate 166. The two guide elements 152 on each end face form a gap 196 that is narrower than the gap 190. The two narrower gaps 196 of the guide elements 152 are aligned with one another and are designed to receive or clamp edge regions of one or some of the plates to be received in the gap 190, such as the rear edge of the fluid chamber housing 38 in the present case (see Fig. 18). The guide elements 152 are arranged such that the narrower gaps 196 run eccentrically with respect to the gap 190. The guide elements 152 are further designed to interact in a form-fitting manner with projections on the plates to be received by the gap 190 or with the second projections 72 of the fluid housing 54 in the longitudinal direction of the gap 190.

[0155] One of the spring elements 150 of the circuit board connector 48 is provided on each end face of the connector strips 192. Each of the spring elements 150 (four in the present embodiment) is arcuate and extends rearwardly from the corresponding connector strip 192, with a front end of the spring element 150 flush with the connector strip 192, a central portion of the spring element 150 bent toward the gap 190, and a rear free end of the spring element 150 extending parallel to the connector plate 164.

[0156] The elements of the circuit board connector 48, apart from the spring tongues 148 (i.e., the spring elements 150, the guide elements 152, the connector plate 164, connecting pins 170, rear partition walls 186, front partition walls 188, connector strips 192), form a base body 197, preferably formed integrally. The base body 197 of the circuit board connector 48 is at least largely made of an electrically insulating material, for example, plastic and / or ceramic. The spring tongues 148 are made of an electrically conductive material with spring properties, preferably metal. The spring elements 150 provided on the base body 197 are preferably made of plastic and / or formed integrally with the base body 197 of the circuit board connector 48. Alternatively, it would also be possible to manufacture the spring elements 150 separately from resilient metal and / or plastic, for example from elastic elements such as rubber buffers, and to attach them to the base body 197 orto be attached to the connector strips 192 (for example by casting, gluing, screwing, clipping).

[0157] Fig. 23 shows an exploded view of a heater 2002 according to a third embodiment. The heater 2002 according to the third embodiment differs from the heater 2 according to the first embodiment with regard to the design of the fluid chamber housing.

[0158] Fig. 24 shows a perspective view of a fluid chamber housing 2038 of the heater 2002 according to the third embodiment, corresponding to Fig. 6. Fig. 25 shows a sectional view of the heater 2002 according to the third embodiment, corresponding to Fig. 17.

[0159] A fluid chamber housing 2038 according to the third embodiment has a first shell 2050 and a second shell 2054 which are formed with linear bulges 2198, 2200, 2202 and 2204 (see Fig. 25) which form integral manifolds 2056 and 2060, so that no separately formed manifolds 56 and 60 are required.

[0160] The first shell 2050 is a plate with a substantially rectangular outline. On two opposite sides, edges of the first shell 2050 are formed as standing seams 2206 and 2208, respectively. Both standing seams 2206 and 2208 have a shoulder 2210 and 2212, respectively. Within the standing seams 2206 and 2208, the linear bulge 2198 and 2200 extend along the standing seam 2206 and 2208, respectively. The bulges 2198 and 2200 each have a round, for example, circular segment-shaped, cross-section. Between the bulges 2198 and 2200, fluid guide elements 2214 in the form of (in the present embodiment two) linear indentations are provided at the edge of the bulge 2198, the longitudinal axes of which run coaxially and which extend parallel to the bulge 2198.As with the first shell 50 according to the first embodiment, an area between the fluid guide elements 2214 and the bulge 2200 is designed to be flat in order to accommodate the plate-shaped turbulator 52 and to be in surface contact with it. The shoulders 2210 and 2212 of the standing seams 2206 and 2208 are connected to one another at an edge of the first shell 2050, so that a receiving space for the turbulator 52 is completely enclosed by the first shell 2050.

[0161] The second shell 2054 is a plate with a substantially rectangular outline. On two opposite edges of the second shell 2054, the linear bulge 2202 and 2204 extend parallel to the corresponding edge. Between the bulges 2202 and 2204, fluid guide elements 2216 in the form of (two in the present embodiment) linear indentations are provided at the edge of the bulge 2202. Their longitudinal axes are coaxial and they extend parallel to the bulge 2202.

[0162] When the shells 2050 and 2054 are assembled, one edge of the second shell 2054 rests on the edge of the first shell 2050, formed, among other things, by the shoulders 2210 and 2212. The fluid guide elements 2214 of the first shell 2050 and the fluid guide elements 2216 of the second shell 2054 are configured such that, when the two shells 2050 and 2054 are assembled, they are arranged alternately in a row and spaced apart from one another. The common longitudinal axis of the fluid guide elements 2214 of the first shell 2050 is parallel to the common longitudinal axis of the fluid guide elements 2216 of the second shell 2054.

[0163] The bulges 2198, 2200, 2202, and 2204 locally enlarge a fluid space 2064 enclosed by the shells 2050 and 2054. The fluid guide elements 2214 and 2216 protrude into the fluid space 2064. In other words, the fluid guide elements 2214 and 2216 locally reduce the fluid space 2064. The fluid guide elements 2214 and 2216 delimit a gap between the receiving space for the turbulator 52 and the collecting tube 2056 formed by the bulges 2198 and 2202 (see Fig. 25). The fluid guide elements 2214 and 2216 are provided, corresponding to the elongated holes 88, 90, 94 and 96 of the first embodiment, to effect or enable a homogenization of a fluid flow flowing laterally out of the collecting tube 2056 or a liquid flow flowing laterally out of the collecting tube 2056 over the length of the collecting tube 2056.

[0164] According to the present embodiment, no fluid guide elements are provided between the receiving space for the turbulator 52 and the collecting tube 2060 formed by the bulges 2200 and 2204. The collecting tube 2060 is thus designed as a fluid outlet tube, and the collecting tube 2056 as a fluid inlet tube. If fluid guide elements are also provided between the receiving space for the turbulator 52 and the collecting tube 2060 formed by the bulges 2200 and 2204, the heater 2002 according to the third embodiment can optionally use the collecting tube 2056 or the collecting tube 2060 as the fluid inlet tube, as in the heater 2 according to the first embodiment.

[0165] On the front end faces, the bulges 2202 and 2204 of the second shell 2054 each have an opening 2218 and 2220, respectively, which are designed to be connected to fluid connections 2022 and 2024, respectively. In the heater 2002, these openings are formed in the form of separate fluid connection pieces. The connections between the second shell 2054 and the fluid connections 2022 and 2024 are each sealed by a sealing ring 2222.

[0166] The first shell 2050 and the second shell 2054 are in particular made of an aluminum alloy, preferably the alloy EN-AW 3003.

[0167] The fluid connections 2022 and 2024 can be made of metal, in particular an aluminum alloy such as EN-AW 3003, or of plastic. Metal fluid connections 2022 and 2024 can be designed, in particular, as a turned part or as a die-cast part.

[0168] Fig. 23 shows that the heater 2002 does not have a positioning block. In the third embodiment, the positioning of the heating elements 40 and 42 on the fluid chamber housing 2038 is achieved by means of the circuit board connector 48, which interacts positively with projections 2072 on a rear edge of the second shell 2054, and its guide elements 152, which interact positively with the heating elements 40 and 42, respectively (see Fig. 22). Alternatively, it would also be possible to ensure the predetermined positioning of the heating elements 40 and 42 on the fluid chamber housing 2038 purely through process engineering.

[0169] List of reference symbols

[0170] 2 heaters

[0171] 4 protective housings

[0172] 6 first protective housing shell

[0173] 8 second protective housing shell

[0174] 10, 12 Leg section of the first protective housing shell

[0175] 14 Middle section of the first protective housing shell

[0176] 16, 18 Leg section of the second protective housing shell

[0177] 20 Middle section of the second protective housing shell

[0178] 22, 24 Fluid connection

[0179] 26 low-voltage plugs

[0180] 28 high-voltage connectors

[0181] 30 to 36 holders

[0182] 38 fluid chamber housing

[0183] 40 first heating element

[0184] 42 second heating element

[0185] 44 Positioning block

[0186] 46 Core assembly

[0187] 48 board connectors

[0188] 50 first shell of the fluid chamber housing

[0189] 52 Turbulator of the fluid chamber housing

[0190] 54 second shell of the fluid chamber housing

[0191] 56 first manifold of the fluid chamber housing

[0192] 58 Closure of the first collecting tube

[0193] 60 second manifold of the fluid chamber housing

[0194] 62 Closure of the second collecting pipe

[0195] 64 Fluid space

[0196] 66 Rebound on the first shell

[0197] 68 Rebound on the second shell

[0198] 70 first projection on the second bowl

[0199] 72 second projection on the second bowl

[0200] 74 Contact surface of the second shell inside of the first shell

[0201] Contact surface of the first shell

[0202] Inside of the first shell

[0203] Outside of the second shell first groove-shaped depression in the second shell second groove-shaped depression in the second shell short slot in the second shell long slot in the second shell

[0204] Round hole in the second shell Short slotted hole in the collecting tube Long slotted hole in the collecting tube

[0205] Round hole in the collecting pipe

[0206] Heat side of the first heating element

[0207] Cold side of the first heating element

[0208] Control circuit area on the first heating element

[0209] Heating element plug

[0210] Power range on the first heating element, 112, 114 Heating zone on the first heating element

[0211] Contact on the first heating element

[0212] Heat side of the second heating element

[0213] Cold side of the second heating element

[0214] Power range on the second heating element, 126, 128 Heating zone on the second heating element

[0215] Contact on the second heating element

[0216] Projection on the positioning block

[0217] Frame for heating element plug first fluid connection recess on the first protective housing shell second fluid connection recess on the first protective housing shell high-voltage plug recess

[0218] Low-voltage plug recess

[0219] Standing seam on the first protective housing shell

[0220] Pressure compensation element

[0221] Spring tongue of the board connector 150 Spring element of the board connector

[0222] 152 Guide element of the board connector

[0223] 154 Weld seam of the protective housing

[0224] 156, 158 Circumferential weld at fluid connection

[0225] 160 folded shoulder of the second protective housing shell

[0226] 162 installation space

[0227] 164 Connector plate of the board connector

[0228] 166 Front of the connector plate

[0229] 168 Back of the connector plate

[0230] 170 connecting pin

[0231] 172 Middle section of the spring tongue

[0232] 174 Leg section of the spring tongue

[0233] 176 free end of the leg section of the spring tongue

[0234] 178 bend of the leg section of the spring tongue arranged at the free end

[0235] 180 Narrow section of the spring tongue formed by leg sections

[0236] 182 Opening in the middle section of the spring tongue

[0237] 184 Fixing element

[0238] 186 rear partition of the board connector

[0239] 188 front partition of the board connector

[0240] 190 gap of the board connector

[0241] 192 Connector strip of the board connector

[0242] 194 Rib on connector strip of the board connector

[0243] 196 narrower gap

[0244] 197 Base body of the board connector

[0245] 1002 Heater according to the second embodiment

[0246] 1004 Protective housing according to the second embodiment

[0247] 1008 second protective housing shell according to the second embodiment

[0248] 1038 Fluid chamber housing

[0249] 1064 Fluid space

[0250] 1104 Control circuit area

[0251] 1108 Power range 2002 heater according to the third embodiment

[0252] 2022, 2024 Fluid connection of the heater according to the third embodiment

[0253] 2038 Fluid chamber housing of the heater according to the third embodiment

[0254] 2050 first shell of the fluid chamber housing of the heater according to the third embodiment

[0255] 2054 second shell of the fluid chamber housing of the heater according to the third embodiment

[0256] 2056, 2060 integral manifolds

[0257] 2064 Fluid Space

[0258] 2198, 2200 linear bulge in the first shell of the

[0259] Fluid chamber housing of the heater according to the third embodiment

[0260] 2202, 2204 linear bulge in the second shell of the fluid chamber housing of the heater according to the third embodiment

[0261] 2206, 2208 Standing seam at the edge of the first shell of the fluid chamber housing of the heater according to the third embodiment

[0262] 2210, 2212 recess in the standing seam of the first shell of the fluid chamber housing of the heater according to the third embodiment

[0263] 2214 Fluid guide element of the first shell of the fluid chamber housing of the heater according to the third embodiment

[0264] 2216 Fluid guide element of the second shell of the fluid chamber housing of the heater according to the third embodiment

[0265] 2218, 2220 Opening in the bulges of the first shell of the fluid chamber housing of the heater according to the third embodiment

[0266] 2222 Sealing ring between fluid connection and second shell of the fluid chamber housing of the heater according to the third embodiment

[0267] A Attaching the first heating element to the fluid chamber housing B Attaching the second heating element to the fluid chamber housing C Attaching the positioning block D Attaching the core assembly to the first protective housing shell E Connecting the low-voltage plug to the first heating element

[0268] F Connection of the high-voltage connector to the first heating element G Attachment of the circuit board connector to the core assembly H Attachment of the second protective housing shell to the first

[0269] Protective housing shell

[0270] I Attaching the holders to the first protective housing shell

[0271] J, K, L possible flow direction

[0272] M Spreading of the leg sections of the first protective housing shell a Angle of attack of the fluid chamber housing relative to the second

[0273] Protective housing shell

Claims

Claims 1. A heater (2; 1002; 2002) with a fluid chamber housing (38; 1038; 2038) having an outer wall designed to enclose a fluid chamber (64; 1064; 2064) in a fluid-tight manner, apart from at least one fluid connection (22, 24; 2022, 2024) of the fluid chamber housing (38; 1038; 2038), at least one first heating element (40) and at least one second heating element (42), which are arranged on two opposite sides of the fluid chamber (64; 1064; 2064) and which are designed to be able to heat a fluid flowing through the fluid chamber (64; 1064; 2064) or accommodated in the latter, wherein the first heating element (40) has a power range (108;1108), in which the first heating element (40) emits heat and which has individually controllable heating zones (110, 112, 114), and the second heating element (42) has a power range (122) in which the second heating element (42) emits heat, characterized in that the power range (122) of the second heating element (42) has individually controllable heating zones (124, 126, 128), which are each opposite a corresponding heating zone (110, 112, 114) of the first heating element (40); 2. Heater (2; 1002; 2002) according to claim 1, characterized in that the first heating element (40) has a control circuit area (104; 1104) in which control elements are arranged which serve to control the power range (108; 1108) of the first heating element (40) and / or to control the power range (122) of the second heating element (42).

3. Heater (2; 1002; 2002) according to claim 2, characterized in that the heating zones (110, 112, 114) of the first heating element (40) are arranged in a row and the control circuit area (1104) of the first heating element (40) is arranged along the heating zones (110, 112, 114) of the first heating element (40).

4. Heater (1002) according to claim 2 or 3, characterized in that the fluid chamber housing (1038), the first heating element (40) and the second heating element (42) are each plate-shaped, the first heating element (40) is attached to the outer wall of the fluid chamber housing (1038) in such a way that the control circuit area (1104) is arranged away from the fluid chamber (1064) in a longitudinal direction of the fluid chamber housing (1038) and / or a width direction of the fluid chamber housing (1038).

5. Heater (2; 1002; 2002) according to claim 2, characterized in that the control circuit area (1104) of the first heating element (40) and the heating zones (110, 112, 114) of the first heating element (40) are arranged in a row, and the control circuit area (1104) of the first heating element (40) is arranged closer to the at least one fluid connection (22, 24; 2022, 2024) than the heating zones (110, 112, 114) of the first heating element (40) and / or than the heating zones (124, 126, 128) of the second heating element (42).

6. Heater (2; 1002; 2002) according to one of claims 1 to 5, characterized in that the heating zones (124, 126, 128) of the second heating element (42) are larger than the heating zones (110, 112, 114) of the first heating element (40).

7. Heater (2; 1002; 2002) according to one of claims 1 to 6, characterized in that the heating zones (110, 112, 114) of the first heating element (40) are of equal size and / or the heating zones (124, 126, 128) of the second heating element (42) are of equal size.

Images