VEHICLE HEATING MODULE AND ASSOCIATED THERMISTOR HEATER FOR VEHICLE

Abstract

A thermistor heater for a vehicle comprises a flat heat-conducting tube (110) and a PTC thermistor assembly (120). The flat heat-conducting tube (110) has a connection opening (111). The PTC thermistor assembly (120) is inserted into the flat heat-conducting tube (110) and comprises a plurality of ceramic resistors (121), a first electrode sheet (122), a second electrode sheet (123), a third electrode sheet (124), and an insulating layer (125). The ceramic resistors (121) comprise a first ceramic resistor (1211) fixed by the first sheet (122) and disposed between the connection opening (111) and a second ceramic resistor (1212) fixed to the second sheet (123). The third sheet (124) is arranged on another side of each resistor (121).The layer (125) covers a portion of the second sheet (123) and is arranged between the first sheet (122) and the second sheet (123).

Description

Title of the invention: VEHICLE HEATING MODULE AND ASSOCIATED THERMISTOR HEATER FOR VEHICLE

[0001] BACKGROUND Technical field

[0002] The invention relates to a heater, in particular a thermistor heater for a vehicle and a vehicle heating module provided with the thermistor heater for a vehicle.

[0003] Related art

[0004] A positive temperature coefficient (PTC) heater has the advantages of long service life, energy saving, low thermal resistance and high thermal conversion efficiency, and no safety hazards such as burns or fires caused by the heating of an electric heating tube, so it has been gradually applied to a vehicle interior (such as seats, backrests or handles) to serve as a heater. A general PTC heater comprises heating pipes, ceramic resistors and fins. Heat from the ceramic resistors when energized is diffused by the fins.

[0005] However, the heat exchange efficiency and heating power of a PTC heater are related to the volume of the fins and ceramic resistors, so a PTC heater has a considerable volume. As a result, it can only heat a small local area or heat different areas in a switching mode, so PTC heaters have a low possibility of being adopted and a high energy consumption.

[0006] The heat exchange area of ​​the fin is related to the heat exchange efficiency, and the volume of the ceramic resistor is also related to the heating efficiency. Therefore, PTC heaters all have a considerable volume and are not usable in a small area.

[0007] In view of this, the inventors devoted themselves to the above-mentioned prior art, carried out intensive research and cooperated with the application of science to attempt to solve the above-mentioned problems. Ultimately, the present invention is proposed, being reasonable and effective in overcoming the above drawbacks.

[0008] SUMMARY

[0009] An object of the invention is that a vehicle heating module or a heater vehicle thermistor is able to heat a corresponding position according to different demands to save energy consumption.

[0010] To achieve the above objective, a thermistor heater for a vehicle is provided, which comprises a heat-conducting flat tube and a positive temperature coefficient (PTC) thermistor assembly. One end of the heat-conducting flat tube has a connection opening. The PTC thermistor assembly is inserted into the heat-conducting flat tube and comprises a plurality of ceramic resistors, a first electrode sheet, a second electrode sheet, a third electrode sheet, and an insulating layer. The ceramic resistors are arranged in a row and comprise a first ceramic resistor and a second ceramic resistor. The first ceramic resistor is arranged between the connection opening and the second ceramic resistor.The first electrode sheet is disposed on one side of each ceramic resistor, is correspondingly fixed on the first ceramic resistor, and includes a first connection terminal passing out of the connection opening. The second electrode sheet is disposed on the same side of each ceramic resistor as the first electrode sheet, is correspondingly fixed on the second ceramic resistor, and includes a second connection terminal passing through the connection opening. The third electrode sheet is disposed on another side of each ceramic resistor, is fixed on each ceramic resistor, and includes a third connection terminal passing through the connection opening. The insulating layer covers a portion of the second electrode sheet and is disposed between the first electrode sheet and the second electrode sheet.

[0011] In particular, the invention relates to a thermistor heater for a vehicle comprising a flat thermally conductive tube, characterized in that it comprises a connection opening defined at one end thereof; and a positive temperature coefficient (PTC) thermistor assembly, inserted into the flat heat-conducting tube, and in that it comprises: a plurality of ceramic resistors, arranged in a row, comprising a first ceramic resistor and a second ceramic resistor, the first ceramic resistor being arranged between the connection opening and the second ceramic resistor; a first electrode sheet, disposed on one side of each ceramic resistor, correspondingly fixed on the first ceramic resistor, and comprising a first connection terminal passing out of the connection opening a second electrode sheet, arranged on the side of each ceramic resistor in the same manner as the first electrode sheet, correspondingly fixed on the second ceramic resistor, and comprising a second connection terminal passing out of the connection opening; a third electrode sheet, disposed on another side of each ceramic resistor, fixed on each ceramic resistor, and comprising a third connection terminal passing out of the connection opening; and an insulating layer, covering a portion of the second electrode sheet, and disposed between the first electrode sheet and the second electrode sheet.

[0012] According to one embodiment of the invention, another end of the flat heat-conducting tube is a closed end.

[0013] According to one embodiment of the invention, the heater further comprises two insulating sleeves, the insulating sleeves being correspondingly overlapped and jointly covering the first electrode sheet, the second electrode sheet, the third electrode sheet and each ceramic resistor.

[0014] According to one embodiment of the invention, an overlap length is defined between any one of the insulating sleeves and another insulating sleeve, and the overlap length is greater than 5 mm.

[0015] According to one embodiment of the invention, the heater further comprises an insulating sleeve, the insulating sleeve covering the first electrode sheet, the second electrode sheet, the third electrode sheet and each ceramic resistor.

[0016] According to one embodiment of the invention, the first electrode sheet is arranged between the connection opening and the second electrode sheet, and the second electrode sheet is extended by a connection portion towards the connection opening so as to pass the second connection terminal outside the connection opening.

[0017] According to one embodiment of the invention, the insulating layer covers the connection part.

[0018] According to one embodiment of the invention, the first connection terminal, the second connection terminal and the third connection terminal are arranged in parallel.

[0019] To achieve the above objective, the invention further provides a vehicle heating module, which comprises a plurality of vehicle thermistors and a plurality of fin assemblies, each vehicle thermistor heater comprises a thermally conductive flat tube and temperature coefficient thermistor assembly positive (PTC). One end of the flat thermally conductive tube has a connection opening. The PTC thermistor assembly is inserted into the flat thermally conductive tube and comprises several ceramic resistors, a first electrode sheet, a second electrode sheet, a third electrode sheet, and an insulating layer. The ceramic resistors comprise a first ceramic resistor and a second ceramic resistor. The first ceramic resistor is arranged between the connection opening and the second ceramic resistor. The first electrode sheet is arranged on one side of each ceramic resistor, is correspondingly fixed on the first ceramic resistor, and comprises a first connection terminal passing out of the connection opening.The second electrode sheet is disposed on the same side of each ceramic resistor as the first electrode sheet, is correspondingly fixed on the second ceramic resistor, and includes a second connection terminal passing through the connection opening. The third electrode sheet is disposed on another side of each ceramic resistor, is fixed on each ceramic resistor, and includes a third connection terminal passing through the connection opening. The insulating layer covers a portion of the second electrode sheet and is disposed between the first electrode sheet and the second electrode sheet. Two opposite sides of each thermally conductive flat tube separately have a flat wall. Each PTC thermistor assembly is separately fixed on each flat wall of one of the corresponding thermally conductive flat tubes.Each flat heat-conducting tube and each set of fins are arranged side by side and alternately. Each flat wall is fixed on one of the adjacent sets of fins.

[0020] In particular, the vehicle heating module is characterized in that it comprises a plurality of vehicle thermistor heaters as above, each heat-conducting flat tube comprising a flat wall disposed respectively on its two sides, and each PTC thermistor assembly fixed on each flat wall of a corresponding one of the heat-conducting flat tubes; and several sets of fins, each thermally conductive flat tube and each set of fins being arranged side by side and in an alternating manner, and each flat wall being fixed on one of the adjacent sets of fins.

[0021] According to one embodiment of the invention, each set of fins has a structural strength greater than that of each flat thermally conductive tube.

[0022] In the vehicle heating module and its vehicle thermistor heater according to the invention, the first electrode sheet and the second sheet electrode-forming sheets are fixed on the first ceramic resistor and the second ceramic resistor, respectively, and the insulating layer is blocked between the first electrode-forming sheet and the second electrode-forming sheet, so that the heater is capable of implementing heating on a corresponding position according to different demands to save power consumption.

[0023] BRIEF DESCRIPTION OF THE DRAWINGS

[0024] [Fig.l] is an exploded view of the PTC thermistor assembly according to the invention;

[0025] [Fig.2] is a perspective view of the PTC thermistor assembly according to the invention;

[0026] [Fig.3] is another perspective view of the PTC thermistor assembly according to the invention, from another point of view;

[0027] [Fig.4] is an exploded view of the PTC thermistor assembly and the insulating sleeve according to the invention;

[0028] [Fig.5] is an exploded view of the thermistor heater for a vehicle according to the invention;

[0029] [Fig.6] is a perspective view of the thermistor heater for a vehicle according to the invention;

[0030] [Fig.7] is a side view of the vehicle thermistor heater and each set of fins according to the invention; and

[0031] [Fig.8] is a perspective view of the heating module according to the invention. DETAILED DESCRIPTION

[0032] In describing the invention, it is to be understood that the orientations or positional relationships indicated by the terms "front", "rear", "left", "right", "front end", "rear end", "distal end", "longitudinal", "transverse", "perpendicular", "top" and "bottom" are based on the orientation or positional relationships shown in the drawings; they are used solely for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the devices or elements indicated must have a specific orientation or must be assembled or used in a specific orientation. They are therefore not to be construed as limitations on the disclosure.

[0033] Terms used in the description, such as "first", "second", "third", "fourth" and "fifth", refer to various elements, assemblies, areas, layers and / or portions. These elements, assemblies, areas, layers and / or portions should not be limited by these terms. These terms may only be used to distinguish one element, assembly, area, layer and / or portion from another. Unless otherwise stated, Unless expressly indicated by the context, terms such as "first", "second", "third", "fourth" and "fifth" do not imply an order or sequence.

[0034] As used herein and not otherwise defined, terms such as "substantially" and "approximately" are used to describe and represent small variations. When used in connection with an event or circumstance, the terms may include the exact time at which the event or circumstance occurs, as well as the event or circumstance occurring at a nearby point. For example, when associated with a value, the terms may include a range of variation less than or equal to ±10% of the value, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%.

[0035] The technical content of the present description will become clear from the detailed description of the embodiments accompanied by the illustration of the associated drawings, which follows. It is understood that the embodiments and drawings described herein are to be considered as illustrative rather than restrictive.

[0036] The invention relates to a thermistor heater 100 for a vehicle used for interiors (such as seats, backrests or handles) or for heating cold winds blown by air conditioners of vehicles, hybrid vehicles or electric vehicles. With reference to Figures 1 to 5, it appears that the thermistor heater 100 for a vehicle comprises a flat heat-conducting tube 110 and a positive temperature coefficient (PTC) thermistor assembly 120.

[0037] In this embodiment, the flat thermally conductive tube 110 may be made of, but is not limited to, aluminum or copper. Two ends of the flat thermally conductive tube 110 separately have a connection opening 111 and a closed end 112. The interior of the flat thermally conductive tube 110 has a receiving space 113. The receiving space 113 communicates with the exterior of the flat thermally conductive tube 110 through the connection opening 111. Each of the two opposite sides of the flat thermally conductive tube 110 is separately provided with a flat wall 114, the flat walls being parallel to each other.In the embodiment, each of the two side edges of the flat heat-conducting tube 110 is arranged with an arcuate wall 115, without limitation, for example, two side edges of the flat heat-conducting tube 110 can also be made flat so that the flat heat-conducting tube 110 has a rectangular tubular shape. The reason why the embodiment adopts the arcuate wall 115 is that the arcuate wall 115 has a larger heat exchange surface than a plane, provided that the thickness of the flat heat-conducting tube 110 is the same.

[0038] The PTC thermistor assembly 120 is inserted into the receiving space 113 of the flat thermally conductive tube 110. In detail, the PTC thermistor assembly 120 is fixed on inner walls of two flat walls 114 of the flat thermally conductive tube 110 so that the PTC thermistor assembly 120 is thermally connected to the flat thermally conductive tube 110. In this embodiment, to improve the heat transfer effect between the PTC thermistor assembly 120 and the flat thermally conductive tube 110, a thermal glue (not shown in the figures) is arranged between the PTC thermistor assembly 120 and the flat thermally conductive tube 110, but not limited to this. The PTC thermistor assembly 120 comprises several ceramic resistors 121, a first electrode sheet 122, a second electrode sheet 123, a third electrode sheet 124 and an insulating layer 125.

[0039] The ceramic resistors 121 are arranged in a row and include at least one first ceramic resistor 1211 and at least one second ceramic resistor 1212. The first ceramic resistor 1211 is arranged between the connection opening 111 and the second ceramic resistor 1212. In this embodiment, the number of the first ceramic resistor 1211 and the second ceramic resistor 1212 is three, but not limited to three. The number of each of the first ceramic resistors 1211 and the second ceramic resistors 1212 can be adjusted according to the required heating length or width. Referring to Figures 1 and 2, it is apparent that the first ceramic resistors 1211 are arranged side by side and sequentially from the connection opening 111 along the longitudinal direction of the flat heat-conducting tube 110.The second ceramic resistors 1212 are arranged side by side and sequentially along the longitudinal direction of the flat heat-conducting tube 110. In other words, each first ceramic resistor 1211 is always arranged between the connection opening 111 and each second ceramic resistor 1212, but no contact exists between two ceramic resistors 121.

[0040] In the embodiment, the first electrode foil 122 may be made of aluminum or copper, but this is not limiting. The first electrode foil 122 is arranged on one side of each ceramic resistor 121 and is correspondingly fixed on the first ceramic resistor 1211. In detail, the first electrode foil 122 of the embodiment is fixed on each first ceramic resistor 1211, i.e., the first electrode foil 122 is simultaneously fixed on three first ceramic resistors 1211. The first electrode foil 122 has a first connection terminal 1221 passing out of the connection opening 111.

[0041] In the embodiment, the second electrode sheet 123 may be made of aluminum or copper, but this is not limiting. The second sheet 123 forming electrode and the first electrode sheet 122 are arranged in parallel on the same side of each ceramic resistor 121 and are correspondingly fixed on each second ceramic resistor 1212. In detail, the second electrode sheet 123 of the embodiment is fixed on each second ceramic resistor 1212, that is, the second electrode sheet 123 is simultaneously fixed on three second ceramic resistors 1212, and the second electrode sheet 123 and the first electrode sheet 122 are both arranged along the longitudinal direction of the flat heat-conducting tube 110 side by side. The second electrode sheet 123 has a second connection terminal 1231 passing out of the connection opening 111 of the flat heat-conducting tube 110.

[0042] In the embodiment, the third electrode sheet 124 may be made of, but is not limited to, aluminum or copper. The third electrode sheet 124 is arranged on the other side of each ceramic resistor 121 and attached to each ceramic resistor 121. In detail, the third electrode sheet 124 is attached to three first ceramic resistors 1211 and three second ceramic resistors 1212, and the area of ​​the third electrode sheet 124 is approximately the sum of the first electrode sheet 122 and the second electrode sheet 123. The third electrode sheet 124 has a third connection terminal 1241 passing out of the connection opening 111 of the flat heat-conducting tube 110.The first connection terminal 1221, the second connection terminal 1231 and the third connection terminal 1241 protrude from the connection opening 111 and the first connection terminal 1221, the second connection terminal 1231 and the third connection terminal 1241 are arranged in parallel side by side so as to be connectable and wired to a power source.

[0043] In the embodiment, the insulating layer 125 is, but is not limited to, a polyimide (Kapton) film or an aluminum oxide ceramic substrate. The insulating layer 125 covers a portion of the second electrode sheet 123 and is blocked between the first electrode sheet 122 and the second electrode sheet 123.Therefore, the insulating layer 125 is capable of preventing the first electrode sheet 122 and the second electrode sheet 123 from forming an electrical connection, so as to ensure that the first electrode sheet 122 and the second electrode sheet 123 can operate independently without mutual interference so as to enable the heater to be able to implement heating corresponding to either the first electrode sheet 122 or the second electrode sheet 123 or both to save power consumption and improve the possibility of adopting various . combinations.

[0044] Furthermore, with reference to FIGS. 5 and 6, it is apparent that the closed end 112 of the flat thermally conductive tube 110 is made by pressing and laser welding a distal end of the flat thermally conductive tube 110 to form a water-resistant seal. This can omit the arrangement of a sealing ring, reduce costs, and effectively ensure sealing. In addition, regular maintenance, checking, and replacement of consumables (i.e., the sealing ring) are not required. As shown in [Fig. 5], it is noted that each ceramic resistor 121 in the embodiment is arranged on the side biased toward the flat thermally conductive tube 110 instead of being arranged in the center of the flat thermally conductive tube 110 like the related art.Thus, when the flat heat-conducting tube 110 is associated with an air conditioner, the side of the flat heat-conducting tube 110, which is adjacent to each ceramic resistor 121, can be arranged toward the air outlet of the air conditioner for installation so that the air flow from the air conditioner can be in direct contact with the areas of the flat heat-conducting tube 110 corresponding to each ceramic resistor 121 for rapid heating. This can effectively improve the power of the thermistor heater 100 for a vehicle according to the invention.

[0045] Referring to Figures 4 and 5, it appears that the vehicle thermistor heater 100 of the present disclosure further comprises an insulating sleeve 130. In this embodiment, the insulating sleeve 130 is, but is not limited to, a polyimide (Kapton) film or an aluminum oxide ceramic substrate. The insulating sleeve 130 covers the first electrode sheet 122, the second electrode sheet 123, the third electrode sheet 124 and each ceramic resistor 121 so as to insulate them from the flat heat-conducting tube 110. In this embodiment, the number of insulating sleeves 130 is two, and the insulating sleeves 130 are superimposed and inserted into each other correspondingly, and jointly cover the first electrode sheet 122, the second electrode sheet 123, the third electrode sheet 124 and each ceramic resistor 121.In detail, the insulating sleeve 130 is longitudinally U-shaped, and the U-shaped openings of two insulating sleeves 130 face each other to allow the two insulating sleeves 130 to overlap and fit into each other correspondingly, and cover the first electrode sheet 122, the second electrode sheet 123, the third electrode sheet 124 and each ceramic resistor 121. In addition, in this embodiment, any one of the insulating sleeves 130 has an overlapping length with another insulating sleeve 130, the overlapping length is at least more than 5 mm so that the creepage distance of the electrode is more than 8 mm for . effectively guarantee the insulation effect.

[0046] Furthermore, as shown in Figures 1 to 5, the first electrode sheet 122 is disposed between the connection opening 111 and the second electrode sheet 123, such that the second electrode sheet 123 is extended by a connection portion 1232 toward the connection opening 111 to pass the second connection terminal 1231 out of the connection opening 111. In detail, the connection portion 1232 comprises a first extended portion 1233 and a second extended portion 1234.The first portion 1233 extends from the body of the second electrode sheet 123 toward the first electrode sheet 122, the second portion 1234 extends from a side edge of the first portion 1233 toward the connection opening 111 and is located on one side of the first electrode sheet 122 so as to give the connection portion 1232 an L shape to prevent interference with the first electrode sheet 122. In addition, the insulating layer 125 covers the connection portion 1232 to prevent the first electrode sheet 122 and the second electrode sheet 123 from electrically connecting.

[0047] With reference to Figures 7 and 8, it appears that the invention also provides a vehicle heating module, which comprises at least several vehicle thermistor heaters 100 as mentioned above and several fin assemblies 200.

[0048] In the embodiment, the fin assembly 200 is formed by, but not limited to, aluminum or copper fins that are folded and arranged closely in a corrugated shape. Each thermally conductive flat tube 110 and each fin assembly 200 are arranged side by side and alternately. In detail, each flat wall 114 is attached to an adjacent one of the fin assemblies 200 by vacuum brazing. Each fin assembly 200 projects from a side edge of an attached flat wall 114 and is at least coplanar with the actuated walls 115 on two sides. Further, each fin assembly 200 is larger than each thermally conductive flat tube 110 in structural strength to prevent the thermally conductive flat tube 110 from being damaged or deformed during pressing.In detail, in the embodiment, the fin assembly 200 is larger than the thermally conductive flat tube 110 in thickness to make the fin assembly 200 larger than the thermally conductive flat tube 110 in structural strength, without limitation.

[0049] Furthermore, as shown in [Fig.7], the top of the fin assembly 200 located at the uppermost position in the figure may be further arranged with a thermistor heater 100 for a vehicle, and the lower portion of the fin assembly 200 located at the lowermost position in the figure is arranged with a bottom plate 300 in aluminum or copper to improve the heat transfer and heating effects of the top and bottom of the vehicle heating module.

[0050] In addition, as shown in [Fig.8], the vehicle heating module according to the present disclosure also comprises an insulating frame 400. The insulating frame 400 is formed outside each vehicle thermistor heater 100 and each fin set 200 by plastic injection molding. The insulating frame 400 is provided with a connector opening 410 corresponding to each connection opening 111 of each vehicle thermistor heater 100 for connecting a corresponding connector (not shown in the figures).

Claims

Claims

1. A thermistor heater for a vehicle, characterized in that it comprises a flat heat-conducting tube (110), comprising a connection opening (111) defined at one end thereof; and a positive temperature coefficient (PTC) thermistor assembly (120), inserted into the flat heat-conducting tube (110), and in that it comprises: a plurality of ceramic resistors (121), arranged in a row, comprising a first ceramic resistor (1211) and a second ceramic resistor (1212), the first ceramic resistor (1211) being arranged between the connection opening (111) and the second ceramic resistor (1212); a first electrode sheet (122), disposed on one side of each ceramic resistor (121), correspondingly fixed on the first ceramic resistor (1211), and comprising a first connection terminal (1221) passing out of the connection opening (111);a second electrode sheet (123), arranged on the side of each ceramic resistor (121) in the same manner as the first electrode sheet (122), correspondingly fixed on the second ceramic resistor (1212), and comprising a second connection terminal (1231) passing out of the connection opening (111); a third electrode sheet (124), arranged on another side of each ceramic resistor (121), fixed on each ceramic resistor (121), and comprising a third connection terminal (1241) passing out of the connection opening (111); and an insulating layer (125), covering a part of the second electrode sheet (123), and arranged between the first electrode sheet (122) and the second electrode sheet (123).;

2. A thermistor heater for a vehicle according to claim 1, characterized in that another end of the heat-conducting flat tube (110) is a closed end (112).

3. A vehicle thermistor heater according to claim 1, characterized in that it further comprises two insulating sleeves (130), the insulating sleeves (130) being correspondingly overlapped. laying and jointly covering the first electrode sheet (122), the second electrode sheet (123), the third electrode sheet (124) and each ceramic resistor (121).

4. A thermistor heater for a vehicle according to claim 3, characterized in that an overlap length is defined between any one of the insulating sleeves (130) and another of the insulating sleeves (130), and the overlap length is greater than 5 mm.

5. A vehicle thermistor heater according to claim 1, characterized in that it further comprises an insulating sleeve (130), the insulating sleeve (130) covering the first electrode sheet (122), the second electrode sheet (123), the third electrode sheet (124) and each ceramic resistor (121).

6. A thermistor heater for a vehicle according to claim 1, characterized in that the first electrode sheet (122) is disposed between the connection opening (111) and the second electrode sheet (123), and the second electrode sheet (123) is extended by a connection portion (1232) toward the connection opening (111) so as to pass the second connection terminal (1231) outside the connection opening (111).

7. A thermistor heater for a vehicle according to claim 6, characterized in that the insulating layer (125) covers the connection portion (1232).

8. A thermistor heater for a vehicle according to claim 1, characterized in that the first connection terminal (1221), the second connection terminal (1231) and the third connection terminal (1241) are arranged in parallel.

9. A vehicle heating module characterized in that it comprises a plurality of vehicle thermistor heaters according to one of claims 1 to 8, each heat-conducting flat tube (110) comprising a flat wall (114) arranged respectively on its two sides, and each PTC thermistor assembly (120) fixed on each flat wall (114) of a corresponding one of the heat-conducting flat tubes (110); and a plurality of fin assemblies (200), each heat-conducting flat tube (110) and each fin assembly (200) being arranged side by side and alternately, and each flat wall (114) being fixed on an adjacent one of the fin assemblies (200).

10. Vehicle heating module according to claim 9, characterized in that each set of fins (200) has a structural strength greater than that of each thermally conductive flat tube (110).

Images