PTC heater assembly

Abstract

The present invention relates to a PTC heater assembly, comprising: a housing having a storage space formed therein; a PTC frame having a plurality of hollow holder portions formed at intervals along a longitudinal direction and having a terminal fastening portion at one end in the longitudinal direction; a plurality of PTC elements inserted into the holder portion of the PTC frame; a terminal plate extending along a longitudinal direction and making surface contact with one side and the other side of the PTC elements; and an insulating film attached to the outer side of the terminal plate, wherein the terminal plate is composed of a pair of first terminal plates facing each other that group and energize some of the plurality of PTC elements, and a pair of second terminal plates faceting each other that are separated from the first terminal plate and energize the remainder of the PTC elements. Accordingly, even if either the first terminal plates or the second terminal plates generate heat due to energization, it is possible to prevent current from flowing into or heat from being conducted to the other, thereby enabling more accurate and precise temperature control and preventing unnecessary current from flowing.

Description

PTC heater assembly

[0001] The present invention relates to a PTC heater assembly, and more particularly, to a PTC heater assembly capable of maximizing independent heating efficiency and significantly reducing assembly defect rates by improving the configuration and joint structure of the heater assembly.

[0002]

[0003] Typically, vehicles are equipped with a heating system to heat the interior or to dehumidify or defrost the windshield.

[0004] These heating devices require the coolant surrounding the engine to flow into the heater after the engine is started. Therefore, it takes a long time for the coolant to heat up and heat the interior. Consequently, the vehicle must remain cold for a certain period of time after starting.

[0005] Recently, there is a trend toward producing electric vehicles, and since these electric vehicles do not have separate engines and coolant configurations, electric heaters using electric resistance elements are being produced.

[0006] The above electric heater uses a PTC heater assembly having a built-in PTC element.

[0007] Hereinafter, a PTC heater assembly according to the prior art will be described with reference to FIG. 1.

[0008] As shown, a PTC heater assembly according to the prior art is composed of a (+) terminal plate (50) and a (-) terminal plate (52), a PTC element (40) interposed therebetween, a PTC frame (30) accommodating the PTC element (40), an insulating film (20) adhered to the outer surfaces of the (+) and (-) terminal plates (50, 52) and the PTC frame (30), and a housing (10) accommodating the PTC frame (30) to which the insulating film (20) is adhered on the inside.

[0009] However, in the case of the PTC heater assembly according to the prior art, when current is applied to the (+) and (-) terminal plates (50, 52), the entire plurality of PTC elements (40) interposed therebetween generates heat, so there was a problem that it was difficult to control the heating temperature intensity, that is, to precisely control and maintain the temperature setting.

[0010] Recently, as a solution to the above-mentioned problem as shown in Fig. 2, Korean Patent Publication No. 1913121 (October 24, 2018) discloses an "independently controlled PTC heater and device" capable of independently controlling a PTC element to maximize energy and heating efficiency.

[0011] However, in the case of the "independent control PT heater and device" according to the prior art, the first opening (121-1) and the second opening (121-2) formed in the guide frame (120) into which the PT elements (110-1, 110-2) are inserted are arranged in positions that are offset from each other (in different directions), and since the first opening (121-1) and the second opening (121-2) are offset from each other, the overall width of the guide frame (120) must be manufactured relatively wide, and thus, there is a problem that the volume and weight increase accordingly, thereby increasing the manufacturing cost.

[0012] In addition, in the case of the common electrode plate (150), since it is structured to contact all surfaces of the PTC elements (110-1, 110-2) inserted into the first opening (121-1) and the second opening (121-2), the same current always flows to the other PTC element (110-2) that does not need to be heated, which not only wastes current unnecessarily, but also causes the heat generation of the heating PTC element (110-1) to affect the other PTC element (110-2) through the common electrode plate (150), which has a problem of reducing the efficiency of independent heating.

[0013] [Prior Art Literature]

[0014] [Patent Document]

[0015] (Patent Document 1) Korean Patent Publication No. 1096286 (December 13, 2011)

[0016] (Patent Document 2) Korean Patent Publication No. 1913121 (October 24, 2018)

[0017] The present invention has been devised to solve the above problems, and provides a PTC heater assembly that can not only maximize independent heating efficiency by improving the configuration and joint structure of the heater assembly, but also significantly reduce the assembly defect rate, thereby greatly improving the reliability of product quality.

[0018]

[0019] In order to achieve the above-described object, a PTC heater assembly according to the present invention comprises: a housing having a storage space formed therein; a PTC frame having a plurality of hollow holder portions formed at intervals along a longitudinal direction and having a terminal fastening portion at one end in the longitudinal direction, the PTC frame being accommodated in the storage space; a plurality of PTC elements inserted into the holder portion of the PTC frame; a terminal plate extending along the longitudinal direction and making surface contact with one side and the other side of the PTC elements; and an insulating film attached to the outer side of the terminal plate, wherein the terminal plate is characterized by comprising a pair of first terminal plates that group some of the plurality of PTC elements and conduct current and face each other, and a pair of second terminal plates that are separated from the first terminal plates and conduct current to the remainder of the PTC elements and face each other.

[0020] The first terminal plate is characterized in that it comprises a first conductive plate that faces and makes contact with the PTC element, a terminal portion that extends thinly from the outer side of one end of the first conductive plate toward the terminal fastening portion and is coupled to the terminal fastening portion, and the second terminal plate is characterized in that it comprises a second conductive plate that faces and makes contact with the PTC element, a terminal portion that protrudes from one end of the second conductive plate and extends in a direction that penetrates the terminal fastening portion.

[0021] When viewed from the side, the terminal portion of the first terminal plate is characterized in that it is bent toward the PTC element from the end of the first conductive plate and intersects with one side of the PCT element.

[0022] The PTC frame is characterized in that a first fitting groove and a second fitting groove are formed to accommodate and fit the terminal portions of the first terminal plate and the second terminal plate, respectively, and the depth of the first fitting groove is formed deeper than the depth of the second fitting groove.

[0023] The first terminal plate and the second terminal plate are characterized in that a fastening bending portion is formed at an end opposite to the end where the terminal portion is installed, and the PTC frame is characterized in that a third fastening hole and a fourth fastening hole are formed to fasten the fastening bending portions of the first terminal plate and the second terminal plate.

[0024] Each of the above terminal portions is characterized by having its end portion folded to form a double-structured overlapping portion.

[0025]

[0026] According to the present invention having the configuration described above, by configuring a pair of first terminal plates and second terminal plates that independently group a plurality of PTC elements, even if either the first terminal plate or the second terminal plate generates heat due to current flow, current can be prevented from flowing into the other or heat can be conducted thereto, thereby enabling more accurate and detailed temperature control and having the effect of blocking unnecessary current from flowing.

[0027] In addition, the first terminal plate includes a terminal portion that is bent toward the PTC element from the end of the first conductive plate and intersects one side of the PCT element, and the PTC frame forms a first fitting groove corresponding to the terminal portion, thereby allowing the PTC frame to contact the inner walls on both sides of the first fitting groove to greatly increase the coefficient of friction, thereby maintaining a more solid and stable bonding state, and has a very useful effect of being able to suppress a large increase in the overall width or weight of the PTC frame as much as possible.

[0028] In addition, each terminal portion forms a double-structured overlapping portion, thereby increasing the fastening rigidity as the thickness increases, thereby improving the lifting phenomenon when assembling to the PTC frame, and significantly increasing the current conduction rate, thereby having the effect of stably securing the amount of current.

[0029]

[0030] Fig. 1 is an exploded perspective view showing the configuration of a PTC heater assembly according to the prior art.

[0031] Fig. 2 is an exploded perspective view showing the configuration of a PTC heater assembly according to another prior art.

[0032] FIG. 3 is a perspective view showing a PTC heater assembly according to an embodiment of the present invention.

[0033] Figure 4 is an exploded perspective view of Figure 2.

[0034] Figure 5 is a side cross-sectional view of Figure 3.

[0035] Figure 6 is an enlarged view showing the configuration of the terminal plate of Figure 4.

[0036] Fig. 7 is a plan view of the PTC frame of Fig. 4.

[0037] Fig. 8 is a side view showing another embodiment of an overlapping portion formed on the terminal plate of Fig. 4.

[0038] Hereinafter, a preferred embodiment of a PTC heater assembly according to the present invention will be described in detail based on the attached drawings.

[0039] For reference, the terms and words used in this specification and claims should not be interpreted as limited to their usual or dictionary meanings, but should be interpreted with meanings and concepts that are consistent with the technical idea of ​​the present invention, based on the principle that the inventor can appropriately define the concept of the term to best explain his or her own invention.

[0040] In addition, it should be understood that the embodiments described in this specification and the configurations illustrated in the drawings are only the most preferred embodiments of the present invention and do not represent all of the technical ideas of the present invention, and therefore, there may be various equivalents and modified examples that can replace them, not only at the time of filing this application but also thereafter.

[0041] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings 3 to 8.

[0042] As shown, the PTC heater assembly according to the present invention includes a housing (100) having a storage space (101) formed therein, a PTC frame (200) which is stored in the storage space (101) and has a plurality of hollow holder portions (201) formed at intervals along the longitudinal direction and having a terminal fastening portion (210) at one end in the longitudinal direction, a plurality of PTC elements (300) inserted into the holder portions (201) of the PTC frame (200), a terminal plate (400) which makes surface contact with one side and the other side of the PTC element (300) and extends along the longitudinal direction, and an insulating film (500) attached to the outer side of the terminal plate (400).

[0043] In particular, the terminal plate (400) is composed of a pair of first terminal plates (410) that group some of the plurality of PTC elements (300) and conduct electricity and face each other, and a pair of second terminal plates (420) that are separated from the first terminal plate (410) and conduct electricity to the remainder of the PTC elements (300) and face each other.

[0044] In this case, the first terminal plate (410) comprises a first conductive plate (411) that faces and makes contact with the PTC element (300), and a terminal portion (412) that extends thinly from the outer side of one end of the first conductive plate (411) toward the terminal fastening portion (210) and is coupled to the terminal fastening portion (210).

[0045] The second terminal plate (420) comprises a second conductive plate (421) that faces and makes contact with the PTC element (300), and a terminal portion (422) that protrudes from one end of the second conductive plate (421) and extends in a direction that penetrates the terminal fastening portion (210).

[0046] The above housing (100) is an external member that extends to a certain length and forms a storage space (101) inside, and safely protects the PTC frame (200), PTC element (300), terminal plate (400), and insulating film (500) described later, while fundamentally blocking the penetration of moisture or foreign substances from the outside.

[0047] Here, it is preferable that the housing (100) be manufactured from a metal material such as aluminum that has excellent heat transfer efficiency.

[0048] The terminal plates (400) that make surface contact with one side and the other side of the PTC element (300) are arranged to have opposite polarities (positive and negative).

[0049] The above PTC frame (200) extends along the longitudinal direction, and a plurality of hollow holder portions (201) into which a plurality of PTC elements (300) are inserted are formed along the longitudinal direction.

[0050] That is, the PTC element (300) can stably perform heat generation by current conduction without shaking by the holder part (201).

[0051] It is preferable that the above PTC frame (200) be manufactured from a synthetic resin material so that the terminal plates (400) installed on one side and the other side with a plurality of PTC elements (300) interposed therebetween can maintain an insulating state without contacting each other.

[0052] In addition, a terminal fastening portion (210) is installed at one end of the PTC frame (200), in which a pair of first fastening holes (211) and second fastening holes (212) are formed so that the terminal portion (412) of the first terminal plate (410) and the end of the terminal portion (422) of the second terminal plate (420) penetrate each other.

[0053] In the PTC frame (200) according to the present invention, a first fitting groove (220) and a second fitting groove (230) are formed into which the terminal portion (412) of the first terminal plate (410) and the terminal portion (422) of the second terminal plate (420) are respectively fitted.

[0054] Here, when viewed from a plan view, the widths of the first fitting groove (220) and the second fitting groove (230) are formed to be different from each other, but the width of the first fitting groove (220) is formed to be narrower than the width of the second fitting groove (230), and the depth of the first fitting groove (220) is formed to be deeper than the depth of the second fitting groove (230).

[0055] This is because, when viewed along the longitudinal direction, the terminal portion (412) constituting the first terminal plate (410) is bent toward the PTC element (300) and intersects with one side of the PCT element (300), thereby making it possible to form the terminal portion (412) higher and narrower than the terminal portion (422) of the second terminal plate (420).

[0056] That is, the terminal portion (412) of the first terminal plate (410) fitted into the first fitting groove (220) is formed by being erected, and the first fitting groove (220) can be fixed more stably by receiving the terminal portion (412) on one side in the vertical direction.

[0057] In addition, when viewed from a plan view, both sides of the terminal portion (412) of the first terminal plate (410) can contact the entire inner wall surfaces on both sides of the first fitting groove (220) to greatly increase the coefficient of friction, so that even when the PTC frame (200) is lifted and turned over, erected, or shaken in order to assemble the 'PTC heater assembly', the first terminal plate (410) connected to the terminal portion (412) can stably maintain a solid fixed state without coming off.

[0058] In addition, the first fitting groove (220) has a very useful effect of being able to suppress the increase in the volume occupied as much as possible by minimizing the overall width of the PTC frame (200) as the width of the space for accommodating the terminal portion (412) on one side is greatly reduced due to this structural characteristic.

[0059] Accordingly, it is preferable that the width and height of the first fastening hole (211) and the second fastening hole (212), into which the terminal portion (412) of the first terminal plate (410) and the end portion of the terminal portion (422) of the second terminal plate (420) are fitted, be formed differently.

[0060] As shown, the first fastening hole (211) is configured to be narrower and higher than the second fastening hole.

[0061] In addition, a third fastening hole (240) and a fourth fastening hole (250) are formed in the PTC frame (200) to fasten the first terminal plate (410) and the second terminal plate (420) of the terminal plate (400) at different positions from the terminal fastening portion (210).

[0062] That is, the third fastening hole (240) and the fourth fastening hole (250) are hollow holes, and are configured to allow additional fastening at the opposite ends facing the respective terminal portions (412, 422) of the first terminal plate (410) and the second terminal plate (420).

[0063] As described above, when viewed in the longitudinal direction, it is preferable that the terminal portion (412) of the first terminal plate (410) is bent toward the PTC element (300) from the end of the first conductive plate (411) and intersects with one side of the PCT element (300).

[0064] Specifically, the terminal portion (412) has the same thickness as the first conductive plate (411) and is formed with a relatively small width, and is preferably configured to extend toward the terminal fastening portion (210), but is bent at 90° with respect to the first conductive plate (411) so that the edge portion thereof faces the PTC element (300).

[0065] Meanwhile, the PTC element (300) is a plurality of components inserted into the holder portion (201) of the PTC frame (200), and can be manufactured in a rectangular plate-shaped structure.

[0066] However, there is no need to place any special restrictions on its shape.

[0067] The PTC element (300) inserted into the holder portion (201) of the above PTC frame (200) is heated by the current that passes through it by contacting a pair of first terminal plates (410) and second terminal plates (420) on one side and the other side, respectively.

[0068] The first terminal plate (410) and the second terminal plate (420) divide the PTC element (300) into two groups along the length direction and independently supply current to each of them. Therefore, even if either the first terminal plate (410) or the second terminal plate (420) generates heat due to current flow, current can be prevented from flowing into the other or heat can be conducted thereto. Therefore, the temperature can be controlled more accurately and precisely, and there is an effect of blocking unnecessary current from flowing.

[0069] In the first terminal plate (410) and the second terminal plate (420), a bending portion (413, 423) for fastening to the third fastening hole (240) and the fourth fastening hole (250) is formed at the opposite end to the end where the terminal portion (412, 422) is installed.

[0070] In addition, each terminal portion (412, 422) is bent to form a double-structured overlapping portion (412a, 422a) to increase the fastening strength.

[0071] That is, by forming a double-structured overlapping portion (412a, 422a), the thickness is doubled, thereby increasing the fastening strength, thereby improving the lifting phenomenon during assembly of the PTC frame, and also significantly increasing the current conduction rate, thereby having the effect of stably securing the amount of current.

[0072] That is, as shown in Fig. 8, the overlapping portion (412a) of the terminal portion can be bent in a 'V' shape and elastically seated or joined to the inner wall surface of the first fitting groove (220).

[0073] The overlapping portion (412a, 422a) having the above double structure can also be formed by additionally adding a separate terminal plate corresponding to each terminal portion (412, 422) through welding.

[0074] Meanwhile, the insulating film (500) is attached to the upper and lower outer surfaces of the first terminal plate (410) and the second terminal plate (420), respectively, and serves as an insulating film to block current flowing through the first terminal plate (410) and the second terminal plate (420) from being transmitted to the housing (100).

[0075] It is preferable to additionally apply or attach an elastic synthetic resin material to the upper part of the above insulating film (500). This is to maximize the internal residual stress when the housing is compressed.

[0076] Here, the insulating film (500) is preferably composed of a synthetic resin material having elasticity and an insulator having excellent insulation and heat dissipation properties, but is not necessarily limited thereto, and various excellent materials that can maximize insulation, adhesion, and internal residual stress when compressing the housing (100) can be applied.

[0077]

[0078] The present invention described above is not limited to the above-described embodiments and the attached drawings, and it will be apparent to a person skilled in the art to which the present invention pertains that various substitutions, modifications, and changes are possible within the scope that does not depart from the technical spirit of the present invention.

Claims

1. A housing having a storage space formed inside; A PTC frame which is stored in the storage space above and has a plurality of hollow holder sections spaced apart along the longitudinal direction and has a terminal fastening section at one end in the longitudinal direction; A plurality of PTC elements inserted into the holder portion of the above PTC frame; A terminal plate extending along the longitudinal direction and having surface contact with one side and the other side of the PTC element; and Including an insulating film attached to the outside of the terminal plate, A PTC heater assembly characterized in that the terminal plate comprises a pair of first terminal plates facing each other and energizing some of the plurality of PTC elements by grouping them, and a pair of second terminal plates facing each other and energizing the remainder of the PTC elements, separated from the first terminal plate.

2. In paragraph 1, The above first terminal plate, A first conductive plate that faces and makes contact with the PTC element, and a terminal portion that extends from the outer side of one end of the first conductive plate toward the terminal fastening portion and is connected to the terminal fastening portion, The above second terminal plate, A PTC heater assembly characterized by comprising a second conductive plate that faces and makes contact with the PTC element, and a terminal portion that extends thinly from the outer side of one end of the second conductive plate toward the terminal fastening portion and is connected to the terminal fastening portion.

3. In paragraph 2, A PTC heater assembly, characterized in that the terminal portion of the first terminal plate is bent toward the PTC element from the end of the first conductive plate and intersects with one side of the PCT element.

4. In paragraph 3, A PTC heater assembly, characterized in that the PTC frame has first and second fitting grooves formed to accommodate and fit the terminal portions of the first terminal plate and the second terminal plate, respectively, and the depth of the first fitting groove is formed deeper than the depth of the second fitting groove.

5. In any one of paragraphs 2 to 4, The first terminal plate and the second terminal plate are each provided with a bending portion for fastening at an end opposite to the end where the terminal portion is installed. A PTC heater assembly, characterized in that a third fastening hole and a fourth fastening hole are formed in the above PTC frame to fasten the bending portions for fastening the first terminal plate and the second terminal plate.

6. In paragraph 4, A PTC heater assembly characterized in that each of the above terminal parts is formed by bending the end part to form a double-structured overlapping part.

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