Heating body and air heat register

Abstract

The invention relates to a heating body (4) having a flat, elongate heating module (18), in which a heating element (42) is provided within an insulating film (44), and an enclosure (16), in the interior of which the heating module (18) extends and which has two wall portions lying opposite each other, the inner faces of the wall portions lying flat on the heating module (18). The heating element (42) has a carrier plate (22) with edge portions, on which projections (30) are formed, two cover layers (40), which extend parallel to the carrier plate (22) on two opposing sides of the carrier plate (22), and at least one heating wire (38), which is wound around the carrier plate (22) between the projections (30) thereof and is covered by the cover layers (40). The projections (30) on the carrier plate (22) are dimensioned in such a way so as to project beyond the portions of the heating wire (38) lying on the edge portions. The invention further relates to an air heat register (2) having at least two heating bodies (4) according to the invention, said heating bodies being provided parallel to each other, and an air-permeable region between the at least two heating bodies (4) for conducting air to be heated.

Description

[0001] Radiators and air heating registers

[0002] Description

[0003] Technical field

[0004] The present disclosure relates to a heating element according to the preamble of claim 1, in particular to a heating element with a flat, elongated heating module in which a heating element is arranged within an insulating film, and a casing, in particular designed as a sheathing tube, preferably as a sheathing tube made of metal or plastic, in the interior of which the heating module extends, at least partially, and which has two opposing wall sections, wherein the inner surfaces of the wall sections lie flat against the heating module. The disclosure further relates to an air heating register comprising at least two heating elements arranged parallel to one another and an air-permeable area arranged between the at least two heating elements for the passage of air to be heated.

[0005] State of the art

[0006] A heating element of this type is known, for example, from DE 10 2017 120 467 A1, which describes the construction of an insulated heating register. According to DE 10 2017 120 467 A1, a heating module with several PTC heating elements, contact plates, and an insulating sleeve is pressed into a frame formed as an extruded aluminum profile or as a sheathing tube. Additionally, a heat-emitting element in the form of corrugated fins is fixed to the extruded profile by rolling a shoulder onto it.

[0007] The disadvantage of this type of radiator, according to current technology, is that cyclical operation with many on / off phases leads to a drastic malfunction: The thermal stress causes the various components to shift relative to each other. This can cause the heating module to migrate out of the extruded profile and / or the insulation to tear, which can directly lead to a short circuit.

[0008] Disclosure of the invention

[0009] The object of the present invention is therefore to provide a radiator with an at least partially insulated heating module, in which damage to an insulating shell during cyclic operation of the radiator is prevented or at least the probability of such damage is reduced.

[0010] This problem is solved with respect to a radiator by features of claim 1 and with respect to an air heating register by features of claim 10. Advantageous further developments are the subject of the dependent claims.

[0011] A heating element as disclosed comprises a heating module and a surround. The heating module is a flat, elongated component in which a heating element is arranged within an insulating film. The heating module, which may have a substantially rectangular cross-section and preferably be substantially cuboid, extends at least partially inside the surround, which may also have a substantially rectangular cross-section and comprises two opposing wall sections, the inner surfaces of which rest flat against the heating module. The surround may be made of a metal, preferably aluminum, or of a plastic.

[0012] The enclosure can preferably be designed as a sheathing tube which, in the assembled state of the heating element, is deformed such that the inner surfaces of the wall sections lie flat against the heating module and the heating module is pressed into the sheathing tube. Alternatively to the sheathing tube design, the enclosure can have a frame or positioning frame into which the heating module is inserted, or it can have cover plates arranged on two opposite sides of the heating module where the frame or positioning frame does not extend. Furthermore, the heating element can have a clamping device that presses the cover plates against the heating module.

[0013] According to the disclosure, the heating element comprises a carrier plate, which may, in particular, have a substantially rectangular outline. Projections, especially crenellated ones, are formed on the edge sections of the carrier plate, particularly on its long sides. The heating element has two cover layers, which may, in particular, have a substantially rectangular outline and which extend parallel to the carrier plate on two opposite sides of the carrier plate. In other words, the cover layers are designed such that they sandwich the carrier plate between them. The heating element has at least one heating wire, which is wound around the carrier plate, between its projections, and covered by the cover layers. The projections on the carrier plate are dimensioned such that they extend beyond the sections of the heating wire that rest on the edge sections.The projections can be designed in such a way that they do not protrude above the surface layers.

[0014] By providing the projections, the insulating film can be advantageously spaced away from the heating wire, so that thermal expansion of the heating wire causes no or only minimal mechanical stress in the insulating film, thus reducing the likelihood of damage to the insulating film. Furthermore, the use of a heating wire allows for an extension of the voltage range up to 1,500 volts, an extension of the operating temperatures to over 220°C, an increase in power, a reduction in the inrush current, and / or simplified control of the heating element. According to one aspect of the disclosure, the electrical resistance of the heating wire can remain constant over a predetermined temperature range.In particular, the electrical resistance can be designed to be so constant that it fluctuates between -55°C and 105°C within a maximum range of + / - 100 ppm per Kelvin, preferably within a maximum range of + / - 40 ppm per Kelvin.

[0015] If a heating wire with constant electrical resistance is used, the control of the heating element can be simplified, especially without pulse width modulation.

[0016] According to one aspect of the disclosure, the heating wire can be made of metal, in particular of a nickel-chromium or copper-nickel-manganese alloy. Specifically, the copper-nickel-manganese alloy can have a copper content between 53 and 57 percent, a nickel content between 43 and 45 percent, and a manganese content between 0.5 and 1.2 percent, or a copper content between 82 and 84 percent, a nickel content between 2 and 4 percent, and a manganese content between 12 and 15 percent.

[0017] By using a nickel-chromium or copper-nickel-manganese alloy as disclosed, a constant electrical resistance of the heating wire can be achieved cost-effectively.

[0018] According to one aspect of the disclosure, the carrier plate and / or the cover layers may be made of polyimide, polyetherimide, glass, ceramic or pressed mica and / or the insulating film may be made of polyimide or polyetherimide.

[0019] Such a choice of material allows the heating element according to the disclosure to be operated even at higher temperatures and at operating voltages up to 1,500 volts. According to one aspect of the disclosure, the carrier plate can be bonded or welded to the cover layers.

[0020] By gluing or welding the layers of the carrier plate to the cover layers, the heating element can be advantageously sealed from the environment.

[0021] According to one aspect of the disclosure, the carrier plate and / or the cover layers may have recesses dimensioned such that both sections of the heating wire extending parallel to the carrier plate in the recesses are in contact with the carrier plate and the corresponding cover layer, and the carrier plate is in direct surface contact with the corresponding cover layer.

[0022] If the substrate and the top layer are in direct contact with each other, heat transfer from the substrate to the top layers can be improved.

[0023] According to one aspect of the disclosure, a cable guide can be provided in the carrier plate. The cable guide can be designed such that a cable can be led from one end face of the carrier plate to an opposite end face of the carrier plate, in particular spaced apart from wound sections of the heating wire.

[0024] If cable routing is provided in the carrier plate, the heating element can be designed in such a way that electrical connections of the heating wire extend only to one end face of the heating module.

[0025] According to one aspect of the disclosure, the carrier plate can be made up of multiple parts. The cable routing can extend along an interface between two parts of the carrier plate. The cable routing can extend only in one of the parts of the carrier plate or in several, in particular in two, parts of the carrier plate that are adjacent to each other when the carrier plate is assembled.

[0026] According to one aspect of the disclosure, at least one of the cover layers may have a recess on a side facing away from the support plate for receiving a temperature sensor.

[0027] By enabling the placement of a temperature sensor near the insulating film, it is possible to monitor the film simultaneously with the heating wire.

[0028] An air heating register according to the disclosure has at least two heating elements arranged parallel to each other, as well as an air-permeable area arranged between the at least two heating elements for the passage of air to be heated.

[0029] The safety of known air heating registers can be increased by using radiators that comply with the disclosure requirements.

[0030] Brief description of the drawings

[0031] The present disclosure is described in more detail below with reference to a preferred embodiment and the accompanying drawings. These show:

[0032] Fig. 1 shows a perspective view of an air heating register according to the disclosure with several radiators;

[0033] Fig. 2 is a perspective view of several of the radiators shown in Fig. 1 without frames; Fig. 3 is an exploded view of the air heating register without frames, in which components of one of the radiators and two heat emission elements are shown separately;

[0034] Fig. 4 shows a perspective view of components of a carrier plate according to the disclosure with electrical connections;

[0035] Fig. 5 shows a perspective view of the carrier plate and a heating wire;

[0036] Fig. 6 shows a perspective view of components of a heating element according to the disclosure;

[0037] Fig. 7 shows a detailed view of the carrier plate wrapped with the heating wire according to the section marked “VII” in Fig. 6;

[0038] Fig. 8 shows a perspective view of components of the radiator according to the disclosure; and

[0039] Fig. 9 shows a perspective view of the radiator.

[0040] Detailed description of the preferred embodiment

[0041] Fig. 1 shows a perspective view of an air heating register 2 according to the disclosure, which is equipped with several radiators 4 according to the disclosure. The air heating register 2 further has heat emission elements 6 in the form of corrugated fins, by means of which the radiators 4 are connected to each other.

[0042] Both the radiators 4 and the heat-emitting elements 6 are elongated and flat and are arranged alternately and parallel to each other such that each radiator 4 extends between two heat-emitting elements 6. In other words, the radiators 4 and the heat-emitting elements 6 form a plate-shaped structure. This plate-shaped structure, i.e., the radiators 4 and the heat-emitting elements 6, is enclosed by a frame with a substantially rectangular outline. Longitudinal side elements 8 of the frame extend parallel to the radiators 4 and the heat-emitting elements 6, respectively. Transverse side elements 10 of the frame extend perpendicular to the radiators 4 and the heat-emitting elements 6, respectively.

[0043] A connection-side transverse side element 10 of the transverse side elements 10 is provided with openings 12 through which electrical connections 14 of the radiators 4 or cables to the radiators 4 extend.

[0044] Fig. 2 shows a perspective view of several of the radiators 4 shown in Fig. 1 without the longitudinal side elements 8 and without the transverse side elements 10.

[0045] The radiators 4 each have a surround 16 in the form of a sheathing tube.

[0046] 17 and a heating module 18 partially arranged within the outer tube 17. The outer tubes 17 are each designed as elongated profile elements with a cuboid interior. The heating modules 18 are each elongated and flat and are inserted into the corresponding outer tube 17 or into the corresponding interior (see arrow A in Fig. 3). The heating modules

[0047] The 18 are pressed together with the respective casing tube 17 (see arrows B in Fig. 3). For this purpose, two opposing wall sections of the casing tube 17 are moved towards each other in such a way that the inner surfaces of the wall sections lie flat on the heating module 18.

[0048] On the outer tubes 17 or on the longitudinal edges of the outer tubes 17, pressure tabs 20 or crimp edges (see Fig. 2 and Fig. 9) are formed such that the heat-emitting elements 6, each formed by a corrugated band, can be arranged between two pressure tabs 20 and connected to the corresponding outer tube 17 by forming the pressure tabs 20. In this way, several heating elements 4 according to the disclosure can be assembled into the air heating register 2 according to the disclosure by means of several heat-emitting elements 6 (cf. arrows C in Fig. 3). The heat-emitting elements 6 are designed such that they form an air-permeable area according to the disclosure for the passage of air to be heated.

[0049] The construction of a heating module 18 according to the disclosure is illustrated in Figures 4 to 8.

[0050] Fig. 4 shows an exploded view of a carrier plate 22 of the heating module 18. The carrier plate 22 has two plates 24 with substantially rectangular outlines. A return line 26 is sandwiched between the plates 24. The return line 26 extends from the terminal-side end face of the carrier plate 22 to the end face of the carrier plate 22 opposite the terminals 14. A through-hole 28 is provided in one or both plates 24 at each end face of the carrier plate 22. In the assembled state, ends, or at least one end, of the return line 26 extend through the through-holes 28.

[0051] Projections 30 are provided on the longitudinal sides of the plates 24 and the support plate 22. Openings 32 are provided on the connection-side end face of the plates 24, through which a clamp 34 extends when the support plate 22 is mounted, connecting the two plates 24 to each other. Recesses 36 for receiving the electrical connections 14 are provided on the connection-side end face of the support plate 22 and the plates 24.

[0052] Fig. 5 shows an exploded view of the mounted carrier plate 22 and a spirally shaped heating wire 38. In the assembled state of the heating module 18, the heating wire 38 is wound around the carrier plate 22. One end of the heating wire 38 is directly connected to one of the electrical terminals 14 (for example, by crimping, welding, or soldering). The other end of the heating wire 38 is connected to the end of the return conductor 26 opposite the terminal (for example, by crimping, welding, or soldering). The return conductor 26 connects the end of the heating wire 38 opposite the terminal to the other of the electrical terminals 14. The end of the return conductor 26 opposite the terminal is connected to the corresponding electrical terminal 14, for example, by crimping, welding, or soldering.

[0053] The heating wire 38 is ribbon-shaped and thus has a substantially rectangular cross-section. Alternatively, the heating wire 38 can also have a round cross-section.

[0054] The carrier plate 22, wrapped with the heating wire 38, forms a heating element 42 according to the disclosure with two cover layers 40. An exploded view of the heating element 42 is shown in Fig. 6. The carrier plate 22, wrapped with the heating wire 38, is sandwiched between the two cover layers 40. The carrier plate 22, or its plates 24, and the cover layers 40 are made of pressed mica. The carrier plate 22, or its plates 24, can be connected to the cover layers 40 by gluing or welding (see arrows D in Fig. 6).

[0055] Fig. 7 shows a detailed view according to the section labelled “VII” in Fig. 6 of the connection-side end of the carrier plate 22 wrapped with the heating wire 38. The projections 30 are dimensioned such that the heating wire 38 dips into the edge sections of the carrier plate 22 between the projections 30 and is thus secured against slippage.

[0056] Fig. 8 shows an exploded view of the heating element 4. The heating element 4 is formed by wrapping the heating element 42 multiple times, in particular three times, with an insulating film 44, and pressing the heating element 42 wrapped with the insulating film 44 into the sheathing tube 17. The insulating film 44 is made in particular of a polyimide or polyetherimide (e.g., Kapton®).

[0057] One end of the insulating foil 44 facing away from the connection is formed by a

[0058] A tube fold 46 is formed, which is in particular glued, welded, or crimped. A free edge of the insulating film 44, located on the outside after winding, is glued, welded, or crimped to a section of the insulating film 44 located below the free edge. The free edge can be glued, welded, or crimped to a flat side of the planar insulating film 44 (see dashed line 48 in Fig. 8) and / or to a longitudinal side of the elongated insulating film 44 (see dash-dot line 50 in Fig. 8). The insulating film 44 is thus formed in a bag-like manner.

[0059] Fig. 9 shows a perspective view of the radiator 4. The connection-side end of the insulation foil 44 can be closed by means of a sealing element (not shown). In the described embodiment, the connection-side end of the insulation foil 44 is closed during assembly with the air heating register 2 by means of the connection-side transverse side element 10.

[0060] Reference symbol list

[0061] 2 air heating registers

[0062] 4 radiators

[0063] 6 Heat emission element

[0064] 8 Long side element of a frame

[0065] 10 Cross-side element of the frame

[0066] 12 Opening for electrical connection

[0067] 14 Electrical connection

[0068] 16 Border

[0069] 17 Sheathing tube

[0070] 18 Heating module

[0071] 20 Press-on tab

[0072] 22 Carrier plate

[0073] 24 Plate of the carrier plate

[0074] 26 Return line

[0075] 28 Breakthrough for return line

[0076] 30 mm lead on the carrier plate

[0077] 32 Breakthrough for bracket

[0078] 34 bracket

[0079] 36 Recess for electrical connection

[0080] 38 heating wire

[0081] 40 Top layer

[0082] 42 Heating element

[0083] 44 insulating foil

[0084] 46 Tube crimp

[0085] 48; 50 free edge of the insulating foil

[0086] A. Inserting the heating module into the casing tube

[0087] B. Pressing the heating module into the casing tube

[0088] C Attaching the heat emitting element to the radiator

[0089] D Connecting the top layer to the substrate

[0090] E. Inserting the heating element into the insulation foil

Claims

Claims 1. A heating element (4) with a flat, elongated heating module (18) in which a heating element (42) is arranged within an insulating film (44), and a frame (16) in the interior of which the heating module (18) extends and which has two opposing wall sections, wherein the inner sides of the wall sections lie flat on the heating module (18), characterized in that the heating element (42) has a carrier plate (22) with edge sections on which projections (30) are formed, the heating element (42) has two cover layers (40) which extend parallel to the carrier plate (22) on two opposite sides of the carrier plate (22), the heating element (42) has at least one heating wire (38) which is wound around the carrier plate (22), between its projections (30) and covered by the cover layers (40), and the projections (30) on the carrier plate (22) are dimensioned such thatthat they extend beyond the sections of the heating wire (38) resting on the edge sections.

2. Heating element (4) according to claim 1 , characterized in that an electrical resistance of the heating wire (38) is constant over a predetermined temperature range.

3. Heating element (4) according to claim 1 or 2, characterized in that the heating wire (38) is made of a nickel-chromium or copper-nickel-manganese alloy.

4. Radiator (4) according to one of claims 1 to 3 characterized in that the carrier plate (22) and / or the cover layers (40) are made of polyimide, polyetherimide, glass, ceramic or pressed mica and / or the insulating film (44) is made of polyimide or polyetherimide.

5. Radiator (4) according to one of claims 1 to 4, characterized in that the carrier plate (22) is bonded or welded to the cover layers (40).

6. Heating element (4) according to one of claims 1 to 5, characterized in that the carrier plate (22) and / or the cover layers (40) have recesses which are dimensioned such that both sections of the heating wire (38) extending parallel to the carrier plate (22) in the recesses are in contact with the carrier plate (22) and the corresponding cover layer (40) and the carrier plate (22) is in direct surface contact with the corresponding cover layer (40).

7. Heating element (4) according to one of claims 1 to 6, characterized in that a cable guide is provided in the carrier plate (22) through which a cable is guided from an end face of the carrier plate (22) to an opposite end face of the carrier plate (22) spaced apart from wound sections of the heating wire (38).

8. Radiator (4) according to claim 7, characterized in that the support plate (22) is formed in multiple parts and the cable routing extends along an interface between two parts (24) of the support plate (22).

9. Radiator (4) according to one of claims 1 to 7, characterized in that at least one of the cover layers (40) has a recess for receiving a temperature sensor on a side facing away from the carrier plate (22).

10. Air heating register (2) with at least two heating elements (4) arranged parallel to each other according to one of claims 1 to 9 and an air-permeable area arranged between the at least two heating elements (4) for the passage of air to be heated.

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