Patent Grant
11147127
This application claims the benefit of priority under 35 U.S.C. § 119 of German Application 20 2018 101 634.2, filed Mar. 23, 2018, the entire contents of which are incorporated herein by reference.
The present invention pertains to a device for converting electricity into heat. Such devices are used, on the one hand, in conjunction with electric heaters or as electric heaters in order to provide heat for a certain purpose, especially for heating. On the other hand, such devices are used in applications in which larger amounts of generated electricity shall be removed as rapidly as possible and are used in this application as load resistors or components of a load resistor.
The technical principle of action is the same in both cases: Electric current is sent through an electric heating element, typically a resistance wire or heat conductor, and it generates heat, which is then removed as efficiently as possible either to the object to be heated or to the surrounding area.
A typical configuration for such a device is known, for example, from DE 203 11 068 U1. It comprises essentially a flat winding support consisting of an electrically insulating material, onto which a resistance wire is wound. The winding support on which a resistance wire is thus wound is inserted into a housing such that it is ensured that an electrical insulation of the resistance wire against the housing is present. This may be brought about, for example, by at least one additional layer of insulation.
An essential drawback of the prior-art devices for converting electricity into heat, which correspond to this principle of configuration, is that they are optimized essentially for one mode of operation. For their use in heaters, this means that a plurality of heating stages cannot be achieved with them or they cannot be achieved efficiently. It follows for the use as a load resistor that a plurality of different model series, which are each configured for power consumption in a certain range, must be fabricated and stocked.
An object of the present invention is to provide a device for converting electricity into heat, which can be used in a flexible manner, so that it can also be used, on the one hand, in cases with different heating stages as electric heaters and especially as an electric heater for heating a pipe and can be used, on the other hand, as a load resistor for different amounts of energy to be removed.
The device for converting electricity into heat comprises a first flat winding support consisting of an electrically insulating material, onto which a first electric heating element, usually a resistance wire or heat conductor, is wound.
An object is flat in the sense of this disclosure if its two largest surfaces, which form the flat sides, are located opposite each other and all points of one of these surfaces are located essentially at the same distance from the other of these surfaces.
The first flat winding support thus wound on is inserted into a housing such that it is ensured that an electrical insulation of the electric heating element against the housing is present, This can be achieved, for example, by a stack being formed, which has at least one additional insulation plate each on both flat sides of the flat winding support, which insulation plate covers at least the wound-on area of the flat winding support and preferably protrudes laterally, so that insulation of the long sides of the flat winding support, which extend at right angles to the flat sides of the flat winding support, is achieved against the housing.
It is essential for the present invention that the device for converting electricity into heat has at least one more, second flat winding support consisting of an electrically insulating material, onto which a second electric heating element is wound, which winding support is inserted into the housing such that it is ensured that an electrical insulation of all electric heating elements is present against the housing and, if they are not connected in parallel or in series with another, from one another.
This second electric heating element and optionally present additional electric heating elements may then be used to vary the heat output or the energy dissipation by switching over the current between the individual heating elements, especially the first electric heating element and the second electric heating element, and/or by allowing the current to flow in parallel or in series through a plurality of the electric heating elements, especially through the first electric heating element and the second electric heating element.
It should be noted that the terms “first” and “second” used are variable. They may consequently be attributed to any electric heating element and/or to any flat winding support of a given device for converting electricity into heat and they do not imply any predefined arrangement in a row, so that it is not ruled out, for example, that at least one additional free winding support is arranged between the first flat winding support and the second flat winding support.
Especially if the first electric heating element and the second electric heating element are configured for operation with different voltages, i.e., for example, one of them for operation with the on-board voltage network of a vehicle and the other a line voltage, it may be considered to be advantageous if the electrical insulation for the galvanic separation of the first electric heating element from the second electric heating element has a higher dielectric strength than the electrical insulation of the electric heating elements against the housing. The especially high requirements on the electrical insulation of such different networks from one another can be met in this manner with manageable effort.
A dielectric strength of several thousand V should preferably be reached especially between the first electric heating element and the second electric heating element.
It is especially preferred in this connection if the wound-on first flat winding support and the wound-on second flat winding support are parts of a stack. Provisions are made in a variant of this configuration for at least one insulation plate consisting of an electrically nonconductive material, for example, Micanite, and/or at least one insulation mat and/or an insulation film, for example, a polyimide film or a Nomex film, which are arranged between the respective electrical heating elements, with which the wound-on flat winding supports are wound on, to be present in the stack for insulating two mutually adjacent, wound-on flat winding supports from one another and for ensuring galvanic separation. The use of insulation plates, webs of insulation mats and/or webs of insulation films and especially the use of stacks of these components represents a reliable, defined and yet technologically simple solution for insulation and for bringing about galvanic separation.
Using at least also a web of an insulation mat and/or an insulation film is highly advantageous especially if the device for converting electricity into heat is exposed to mechanical loads, as they occur to a special extent when the device for converting electricity into heat is shaped, e.g., bent. It may happen in this connection that insulation plates will crack or break, which leads to a local reduction of the dielectric strength. An insulation mat and/or an insulation film can effectively prevent this.
According to a preferred variant of the present invention, the first electric heating element and the second electric heating element are wound on differently, for example, with different pitches, so that electric heating elements of different lengths are arranged on winding supports of equal length, and/or the first electric heating element and the second electric heating element possess different physical properties. These may comprise especially a different cross section of resistance wires consisting of the same material and/or of different materials of the electric heating elements, especially of resistance wires. A substantial change can be achieved in this manner in the heat output and in the load dissipation depending on which of the heating circuits or load dissipation circuits represented by the respective winding support, onto which an electric heating element is wound, is operated.
It proved to be advantageous in this connection to make the electrical insulation of mutually adjacent winding supports by the use of a plurality of insulating materials in the form of insulation plates, especially Micanite plates, and/or webs of insulation mats and/or insulation films, for example, a polyimide film or a Nomex film, between the two mutually adjacent, wound-on flat winding supports to be insulated from one another. Such a multipart configuration of the implementation of a desired electric strength likewise shows its advantages especially if mechanical stresses occur, because cracking occurs in several insulation plates under such conditions in the normal case at different points. As a consequence, through cracking, which may occur when a single, but now correspondingly thicker insulation plate is used, which use is, of course, possible, in principle, and is actually obvious, is avoided through a multipart, stacked configuration of the insulation to the greatest extent possible.
It is especially preferred if the first electric heating element and the second electric heating element are provided each with separate terminals. This maximizes the number of modes of operation, in which the device for converting electricity into heat can be operated.
It is advantageous for many applications if both terminals of the first electric heating element and/or both terminals of the second electric heating element are located each at the same end of the first and/or second flat winding support.
One possibility of achieving this in an electric heating element wound onto a flat winding support is that at least one of the terminals of an electric heating element is returned next to the winding from the end of the flat winding support, at which the end of the winding is located, to the end of the flat winding support, at which the beginning of the winding is located. This is preferably brought about via a return conductor, made of a punched, water-cut (www.peel-plate.com/en/technical-details/sheet-processing/sheet-water-jet-cutting/), hydrogen-cut or laser-cut sheet metal, which may especially preferably consist of steel, stainless steel, aluminum or copper.
It proved to be advantageous in this connection if at least two of the terminals of an electric heating element are returned next to the winding from the end of the flat winding support, at which the end of the winding is located, to the end of the flat winding support, at which the beginning of the winding is located, the return extending on different sides next to the winding in case of adjacent electric heating elements.
Another possibility of achieving this in case of an electric heating element wound on a flat winding support is that at least one of the electric heating elements is returned from the end of the first flat winding support, at which the end of the winding is located, to the end of the flat winding support, at which the beginning of the winding is located, by winding the electric heating element onto another flat winding support in the opposite winding direction, wherein the winding of the electric heating element, which is wound onto the first flat winding support, is electrically insulated from the winding of the electric heating element, which is wound onto the additional flat winding support. This electrical insulation can also be brought about especially by having at least one additional insulation plate between the two flat winding supports, which covers at least the wound-on area of the flat winding supports and possibly optionally protrudes over it laterally, so that an insulation of the long sides of the flat winding support, which extend at right angles to the flat sides of the flat winding support, is achieved against the housing.
In a variant of this variant, the first flat winding support and/or the additional flat winding support have structures on the end face facing away from the terminals of the electric heating element, via or through which structures the electric heating element is guided over its course from the first flat winding support to the second flat winding support, which facilitates the arrangement of the electric heating element on the respective winding support and improves the stability of this arrangement.
At least one of the flat winding supports is preferably formed by a stack of insulation plates. The length of the heating element, which can be accommodated on this winding support, can be increased in this manner. Moreover, such an arrangement also makes it, however, possible to arrange galvanically mutually separated electric heating elements in a “sandwich-like” manner, i.e., such that another winding support, on which an electric heating element is wound, is located between two insulation plates, which belong to a multipart flat winding support.
Such an arrangement is configured in an especially preferred variant of the present invention such that electric heating elements with a lower heat output and/or electric heating elements that are intended for the operation with a lower operating voltage are arranged farther outside, i.e., farther away from the body to be heated than are electric heating elements with a higher heat output and/or electric heating elements that are intended for the operation with a higher operating voltage.
The overall arrangement of the device for converting electricity into heat is preferably compacted or compressed. This can preferably lead to a gap-free arrangement of the components in the interior of the housing, in which the electric heating elements are then especially also pressed into insulation supports and/or winding supports, which leads to a further improvement of their insulation.
It is especially preferred in this connection if the compaction and/or compression take place to a lesser extent in the area of the terminals, which is achieved especially preferably if the housing has a larger cross section in the area of the terminals, so that it has a step when viewed from the outside.
The electric heater according to the present invention for heating a body, especially a pipe, is characterized in that it has a device for converting electricity into heat comprises a housing, a first flat winding support comprised of an electrically insulating material, first electrical insulation, a first electric heating element wound on the first flat winding support, the first flat winding, supported in a wound state on the first flat winding support, being disposed in the housing electrically insulated relative to the housing by the first electrical insulation, a second flat winding support comprised of an electrically insulating material, second electrical insulation, further electrical insulation and a second electric heating element wound on the second flat winding support galvanically separated from the first electric heating element by the further electrical insulation, the second electric heating element being disposed in the housing electrically insulated relative to the housing by the second insulation such that first electric heating element and the second electric heating element are electrically insulated relative to the housing. It is especially preferred in this connection that the device for converting electricity into heat is shaped such that a section of the housing of the device for converting electricity into heat is in contact with an outer contour of the body. Such an electric heater may advantageously be used especially for operating absorption refrigerators, which are used, for example, for minibars or in mobile homes, because a plurality of modes of operation can be achieved by means of them in an extremely compact arrangement.
In a preferred variant of this electric heater for heating a pipe, the device for converting electricity into heat is shaped into a U-shaped form, and an arc of the U is adapted semicircularly to the outer contour of the pipe and the legs of the U extend away from the central plane of the body, especially pipe, at right angles to a central plane of the body, especially pipe, in which plane a central axis of the body, especially pipe, is located. Not only is it possible in this manner to improve the seating of the electric heater on the body, especially pipe, but the heating effect attained can, moreover, also be optimized, while the possibility of removal still remains simple, if the electric heater is configured such that the legs of the U are heated as well.
The present invention will be explained in more detail below on the basis of the figures, which show exemplary embodiments. The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
In the drawings:
Referring to the drawings, not all reference numbers are shown in all figures for the sake of clarity. Identical components of the same exemplary embodiments have the same reference numbers in all figures unless indicated otherwise.
Depending on how the electric heating element 140, 150 is configured, especially in terms of the selected material and the cross section, and on how the winding supports 110, 130 are wound on, especially in terms of the number of turns and the winding pitch, heating circuits with different heat outputs can thus be provided in a very simple manner, and these heating circuits permit, depending on the actuation, different operating stages, or it is also possible to provide heating circuits for use with different voltage sources, e.g., the on-board voltage network of a vehicle, on the one hand, and the normal stationary a.c. voltage network, on the other hand.
While it is also possible, in principle, to use rectangular or strip-shaped winding supports 110, 130, these always have projections 111a, 111b, 112a, 112b, 131a, 131b, 132a, 132b, which locally broaden the winding support 110, 130, in both end areas 111, 112 and 131, 132 in the exemplary embodiment shown, and the broadening is greater in this exemplary embodiment in one direction due to the projections 111a, 112a, 131a, 132a than the broadening in the other direction due to the projections 111b, 112b, 131b, 132b.
All projections 111a, 111b, 112a, 112b, 131a, 131b, 132a, 132b have the purpose of ensuring that the electric heating element 140, 150, with which the respective winding support 110, 130 is wound on, is spaced apart from the housing 190.
The projections 111a, 112a, 131a, 132a have, moreover, the function of making possible an electrical connection of the two ends of the electrical heating elements 140, 150 configured as a heating wire on the same side of the device 100 for converting electricity into heat by establishing a contact to a terminal wire 141, 151, which is returned to the terminal side parallel to the winding direction and spaced apart from the winding by the projections 111a, 112a, 131a, 132a, from the end of the winding, which end is opposite the terminal side, as is shown in the exemplary embodiment, via a contact point 113, 133 provided on the winding support 110, 130.
It is, however, also possible, as an alternative to this, to return an end section of the electric heating elements 140, 150 parallel to the winding direction and through the projections 111a, 112a, 131a, 132a spaced apart from the winding to the terminal side and to establish the connection to a terminal wire there.
The other end of the electric heating elements 140, 150 is electrically connected to an additional terminal wire 142, 152 via a contact point 114, 134 provided at the terminal-side end of the winding support 110, 130. The electrical connection at a contact point 114, 134 may be established especially by welding, riveting, crimping or soldering not only in this exemplary embodiment but quite generally as well.
The wound-on winding supports 110, 130 are arranged next to each other in the device 100 for converting electricity into heat and are part of a stack, which also contains, moreover, electrically insulating insulation plates 120, 121, 122, which should, however, preferably have the best possible heat conduction. The insulation plates 120, 121, 122 may consist, for example, of Micanite.
The electric heating elements 140, 150 are electrically insulated from one another by the insulation plate 120 and a galvanic separation is thus guaranteed between the electric heating elements 140, 150 especially in the area of the winding supports, while the electrical insulation of the electric heating elements 140 and 150 from the housing 190 is ensured by the insulation plates 121 and 122, respectively. However, individual insulation plates 120, 121, 122 or all insulation plates 120, 121, 122 may, in principle, also be insulated from one another and from the housing 190 by embedding in an electrically insulating, but heat-conducting powder or granular material, for example, magnesium oxide. The overall arrangement is preferably compressed together in both cases. This may preferably lead to a gap-free arrangement, in which the electric heating elements are then especially also pressed into insulation supports and/or winding supports.
In two different perspectives,
The electrical heating element 540 is wound in this configuration on the multipart winding support 510 thus formed around this stack of insulation plates, i.e., around the upper insulation plate 590 and the lower insulation plate 591 in the exemplary embodiment shown and is connected to terminal wires 541, 542 via contact points 514, 515.
The multipart configuration of the winding support 510 has especially two effects:
On the one hand, it is made possible hereby that, as is shown especially clearly in
On the other hand, the length of the electric heating element 540 wound on the winding support can be increased due to a multipart, stack-like configuration of the winding support 510, which may represent an important degree of freedom for providing a desired heat output.
As it becomes especially clear in the enlarged details enlarged on the same scale, which are shown as
While the use of rectangular or strip-shaped winding supports 210a, 210b, 230a, 230b is also possible, in principle, these have respective projections 211a, 211b, 212a, 212b, 231a, 231b, 232a, 232b, which locally broaden each winding support 210a, 210b, 230a, 230b, in the exemplary embodiment shown, the broadening being symmetrical in this exemplary embodiment. It is ensured hereby, in particular, that the wound-on areas of the winding supports 210a, 210b, 230a, 230b are spaced apart from the housing 290.
The possibility of providing an electrical connection of the two ends of the electric heating elements 240a, 240b and 250a, 250b on the same side of the device 200 for converting electricity into heat is made possible here by the arrangement of these heating elements in pairs, in which the respective electric heating elements 240a and 240b as well as 250a and 250b are connected in series. This can be embodied in an especially simple manner by simply using the same electric heating element or the same heating wire for both windings, as is seen especially clearly in
It is therefore especially advantageous to provide projections 214a, 214b, 234a, 234b on the end face located opposite the terminals, via which projections a connection section 240c and 250c, respectively, of the electric heating element can then be led, which can be seen especially clearly in the enlarged detail shown in
The electric heating elements 240a, 240b, 250a, 250b are then contacted each via contact points 213a, 213b, 233a, 233b provided on the winding supports 210a, 210b, 230a, 230b, via which a contact is established to a terminal wire 241a, 241b, 251a, 251b.
As is seen especially clearly in
The respective electric heating elements 240a, 240b and 250a, 250b belonging to one heating circuit are electrically insulated from one another by the insulation plates 222 and 224 such that short-circuits between the respective windings are avoided. The insulation plate 223 ensures this for the electric heating elements 240b and 250a, which are arranged adjacent to one another but belong to different heating circuits, while the electrical insulation of the electric heating elements 240a and 250b from the housing 290 is ensured by the insulation plates 221 and 225. Individual insulation plates or all the insulation plates 221, 222, 223, 224, 225 may, however, also be replaced, in principle, by embedding the electric heating elements 240a, 240b, 250a, 250b in an electrically insulating, but heat-conducting power or granular material, for example, magnesium oxide, for insulation from one another and from the housing 290. The overall arrangement is preferably compressed together in both cases. This may preferably lead to a gap-free arrangement, in which the electric heating elements are then especially also pressed into the insulation support and/or the winding support.
A stack configuration expanded according to this configuration principle may, of course, also have even more heating circuits.
Four winding supports 310a, 310b, 330a, 330b, on which a respective electric heating element 340a, 340b, 350a, 350b is wound in the form of a heating conductor, are present here as well, and the electric heating elements 340a and 340b, on the one hand, and the electric heating elements 350a and 350b, on the other hand, are connected in series, so that two heating circuits are likewise formed, but they are arranged next to one another rather than one on top of another in this variant.
Essentially rectangular or strip-shaped winding supports 310a, 310b, 330a, 330b are used in this example; an electrical insulation in the lateral direction is brought about by bar-shaped insulation strips 380.
The possibility of establishing an electrical connection of both ends of the electric heating elements 340a, 340b and 350a, 350b on the same side is made possible by the arrangement of said heating elements in pairs here as well, in which arrangement the respective heating elements 340a and 340b as well as 350a and 350b are connected in series. This can takes place by the provision of projections 314a, 314b, 334a, 334b on the end face located opposite the terminals here as well, over which projections a connection section 340c and 350c of the respective electric heating element is then led.
The electric heating elements 340a, 340b, 350a, 350b are then contacted again via contact points 313a, 313b, 333a, 333b provided on the winding supports 310a, 310b, 330a, 330b, at which contact points a respective contact is established to a terminal wire 341a, 341b, 351a, 351b.
As is seen especially clearly in
The respective electric heating elements 340a, 340b and 350a, 350b belonging to one heating circuit are insulated electrically from one another by the insulation plate 322 such that short-circuits between the respective windings are avoided. The electrical insulation of the electric heating elements 340a and 350a as well as 340b and 350b from the housing, not shown, is ensured by the insulation plates 321 and 323, respectively.
Depending on how the electric heating elements, not shown, are configured, especially in terms of the selection of the material and the cross section, and on how the winding supports 1110, 1130 are wound on, especially in terms of the number of turns and the winding pitch, heating circuits with different heat outputs can thus be provided in a very simple manner, which permit different operating stages depending on the actuation, or it is also possible to provide heating circuits for use with different voltage sources, e.g., the on-board voltage network of a vehicle, on the one hand, and the normal, stationary a.c. voltage network, on the other hand.
The device 1100 for converting electricity into heat was shaped to assume a U-shape, in which the arc 1101 of the U, which connects the legs 1102, 1103 of the U, follows a semicircular contour, which is adapted to the external radius R of the pipe 1001.
It is seen at the same time that a respective section 1110a, 1110b, 1130a, 1130b of the wound-on winding support 1110, 1130 also extends in the area, which is formed by the legs 1102, 1103 of the U and which extends over the center of the cross section of the pipe 1001. Not only is thus the mechanical seating of the device 1100 for converting electricity into heat on the pipe 1001 to be heated improved by the legs 1102, 1103 of the U, but it is also ensured that the part of the circumference of the pipe, via which heat can be introduced, is also enlarged or maximized.
The exemplary embodiment of an electric heater 2000 for heating a pipe 2001 with an external radius R, which exemplary embodiment is shown in
The device 2100 for converting electricity into heat was shaped for this purpose such that it assumes a U-shape, in which the arc 2101 of the U, which connects the legs 2102, 2103 of the U, follows a semicircular contour, which is adapted to the external radius R of the pipe 2001, wherein a respective section 2110a, 2130a of the wound-on winding supports 2110, 2130 also extends in the area formed by the legs 2102, 2103 of the U, which area extends over the center of the cross section of the pipe 2001, which leads to the same effects as in the case of the electric heater 2000.
However, the electric heater 2000 differs from the electric heater 1000 in terms of the arrangement of the wound-on winding supports 2110, 2130, which are not stacked here, but are arranged next to one another each in a half of the U. This leads to an electric heater 2000, which leads only to a smaller enlargement of the cross section of the pipe in the area being heated with it and is thus well suited precisely for use in a small available installation space in this dimension.
The variant of a stacked arrangement shown in
The two ends of the electric heating elements 640, 650 are connected electrically on the same side of the winding supports 610, 630 in this example as well, but the return is via return plates 614, 634 here, which extend on different sides of the electric heating elements 640, 650.
A “sandwich-like” arrangement of the electric heating elements 740, 750 is formed in the exemplary embodiment that is shown in
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
List of Reference Designations:
| Number | Date | Country | Kind |
|---|---|---|---|
| 20 2018 101 634.2 | Mar 2018 | DE | national |
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| 20190297678 A1 | Sep 2019 | US |
