BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a perspective side-view onto an embodiment of a heat-generating element in a blown-up representation;
FIG. 2 a top view of the embodiment shown in FIG. 1;
FIG. 3 a cross-sectional view along the line III-III according to the depiction in FIG. 2;
FIG. 4 a perspective side-view of the embodiment shown in FIG. 1 to 3, in the assembled state;
FIG. 5 a longitudinal view of the end piece of an alternative embodiment of a heat-generating element according to the invention;
FIG. 6 a cross-sectional view of the embodiment shown in FIG. 6 by means of a third embodiment of a heat-generating element according to the invention;
FIG. 7 a cross-sectional view of a third embodiment of the heat-generating element according to the invention;
FIG. 8 a side-view in blown-up representation of a fourth embodiment of a heat-generating element according to the invention;
FIG. 9 the left frontal end of the embodiment shown in FIG. 8;
FIG. 10 a cross-sectional view of a fifth embodiment of the heat-generating element according to the invention; and
FIG. 11 a perspective side-view of an embodiment of a heating device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a perspective side-view of the essential parts of an embodiment of a heat-generating element in a blown-up representation. The heat-generating element has a positioning frame 2, made of injection-moulded plastic, whose middle longitudinal axis forms a bisecting plane of the heat-generating element. This element is essentially formed with one side the mirror image of the other, and initially has contact plates 4 provided on each side of the positioning frame 2, said contact plates 4 holding between them the PTC elements 6 held in the positioning frame 2. On the exterior side of the contact plates 4 is located a two-layer insulating layer 8, comprising an exterior insulating foil 10 and an inner ceramic plate 12, that fits directly against the contact plate 4. The ceramic plate 12 is a relatively thin aluminium oxide plate that provides very good electric dielectric strength of roughly 28 kV/mm and good thermal conductivity of more than 24 W/(m K). The plastic foil 10 in this case is formed by a polyamide foil that has good thermal conductivity of roughly 0.45 W/(m K) and dielectric strength of 4 kV/mm. Located between the plastic foil 10 and the ceramic plate 12 is a wax layer, with a thickness of a few μm, whose melting point is coordinated with regard to the operating temperature of the heat-generating element, namely in such a way that the wax melts at the operating temperature and becomes distributed between the plastic foil and the ceramic plate 12, which fit closely together under compressive stress, with the distribution being of such a manner that a levelling film is created that furthers good heat transfer between the two parts 10, 12 of the insulating layer 8. The combination of plastic foil 10 and ceramic plate 12 leads to an insulating part 8 that has good electrical characteristics and thermal conductivity characteristics and, particularly with respect to voltages of up to 2,000 V, that is not subject to flashover, but which simultaneously displays the necessary strength. Any stress peaks that can, in particular, be generated by pressure against the heat-emitting elements that fit against the heat-generating element are relieved and homogenized by the insulating foil positioned around the exterior. The wax that is arranged between the two parts 10, 12 of the insulating layer, as well as, optionally, an adhesive that is also provided there and that connects the two parts 10, 12 to one another, furthers this relief of stress peaks. Accordingly, there is no risk of the relatively brittle ceramic layer breaking, even at higher compressive stresses that hold a layer composition of heat-generating and heat-emitting elements under an initial tension.
The insulating layer 8 is preferably glued to the exterior side of the contact plate 4. This is located roughly centred, below the insulating layer 8, and is formed with a width less than that of the insulating layer 8. The respective contact plate 4 projects beyond the insulating layer 8, however, at the face sides. The width of the contact plate 4 is initially considerably reduced at these ends that project beyond the insulating layer 8. At the right end as seen in FIG. 1, the contact plate 4 has an attachment tab 14, which is narrowed by cutting free some of the width of the contact plate 4 and into which a cut 16 is made. At the opposite end, shown in FIG. 1 at the left, a corresponding narrowed attachment tab 18 with a cut 16 is likewise provided. From the side edge of this attachment tab 18, a tab 20, bent out of the level of the contact plate 4, goes off, forming the basis of a plug connection 22 that projects beyond the positioning frame 2 on the face side.
The tab 20 meshes with a slot 24 cut into the positioning frame 2, with said slot 24 opening towards the face side of the positioning frame 2. On its face side end regions, the positioning frame 2 furthermore has pegs 26, that extend along the height of the heat-generating element, i.e., that go off at right angles from the surface of the positioning frame 2. During assembly, these pegs 26 are introduced into the cuts 16. Subsequently, the pegs 26 are melted to form a thickening of melted material and the contact plate 4 is secured to the positioning frame 2 in this manner. As can be derived in particular from FIGS. 1 and 4, the positioning frame 2 has, in addition to the pegs 26, additional positioning aids for precise arrangement of the contact plate 4 on the positioning frame 2. In this way, the positioning frame 2 forms, firstly, face-sided attachment pegs 28 on the face-sided ends of the contact plate 4, said attachment pegs 28 extending slightly beyond the upper side of the contact plate 4 and being spaced at a distance to one another that roughly corresponds to the length of the contact plate 4. In this way, the contact plate 4 is positioned lengthwise. Secondly, across the width, the positioning frame 2 forms bordering edges 30 that extend along almost the entire length of the contact plate 4, said bordering edges 30 likewise extending beyond the upper side of the contact plate 4 and being spaced at a distance to one another that is slightly larger than the width of the contact plate 4. Projecting beyond this bordering edge 30 on both sides are bordering tabs 32 with locking protuberances in the interior, by means of which a heat-emitting element that is arranged on the heat-generating element can be fixed in place for assembly purposes.
In the heat-generating element, as can be seen in FIG. 3, opposing surfaces of the PTC elements 6 fit against the interior surfaces of the contact plates 4, which are fixed in place in a frame opening 34 of the positioning frame 2. As can be seen in FIG. 1, six PTC elements 6 in each case are located within a frame opening 34. Two equally sized frame openings 34 are provided, arranged one behind the other along the length. The PTC elements are packed at a distance to the material of the positioning frame 2 by means of an insulating gap 36. This insulating gap 36 also extends in a direction parallel to the supporting plane between the interior side of the contact plate 4 and a narrowed interior edge 38 of the positioning frame that surrounds the circumference of the frame opening 34. Accordingly, the current-carrying parts of the heat-generating element, i.e., the two contact plates 4 and the PTC elements 6, are spaced at a distance from the material of the positioning frame 2 by means of the insulating gap 38. In the embodiment shown in FIG. 1 to 4, this distance is ensured by an insulating spacing medium 40, which surrounds the front end of the interior edge 38 around the circumference. In the embodiment shown, the insulating spacing medium 40 is formed by a silicone strip that holds the front area of the interior edge 38 and surrounds it around the circumference.
It is not absolutely required that the current-carrying parts of the heat-generating element fit directly against the insulating spacing medium 40. Rather, the spacing medium is only intended to prevent the current-carrying parts from coming into direct contact with the plastic material of the positioning frame 2. The insulating characteristics of the spacing medium 40 are selected in such a way that in any case, it has a better insulating effect than does the plastic material of the positioning frame 2. The length of the spacing medium 40 across the width is selected in such a way that in any case, it extends to the end of the contact plate 4 corresponding to the width. The spacing medium 40 covers the sides of the interior edge 30 that are open to the top and to the bottom, as well as an edge 42 that is formed by the interior edge 38 and that surrounds the frame opening 34 around the circumference. The spacing medium 40 can accordingly also be understood as the interior insulating jacket coating the edge surrounding the circumference of the frame opening 34, which prevents both direct contact between the PTC element 6 and the thermoplastic material of the positioning frame 2 and direct contact of the contact plates 4 with the positioning frame 2, and ensures a minimum distance between the named parts that is to be maintained for electrical insulation.
In addition to electrical insulation of the current-carrying parts of the heat-generating element, the embodiment shown in FIG. 1 to 4 also offers complete encapsulation of these parts. To this end, the insulating layer has an edge section 44 that extends across (FIG. 3) the contact plate 4 on both sides. Between this edge section 44 and the interior edge 38 of the positioning frame 2 is located a sealing bead 46, which is positioned in such a manner that it lies against and forms a seal with both the positioning frame 2 and the insulating layer 8. In the circumferential direction, i.e., across the width, the encapsulation accordingly has the opposing insulating layers 8 and the arrangement of two sealing elements 46, which extend essentially at right angles, with the material of the positioning frame 2 provided between them. The encapsulation is selected in such a way that no moisture or dirt can penetrate into the current-carrying parts from outside.
The sealing bead 46 is formed by a plastic adhesive that fixes the insulating layer 8 in place with respect to the positioning frame 2, consequently enclosing all parts of the heat-generating element provided within the insulating layers 8. In this development, it is possible to do without fixing the PTC elements 6 in place to the contact plates 4 with respect to the insulating layer 8, as far as positioning during operation of the heat-generating element. Nevertheless, for manufacturing reasons, such an attachment may be expedient.
Elastomers, for example, silicone or polyurethane, have proven suitable for forming the sealing bead 46 in the form of an adhesive. As can particularly be derived from FIG. 2, the sealing bead 46 extends along the length of the positioning frame and is provided between the outer edge of the frame opening 34 and the bordering edge 30. The sealing element fits against the interior edge 38, which has a reduced thickness. On the exterior side, directly adjacent to the sealing element 46, a sealing medium bordering edge 48 is provided that is formed by the positioning frame 2. With a view to the best possible sealing, the sealing bead 46 can fit closely against this edge that extends at right angles to the receptacle level for the PTC elements.
FIGS. 5 and 6 show an alternative embodiment of a heat-generating element according to the invention, with a positioning frame 2 on which the existing lower contact plate 4u is arranged by means of molding around. After the manufacture of the positioning frame 2 by means of injection moulding, this frame forms one unit together with the lower contact plate 4u. To this end, the contact plate 4u can have cuts or through holes in its edge, through which the highly insulating plastic mass that forms the positioning frame can flow during the injection moulding and can consequently connect the contact plate 4 to the positioning frame. The lower contact plate 4u is bent towards the middle of the positioning frame at its ends, so that the contact plate 4u is securely surrounded by the material forming the positioning frame 2. In the case of the embodiment shown, the positioning frame 2 is formed from an electrically high-grade, temperature-resistant (200° C.) silicone. The embodiment accordingly has a CTI value that guarantees reliable operation at voltages of roughly 500 V.
In the case of the embodiment shown in FIG. 6, the positioning frame is manufactured while maintaining the fundamental configuration that was already described with reference to the preceding embodiments, in which a sealing adhesive edge 46 is provided between the material of the positioning frame 2 and the insulating layer 8, said adhesive edge 46 being in this case formed from an elastomer adhesive. The two-sided insulating layers 8 lie on the positioning frame 2, with this adhesive strip 46 as an intermediate layer. In this case, the strip 46 fitting against the lower insulating layer 8u especially serves the adhesive connection. The sealing characteristics of this strip do not figure in to any great extent. Alternatively or additionally, the insulating layer 8 can also be glued flat to the exterior side of the contact plate 4u.
Alternative developments are also possible, however, in which both the electric strip conductor 4u and the insulating layer 8u lying on it are inserted into a mould and extruded from the highly insulating plastic mass of the positioning frame 2 (FIG. 7). After the removal of the mould, the PTC elements 6 are inserted into the frame openings 34. On the opposite side, an electric strip conductor 4 is now positioned on the PTC element(s) 6. The insulating layer 8 that is positioned directly on to this electric strip conductor 4 is connected to the positioning frame 2 with an adhesive edge 46 with sealing function. Otherwise, the modification shown in FIG. 7 and described here corresponds to the previously described developments as far as the positioning of the contact plate(s) 4 and the formation of the contact elements at the face-sided end(s) of the positioning frame 2.
FIGS. 8 and 9 show a fourth embodiment of a heat-generating element according to the invention. Components that are the same as those in the preceding embodiments are identified with the same reference numbers.
In the embodiment shown in FIGS. 8 and 9, the PTC elements 6 are held in two frame openings 34 of a longish positioning frame 2. The PTC elements 6 can lie directly on the edge of the positioning frame 2, said edge surrounding the frame openings 34. Between the frame openings 34 and the longish side edge of the positioning frame 2, two sealing beads 46 are also located, one each on the top and bottom of the positioning frame, where each sealing bead 46 is in the form of a band-shaped, glued-on silicone strip that projects beyond the upper side of the positioning frame. In the case of the embodiment shown, the mutually opposing upper sides of the sealing beads 46 lie roughly at the level of the upper side of the PTC elements. In other words, the two sealing beads 46, together with the thickness of the positioning frame 2 at this side edge have a height that roughly corresponds to the height of the PTC elements.
Positioning frame heads 100, which project beyond the positioning frame 2 on both sides, are provided on both face ends of the positioning frame 2, with said positioning frame heads 100 forming positioning aids for precise arrangement of the contact plates 4. Each of the contact plates 4 has tongues cut out of its face ends, wherein the left tongue forms the plug connection 50 and wherein only a positioning tongue 102 is provided on the right side, said positioning tongue 102 being held in a positioning opening 104 cut into the positioning frame 100 and insulated from it on all sides, so that the contact plate 4 is held securely in the length and width directions relative to the positioning frame 2. The positioning frame head 100 furthermore has a lead-through opening 105 for the plug connection 50.
The positioning frame heads 100 furthermore form a securing means in the form of locking arms 106 that encompass the insulating layer 8 on the outside, namely, on its face side. The locking arms 106 are linked to the immobile part of the positioning frame head 100 via a shared torsion hinge 108. During the assembly of the embodiment shown in FIGS. 8 and 9, the locking arms 106 can be pivoted around this torsion hinge 108, so that the opposing locking arms 106 open up a free area between them that can just hold the insulating layer 108, formed as a flat ceramic plate. After the release of the torsion hinge 108, the locking arms swing back and span the insulating layer 106. In this connection, the insulating layer 8 is pre-tensioned in the direction of the positioning frame 2, with a sealing bead 46 being placed in between.
The embodiment shown in FIGS. 8 and 9 can be formed on one side with hinged insulating layers 8 correspondingly locked against the positioning frame 2, whereas on the other side, the insulating layer and/or the contact plate 4 can be secured to the positioning frame 2 in a manner such as that already described in the preceding with reference to FIGS. 6 and 7.
FIG. 10 shows a further modified embodiment. Again, components that are the same in this embodiment as in the previously discussed embodiments are given the same reference numbers.
In the embodiment shown, the sealing beads 46 are formed on opposing side surfaces of the positioning frame 2 as a single piece, on the positioning frame 2 that is formed as an injection moulding component. In the embodiment shown, the positioning frame 2 is injected from silicone. The PTC elements 6 are placed into this frame 2. The insulating layers 8 are positioned on both sides of the sealing bead 46. The components held within the positioning frame 2, the contact plate 4 and PTC elements 6 are clamped between the insulating layers 8. These, in turn, are pretensioned with respect to each other via separate clamp elements 62, which can, for example, be formed by plastic clips formed in a C-shape, that both provide initial tension to the insulating layers 8 with respect to each other, with the positioning frame 2 placed in between, and that also serve the relatively soft and unstable positioning frame 2 as a side border, so that the positioning frame 2 essentially cannot bulge outwards in the supporting plane of the PTC elements 6. Accordingly, the clamp elements 62 are, in any case, arranged so that they are distributed at pre-determined distances along the entire length of the positioning frame 2. The snap-in protuberances of the clamp elements 62 that work with the insulating layer 8 can be assigned snap-in depressions or snap-in protuberances that are mounted on sides of the insulating layer. In addition, the snap-in protuberances can be connected to the insulating layer 8 by means of gluing. Each development that, during the practical use of the heat-generating element, prevents the clamp elements 62 from sliding away from the surface of the insulating layer 8, on the one hand, and that does not hinder the flattest possible positioning of the heat-emitting elements on the exterior side of the insulating layer 8, is conceivable.
FIG. 11 shows an embodiment of a heating device according to the invention. This comprises a holding device in the form of a frame 52, closed around the circumference, which is formed from two frame hulls 54. Within this frame 52, multiple layers of identically formed heat-generating elements 60 (for example, according to FIG. 1 to 4), running parallel to one another, are held. Furthermore, the frame 52 contains a spring (not shown), by means of which the layer composition is held in the frame 52 at an initial tension. Preferably, all heat-emitting elements 56 are arranged directly adjacent to a heat-generating element 60. The heat-emitting elements 56 shown in FIG. 11 are formed by means of strips of aluminium plating bent in a meandering fashion. The heat-generating elements 60 are located between these individual heat-emitting elements 56 and behind the lengthwise bars 58 of one of the air inlet or outlet openings of the grid that penetrates the frame 52. One of these lengthwise bars 58 is removed from the middle of the frame 52 for the purposes of the depiction, so that a heat-generating element 60 can be seen there.
The force of the spring held in the frame 52 can be dimensioned in such a way that this not only pre-tenses the heat-generating elements 60 and the heat-emitting elements 56 against each other, but additionally so that the corresponding sealing beads 46 are pressed with an initial tension against the insulating layer 8 or the positioning frame 2 in a manner that forms a seal. The sealing effect in this context can be generated solely by the spring force. Additionally, the individual heat-generating elements can be provided with clamp elements or other securing means that provide the initial tension. It is also possible to glue the sealing bead to the insulating layer and/or the positioning frame in a manner that forms a seal. In this case, because of the initial tension of the spring held in the frame, the sealing bead is, in any case, compressed and the contact plate 4 is held flush against the upper side of the PTC element 6, in order to achieve good contacting there. It is self-evident that lead-through or positioning openings 104, 105 cut into the positioning frame are, in this case, dimensioned so that they allow a certain mobility of the contact plate 4 for compressing the sealing bead 46.
In the case of the embodiment shown in FIG. 11, the heat-emitting elements, i.e., the radiator elements, are potential-free, because they lie against the current-carrying parts, with the insulating layer 8 in between. The frame 52 is preferably formed from plastic, as a result of which the electrical insulation can be further improved. Additional protection, particularly against unauthorized contact with the current-carrying parts of the heating device, is additionally provided by the grid, which is likewise formed from plastic and developed as a single piece with the frame hulls 54.
Because the heat-emitting elements 56 fit closely against the current-carrying parts, with an insulating layer 8 placed in between, the heat-emitting elements 56, i.e., the radiator elements, are potential-free. The frame 52 is preferably formed from plastic, as a result of which the electrical insulation can be further improved. Additional protection, particularly against unauthorized contact with the current-carrying parts of the heating device, is additionally provided by the grid, which is likewise formed from plastic and developed as a single piece with the frame hulls 54.
On one face side of the frame 52, a plug connection is located in a manner known per se, with power supply lines and/or control lines going off of it, by means of which the heating device can be connected for control and power supply purposes in a vehicle. On the face side of the frame 52, a housing is indicated which can also have control or regulating elements, in addition to the plug connection.
Even although in the case of the embodiment shown in FIGS. 8 and 9, an attachment edge 30, which projects beyond the sealing edge 46 and which is formed on the positioning frame 2, is missing, the side surface of the heat-generating element, where said side surface can be seen in the side-view, is essentially formed by the side wall of the positioning frame in the case of this embodiment, as well. In the case of the embodiment shown in FIGS. 8 and 9, only the relatively thin sealing bead 46 and the thin ceramic plate 8 project beyond the contact surface for the sealing bead 46 on the sides of the positioning frame 2. It is pointed out that the embodiment shown in FIGS. 8 and 9 has a completely flat surface that extends completely along the width of the heat-generating element. The attachment of the ceramic plate 8 to the positioning frame 2 is accomplished solely by means of the locking arms 106 provided on the face side. If the contact force applied in this way is not sufficient to press the ceramic plate 8 to the sealing bead 46 in the middle area, as well, a corresponding contact force, and therefore shielding of the PTC elements against the air that flows across the heat-generating element, results during the installation of the same into a housing, preferably a frame, due to the spring bias of the layers pressed together in the frame.
Patent Application
20080073336
