The application relates to a printed circuit board according to the preamble of claim 1 and to a fluid heater configured with such a printed circuit board.
Such fluid heaters are preferably used for heating gaseous or liquid media, for example air or water. The basic design of these fluid heaters is explained, for example, in document DE 10 2016 122 767 A1, which belongs to the Applicant. This fluid heater configured for heating air has a heating element configured as a tubular heating element, the heat of which is transferred to the fluid to be heated via a heat exchanger, also called a heat distribution element. In the fluid heater specifically described in DE 10 2016 122 767 A1, this heat distribution element is configured as a metal sponge or wire mesh/wire netting, wherein the fluid flows through the pores or conduits formed as a result. Of course, other heat distribution elements, for example extruded profiles or corrugated ribs, may also be used for heat exchange. The heating element is driven by control and power electronics, the circuitry of which is formed on a printed circuit board/conductor board, and which is arranged in an electronics housing attached to a housing accommodating the heating element and the heat distribution element. An inlet and an outlet for the fluid to be heated are also formed on this housing.
Document DE 10 2012 209 936 A1 describes a thick-film heater in which conducting paths are applied to a substrate by an additive process. These conducting paths form a heating resistor of a heating device.
In DE 10 2018 106 354 A1, also belonging to the Applicant, it is proposed to use power semiconductors arranged on the printed circuit board as heating elements, so that the heat generated during operation of the power semiconductors is transferred to the fluid to be heated via a heat distribution element.
The problem with this solution is that the heat generated by the power semiconductors is only generated at specific points in relation to the total heat exchange surface, so that considerable effort is required to enable areal heat transfer by designing the heat distribution element accordingly. In addition, the technical equipment required for this solution is considerable, since the interconnection of the power semiconductors used essentially for heating is complex compared with conventional solutions using tubular heating elements or PTC heating elements and is also expensive due to the comparatively high price of the semiconductors.
In contrast, the object of the application is to further develop the printed circuit board provided with a circuit forming a control or power electronics and a heater configured therewith in such a way that effective heating of a fluid is made possible with reduced effort, in particular reduced circuitry-related effort.
This object is solved with respect to the printed circuit board by the feature combination of an independent claim for a printed circuit board and with respect to the heater by the features of an independent claim for a heater.
Advantageous further developments of the application are the subject matter of the dependent claims.
The printed circuit board/conductor board according to the application is provided with at least one heating line configured for a predetermined heating power for heating a fluid. This heating line is formed by conducting paths shaped via a subtractive process, for example by etching, whose cross-section, length, and material are designed according to the heating resistance required for the heating power. The material is accordingly selected such that it can be machined via a subtractive process, for example by etching or milling.
According to the application, the printed circuit board/conductor board is thus initially formed with a continuous layer/coat of the conducting path material, from which the areas not forming a conducting path are then removed by etching or
A solution of this kind makes adapting to different heating powers possible in a simple manner by suitable selection of the cross-section and geometry of the heating line, wherein the circuitry-related effort is considerably reduced compared to the solution described at the beginning with power semiconductors specially configured for heating. According to the application, such power semiconductors are required at most for driving or respectively controlling the heating circuit. Thus, according to the application, the parasitic side effect resulting from the fact that the conducting-path portions are heated by energization is exploited when the conducting path is energized.
According to the application, the printed circuit board is configured with a heat dispersion layer for heat transfer to the fluid. This heat dispersion layer may be configured, for example, as a molded part that is integrated into the layer structure of the printed circuit board and is optimized with regard to fluid guidance and heat transfer. By integrating the heat dispersion layer into the printed circuit board/conductor board structure, the device-related effort is reduced compared to conventional solutions in which a separate heat distribution element, for example heat exchange surfaces or the like, have to be applied.
The printed circuit board is preferably designed as an IMS (Insulated Metal Substrate) conductor board, in which a heat dispersion layer is already conceptually integrated.
Another significant advantage of the solution according to the application is that the suitable surface extension of the heating lines/conducting paths ensures uniform heat distribution for heating the fluid.
In one configuration example of the application, in addition to the heating line, a control circuit and/or power electronics is formed on the printed circuit board/conductor board, which is configured, for example, for driving the heating line or other electronic components.
According to a preferred configuration example of the application, several heating lines are configured on the printed circuit board, which are individually drivable.
Each IMS printed circuit board may be configured in multiple layers with at least two functional layers, in each of which a heating element and/or the control circuit and/or power electronics may be configured. Accordingly, one layer of the IMS printed circuit board may be configured as a heating element and another layer may form a control circuit or power electronics. Of course, mixed forms are also possible, in which one layer is effective both as a heating element and in the sense of driving components. In principle, the IMS printed circuit board may also be configured as a single layer, wherein this layer fulfills the function of both a heating element and a control circuit/power electronics.
Heat transfer is further improved if at least sections of the heating line are configured as meander-shaped conducting paths. Alternatively, however, the conducting paths may also be connected in series and/or in parallel in a parallel arrangement or the like.
The manufacture of the printed circuit board and its connector elements is particularly simple if the latter and other functional elements are configured by bending tabs or edge portions of the IMS conductor board. For example, it is possible to lead a conducting-path terminal portion to such an edge portion and then to form a contact tab or the like by bending it.
Furthermore, it is possible that at least one heating line is configured in the bent portion, which is contacted via portions of the conducting path that are routed over the bent areas. It is also possible to have at least one heating line run in sections in the bent portion.
The heater according to the application has a heating element configured with a printed circuit board of the type described above.
The conducting path may be meander-shaped or bifilar.
It is particularly preferred if the printed circuit board bounds at least in sections a fluid conduit through which the fluid flows or a fluid compartment which accommodates the fluid. I.e., in such a variant, the printed circuit board forms part of the fluid conduit/fluid compartment. This concept, with a fluid compartment bounded in sections by the printed circuit board, is the subject matter of a parallel patent application filed by the Applicant.
Preferred configuration examples of the application are explained in more detail below with reference to schematic drawings. The following is shown:
The housing 2 according to the application also accommodates at least one printed circuit board 14 (see
A clearance not visible in
In a manner known per se, sealing contours 30 are formed on the end edges of the center part 4 visible in
In the configuration example shown (see also
The components described sit—as explained above—on the printed circuit board 14, so that their power dissipation is also transferred to the fluid in the form of heat. Such a solution, in which the electronic components, for example semiconductor components, are configured as heating elements, is explained in DE 10 2018 106 354 A1 described at the beginning. In contrast to this solution, heating lines of the two heating circuits 24, 26 formed by conducting paths are configured with respect to the heating power to be transmitted. As explained at the beginning, however, the printed circuit board according to the application is not limited to a configuration example in which the conducting paths are configured together with control elements and/or a power electronics—in principle, it is sufficient if only one heating line formed by at least one conducting path is configured on the printed circuit board 14, which is configured with regard to the heating of a fluid.
As mentioned above, the printed circuit board 14 is configured as an IMS printed circuit board. According to
On this heat dispersion layer 62, which is configured for optimum heat transfer to the fluid to be heated, an integrated insulating layer 64 is applied, which typically has a layer thickness of 75 μm to 200 μm and is made of a material with good electrical insulation properties, preferably plastic. The conducting path 66 forming the actual heating line 58, 60 is then applied to this insulating layer 64. The conducting path 66 consists of a material that can be processed by etching or milling, such as copper, zinc, silver, gold, or nickel, wherein copper is preferred.
As explained in DE 10 2018 106 354 A1, a conducting-path layer is first applied over the entire surface and then the meander-shaped or bifilar structure of the heating lines 58, 60 and the conducting-path portions leading to the aforementioned components/switch elements, which will be explained in more detail below, is produced by an etching process, resulting in the heating-line structure indicated in
For electrical insulation and moisture protection, an insulating layer, for example a layer of solder resist 68, may then be applied to this etched IMS conductor board 14 in a further work step, covering the conducting-path structure. Here, areas are left out on which the above-mentioned switch elements 42, 44 and electronic components 54, 56 are applied in a subsequent assembly operation—for example in an SMD process. After this equipping according to an equipping plan, the outer shape of the IMS printed circuit board 14 is formed in a fourth work step by punching, milling and/or sawing.
The structure of the heating lines 58, 60 is configured with regard to the desired heating power. The heating resistance of the two heating lines 58, 60 is essentially determined by the material, the length and the cross-section of the conducting paths 66, which are arranged, for example, in a meandering or bifilar manner. Accordingly, the conducting path width b and the layer thickness d of the conducting path 66 and their length are selected in such a way that the heating resistance required for the predetermined heating power is obtained. The heating resistance may also be changed locally by varying the cross-section (b, d). This local variation of the heating resistance can be used to deliberately generate hot spots that form a kind of fuse and melt in the event of excessive temperature development or current flow. Likewise, zones with fewer conducting paths, and thus lower power density, can be generated locally. The spacing a of the individual conducting paths 66 of the meander structure also has an influence on the power density.
Of course, as mentioned above, other structures may be used instead of the meander-shaped structure, for example parallel conducting paths arranged in parallel or series, bifilar structures, or mixed forms of these structures. In the configuration example shown in
The individual heating line 60 of the second heating circuit 26 has a corresponding structure, wherein the heating power of the individual heating lines 58a, 58b and 60 in the illustrated configuration example is configured according to the desired maximum heating power.
In the area overlapping the lower lid 8, a further printed circuit board 14′ is formed, which can be configured in accordance with the printed circuit board 14 with a heating circuit and/or other components of the control and/or power electronics. In principle, it is also possible to configure the printed circuit board 14 with several heating circuits as a ‘heating board’, while the additional printed circuit board 14′ accommodates the electronic components required for control and regulation, i.e., the components of the control and power electronics, so that each printed circuit board 14, 14′ is optimized with regard to the respective function (heating—control, regulation). The printed circuit boards 14, 14′ are held in a sealing manner on the center part 4 via suitable sealing elements 76, 78, so that a fluid compartment 80 is formed by the printed circuit boards 14, 14′ and the center part 4, through which the fluid to be heated flows or in which the fluid to be heated is accommodated. The printed circuit boards 14, 14′ according to the application thus directly bound the fluid compartment 80. This is a significant difference from the solution according to DE 10 2018 106 354 A1, in which the printed circuit board is applied to the circumferential walls of the fluid compartment, so that there is no direct heat input from the printed circuit board into the fluid.
In the configuration example shown in
The printed circuit boards 14, 14′ are arranged in such a way that the heat dispersion layers 62 described above bound the fluid compartment in sections, while the electronic components and the heating lines 58a, 58b, 60 are arranged with the conducting paths 66 facing the two free spaces 85, 87. As mentioned above, further printed circuit boards or other elements of the control/power electronics not shown here can be arranged in these clearances 85, 87.
In the section according to
In the configuration example shown in
In the configuration example shown, the fluid guiding element 84, 84′ is formed with a continuous floor plate 86 facing the fluid compartment 80, from which projections 88 extend towards the printed circuit board 14, 14′, so that fluid-guiding conduits 90 are formed between adjacent projections. The flow guidance is selected in such a way that, for example, the inlet to the fluid heater 1 is in fluid connection with the conduits 90, so that the flow in the conduits 90—as indicated in
As already explained in connection with
As explained above, the projections 88 rest with their drop-shaped end faces on the heat dispersion layer 62 of the respective printed circuit board 14, 14′, wherein a sealing arrangement is preferably selected so that a defined flow is ensured within the conduits 90. However, a certain amount of leakage is in principle unproblematic. In this configuration example, too, the sealing of the fluid compartment 80 with respect to the free clearances 85, 87 and the exterior space 28 is affected by suitable sealing elements 76, 78.
As explained, a distinctive feature according to the application is that, on the one hand, the printed circuit boards 14, preferably IMS printed circuit boards 14, 14′ are configured as heating elements and, on the other hand, bound a part of a fluid compartment receiving the heating fluid. Further embodiments of this concept are explained with reference to
In a further embodiment of the application, a heating line may also be formed completely or in sections in the bent region, wherein contact is then preferably made via the conducting path 66. In such a configuration example, the heating line is thus also formed in the narrower bent sidewalls of the fluid channel. Of course, in such a configuration example, contact may also be made via contact tabs bent out of this bent sidewall, in the area of which a respective conducting-path terminal portion (66′) then ends.
In
The IMS printed circuit boards may also be configured with multiple layers, so that conducting-path layers are formed, separated by insulation layers, and lying one on top of the other, which then each form part of a heating line/heating circuit and/or the control or power electronics. For example, a passive sensor element may be integrated, wherein one conducting-path layer is configured for power distribution and the other conducting-path layer is configured essentially as a heating line. In principle, however, several layers may also be formed as a heating line, wherein the respective heating power is adapted by varying the cross-section, in particular the conducting path thickness d.
In principle, the fluid compartment 80 in such variants may also be bounded on the one hand by a single layer printed circuit board and on the other hand by a multilayer printed circuit board with a heating or current distribution function.
Disclosed are a printed circuit board with a heating line formed from conducting paths and a heater implemented with such a printed circuit board.
Number | Date | Country | Kind |
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10 2019 214 314.8 | Sep 2019 | DE | national |
10 2019 133 043.2 | Dec 2019 | DE | national |
This application is a US National Phase of International Application Number PCT/EP2020/075772, filed Sep. 15, 2020, claiming priority to DE102019214314.8, filed Sep. 19, 2019, and DE102019133043.2, filed Dec. 4, 2019, the contents of which are incorporated into the subject matter of the present application by reference.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2020/075772 | 9/15/2020 | WO |