Source: http://www.patentsencyclopedia.com/app/20130161307
Timestamp: 2018-11-21 04:06:09
Document Index: 249030571

Matched Legal Cases: ['art 122', 'art 122', 'arts 122', 'arts 122', 'arts 122', 'arts 122', 'arts 122', 'arts 122']

HEAT GENERATING ELEMENT - Patent application
Patent application title: HEAT GENERATING ELEMENT
Inventors: Franz Bohlender (Kandel, DE) Eberspacher Catem Gmbh & Co. Kg (Herxheim, DE) Michael Niederer (Kapellen-Drusweiler, DE) Christian Morgen (Rulzheim, DE)
Patent application number: 20130161307
A heat generating element for an electrical heating device of a motor vehicle includes a positional frame which forms a receptacle in which a PTC element is accommodated, and two contact plates abutting on oppositely situated sides of the PTC element. A heat generating element has a sheet metal cover that is connected to the positional frame. Also provided are a frame, which has oppositely situated side openings for the passage of a medium to be heated, and a layer structure, which is arranged in the frame and which comprises layers of corrugated-rib and heat generating elements, such that the heat generating element has at least one PTC element arranged between two parallel contact plates. The electrical heating device is protected against EMC via sheet metal covers that are arranged on both sides of the heat generating element and between the corrugated-rib elements and the contact plates.
1. A heat generating element for an electrical heating device of a motor vehicle, the heat generating element being configured for arrangement between two corrugated-rib elements, each of which comprises a meander-type bent sheet metal strip and a sheet metal cover that covers exposed ends of the meander-type bent sheet metal strip, the heat generating element comprising: a positional frame that forms a receptacle in which a PTC element is accommodated, two contact plates abutting on oppositely situated sides of the PTC element, and a screening with a screening sheet metal cover that is connected to the positional frame and that is separated electrically from the assigned contact plate by an insulating layer.
2. A heat generating element according to claim 1, wherein the sheet metal covering has an edge that surrounds the positional frame essentially fully circumferentially.
3. A heat generating element according to claim 1, wherein the sheet metal cover is clipped to the positional frame.
4. An electrical heating device comprising: a frame, which has openings formed on oppositely situated sides thereof for the passage of a medium to be heated, and a layer structure which is arranged in the frame and which comprises layers of corrugated-rib elements and heat generating elements, wherein each heat generating element has e PTC element arranged between two parallel contact plates, wherein each heat generating element is provided with sheet metal covers, wherein one of the sheet metal covers is arranged on one side of the assigned heat generating element between the corrugated-rib element and one of the contact plates of the heat generating element and the other sheet metal cover is arranged between the corrugated-rib element and the contact plate on the oppositely situated side of the assigned heat generating element and is separated electrically from the assigned contact plate by an insulating layer.
5. An electrical heating device according to claim 4, wherein the sheet metal cover that is arranged on the one side of the heat generating element is assigned to the heat generating element and the sheet metal cover arranged on the other side is assigned to the corrugated-rib element.
6. An electrical heating device according to claim 4, wherein the sheet metal cover provided on the one side of the heat generating element has an edge that surrounds a positional frame essentially fully circumferentially.
7. An electrical heating device according to claim 4, wherein the sheet metal cover provided on the other side of the heat generating element is formed by a covering element that is connected to the corrugated-rib element.
8. An electrical heating device according to claim 4, wherein the sheet metal cover provided on the other side of the heat generating element is formed by several covering elements, and wherein each covering element is assigned to a single corrugated-rib element.
9. An electrical heating device according to claim 4, further comprising a connecting housing, which is provided on a face-side end of the layer structure and which is provided with a screening housing element that is connected in a conducting manner to the sheet metal covers.
10. An electrical heating device according to claim 9, wherein the screening housing element is formed as a metal shell that accommodates a plastic housing element.
11. An electrical heating device comprising: a frame, which forms on oppositely situated sides openings for the passage of a medium to be heated, and a layer structure, which is arranged in the frame and which comprises layers of corrugated-rib elements and heat generating elements, wherein each heat generating element has a PTC element arranged between two parallel contact plates, wherein, each heat generating element is provided on both sides with a sheet metal cover arranged between the corrugated-rib elements and the contact plate; the sheet metal cover provided on the one side of the associated heat generating element has an edge that surrounds the positional frame essentially fully circumferentially; the sheet metal cover provided on the other side of the associated heat generating element is formed by a covering element that is connected to the corrugated-rib element and a connecting housing, which is provided on a face-side end of the layer structure and which is provided with a screening housing element that is connected in a conducting manner to the sheet metal covers.
12. An electrical heating device according to claim 11, wherein the screening housing element is formed as a metal shell that accommodates a plastic housing element.
13. An electrical heating device for a motor vehicle, comprising: a frame, which forms on oppositely situated sides openings for the passage of a medium that is to be heated, a layer structure, arranged in the frame and comprising layers of corrugated-rib and heat generating elements, wherein each heat generating element has a PTC element arranged between two parallel contact plates, and a connecting housing that accommodates electrical contact elements of several heat generating elements, wherein the connecting housing comprises a screening housing element, a plastic housing element that is accommodated in the screening housing element and that forms function surfaces for the accommodation of a control device and/or for the connection of the electrical heating device and a housing cover element that can be laid onto the screening housing and/or the plastic housing element in a sealing manner.
14. An electrical heating device according to claim 13, wherein the connecting housing has a plastic housing element, wherein the control device has at least one power switch and a heat sink that is assigned to the power switch, and wherein the screening housing element is connected in an electrically conducting manner to the heat sink.
15. An electrical heating device according to claim 14, wherein the heat sink is retained in the plastic housing element in a sealing manner and such that it is movable within limits.
16. An electrical heating device according to claim 13, further comprising a connecting bolt retained in the plastic housing element that is connected in an electrically conducting manner to the screening housing element.
17. An electrical heating device according to claim 13, further comprising a sleeve receptacle formed on the connecting housing for the sealing accommodation of a connection piece that protrudes from the heat generating element.
[0002] The present invention relates to a heat generating element, particularly for an electrical heating device of a motor vehicle, with a positional frame, which forms a receptacle in which at least one PTC element is accommodated, and two contact plates abutting on oppositely situated sides of the PTC element.
[0004] Such heat generating elements are generally known as a constituent part of an electrical heating device, particularly for heating air in a motor vehicle, whereby such an electrical heating device is likewise to be further developed with the present invention. The heat generating element forms a layer of a layer structure, which normally comprises corrugated-rib elements that abut on both sides of the heat generating element. This layer structure normally has a multiple number of layers of corrugated-rib elements and heat generating elements, whereby the layers are in any case layered one above the other in one plane.
[0005] For example, EP 1 768 457 A1 and EP 1 768 458 A1 can be seen as generic. EP 0 350 528 also discloses a type-defining heat generating element as a part of an electrical heating device for heating air.
[0006] Electrical heating devices comprising a heat generating element of the generic type occasionally lead to electromagnetic disturbances that, particularly within a motor vehicle, are unwanted because these make themselves known acoustically in the vehicle interior, for example, during the operation of a radio.
[0007] The object of the present invention is consequently to specify a heat generating element, particularly for an electrical heating device for a motor vehicle, as well as an electrical heating device, which provide for the EMC problems in an improved manner.
[0008] To resolve this problem, the present invention suggests a heat generating element arranged between two corrugated-rib elements, each of which comprises a meander-type bent sheet metal strip and a sheet metal cover that covers exposed ends of the meander-type bent sheet metal strip.
[0009] A positional frame forms a receptacle in which at least one PTC element is accommodated, and two contact plates abut on oppositely situated sides of the PTC element. A screening with a screening sheet metal cover is connected to the positional frame that is separated electrically from the assigned contact plate by an insulating layer.
[0010] This positional frame is normally manufactured from a material that is not electrically conducting, and it forms at least one, normally more, receptacles for at least one PTC element. It is also possible to provide several PTC elements in one receptacle. Contact plates, which are fed current with different polarity, abut on oppositely situated sides of the PTC element or PTC elements. Such contact plates are normally formed from a sheet metal strip by means of punching, where applicable, by bending.
[0011] The heat generating element according to the invention additionally has a sheet metal cover that is connected to the positional frame. This sheet metal cover is normally provided such that it is electrically insulated from the two contact elements. It can be insulated with respect to the assigned contact plate by an air clearance, i.e., it can abut only the positional frame but not the contact plate. Normally, and particularly with a view to a good thermal transfer, however, the sheet metal cover abuts indirectly on the contact plate assigned to it. Indirect abutment regularly necessitates that an insulating layer be inserted between the sheet metal cover and the assigned contact plate. This insulating layer can be formed from a plastic film and/or a ceramic layer. The insulating layer can also be applied by means of spraying plastic and/or ceramic onto the outer surface of the contact plate and/or onto the inner surface of a sheet metal cover.
[0012] The sheet metal cover can be joined to the positional frame in any manner, for example, it can be joined by being overmoulded to this into one unit or also subsequently by being attached to a positional frame that is initially prepared by injection moulding.
[0013] In the heat generating element according to the invention, the sheet metal cover forms screening for the heat generating element. Accordingly, an electrical heating device that comprises the heat generating element gives less cause for EMC problems. Sheet metal covers can be provided on oppositely situated side surfaces and for each of the contact plates, preferably with an intermediate positioning of an insulating layer in each case abutting thereupon, so that the heat generating element is covered on its outer side completely by sheet metal. The sheet metal cover normally forms the contact base for the corrugated-rib element or corrugated-rib elements. A meander-type bent sheet metal strip is not necessarily given as a corrugated-rib element in the context of the present invention. The corrugated-rib element can also be manufactured as an extruded section of aluminum. The individual ridges of such a profile form corrugated ribs of the mentioned corrugated-rib element.
[0014] According to a preferred further development of the present invention, the sheet metal cover has an edge that surrounds the positional frame essentially fully circumferentially. This edge normally extends across the entire height of the positional frame, i.e., up to or even over the plane that is defined by the contact plate arranged on the oppositely situated side. This applies in any case in the case in which the side oppositely situated to the contact plate with the circumferentially surrounded edge is also provided with a flat contact plate for further screening of the heat generating element. Naturally it is possible to provide each oppositely situated side of the heat generating element with contact plates with an edge surrounding the positional frame, and namely such that the respective edge pieces of the contact plates are complementary to one another with the objective that the positional frame is not only divided by the sheet metal covers completely on the top or bottom, but also is surrounded on its outer edge essentially fully circumferentially by the screening defined by the sheet metal covers.
[0015] In view of the simplest possible manufacture of the heat generating element, it is however to be preferred to form only one sheet metal cover with an edge that surrounds the positional frame essentially circumferentially. This edge is preferably clipped to the positional frame, so that during the assembly of the heat generating element, initially on one side the sheet metal cover can, if applicable, be clipped to the positional frame, after the previous introduction of the insulating layer and the contact plate. After this the positional frame can be placed with its still open side arranged upwardly and into the receptacle(s) of the PTC element or PTC elements. The sheet metal cover clipped to the positional frame accordingly forms a bottom that is permanently connected to the positional frame and that simplifies the placement of the respective layers into the heat generating element. To be understood here as layers are particularly the PTC element or PTC elements as well as the contact plate provided on the side oppositely situated to the sheet metal cover, where applicable, an external insulating layer assigned to this.
[0016] According to an independent aspect of the present invention, this one suggests an electrical heating device of the type mentioned at the beginning which is less susceptible to EMC problems. In this electrical heating device, a sheet metal cover is provided on each side of the heat generating element. The sheet metal cover is located between the corrugated-rib element and the contact plate. An insulating layer is regularly provided between each sheet metal cover and the assigned contact plate.
[0017] With a view to simple and economical assembly with a compact construction of the electrical heating device, according to a preferred further development of the present invention it is suggested to assign the sheet metal cover arranged on the one side to the heat generating element and the sheet metal cover on the oppositely situated side, i.e., the other side, to the corrugated-rib element. The sheet metal cover assigned to the heat generating element is normally joined permanently or detachably to the positional frame, preferably clipped to this through an edge surrounding the positional frame. The sheet metal cover assigned to the corrugated-rib element can be soldered or joined in another way to the corrugated ribs of the corrugated-rib element, for example, joined by means of being flanged with the corrugated-rib element. Such flanging may lead to a clip connection between the corrugated-rib element and the assigned sheet metal cover. In any case, for the discussed further development, one sheet metal cover is normally permanently assigned to the positional frame and the other permanently to the corrugated-rib element, so that in the assembly of the layer structure within the frame, only a reduced number of parts must be handled in order to manufacture an electrical heating device that is improved with respect to EMC problems.
[0018] With a view to improved heating of the air, according to a preferred further development of the present invention it is suggested that the heating block comprise several corrugated-rib elements provided one behind the other in the flow direction of the medium that is to be heated. These corrugated-rib elements are arranged such that they lie one behind the other, each in identical levels. They are normally provided offset to one another, so that the corrugated ribs of the first corrugated-rib element in the flow do not completely cover or screen the corrugated ribs of the following corrugated-rib element. It is rather so that the corrugated ribs of the second corrugated-rib element in the flow direction lie freely in a projection onto the corrugated-rib elements that are arranged one behind the other in the flow direction of the medium to be heated. In this preferred further development, the sheet metal cover provided on the other side comprises several covering elements. Each of the covering elements is assigned to a single corrugated-rib element. The covering elements, arranged one behind the other in the flow direction of the medium to be heated accordingly form the sheet metal cover on the corrugated-rib side. Normally the covering elements abut against one another in the described arrangement of the corrugated-rib elements directly one behind the other in the flow direction, so that there is no disruption of the screening on the corrugated-rib side between the individual corrugated-rib elements.
[0019] According to a preferred further development of the present invention, the electrical heating device has a connecting housing which is provided on a face-side end of the layer structure. Such a connecting housing normally accommodates the electrical connecting elements to selected, normally to all, contact plates, so that the individual heat generating elements are connected electrically in the connecting housing. The connecting housing can also have a control device for driving and regulating the individual heat generating elements. These can be grouped and combined into different heating stages. According to a preferred further development of the present invention, the connecting housing has a screening housing element. This screening housing element can be an element that forms the housing fully or partially and that is manufactured from a metal material. Alternatively, the screening housing element can also be formed only as a metal or sheet metal shell, which surrounds in a screening manner the provided components that form the housing and the sealing of the connecting housing, particularly the housing shell elements effecting the control elements. According to the preferred further development, the screening housing element is connected to the sheet metal covers in an electrically conducting manner. This results in uniform screening that surrounds both the heat generating elements of the layer structure and the connecting housing and accordingly also screens EMC disturbances that can emanate from the connecting housing. The further development furthermore offers the possibility of grounding the screening via the connecting housing.
[0020] The screening housing element is clipped, preferably in a conducting manner, to the sheet metal covers. Accordingly, clip ridges are provided that connect the screening housing element to the sheet metal covers in an electrically conducting manner. The electrically conducting connection does not have to occur directly between the screening housing element and the sheet metal cover. It is rather the case that, because the corrugated-rib elements are normally directly, i.e., in an electrically conducting manner, connected to the assigned sheet metal covers, the electrical contacting between the screening housing element and the sheet metal cover can also occur through the corrugated-rib element.
[0021] The screening housing element can be formed as a cast metal housing. Alternatively, the screening housing element can also be formed as a plastic housing element which is accommodated within a sheet metal shell for screening.
[0022] According to a preferred further development of the present invention, the screening housing element forms entry and exit openings for a cooling channel that is sealed with respect to the interior of the connecting housing. Normally located in this cooling channel is at least one heat sink, which is provided for the cooling of a power switch that is accommodated in the connecting housing and whose power dissipation is emitted in the form of heat to the medium to be heated.
[0023] With its further, independent aspect, the present invention specifies an electrical heating device of the abovementioned type that has an electrical connecting housing that accommodates contact elements from several heat generating elements. The connecting housing is thereby regularly used for the connection of selected, or occasionally all, contact plates to a control device that can be accommodated in the connecting housing. This control device normally comprises an equipped conductor board or circuit board. Today this is frequently equipped with at least one semiconductor power switch, which drives the heat generating elements and thereby produces power dissipation that must regularly be conducted away by means of cooling the power switch. A connecting housing can, however, also alternatively or additionally comprise conductor boards or conductor elements through which the connected heat generating elements are contacted or grouped.
[0024] With a view to the given EMC problems, it is suggested with the present invention to form the connecting housing with a screening housing element, a plastic housing element accommodated in the screening housing element, and a housing cover element that can be laid on to the screening housing element and/or the plastic housing element in a sealing manner. The screening housing element, as well as the housing cover element, is thereby normally formed as screening, i.e., from metal or with a metal insert. The screening housing element and the housing cover element accordingly screen the interior of the connecting housing. The screening housing element and/or the housing cover element are thereby normally electrically connected to the screening of the layer structure, for example, of a sheet metal cover of the heat generating element and/or the corrugated-rib elements of the layer structure, so that the electrical heating device has uniform screening.
[0025] The plastic housing element is correspondingly adapted and formed for the accommodation or retaining of the control device and/or for the retaining of the connecting elements effecting the connection of the electrical heating device. The electrical heating device can be directly connected to a power supply via these electrical connecting elements. Alternatively, corresponding connecting elements can be only retained in the plastic housing element and made accessible to the outer side of the connecting housing via the housing cover element. The plastic housing element is thereby used for the insulating accommodation of the elements of the control device that conduct or switch power current or of the contact surface elements which normally contact or group the connecting elements into several or all heat generating elements.
[0026] By means of this further development, it is accordingly possible on the one hand to effect simple screening of the connecting housing, where applicable while including the layer structure. By means of the plastic housing element, on the other hand, a differentiated embodiment for accommodating and retaining electrically conducting components is created. Since the plastic housing element is inserted into the screening housing element, the electrical or electronic components accommodated in the plastic housing element are also screened.
[0027] According to a preferred further development of the present invention, the control device has at least one power switch. This is a semiconductor power switch, which is provided for the control of the heating power of the heat generating element or heat generating elements and that hereby emits power dissipation. At least one heat sink is accordingly assigned to the power switch. According to the preferred further development, this heat sink is accommodated in the plastic housing element. Consequently, accommodation surfaces or securing surfaces for retaining the heat sinks can be formed in a simple manner by the plastic housing element. The heat sink is, however, furthermore connected in an electrically conducting manner to the screening housing element and accordingly incorporated into the screening. Consequently, by checking the polarity of the screening housing, it can be determined whether or not the desired insulation of the parts connected to ground continues to be effective, as is taught by EP 2 299 200. It should thereby be noted that the heat sink normally is provided such that it is insulated electrically with respect to the power switch, even though the two components abut each other in a good thermally conducting manner. Accordingly, normally located between the power switch and the heat sink is electrical insulation that hinders the heat passage from the power switch on to the heat sink only slightly.
[0028] According to a preferred further development of the present invention, the heat sink is inserted into the housing in a sealing manner. Accordingly, the sealing of the accommodation space of the connecting housing effected by the interaction of the housing cover element and the screening housing element also is not impaired by the heat sink that lies exposed on the outside of the connecting housing element. This heat sink normally lies exposed in the flow of the medium to be heated and is cooled by this flow. The heat sink is preferably, however, retained such that it is movable in the plastic housing element within limits. The movement of the heat sink normally occurs against a tension that normally is effected by the sealing provided for the heat sink. As a result of the tension, a countermovement is impressed on the heat sink so that this abuts the power switch constantly under tension and can conduct its power dissipation away in a thermally conducting manner. The mobility of the heat sink within the connecting housing is thereby normally selected such that the heat sink can displace 5/10, preferably 7/10, in the insertion movement and thereby can compensate thickness tolerances of the power switch without the sealing being lost. Normally used here as a sealing element is a ring-shaped or cylinder-shaped sealing body made of an elastomer. These materials have proven to be particularly suitable for maintaining a tension and sealing even at relatively high temperatures and over a long period. Normally assigned to the connecting housing is a sealing element, the compression of which causes the power switch to abut the heat sink under tension. With a view to the desired mobility of the heat sink, the connecting housing normally has supporting points distributed on the circumference of a heat sink insertion opening, on which supporting points the sealing element is supported. To the side and next to these supporting points, the sealing element, when compressed, can displace in the direction towards the layer structure and consequently evade the movement of the heat sink within limits. In other words, the sealing element is not supported fully circumferentially in the insertion opening, but instead only on the supporting points that are arranged in the insertion opening distributed in the circumferential direction.
[0029] According to a preferred further development of the present invention, a connecting bolt retained on the plastic housing element is connected in an electrically conducting manner to the screening housing element and accordingly is used for the ground connection of the electrical heating device.
[0030] Finally, according to a further preferred embodiment of the present invention, it is suggested to form on the connecting housing a sleeve receptacle formed for the sealing accommodation of a connection piece protruding from the heat generating element. Accordingly, the connecting housing further developed in this way allows, in interaction with the connection piece of the heat generating element, a sealed assembly of the heat generating element in the connecting housing. The receptacle formed by the heat generating elements is accordingly sealed by the connecting housing. The receptacle is however also accessible through the connecting housing, in order, for example, to introduce contact elements into the heat generating element. It is, however, also possible, after complete assembly of all heat generating elements on the connecting housing, to carry out a sealing test through the same so that essentially the sealing of the fully assembled electrical heating device is checked collectively. The sleeve receptacle is thereby normally formed by a housing base, so that after the sealing test only the housing cover, where applicable, before electronic components have to be inserted, in order to complete the electrical heating device with the control device provided thereupon in a constructional unit.
[0031] In each case, a separate and separately sealed connection piece accommodated in a sleeve receptacle is regularly formed for each contact element of the heat generating element. It is likewise possible, however, to provide a connection piece that accommodates all electrical strip conductors to the interior of the heat generating element and that is accommodated in a sealing manner in the sleeve receptacle of the connecting housing.
[0032] According to a preferred further development of the present invention, a sealing element made of an elastomeric material is located between the sleeve and the sleeve receptacle. This sealing element is placed on to the sleeve before the assembly in a practical manner and it can be joined by means of overmoulding. By means of this firmly bonded joining, there occurs at least on one side a connection between the sealing element and the assigned contact base that is in any case sealed, whereby this contact base can be a surface of the heat generating element and a surface of the connecting housing.
[0033] Further details and advantages of the present invention are given in the following description of embodiments in conjunction with the drawing. Here, the drawing illustrates the basic construction of an electrical heating device into which a heat emitting element is built, which itself can be solely essential to the invention. The drawing shows the following:
[0034] FIG. 1 a perspective side view of an embodiment of an electrical heating device for a motor vehicle;
[0035] FIG. 2 a perspective, exploded side view of a heat generating element of the electrical heating device illustrated in FIG. 1;
[0036] FIG. 3 a perspective face-side view of the embodiment illustrated in FIG. 2;
[0037] FIG. 4 a perspective side view of the embodiment illustrated in FIG. 1 in an exploded view of the main constituent parts of the embodiment;
[0038] FIG. 5 a joining region between a connecting housing and a layer structure of the embodiment of an electrical heating device illustrated in FIGS. 1 and 4 with the omission of various elements;
[0039] FIG. 6 a cross-sectional view along the line VI-VI according to FIG. 1, i.e. a sectional view through a heat generating element according to FIG. 2 at medium height of the same with omission of the screening housing;
[0040] FIG. 7 a perspective face-side view of the embodiment illustrated in FIG. 1 of an electrical heating device, which gives a view into the connecting housing and in which the conductor board and the housing cover are omitted;
[0041] FIG. 8 the detail VIII drawn in FIG. 7 in an enlarged illustration;
[0042] FIG. 9 a cross-sectional view of the connecting housing of the electrical heating device according to FIG. 1 at the height of a heat sink;
[0043] FIG. 10 a perspective side view of a first embodiment of a heating bar which can be built into the electrical heating device according to FIG. 1;
[0044] FIG. 11 a cross-sectional view along the line XI-XI according to the illustration in FIG. 10;
[0045] FIG. 12 a side view of the embodiment of a heating bar illustrated in FIG. 10;
[0046] FIG. 13 a perspective side view according to FIG. 10 onto an alternative embodiment of a heating bar;
[0047] FIG. 14 a cross-sectional view along the line XIV-XIV according to the illustration in FIG. 13;
[0048] FIG. 15 a side view of the further embodiment of a heating bar illustrated in FIG. 13;
[0049] FIG. 16 a perspective exploded view of a frame suitable for accommodating heating bars according to FIGS. 13 to 15;
[0050] FIG. 17 a perspective plan view onto the edge area of a further embodiment of a heating device according to the invention, partially omitting layers of the layered structure, and
[0051] FIG. 18 a partially cut-away perspective side view of the embodiment illustrated in FIG. 17.
[0052] FIG. 1 illustrates an embodiment of an electrical heating device with a power section labelled with the reference numeral 2 and a control section labelled with the reference numeral 4. The power section 2 and the control section 4 form a constructional unit of the electrical heating device.
[0053] The control section 4 is formed on the outside by a connecting housing 6, which--as shown particularly in the illustration according to FIG. 4--consists of a screening housing 8, which is formed as, for example, a deep-drawn or cast, respectively deep-drawn metal shell, a plastic housing element 10, which is inserted into the metal shell 8 and a housing cover 12. In the joined state the housing cover 12 can grasp over a free flange of the sheet metal cup 8 and be formed of metal so that the interior of the control section 4 is completely screened by a metallic connecting housing 6. The housing cover 12 can however also be formed from plastic.
[0054] The housing cover 12 bears a female plug housing 14 for the power current and a further female housing element which is formed as a control plug housing 16. Both plug housings 14, 16 are joined as plastic elements to the metallic housing cover 12 and form guide and sliding surfaces for in each case a male plug element which is not illustrated.
[0055] The plastic housing element 10 accommodates a conductor board 18 within it which is partially covered by a pressure element 20 which is explained in more detail in the following. The conductor board 18 has a plus connecting contact 22 and a minus connecting contact protruding over it, which lie exposed in the power plug housing and are electrically connected to the strip conductor. The conductor board 18 furthermore bears a control contact element 26 which contains control element contacts and which can be reached by lines via the control plug housing 16. As can be seen from FIG. 4, the control plug housing 16 is arranged offset to the control contact element 26. This distance is required due to the installation situation of the electrical heating device in the motor vehicle. The electrical contacting between the control contact element 26 and the control plug housing 16 or the contact elements provided there occurs through the electrical leads which are routed inside the housing cover 12. Furthermore, in the assembled state the housing cover has a connecting bolt 28 protruding over it for the ground connection which is electrically connected to the screening housing 8.
[0056] On the end side oppositely situated to the conductor board 18 the plastic housing element 10 forms two cooling channels 30 for heat sinks 32 which are only indicated in FIG. 4, but can be recognised more clearly in FIGS. 1 and 5. The free end of the heat sinks 32 comprises several cooling ridges extending essentially parallel to one another which define in each case air passage channels 34. The heat sinks 32 are made of a good thermally conducting material, for example aluminum or copper.
[0057] The omitted sheet metal shell 8, which is not illustrated in FIG. 5, has, as elucidated in particular in FIGS. 1 and 4, corresponding to the cooling channels 30, oppositely situated passage openings 36 for air which are provided as entry and exit openings for the cooling channels 30. These passage openings 36 are formed in the metal shell 8. At about central height in the longitudinal direction the metal shell 8 has latching openings 38, through which after the final assembly of the control section 4 on the power section 2 latching lugs 40 penetrate, which are positively locked in engagement with the power section 2 and formed on the outer edge of the plastic housing element 10 (cf. FIG. 1). On oppositely situated face sides the metal shell 8 also has in each case mounting holes 42 which will be dealt with in more detail in the following (cf. FIG. 4).
[0058] The power section 2 has a frame 44 which is circumferentially enclosed in the embodiment according to FIG. 1 and circumferentially surrounds a layer structure labelled with the reference numeral 46 which is also designated as a heating block. The frame 44 is formed from two frame elements 48, which are latched together by latching connections which are labelled with reference numeral 50 (male latching element) and reference numeral 52 (female latching element), in particular in FIG. 16.
[0059] On oppositely situated outer sides 54 the frame 44 forms in each case openings 56 for the passage of air to be heated by the air heater illustrated in the embodiment. In the illustrated embodiment these openings 56 are stiffened by lateral struts 58, which join oppositely situated side edges of the frame 44.
[0060] In its interior the frame 44 defines an accommodation space 60 which is adapted such that the layer structure 46 can be accommodated closely fitted in the frame 44.
[0061] The heating block or layer structure 46 is essentially formed by the heating bars 62 which are illustrated in FIGS. 10 and 13 and which are arranged one above the other layered in the receptacle 60. The heating bars 62 consist of at least two corrugated-rib elements 64, which accommodate a heat generating element 66 between them. As FIGS. 10 and 11 elucidate, the corrugated-rib elements consist of meander-type, bent sheet metal strips 68, which are covered on one side by a sheet metal cover 70 and grasped at the edge by a bent edge 72 of the sheet metal cover 70. The respectively other upper side of the meander-type bent sheet metal strips 68 is free and is directly formed by bent free ends 74 of the sheet metal strip 68. With the heating bar 62 illustrated in FIGS. 10 and 11 in the passage direction of the air to be heated, i.e. at right angles to the surface of the frame 44 clamped by the outer sides 54, two corrugated-rib elements 64 are provided in each case adjacently. This arrangement of corrugated-rib elements 64 provided one behind the other in the flow direction forms a layer. Here, in each layer labelled with the reference letter L one corrugated-rib element 64 is provided in each case per level E. S indicates the flow direction of the air flow to be heated in FIG. 11. Accordingly, this first meets the first level E1, i.e. the corrugated-rib elements 64 of the first layer L1 and the second layer L2 provided in the first level and only thereafter the corrugated-rib elements 64 provided in the second level E2. The corrugated-rib elements 64 are here arranged in the flow direction S, i.e. strictly one behind the other at right angles to the outer side 54 defining the opening 56. Here, the heat generating element 66 forms a flat contact base for the corrugated-rib elements 64.
[0062] As can be seen especially from FIG. 2, the heat generating element 66 consists of several layers lying one above the other. The heat generating element 66 is essentially constructed symmetrically, whereby a positional frame labelled with the reference numeral 76 and made from an electrically insulating material, in particular plastic, is provided in the centre. The positional frame 76 forms in the present case three receptacles 78 for PTC elements 80. Several, at least two, PTC elements 80 are accommodated in a receptacle 78. Both outer receptacles 78 each accommodate four PTC elements 80. Contact plates 82 abut oppositely situated sides of the PTC elements 80. These two contact plates 82 are formed identically and punched out from electrically conducting sheet metal. The contact plates 82 are placed on the PTC elements 80 as separate elements, with the positional frame 76 or at least the receptacle of the positional frame 76 sandwiched in between the contact plates 82. They can be additionally provided with a vapour deposited electrode layer, as generally normal. The electrode layer is however not a contact plate 82 for the purpose of the invention.
[0063] As FIG. 11 particularly shows, the PTC element 80 assigned to a level E1 is located within the front and rear sides of the assigned corrugated-rib elements 64. In other words there is no PTC element 80 located between two corrugated-rib elements 64 provided in one layer L1. In this way a thermal interaction between the PTC elements of different levels E1, E2 is avoided.
[0064] The contact plates 82 are dimensioned such that they are accommodated within the positional frame 76, but are arranged circumferentially with a spacing to the positional frame 76. The circumferential gap so formed is labelled with the reference numeral 84 in FIG. 11. At approximately the height of the contact plates 82 the positional frame 76 forms a circumferential sealing groove 86 into which elastomeric adhesive edging 88 is filled as annular beading. This adhesive edging 88 surrounds all the receptacles 78 fully circumferentially and is used for the adherence of an insulating layer with the reference numeral 90, which in the present case is formed from an insulating plastic film and which extends up to a marginal region of the positional frame 76, in any case in the circumferential direction protruding over the adhesive edging 88 with excess. Due to joining the insulating layer 90 with the positional frame 76, facilitated by the adhesive edging 88, the receptacle 78 and the contact plates 82 are hermetically sealed with respect to the outer circumference.
[0065] Access to the interior of the positional frame 76 is solely given on the face side of the positional frame 76 and by connection pieces 92 which are formed as one part from its material and which fully circumferentially surround a channel 94 for accommodation of pin-shaped contact elements 96. On their free ends the connection pieces 92 bear sealing elements 98, formed from a thermoplastic elastomer or from PTFE, with a labyrinth type of sealing structure, which can be joined to the associated connection pieces 92 by overmoulding or plugging on. On the face side of each positional frame 76 two connection pieces 92 with identical embodiment and sealing are provided for the accommodation of two contact pins 96 for electrically contacting the contact plates 82.
[0066] As can be furthermore taken from FIG. 2, the contact plates 82 have female clip element receptacles 100, manufactured by means of punching and bending, which are formed on sidewards offset protrusions 102 of the contact plates 82, the said protrusions 102 terminating within the circumferential edge provided by the adhesive edging 88 and bridging in each case assigned clip openings 104, 106 formed by the positional frame 76. In the clip openings 106, formed opposite the connection pieces 92 on the positional frame 76, clip ridges 108 are provided, formed with the material of the positional frame 76 as one part. The embodiment and the diameter of these clip ridges 108 correspond to the diameter of a contact pin 96. The contact pins 96 lie exposed in the clip openings 104 and are joined to the female clip element receptacles 100 of the contact plates 82, whereas on the opposite side the female clip element receptacles 100 protrude into the clip openings 106 and are latched with the clip ridges 108. On the connection side of the heat generating element 66 exhibiting the connection pieces 92 the described clip connections can be realised either by positioning the contact plates 82 in their installation position, followed by insertion of the contact pins 96 through the channels 94, or by latching the female clip element receptacles 100 to the contact pins 96 which are already located in position.
[0067] On its upper side illustrated in FIG. 2 the heat generating element 66 is provided with a sheet metal cover 110. This sheet metal cover 110 covers the complete insulating layer 90 assigned to the sheet metal cover 110 and has a circumferential edge 112, which frictionally abuts a circumferential marginal area 114 of the positional frame 76 and accordingly secures the sheet metal cover 110 to the positional frame 76 by a clamping force (cf. also FIG. 11). Furthermore, due to the edge 112 exact positioning of the sheet metal cover 110 relative to the external circumference of the positional frame is ensured. At the free end of the edge 112 the sheet metal cover 110 slightly widens conically, which acts as a funnel-shaped insertion opening for the positional frame. The circumferential edge 112 is only penetrated in the corner regions and at the height of the connection pieces 92 and forms a one-sided screen for the heat generating element 66.
[0068] As FIG. 3 illustrates, the channels 94 formed to match the contact pins 96 are widened radially for the formation of a groove-shaped inspection channel 116. This inspection channel 116 extends from the front free face side of the connection pieces 92 up to the assigned clip opening 104 and accordingly forms an external access to the receptacles 78, which communicate with one another below the insulating layer 90 or the contact plates 82.
[0069] As FIG. 3 furthermore illustrates, the sheet metal cover 110 forms a flat contact base between the slightly upwardly bent lip regions 118 for the circumferential edge 112. These lip regions 118 accordingly give a type of centering for the corrugated-rib elements 64 abutting the sheet metal cover 110 (cf. also FIG. 11).
[0070] In the illustrated embodiment the previously described layer structure 46 is held in the frame 44 under spring tension. For this purpose the frame 44 has spring insertion openings 120, formed by the two frame elements 48, which can be seen in FIGS. 4 and 5 and which, with the auxiliary heater not yet assembled, are exposed on the face side on the controller side of the power section 2. In these spring insertion openings 120 spring elements 121 are inserted for clamping which are described in EP 2 298 582 originating from the applicant and its disclosure content is included in the disclosure of the present application through this reference. Directly adjacent to these spring insertion openings 120, each of the frame elements 48 forms a retaining element part 122. Each retaining element part 122 formed by a frame element 48 is given an oblique ramp surface 124. The retaining element parts 122 are formed such that with joined frame 44 two retaining element parts 122 assigned in each case to a frame element 48 form complete retaining elements 126 on oppositely situated end sides with the retaining element parts 122 of the other frame element 48. These retaining elements 126 have a tapering embodiment towards the free end, so that the oblique ramp surfaces 124 are used for coarse positioning of the control section 4, namely of a positioning opening 127 of the plastic housing element 10 relative to the power section 2 (cf. FIG. 5). Furthermore, after the joining of the frame elements 48 laterally extending grooves 128 on the retaining element parts 122 form a circumferentially closed hole 130 (cf. FIG. 4). A mounting screw can be fitted into this hole 130 through the mounting hole 42 of the metal shell 8 to provide the positioning and fixing of the power section 2 on the control section 4 to realise one constructional unit for the power section 2 and the control section 4.
[0071] As FIGS. 5 and 6 illustrate, the plastic housing element 10 for each heat generating element 66 forms two cylindrical sleeve receptacles 132 which are matched such that the connection pieces 42 together with the sealing elements 98 can in each case be introduced sealed into assigned sleeve receptacles 132. As FIG. 6 illustrates, the sleeve receptacles 132 are widened conically at the end and have initially a widened cylindrical section for accommodating the sealing element 98 and further inside there is a cylindrical section with a smaller diameter which retains the frontally conically tapering connection piece 92 with slight play and thus limits the deformation of the sealing element 98 after assembly.
[0072] The contact pins 96 each penetrate contact surface elements 134 which are formed from sheet metal by punching and bending and which group several contact pins 96 of the same polarity within the connecting housing 6 so that they are assigned to a heating stage. The lower contact surface element is a first plus contact surface element 134, whereas the upper contact surface element is a minus contact surface element 136. As FIG. 7 particularly illustrates, the plastic housing element 10 accommodates a further, second plus contact surface element 138. The minus contact surface element 136 and the plus contact surface elements 134, 138 are separated from one another by a partition ridge 140. This partition ridge 140 protrudes over an abutment level formed by the plastic housing element 10 for the contact surface elements 134, 136, 138. These surfaces of the plastic housing element 10 defined by the abutment level are labelled in FIG. 6 with the reference numeral 142. Due to the ridge 140 the creepage current path between the contact surface elements 134, 138 of the plus polarity and the contact surface element 136 of the minus polarity is extended such that creepage currents between both contacts are not to be expected. Also the air clearance between the contact surface elements 134 and 136, respectively 138 and 136 is displaced. The contact surface elements 134, 136, 138 have semicircular recesses 143 open to the partition ridge 140 between the contact pins 96. In FIG. 6 contact tongues 144, 146 can be seen in each case, which penetrate the conductor board 18 and are formed as one part by punching and bending on the contact surface elements 134 and 136 and which are held raised in contact tongue retention regions 148 relative to the contact bases 142. These details can be seen in FIG. 8. As here illustrated, the respective contact surface elements 134, 136 have at their ends joining lugs 145 which open out into the contact tongues 144, 146. As can be seen furthermore from FIGS. 6 and 8, the contact surface elements 134, 136, 138 for the individual contact pins 96 have formed contact openings manufactured by punching and bending. Accordingly, oppositely situated contact projections 150 abut the external circumference of the contact pins 96 under elastic strain. As can be seen furthermore from FIG. 8, the plastic housing element 10 forms latching projections 152, which are introduced into the latching openings 154 of the contact surface elements 134, 136, 138, which are delimited on the opposite sides of sharp-edged clamping segments 156 of the sheet metal material forming the contact surface elements 134, 136, 138. These clamping segments 156 accordingly claw onto the latching projections 152 and fix the contact surface elements 134, 136, 138 onto the latching projections after being pushed on.
[0073] FIG. 8 also shows the previously described heat sinks 32, which are exposed within the plastic housing element 10 and protrude over the partition ridge 140 on the upper side with a flat contact base 158.
[0074] Centrally between the heat sinks 32 and at the edge of the plastic housing element 10 mounting eyes 160 can be seen in each case for the previously generally mentioned pressure element 20. As particularly illustrated in FIGS. 4 and 9, this is formed honeycomb-shaped with a large number of honeycomb ridges 162 extending at right angles.
[0075] The sectional view according to FIG. 9 illustrates the installation of the heat sink 32 into the plastic housing element 10. As can be seen from FIG. 8, this has a large number of latching posts 166, provided distributed on the circumference of a raised heat sink insertion opening 164 of the plastic housing element 10, which constrict the heat sink insertion opening 164 conically at the edge and form latching shoulders 168, which grasp over a circumferential latching ridge 170 formed on the heat sink 32, thus frictionally preventing pressing out upwards and in the direction onto the connecting housing 6. The contour of the recesses 143 of the contact surface elements 134, 136, 138 corresponds to the contour of the heat sink insertion opening 164 so that its raised edge is closely delimited by the contact surface elements 134, 136, 138. The two plus contact surface elements 134, 138 are formed identically so that they can be alternatively used for the formation of the first or second contact surface element 134 or 138. On the side of the latching ridge 170 opposite the latching shoulder 168 there is a sealing element 172 which circumferentially surrounds the heat sink 32 and is supported on the underside facing away from the latching ridge 170 in the circumferential direction by ridges which cannot be discerned in FIG. 9, so that the sealing element 72 cannot slide in the direction towards the power section 2 through a sealing receptacle labelled with the reference numeral 174. This sealing receptacle 174 is formed in one piece with the plastic housing element and extends the heat sink insertion opening 164.
[0076] In FIG. 9 the sealing element is illustrated in an only slightly compressed embodiment. The sealing element 172 can however be compressed in the longitudinal direction of the sealing receptacle 174 in that sealing between the inner circumferential surface of the cylindrical sealing receptacle 174 and the external circumferential surface of the heat sink 32 is lost. The sealing element 172 can here be compressed by about 2/10 to 7/10 mm by displacement of the latching ridge 170 in the longitudinal extension of the sealing receptacle 174. The equalisation movement is applied by screwing the pressure element 20 onto the mounting eyes 160 after assembly of the conductor board 18, which is provided with two semiconductor power switches 178 on its underside 176 facing the heat sink 32. Each power switch 178 is located on the flat contact base 158 of the assigned heat sink 32. At the height of the power switch 178 the conductor board in each case has a hole 180, which is penetrated by pressure ridges 182 of the pressure element 20. These pressure ridges 182 directly abut the power switch 178 and press it against the heat sink 32. Since the power switch 178 may have substantial manufacturing thickness tolerances, the sealing element 172 provided in the embodiment facilitates an equalisation by the receding of the heat sink 32 in the direction towards the power section 2 without the sealing of the heat sink 32 in the plastic housing element 10 being lost. As can be taken from the overall view, in particular from FIGS. 4 and 9, after screwing against the plastic housing element 10 the pressure element 20 acts on both power switches 176 and presses each of them against the heat sink 32 assigned to them. Due to an insulating layer 184 placed on the contact base 158 of the heat sink 32, the power switch 178 is electrically insulated from the assigned heat sink 32. The insulating layer 174 is a ceramic insulating layer. Also this insulating layer 184 protrudes beyond the heat sink 32 to enlarge the creep path substantially in the width direction (cf. FIG. 9).
[0077] The contact surface elements 134, 136 contact the conductor board 18 through contact tongues 144, 146. A second plus contact tongue 186 (cf. FIG. 4) with the second contact surface element 138 protruding over it connects the heating circuit formed by the second plus contact surface element 138 and the minus contact surface element 136 to the conductor board 18 (cf. FIG. 4). As can be seen furthermore from FIG. 9, the semiconductor power switch 178 contacts the conductor board 18 and switches the power current to the associated circuit. In the present case two heating stages are realised, each of which can be switched and controlled through one of the semiconductor power switches 178.
[0078] Sealed Heat Sink
[0079] As previously described, the heat sink 32 is also retained sealed in the heat sink insertion opening 164. Here the embodiment, i.e. the one in FIG. 9, illustrates a situation in which the power switch 178 has the smallest thickness within the conceivable tolerance range. In this case the latching ridges 170 are located directly below the latching shoulders 168. Touching does not however take place, so that the compression force caused by the--even if only slight--compression of the sealing element 172 acts on the phase boundary between the heat sink 32 and the power switch 178. This power switch 178 in each case abuts on the underside 176 against the conductor board 18 independently of the thickness tolerance. With its pressure ridges 82 the pressure element 20 only relieves the conductor board 18 so that the power switch 178 is held clamped not through the conductor board 18, but rather only between the pressure element 20 and the heat sink 32 effecting the tension with the intermediate positioning of the insulating layer 184.
[0080] Correspondingly, the position of the power switch 178, the conductor board 18 and the pressure element 20 does not change with a power switch 178 having greater thickness. Rather, the heat sink 32 in the heat sink insertion opening 164 is forced in the direction towards the power section 2, so that the sealing element 172 compresses more while retaining the sealing of the heat sink 32 and--compared to the illustration in FIG. 9--the latching ridges 170 are arranged in a further lowered position, i.e. spaced further from the latching shoulders 168.
[0081] Defined Abutment Points for the PTC Element; Air Clearance and Creep Path
[0082] The embodiment of an electrical heating device illustrated in the figures has heat generating elements, which are formed in a special way to lengthen creep paths and to reduce the risk of creepage current transmission. This special arrangement is elucidated in the following, in particular with reference to FIGS. 2 and 11. Thus--as can be seen in FIG. 2--each receptacle 78 specified by a basically flat inner circumferential surface of the positional frame 76 has on oppositely situated sides at least two protrusions labelled with reference numeral 188. The protrusions 188 define supporting points for in each case one PTC element 80 within the receptacle 78. These supporting points 188 prevent the PTC elements 80 from directly abutting the smooth inner wall of the positional frame 76 defining the receptacle 78. Thus, the creep path between opposite surfaces of the PTC elements 80 is enlarged.
[0083] As can be seen in particular in FIG. 2, the supporting points 188 are essentially formed pyramid-shaped and therefore have a form tapering to the tip. Furthermore, the surfaces of the supporting points 188 are curved concave, as the sectional view in FIG. 11 shows. The curvature of the surface also enlarges the creep path further. The previously mentioned circumferential gap 84 provided between the contact plates 82 and the positional frame also contributes to extending the creep paths.
Special EMC Protection of the Embodiment
[0084] Furthermore, the heat generating elements 66 are particularly EMC protected. For example, the positional frame 76 is basically completely surrounded by a screen, which is formed on one hand by the sheet metal cover 110 of the positional frame 76 and on the other hand by the sheet metal cover 70 of the corrugated-rib elements 64. As illustrated in FIG. 11, only a small gap at the edge between the different covers 70, 110 remains. Other than that, the PTC elements 80 are completely enclosed by a metal screen. Accordingly the heat generating elements 66 cannot emit any substantial electromagnetic radiation.
[0085] All the corrugated-rib elements 64 are furthermore joined together by latching elements formed on the metal shell 8, which are not illustrated in the drawing, but can be formed as described in EP 2 299 201 A1 which originates from the applicant, the disclosure of which, to this extent, is included in the disclosure content of this application. It only matters that the metal shell 8 electrically forms joined protrusions which contact the corrugated-rib elements 64 such that all corrugated-rib elements 64 are directly or indirectly electrically joined to the metal shell 8 and are connected to ground.
[0086] Sealing and Sealing Test
[0087] The previously discussed embodiment has heat generating elements 66, the receptacle 78 of which is hermetically sealed with respect to the ambient, so that moisture and contamination cannot access the PTC elements 80. In this way high insulation of the PTC elements 80 is obtained, since any charge carriers of the insulation of the PTC elements 80, which can access the receptacle 78 in the state of the art, impair the insulation. With the present invention also all heat generating elements 66 are inserted into the connecting housing 6. Normally for checking the required sealing after joining the power section 2 a testing bell is placed on the plastic housing element 10 on its free end, which is usually closed off by the housing cover 12, the said testing bell abutting the free edge of the plastic housing element 10 for sealing. Through this testing bell the part of the electrical heating device connected to it is subjected to increased hydrostatic pressure, for example by compressed air. A certain pressure level is held and checked whether it is reduced over time by any leaks. If this is not the case, the component is assessed as passing the test.
[0088] Simplified Assembly
[0089] Accordingly, firstly during the manufacture of the illustrated embodiment the power section 2 is manufactured separately. First, the heat generating elements 66 are assembled. Here, the sheet metal cover 110 can close off the underside and thus, in any case after the adherence of the insulating layer 90 assigned to the sheet metal cover 110, the positional frame 76 which is open on one side on the underside, so that the PTC elements 80 can be inserted from the other side and then the assigned contact plate 82 can be placed on them to finally put the insulating layer 90 in place on the said contact plate and to seal it against the positional frame 76 through the adhesive edging 88. In the described method with particular reference to FIG. 11 the thus prepared heat generating elements 66 are put into a frame element 48 of the frame 44 and namely in each case alternating with respect to the arrangement of corrugated-rib elements 64. As arises particularly from FIG. 4, two corrugated-rib elements 64 normally abut in each case between two heat generating elements 66. In other words a layer L of corrugated-rib elements abut on each side of a heat generating element 66. The comparison between FIG. 4 and FIG. 11 also shows that in the embodiment according to FIG. 4 at least two corrugated-rib elements 64 are arranged in a layer.
[0090] Once all elements of the layer structure 46 have been placed into the frame element 48, the frame 44 is closed by putting the other frame element 48 into place and latching it. Thereafter, the respective spring elements 121 are inserted through the spring insertion openings 120 between the layer structure 46 and an external edge of the receptacle 60 produced by the frame 44. Finally, the spring elements 121 are clamped against one another as described in EP 2 298 582. Thereafter, the power section 2 prepared in this way is joined to the metal shell 8 and the plastic housing element 10. Due to their form tapering to a tip, the ramp surfaces 124 here act as positioning and centering aids, so that the retaining element 126 can be effectively introduced into the positioning opening 127. The retaining element 126 normally here precedes the contact pins 96 so that first coarse positioning is carried out using the retaining elements 126 and then the contact pins 96 are introduced into the cylindrical sleeve receptacles 132.
[0091] Improved Thermal Transfer
[0092] FIGS. 12 to 15 illustrate a further aspect of the present invention in that the corrugated-rib elements 64 provided one behind the other in the flow direction in a layer L are provided in a direction transverse to the flow direction S but offset to one another in their corresponding installation level within the layer structure 46. Accordingly, in the enlarged side view of a heating bar 62 illustrated in FIG. 12 the meander-type, bent sheet metal strips 68 of the corrugated-rib elements 64 can be seen provided in a layer L one behind the other. They are labelled with reference numerals 68.1 and 68.2 and can thus be differentiated. It is apparent that the air to be heated flowing at right angles to the drawing plane flows over almost completely separate meander-type, bent sheet metal strips 68.1 and 68.2. In particular the rear sheet metal strip element is not shaded by the front one. Good thermal transfer is produced. Furthermore, the air flow S to be heated is redistributed during the transfer from the first level E1 to the second level E2, which is accompanied by turbulent flow, by means of which the thermal transfer is also improved.
[0093] FIGS. 13 to 15 show a second embodiment according to FIGS. 10 to 12. The illustrated embodiment of a heating bar only differs from the embodiment previously discussed in that three corrugated-rib elements 64 are arranged one behind the other in a layer L1 respectively L2. Here too, corrugated-rib elements 64 each arranged in a level E1, E2, E3 are each strictly assigned to a PTC element 80. As FIG. 15 illustrates, the air flowing through the heating bar 62 is redistributed many times. The labyrinth of sheet metal strips 68.1, 68.2 and 68.3 formed in each case by the meander-type sheet metal strips 68 provided offset to one another leads to very good thermal transfer and power output.
[0094] Modular Structure of the Frame
[0095] FIG. 16 shows the already previously described frame elements 48 as well as a frame intermediate element 190 which is provided with female and male latching elements 50, 52 corresponding to the frame elements 48, so that the frame intermediate element 190 can be latched between the frame elements 48 in a simple manner. The receptacle 60 provided in the frame for the layer structure 46 is thus enlarged exactly by the width contributed by the corrugated-rib element 46. With the embodiments of heating bars 62 illustrated in FIGS. 10 to 15 the heat generating elements 66 are each formed uniformly, i.e. irrespective of whether two or three PTC elements 80 are arranged one behind the other in the flow direction S; the PTC elements 80 are each accommodated within a uniform positional frame 76. The corrugated-rib elements 64 are however identical. For the heating bars 62 provided with three corrugated-rib elements 64 arranged adjacent to one another and the heating bars 62 provided with two corrugated-rib elements 64, one identical plastic housing element 10 can be used in each case. This is because the frame intermediate element 190 has retaining element parts 122 which interact with the retaining element parts 122 of one of the frame elements 48 in order to form a complete retaining element 126 through which also the widened frame 44 according to FIG. 16 can be joined to the plastic housing element 10. If, for example, four corrugated-rib elements 64 arranged one behind the other in the flow direction form a heating bar, then a second frame intermediate element 190 can be built into the frame 44.
[0096] Compared to the previously described embodiment, FIGS. 17 and 18 illustrate a slightly different embodiment. The same parts are labelled with the same reference numerals. The previously described screening housing element 8 particularly differs in the embodiment shown in FIGS. 17 and 18.
[0097] Instead of a shell-shaped housing element accommodating the plastic housing element 10, a screening contact plate 192 is provided which abuts, positively locked, outer contact bases of the plastic housing element 10. This furthermore forms cavities 194 in which screening contact tongues 196 of the screening contact plate 192 are accommodated. The screening contact tongues 196 are each provided at the height of a heat generating element 66 and contact the edge 112 of this element 66. Furthermore, the screening contact plate 192 forms spring bars 198, formed by punching and bending, which each abut one of the heat sinks 32 on the face side and contact it. As can be especially seen in FIG. 18, the screening contact plate 192 closely surrounds the cylindrical sleeve receptacle 132, which is formed by the plastic housing element 10.
[0098] Furthermore, as can particularly be taken from FIG. 18, the embodiment illustrated in FIGS. 17 and 18 has a connecting bolt 200 connected to ground. This connecting bolt 200 is, for example, held in the plastic housing element 10 by overmoulding. The screening contact plate 192 clipped to the plastic housing element 10 forms a bolt receptacle 202 made through punching and bending which abuts the connection bolt 200 for electrical conduction under elastic circumferential stress.
[0099] Complete screening of all current-carrying elements of the embodiment is produced. Furthermore, the heat sinks 32 are connected to ground through the screening contact plate 192, so that the reliable electrical insulation between the power switch 178 and the heat sink 32 can be checked by monitoring the ground potential obtained on the connecting bolt 200. Any defect in the electrical insulation can be detected and output to prevent the service personnel from receiving an electrical shock during service work on the electrical heating device due to inadequate electrical insulation.
Patent applications by Christian Morgen, Rulzheim DE
Patent applications by Michael Niederer, Kapellen-Drusweiler DE
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