Patent Description:
The assembly of such a conventional control unit usually requires a complex positioning of the electronics housing as well as the control electronics and the adapter (hereinafter collectively referred to as "components" of the control unit) relative to each other, which adversely affects the automation of such an assembly process. The fastening of the components of the control unit to each other or to the adapter is also complex for conventional control units.

It is therefore one of the problems the present invention faces - in particular to eliminate the aforementioned disadvantages - to show new ways for an electrical adapter for connecting a control unit of a heating device to an electrical energy source and to an electrical signal source.

This problem is solved by an electrical adapter according to the independent patent claim <NUM>. Preferred embodiments are subject of the dependent patent claims.

The basic idea of the invention is therefore to provide an electrical adapter for electrically connecting a control device of an electrical heating device to an electrical energy source and to an electrical signal source with a support on which, on the one hand, electrical lines having electrical connections and electrical interfaces for electrically connecting control electronics of the control device to the electrical signal source and to the electrical energy source are present. On the other hand, the support, which is in accordance with the invention, comprises an aperture for forming a screw connection which the adapter can be connected to an electronics housing of the control unit with, and a positioning aid for positioning the adapter relative to the control electronics and/or to the electronics housing.

The electrical adapter according to the invention not only allows a reliable electrical connection of the control electronics of a control unit of an electrical heating device with an electrical signal source and with an electrical energy source, but also a particularly easy-to-implement positioning of the components of the control unit relative to each other and a positionally accurate attachment of said components to each other. This advantageously reduces the assembly work involved in assembling the control unit and improves the automation of a corresponding assembly process.

An electrical adapter for electrically connecting a control unit of an electrical heating device to an electrical energy source and to an electrical signal source, according to the invention, comprises a support made of an electrically insulating plastic material. In addition, the electrical adapter comprises at least one electrical supply line for electrical energy transmission, wherein this supply line is embedded in the plastic material of the support or is at least arranged in or on the plastic material. The supply line merges at one end into an electrical supply connection for electrical and mechanical connection to the electrical energy source and at the other end into a supply interface for electrical - and preferably also mechanical - connection of a control electronics of the control unit. Furthermore, the electrical adapter has at least one electrical signal line for electrical signal transmission, this signal line being embedded in the plastic material of the support or at least arranged in or on the plastic material. The signal line merges at one end into an electrical signal connection for electrical - and preferably also mechanical - connection to the electrical signal source and at the other end into a signal interface for electrical and mechanical connection of the control electronics. In the present context, "embedded" can mean in particular that the respective line is at least partially, preferably completely in at least one location, surrounded by the plastic material of the support for its fixation on or in the support. According to the invention, there is an aperture on the support to form a screw connection, which the adapter can be connected to an electronics housing of the control unit with. In accordance with the invention, the support also comprises at least one positioning aid for positioning the adapter relative to the control electronics and - alternatively or additionally - relative to the electronics housing, the positioning aid being arranged between the two interfaces and the aperture of the adapter. In this way, a particularly reliable electrical connection of the control electronics with the electrical signal source and with the electrical energy source via the adapter can advantageously be achieved, while at the same time a precise positioning of the components of the control unit relative to each other can be realized in a particularly simple manner when assembling the control unit. The adapter thus enables a particularly well automatable and fail-safe assembly process for assembling the control unit.

In accordance with a preferred embodiment of the adapter, the positioning aid is integrally formed on the support and has a protruding positioning pin which is designed to be received in a recess formed on the electronics housing. This recess of the electronics housing is preferably designed to complement the positioning pin. In this way, the desired reliable positioning of the components of the control unit relative to one another can be achieved in a particularly simple manner.

In case of another advantageous embodiment of the adapter, the positioning aid is designed to form a guide. When assembling the control unit, this guide guides the control electronics and - alternatively or additionally - the electronics housing relative to the adapter along a mounting direction. This results in an advantageous, particularly precise positioning of the components of the control unit relative to each other.

In the case of a further advantageous embodiment of the adapter, the aperture is located in a fixing lug which is integrally formed on the support. This makes it possible to achieve a particularly easy-to-implement and at the same time reliable fastening of the components of the control unit to each other.

In accordance with another preferred embodiment of the adapter, exactly one fixing lug with the aperture formed in it is provided. The components of the control unit can therefore be fastened to each other by means of a single screw connection, which is particularly advantageous from a cost and installation point of view, since only one fastening means is required and only one fastening operation needs to be carried out.

Another advantageous embodiment of the adapter is that the supply connection and the signal connection are arranged opposite each other along a main extension direction and the aperture with respect to the main extension direction is located between these two connections. Conveniently, the aperture is located essentially centrally between these two connections along the main extension direction. The screw force of the screw connection realized by means of the aperture can thus be distributed particularly well and evenly.

In accordance with another preferred embodiment of the adapter, the support has a substantially T-type geometry comprising a T-roof extending along the main extension direction and a T-base integrally formed on the T-roof. The T-base extends along a minor extension direction which is substantially perpendicular to the main extension direction. The T-base merges into the T-roof between the supply connection and the signal connection as to form the T-type geometry. The aperture is arranged in an extension of the T-base beyond the T-roof. This enables the worker to have particularly good access to the connections.

In the case of a further advantageous embodiment of the adapter, it is intended that the support comprises a first and a second support part. The first and the second support part each have an L-geometry comprising a first L-limb and a second L-limb, which are arranged at an angle to each other. Preferably, the L-limbs of the L-geometry are arranged essentially at a right angle to each other. The L-limbs of the L-geometry merge into each other in an apex section of the L-geometry. The signal connection is provided at a limb end remote from the apex of the first L-limb of the first support part and the supply connection is provided at the limb end remote from the apex of the first L-limb of the second support part. The signal interface is arranged at the limb end remote from the apex of the second L-limb of the first support part and the supply interface is provided at the limb end remote from the apex of the second L-limb of the second support part. The second L-limbs of the first and second support parts together form the T-base and the first L-limbs of the first and second support parts together form the T-roof of the T-type geometry of the support. The L-geometry of the first support part thus completes the L-geometry of the second support part to the T-type geometry of the support or vice versa. This allows the support parts to be preassembled as separate subassemblies or premanufactured and stocked, which allows a flexible assembly process.

In the case of a further advantageous embodiment of the adapter, the support parts have a tab on each of their apex sections facing away from their first legs. The tabs connect the support parts to each other in such a way that together they define the aperture of the support. Advantageously, only one fastener to form the support can be used, both to fasten the support parts together and to fasten the other components of the control unit to the support.

In accordance with a further preferred embodiment of the adapter, there is a connection collar protruding from the support, which encloses a receptacle of the supply connection to accommodate a supply plug of the power source complementary to the receptacle. This connection collar is suitably colored in a color which is exclusively reserved for the connection collar in the adapter. This color is preferably orange. This allows a particularly safe coupling of an electrical energy source with the supply connector.

In accordance with another advantageous embodiment of the adapter, the support and the connection collar are integrally molded together in a two-stage injection molding process, whereby the plastic material of the support is overmolded with a different collar plastic material of the connection collar or vice versa. It is thus advantageous that the support and the connection collar can be produced in only one injection mold, which proves to be cost-effective, especially in the case of high quantities, by exploiting economies of scale.

In case of a further preferred embodiment of the adapter, the support and the connection collar are designed as separate components. Thus, identically designed supports but different connection collars can be used for different adapters or vice versa.

A further advantageous embodiment of the adapter is that the connection collar comprises a collar housing made of a collar plastic material which surrounds a spring-loaded shielding insert of the connection collar for electrical shielding the supply connection. The shielding insert in turn surrounds a contact insert which forms the receptacle for the connection collar. The shielding insert can be connected mechanically and electrically to the electronics housing of the control unit for its electrical earthing, in particular by means of a clamp which holds the connection collar together mechanically. Advantageously, this allows for keeping interferences away from the control electronics, that can occur when connecting the electrical energy source to the supply connection and which can otherwise lead to the destruction of the control electronics in the worst case.

According to another advantageous embodiment of the adapter, the supply connection is located at a first partition wall of the support. The signal connection is arranged on a second partition wall of the support. The first and the second partition wall are arranged at a distance from each other or directly merging into each other. The first and - alternatively or additionally - the second partition wall have an at least partially circumferential groove in which a seal is or can be accommodated, which can be applied to the electronics housing of the control unit in a fluid-sealing manner. This permits particularly good protection of the adapter's interfaces and the control electronics of the control unit against environmental influences.

In case of another preferred further embodiment of the adapter, the signal line includes an electrical signal busbar or is an electrical signal busbar. Alternatively or additionally the supply line includes a supply busbar or is a supply busbar. Such busbars can be mounted particularly well in automated processes.

Further important features and advantages of the invention result from the subclaims, from the drawings and from the corresponding figure description based on the drawings.

It goes without saying that the features mentioned above and those to be explained below can be used not only in the combination indicated in each case, but also in other combinations or on their own, without leaving the scope of the present invention.

Preferred embodiments of the invention are shown in the drawings and are explained in more detail in the following description, whereby identical reference signs refer to identical or similar or functionally identical components.

<FIG> shows an example of a control unit <NUM> of an electric heating device in a perspective view. The electric heating device can be a high-voltage heating device. An electrical adapter <NUM> in accordance with the present invention - also illustrated as an example in <FIG> - is provided on the control unit <NUM>, which the control unit <NUM> can be connected with to an electrical energy source E and an electrical signal source, which both are not shown in <FIG>.

The example of the electrical adapter <NUM> of <FIG> is illustrated separately in <FIG>, also in a perspective view. Accordingly, the electrical adapter <NUM> comprises a support <NUM> made of an electrically insulating plastic material. In addition, the electrical adapter <NUM> comprises at least one electrical supply line <NUM> - in the example there are shown two electrical supply lines <NUM> - for electrical energy transmission. This supply line <NUM> is embedded in the plastic material of support <NUM>. At one end, the electrical supply line <NUM> merges into an electrical supply connection <NUM> for electrical, and in particular mechanical, connection to the energy source E not shown in <FIG>. At the other end, the supply line <NUM> merges into a supply interface <NUM> for electrical and mechanical connection of control electronics of the control unit <NUM>.

<FIG> further show that the electrical adapter <NUM> comprises at least one electrical signal line <NUM>, wherein three such electrical signal lines <NUM> are shown in <FIG>. An electrical signal can be transmitted via these electrical signal lines <NUM>. The signal lines <NUM> are embedded in the plastic material of support <NUM>. One end of the signal lines <NUM> merges into an electrical signal connection <NUM> for electrical, and in particular mechanical, connection to the electrical signal source not shown in <FIG>. At the other end, the electrical signal line <NUM> merges into a signal interface <NUM> for electrical and mechanical connection of the control electronics of control unit <NUM>.

There is an aperture <NUM> on the support <NUM> for forming a screw connection. Through this screw connection, the adapter <NUM> can be mechanically attached to an electronics housing <NUM> of control unit <NUM>. The fastening of the electronics housing <NUM> of the control unit <NUM> and the support <NUM> to each other can be realized in an interior of the electronics housing <NUM>, in which interior the control electronics of the control unit <NUM> is also located for its protection against environmental influences. The support <NUM> also comprises at least one positioning aid <NUM> which is arranged between the two interfaces <NUM>, <NUM> and the aperture <NUM> for positioning the adapter <NUM> relative to the control electronics and/or the electronics housing <NUM>.

<FIG> shows exactly one such positioning aid <NUM>. The positioning aid <NUM>, for example, is formed integrally, i.e. in one piece and with the same material, on the support <NUM> and has a projecting positioning pin <NUM>. This positioning pin <NUM> is designed to be accommodated in a recess formed in the electronics housing <NUM>. This recess provided on the electronics housing <NUM> can be designed to complement the positioning pin <NUM>. For example, the positioning aid <NUM> is designed in such a way that it forms a guide <NUM> which, when mounting the control unit <NUM>, guides the control electronics and/or the electronics housing <NUM> relative to the adapter <NUM> along a mounting direction <NUM>.

In the example of <FIG>, the aperture <NUM> of the support <NUM> is located in a fixing lug <NUM>, which is integrally formed in the support <NUM>. For example, exactly one fixing lug <NUM> is provided with an aperture <NUM> formed in it. The supply connection <NUM> and the signal connection <NUM> are arranged opposite each other along a main extension direction H of the support <NUM>. The aperture <NUM> is located between these two connections <NUM>, <NUM> with respect to the main extension direction H. In the example shown, the aperture <NUM> is arranged along the main extension direction H essentially centrally between the two connections <NUM>, <NUM>.

<FIG> also shows that the support <NUM> has an essentially T-type geometry <NUM>. This T-type geometry <NUM> comprises a T-roof <NUM> extending along the main extension direction H and a T-base <NUM> integrally formed on the T-roof <NUM>, the T-base <NUM> extending along a minor extension direction N, which is substantially perpendicular to the main extension direction H. To form the T-type geometry <NUM>, the T-base <NUM> merges into the T-roof <NUM> between the supply connection <NUM> and the signal connection <NUM>, preferably centrally or at least substantially centrally. The aperture <NUM> is arranged in a prolongation of the T-base <NUM> beyond the T-roof <NUM>, so that the fixing lug <NUM> can form an extension of the T-base <NUM> beyond the T-roof <NUM>.

<FIG> shows another example of an adapter <NUM> according to the invention in a top view along the mounting direction <NUM>. Accordingly, the support <NUM> comprises a first and a second support part <NUM>, <NUM>. The first and the second support part <NUM>, <NUM> each have an L-geometry <NUM> with a first and with a second L-leg <NUM>, <NUM> arranged at an angle to one another. In the example shown, the L-limbs <NUM>, <NUM> of the L-geometry <NUM> of each of the first and the second support part <NUM>, <NUM> are arranged essentially at a right angle to one another. The L-limbs <NUM>, <NUM> of the L-geometry <NUM> merge into each other in an apex section <NUM> of the L-geometry <NUM>. The signal connection <NUM> is arranged at a limb end <NUM> of the first L-limb <NUM> of the first support part <NUM>, which limb end <NUM> is remote from the apex. The supply connection <NUM> is located at the limb end <NUM> remote from the apex of the first L-limb <NUM><NUM> of the second support part <NUM>. The signal interface <NUM> is located at the limb end <NUM> remote from the apex of the second L-limb <NUM> of the first support part <NUM>. The supply interface <NUM> is located at the limb end <NUM> remote from the apex of the second L-limb <NUM> of the second support part <NUM>. The second L-limbs <NUM> of the first of and the second support part <NUM>, <NUM> together form the T-base <NUM> of the T-type geometry <NUM> of the support <NUM>. The first L-limbs <NUM> of the first and the second support part <NUM>, <NUM> together form the T-roof <NUM> of the T-type geometry <NUM> of the support <NUM>. The L-geometry <NUM> of the first support part <NUM> thus completes the L-geometry <NUM> of the second support part <NUM> to the T-type geometry <NUM> of support <NUM> or vice versa.

<FIG> illustrates a partial section of the example of <FIG>, when cut along a section line A-A drawn in <FIG>. It can be seen from <FIG> that the support parts <NUM>, <NUM> have a tab <NUM> on each of their apex sections <NUM>, facing away from their first limbs <NUM>. The tabs <NUM> connect the support parts <NUM>, <NUM> to each other and together define the aperture <NUM> of the support <NUM>.

As shown in <FIG> and <FIG>, a connection collar <NUM> is provided projecting from the support <NUM> and surrounding a receptacle <NUM> of the supply connection <NUM>. This receptacle <NUM> is used to accommodate a supply plug <NUM> of the power source E, which is complementary to the receptacle <NUM> and which is not illustrated in <FIG> and <FIG>. The Connection collar <NUM> is colored in a color which is reserved exclusively for connection collar <NUM> in the adapter <NUM>. This color of the connection collar <NUM> can be orange. The support <NUM> and the connection collar <NUM>, for example, are manufactured integrally to each other using a two-stage injection molding process. The plastic material of support <NUM> can be overmolded with a different collar plastic material of the connection collar <NUM> or vice versa.

<FIG> shows a further example of the adapter according to the invention in a perspective view. In contrast to the examples of <FIG> and <FIG> described above, the support <NUM> and the connecting collar <NUM> are designed as separate components according to <FIG>.

<FIG> illustrates the example of <FIG> in a perspective exploded view. As to be seen in <FIG>, the connection collar <NUM> comprises a collar housing <NUM> made of a collar plastic material. The collar housing <NUM> partially surrounds a shielding insert <NUM> of the connection collar <NUM> to electrically shield the supply connection <NUM>. The shielding insert <NUM> is spring preloaded by a spring element <NUM>. The shielding insert <NUM> surrounds a contact insert <NUM>, which forms the receptacle <NUM> of the connection collar <NUM>. For its electrical earthing the shielding insert <NUM> can be connected mechanically and electrically to the electronics housing <NUM> of the control unit <NUM>. According to the example shown, the electrical earthing can be realized by a clamp <NUM> which mechanically holds the connection collar <NUM> together.

As shown in <FIG>, on the one hand, supply port <NUM> of adapter <NUM> is located on a first partition wall <NUM> of support <NUM>. On the other hand, signal connection <NUM> is located on a second partition wall <NUM> of support <NUM>. The first and second partition walls <NUM>, <NUM> are, for example, arranged at a distance from each other.

<FIG> shows in a top view along the mounting direction <NUM> a further example of the adapter <NUM> according to the invention, in which - in contrast to the examples of <FIG> described above - the first and the second partitions <NUM>, <NUM> are arranged next to each other in a touching manner or merge into each other.

Claim 1:
An electrical adapter (<NUM>) for electrically connecting a control unit (<NUM>) of a heating device for a motor vehicle to an electrical energy source (E) and to an electrical signal source.
- having a support (<NUM>) made of an electrically insulating plastic material,
- having at least one electrical supply line (<NUM>) for electrical energy transmission, wherein this supply line (<NUM>) is embedded in the plastic material of the support (<NUM>) and merges at one end into an electrical supply connection (<NUM>) for electrical connection to the electrical energy source (E) and at the other end into a supply interface (<NUM>) for electrical and mechanical connection of control electronics of the control unit (<NUM>),
- having at least one electrical signal line (<NUM>) for electrical signal transmission, this signal line (<NUM>) being embedded in the plastic material of the support (<NUM>) and merges at one end into an electrical signal connection (<NUM>) for electrical connection to the electrical signal source and the other end into a signal interface (<NUM>) for electrical and mechanical connection of the control electronics,
characterized in that
- an aperture (<NUM>) is provided on the support (<NUM>) for forming a screw connection, which the adapter (<NUM>) can be connected to an electronics housing (<NUM>) of the control unit (<NUM>) with,
- the support (<NUM>) comprises at least one positioning aid (<NUM>) arranged between the two interfaces (<NUM>, <NUM>) and the aperture (<NUM>) for positioning the adapter (<NUM>) relative to the control electronics and/or the electronics housing (<NUM>),
the aperture (<NUM>) is arranged in a fixing lug (<NUM>) which is integrally formed in the support (<NUM>).
- exactly one fixing lug (<NUM>) with an aperture (<NUM>) formed therein is provided.