CN113411924A - 电加热装置及制造该电加热装置的方法 - Google Patents

电加热装置及制造该电加热装置的方法 Download PDF

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CN113411924A
CN113411924A CN202110278233.8A CN202110278233A CN113411924A CN 113411924 A CN113411924 A CN 113411924A CN 202110278233 A CN202110278233 A CN 202110278233A CN 113411924 A CN113411924 A CN 113411924A
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ptc element
housing
heating device
electric heating
strip conductor
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佛罗莱恩·比托-戈伦
伊夫·克努泊夫
安德里亚斯·库姆派尔
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Helmsdorf Eberkaten Co ltd
Eberspaecher Catem Hermsdorf GmbH and Co KG
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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
    • H05B3/24—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor being self-supporting
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/40—Heating elements having the shape of rods or tubes
    • H05B3/42—Heating elements having the shape of rods or tubes non-flexible
    • H05B3/48—Heating elements having the shape of rods or tubes non-flexible heating conductor embedded in insulating material
    • H05B3/50—Heating elements having the shape of rods or tubes non-flexible heating conductor embedded in insulating material heating conductor arranged in metal tubes, the radiating surface having heat-conducting fins
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H3/00—Air heaters
    • F24H3/02—Air heaters with forced circulation
    • F24H3/04—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element
    • F24H3/0405—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element using electric energy supply, e.g. the heating medium being a resistive element; Heating by direct contact, i.e. with resistive elements, electrodes and fins being bonded together without additional element in-between
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H3/00—Air heaters
    • F24H3/02—Air heaters with forced circulation
    • F24H3/04—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element
    • F24H3/0405—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element using electric energy supply, e.g. the heating medium being a resistive element; Heating by direct contact, i.e. with resistive elements, electrodes and fins being bonded together without additional element in-between
    • F24H3/0429—For vehicles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H3/00—Air heaters
    • F24H3/02—Air heaters with forced circulation
    • F24H3/04—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element
    • F24H3/0405—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element using electric energy supply, e.g. the heating medium being a resistive element; Heating by direct contact, i.e. with resistive elements, electrodes and fins being bonded together without additional element in-between
    • F24H3/0429—For vehicles
    • F24H3/0435—Structures comprising heat spreading elements in the form of fins
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H3/00—Air heaters
    • F24H3/02—Air heaters with forced circulation
    • F24H3/04—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element
    • F24H3/0405—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element using electric energy supply, e.g. the heating medium being a resistive element; Heating by direct contact, i.e. with resistive elements, electrodes and fins being bonded together without additional element in-between
    • F24H3/0429—For vehicles
    • F24H3/0441—Interfaces between the electrodes of a resistive heating element and the power supply means
    • F24H3/0447—Forms of the electrode terminals, e.g. tongues or clips
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H3/00—Air heaters
    • F24H3/02—Air heaters with forced circulation
    • F24H3/04—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element
    • F24H3/0405—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element using electric energy supply, e.g. the heating medium being a resistive element; Heating by direct contact, i.e. with resistive elements, electrodes and fins being bonded together without additional element in-between
    • F24H3/0429—For vehicles
    • F24H3/0452—Frame constructions
    • F24H3/0464—Two-piece frames, e.g. two-shell frames, also including frames as a central body with two covers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H3/00—Air heaters
    • F24H3/02—Air heaters with forced circulation
    • F24H3/04—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element
    • F24H3/0405—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element using electric energy supply, e.g. the heating medium being a resistive element; Heating by direct contact, i.e. with resistive elements, electrodes and fins being bonded together without additional element in-between
    • F24H3/0429—For vehicles
    • F24H3/0452—Frame constructions
    • F24H3/0476—Means for putting the electric heaters in the frame under strain, e.g. with springs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H3/00—Air heaters
    • F24H3/02—Air heaters with forced circulation
    • F24H3/06—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators
    • F24H3/08—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators by tubes
    • F24H3/081—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators by tubes using electric energy supply
    • F24H3/082—The tubes being an electrical isolator containing the heater
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H9/00—Details
    • F24H9/18—Arrangement or mounting of grates or heating means
    • F24H9/1854—Arrangement or mounting of grates or heating means for air heaters
    • F24H9/1863—Arrangement or mounting of electric heating means
    • F24H9/1872—PTC
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/02—Heaters using heating elements having a positive temperature coefficient
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/022—Heaters specially adapted for heating gaseous material
    • H05B2203/023—Heaters of the type used for electrically heating the air blown in a vehicle compartment by the vehicle heating system

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Abstract

本发明涉及一种电加热装置及制造该电加热装置的方法，该电加热装置具有外壳，该外壳包围PTC元件和电连接到PTC元件以用于以不同的极性向PTC元件通电的条状导体。为了提供易于制造并且具有良好效率的电加热装置，本发明提出由聚合物陶瓷一体地模制外壳。

Description

电加热装置及制造该电加热装置的方法
技术领域
本发明涉及一种电加热装置，该电加热装置具有外壳，该外壳包围PTC元件和电连接到PTC元件以用于以不同的极性向PTC元件通电的条状导体。
背景技术
例如从EP 1 768 459 B1中已知一种通用的电加热装置。在该现有技术中，PTC元件位于由绝缘材料制成的位置框架中，该位置框架周向地围绕PTC元件并且保持PTC元件的相反的主侧表面是自由的。在这些主侧表面上，接触片材作为条状导体抵靠，从而形成整体模制在条状导体上的接触凸耳，这些接触凸耳用于电加热装置的电连接。绝缘层被施加到条状导体的与PTC元件相对的外表面。这些绝缘层在插入弹性粘合剂的情况下抵靠在接触片材上。弹性粘合剂被粘结到位置框架上。结果，PTC元件被多部件式外壳包围，使得待加热的介质、或者在空气的情况下由介质携带的任何污染物或水分都无法到达PTC元件和向PTC元件通电的条状导体。
在根据前述现有技术的可替代解决方案中，绝缘层以前述方式抵靠在位置框架上。在位置框架的包覆成型期间，设置在相对侧上的绝缘层已经被粘结到位置框架上。
在先前提到的现有技术中，绝缘层由具有相对良好的导热性的塑料膜和陶瓷层组成。陶瓷层也具有相对良好的导热性。因此，由PTC元件产生的热实际上是通过两层式绝缘层来传导的。然而，由于绝缘层本身具有相对良好的导热性，因此这导致由PTC元件产生的热的相对良好的吸收。因此，电加热装置的效率相对较高，这特别由于由绝缘的塑料材料制成的位置框架仅围绕PTC元件的端侧面，这将长方体形的PTC元件限制为窄边缘的并且与主侧表面相比具有相对较小的表面区域。
然而，因为必须将各种部件接合在一起，所以根据上述现有技术的电加热装置在设计上是相对复杂的。
由US 6,178,292 B1已知一种相对容易制造的根据权利要求1的通用特征的可替代的且更容易制造的电加热装置。在该现有技术中，绝缘塑料化合物完全包围条状导体和PTC元件。仅接触凸耳突出超过由塑料材料形成的外壳。
但是，如果塑料材料在实际的加热单元周围形成有一定的厚度，则上述解决方案只能确保PTC元件和与PTC元件电连接的条状导体的牢固封闭。由于塑料的导热性相对较差，PTC元件产生的热仅抵抗一定的热阻散发到电加热装置的由塑料形成的外部。
在根据EP 2 296 432 A1的现有技术中，外壳由矩形塑料管形成，在该塑料管中插入设置在位置框架中的多个PTC元件以及在两侧上抵靠在主侧面上的接触表面。与US 6,178,292 B1相比，该电加热装置的制造是相对复杂的。该塑料框架具有与根据US 6,178,292 B1的塑料材料相同的缺点。
发明内容
本发明旨在提供一种易于制造且具有良好效率的电加热装置。
为了解决该问题，本发明提出将外壳形成为由聚合物陶瓷模制的一件式外壳。
外壳被一体地形成。聚合物陶瓷围绕由PTC元件和两个条状导体组成的加热单元形成。外壳通常通过模制生产。因此，可以通过将加热单元浸入到包含聚合物陶瓷的熔池中来形成外壳。替代地，外壳也可以通过注塑成型来制造。在这种情况下，通常将PTC元件和条状导体插入注塑模具的模具型腔中。关闭注塑模具，并用聚合物陶瓷填充注塑模具。如果聚合物陶瓷是热塑性材料，则可以在模具型腔中固化聚合物陶瓷。然而，作为塑料组分，聚合物陶瓷也可以具有交联塑料，该交联塑料在注塑模具或其它模具中交联并凝固或硬化。作为塑料组分，聚合物陶瓷可以具有任何固化的或凝固的塑料。考虑到电加热装置在工作期间被加热，这会导致热塑性塑料熔化或至少迅速老化，因此具有陶瓷填充物部分的热固性塑料是优选的。
根据本发明的电加热装置例如适合用于机动车辆中，特别是用作加热被引入到车辆内部的空气的发热单元或在车辆中循环的液体温度控制介质、或用于加热单个单元，例如电池、燃料电池等。由于聚合物陶瓷的非常良好的绝缘性能，根据本发明的电加热装置也可以用在通过较高电压工作的电动车辆中，其中该工作电压也可以用于加热PTC元件并因此被引入到电加热装置中。
然而，可以在不显著降低加热装置的效率的情况下，聚合物陶瓷可以形成有围绕加热单元的足够的层厚度。这是因为聚合物陶瓷的良好导热性确保PTC元件产生的热的良好吸收。
围绕加热单元形成聚合物陶瓷外壳的均匀层产生提高的电气安全性。长方体形的PTC元件通常在八个侧面中的七个侧面上涂覆或围绕有聚合物陶瓷。外壳仅可以在侧表面中的一个侧表面上被接触凸耳突出超过并且因此PTC元件优选地可以在一侧被接触凸耳突出超过，该接触凸耳导电地连接到条状导体上。这些接触凸耳用于电加热装置与电源的电连接。接触凸耳通常形成为插接连接的凸出式插接接触件。PTC元件通常被聚合物陶瓷完全包围。
从上述现有技术中以本身已知的方式，条状导体和接触凸耳优选地分别由接触片材单独形成。在根据本发明的流程中，接触片材中的每一个优选地连接至PTC元件。以这种方式产生一个组件，该组件由加热单元本身形成并且被成形为一个单元。接触片材和PTC元件可以通过导电粘合剂等接合在一起。也可以将接触片材焊接到PTC元件上或通过其它方式连接它们。
导电粘合剂可以被添加导电颗粒，使得确保在接触片材和PTC元件之间具有良好的导电性。PTC元件通常在相反的主侧表面上具有金属化部，接触片材导电地结合到该金属化部上。这种金属化部可以具有一定的粗糙部，该粗糙部也可以穿透不导电的粘合剂，并因此确保接触片材和PTC元件之间的充分接触。
在优选的方法中，将以这种方式形成的组件插入到模具型腔中。突出超过PTC元件的接触凸耳用于在模制外壳的过程中将组件固定在适当的位置处。因此，当仍然能够流动的聚合物陶瓷被插入到模具型腔中时，接触凸耳与模具型腔分离，并且不会被聚合物陶瓷润湿。如果外壳是在浸没熔池中生产的，则在接触凸耳突出到浸没熔池上方的情况下，将组件引入到浸没熔池中。这也确保在模制外壳之后，接触片材能够立即用于PTC元件的电接触。
附图说明
根据结合附图对实施例的所附描述，本发明的其它细节和优点将变得显而易见，在附图中：
图1是本发明的一个实施例的透视侧视图；以及
图2是沿根据图1的II-II线的剖视图。
具体实施方式
在附图中，附图标记2表示电加热装置。电加热装置2具有包围PTC元件6和条状导体8的外壳4。条状导体8电连接至PTC元件6，以用于以不同的极性向PTC元件通电。外壳2是由聚合物陶瓷形成的一件式外壳。
通过热固注塑模制工艺来围绕PTC元件6和条状导体8模制所述聚合物陶瓷。因此，PTC元件6和条状导体8被完全密封在聚合物陶瓷内。仅接触凸耳10突出超过外壳4，该接触凸耳由限定条状导体8的片状的金属件的自由端形成。
该实施例的聚合物陶瓷是无机-有机复合物，该无机-有机复合物由陶瓷填料组成，陶瓷填料例如是Al2O3和有机硅聚合物基质-主要是聚硅氧烷。聚合物陶瓷对外壳的形成基于功能化树脂的化学交联，该功能化树脂可以通过热后处理进一步转化为陶瓷状结构。聚合物陶瓷具有较高的热稳定性以及较低的收缩率、较高的尺寸稳定性和尺寸稳定性。相关的服务特性(例如，电导率、热导率、介电特性)和工艺参数可以通过选择合适的功能性填充剂和粘合剂系统来适应机动车辆内的加热器的特定应用，在该应用中将采用有创造性的电加热装置。聚合物陶瓷材料的使用允许材料的成本低廉、材料的简单的处理并提供外壳4的较高的热稳定性。

Claims (7)

1.一种电加热装置，所述电加热装置包括外壳，所述外壳包围PTC元件和电连接到所述PTC元件以用于以不同的极性向所述PTC元件通电的条状导体，
其特征在于，
所述外壳是由聚合物陶瓷形成的一件式外壳。
2.根据权利要求1所述的电加热装置，其特征在于，所述外壳在一侧被接触凸耳突出超过，所述接触凸耳被导电地连接到所述条状导体。
3.根据权利要求2所述的电加热装置，其特征在于，形成所述条状导体和所述接触凸耳的接触片材。
4.一种制造电加热装置的方法，所述电加热装置具有外壳，所述外壳包围PTC元件和电连接到所述PTC元件以用于以不同的极性向所述PTC元件通电的条状导体，其中PTC元件和所述条状导体被插入到模具型腔中并被聚合物陶瓷围绕，所述聚合物陶瓷固化以形成所述外壳。
5.根据权利要求4所述的方法，其特征在于，所述PTC元件连接至形成接触凸耳和所述条状导体的接触片材，并且由此产生的组件在所述外壳的模制期间通过突出超过所述PTC元件的接触凸耳被保持。
6.根据权利要求4所述的方法，其特征在于，所述外壳被注塑成型。
7.根据权利要求5所述的方法，其特征在于，所述外壳被注塑成型。
CN202110278233.8A 2020-03-17 2021-03-15 电加热装置及制造该电加热装置的方法 Pending CN113411924A (zh)

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