EP1528838A2 - Electrical heater element - Google Patents

Electrical heater element Download PDF

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Publication number
EP1528838A2
EP1528838A2 EP04256795A EP04256795A EP1528838A2 EP 1528838 A2 EP1528838 A2 EP 1528838A2 EP 04256795 A EP04256795 A EP 04256795A EP 04256795 A EP04256795 A EP 04256795A EP 1528838 A2 EP1528838 A2 EP 1528838A2
Authority
EP
European Patent Office
Prior art keywords
electrical contact
heater element
ptc
electrical
contact
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP04256795A
Other languages
German (de)
French (fr)
Other versions
EP1528838B1 (en
EP1528838A3 (en
Inventor
Bertrand Dupont
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Delphi Technologies Inc
Original Assignee
Delphi Technologies Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Delphi Technologies Inc filed Critical Delphi Technologies Inc
Publication of EP1528838A2 publication Critical patent/EP1528838A2/en
Publication of EP1528838A3 publication Critical patent/EP1528838A3/en
Application granted granted Critical
Publication of EP1528838B1 publication Critical patent/EP1528838B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C1/00—Details
    • H01C1/02—Housing; Enclosing; Embedding; Filling the housing or enclosure
    • H01C1/022—Housing; Enclosing; Embedding; Filling the housing or enclosure the housing or enclosure being openable or separable from the resistive element
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C1/00—Details
    • H01C1/14—Terminals or tapping points or electrodes specially adapted for resistors; Arrangements of terminals or tapping points or electrodes on resistors
    • H01C1/1406—Terminals or electrodes formed on resistive elements having 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
    • H05B3/00—Ohmic-resistance heating
    • H05B3/10—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
    • H05B3/12—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material
    • H05B3/14—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material the material being non-metallic
    • 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
    • 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

Definitions

  • the present invention relates to an electrical heater element based on PTC (positive temperature co-efficient) components.
  • the invention also relates to a method of assembling such a heater element.
  • An electrical heater based on PTC components is made in such a way that a pressure is applied on both faces of the PTC component to ensure a good electrical contact and a good thermal contact.
  • Some such heaters elements have a design where the PTC component is enclosed in a tube with insulation devices and it requires a very accurate press-fit process.
  • the good point of this latter assembly is that the tube is grounded and does provide insulation protection regarding, for example, a heating ventilating and air-conditioning (HVAC) module in a motor vehicle.
  • HVAC heating ventilating and air-conditioning
  • the draw back is that fitting the various components together can be difficult and can result in poor alignment of the PTC elements within the tube which may comprise thermal and electrical contact.
  • the fins that transmit the heat to the air are stacked up and require a complex assembly process.
  • the aim of the present invention is to overcome one or more of the above disadvantages.
  • the invention provides an electrical heater as defined in claim 1.
  • An advantage of such a heater element is that it comprises a minimal number of pieces whilst still providing good retention, good electrical contact between the or each PTC component and the first and second electrical contact members, and good thermal contact.
  • a further advantage of a minimal number of pieces is simplicity of assembly.
  • the electrical contact plates may be adapted to be urged into contact with the or each PTC component.
  • the plates may be generally curved in the direction of the or each PTC component or shaped in a way such that they have an increased tendency to oppose a force that would act to reduce the retention and the electrical contact of the or each PTC component.
  • the second electrical contact member may comprise locking means for locking the electrical contact plates together.
  • the or each frame member may be adapted to position the or each PTC component by having apertures in which the or each PTC component may be received.
  • the invention also provides a method of assembling an electrical heater element as defined by claim 2.
  • a heater element according to the invention is particularly well suited to use in an HVAC module of a motor vehicle.
  • a first embodiment of an electrical heater element 1 comprises a first electrical contact member in the form of a battery contact strip 2, first and second frame members 4, 6, one on either of the opposing major sides 13, 15 of the battery contact strip 2, PTC elements 8 (only one of which is identifiable in figure 1), and a second electrical contact member in the form of a grounded casing member 10.
  • the contact strip 2 may comprise any suitable electrically conductive material, such as brass with tin-silver coating.
  • the first and second frame members 4,6 may comprise any suitable electrically insulating material, for instance plastic materials, such as PBT GF30.
  • the casing member 10 may comprise any suitable electrically conductive material such as aluminium.
  • the contact strip 2 is elongated in the sense that it extends along an axis perpendicular to the plane of figure 1 (as shown in figure 2).
  • the first and second frame members 4, 6 similarly extend, and are so adapted, in this case with mating features 12, 14, so as to "click-fit” together around the contact strip 2.
  • one purpose of the frame members 4, 6 is to space the casing member 10 from the contact strip 2.
  • each of the frame members 4, 6 is provided along its length with a series of apertures 16, 18; that is elongate rectangular openings extending from a side of the respective frame member 4, 6 adjacent the battery contact strip 2 to a side 24 26 opposite (the contact strip 2).
  • Each of the apertures 16, 18 is sized to receive a PTC component 8 (in figure 1, only one of the left-hand apertures 16 is shown with a PTC element 8 slotted therein).
  • PTC components 8 are slightly deeper than the apertures 16 so as to stand proud at A for the purpose of ensuring good electrical contact between the PTC components and the casing member 10.
  • the casing member 10 which is shown in figure 1 during the process of assembling the heater element 1, is generally o-shaped in the assembled element 1, but is so adapted, in this case by being made of flexible, resilient material, as to enable the casing member 10 to be manipulated between an "open" o-shape and a "closed” o-shape positions.
  • the casing member 10 has top arms 28, 30 that are adapted to overlap in the assembled heater element and are provided with a series of mating features 32, 34, in this case notches 32 and protrusions 34, for the purpose of locking the casing member 10 in the "closed" o-shape.
  • An electrical contact plate is provided by each of the major sides 36, 38 of the casing member 10.
  • the contact strip 2 with the click fitted frame members 4, 6 therearound and the PTC components received in the frame members 4, 6, may be slidably received or inserted between the contact plates 36, 38.
  • the contact strips 36, 38 are in effect locked together, the contact strip 2, the frame members 4, 6 and the PTC components 8 are retained between the contact plates 36, 38.
  • This tendency to curve has the effect of urging the sides 36, 38 into contact with the respective PTC components 8 thereby to apply a transverse force on the PTC components 8 (in effect they are squeezed between the contact plates 36, 38) so as to retain them and prevent them from moving transversely, and so as to promote a good electrical contact with a contact strip 2 and the casing member 10, and good thermal contact.
  • the contact plates 36, 38 have an increased tendency to oppose a force that would act to reduce the retention, electrical contact, of the PTC components 8.
  • a second embodiment of a heater element 1 differs from the first embodiment in that there are two second electrical contact members 10, 10' and each of the members 10, 10' has a side 36, 38 providing a contact plate.
  • the battery contact strip 2 with the frame member 4 thereon is first placed on a fixture (not shown) that is equipped to crimp the corresponding casing member 10.
  • the PTC components 8 are then positioned, followed by the second casing member 10.
  • the first casing member 10 is crimped, controlling the pressure of the displacement to ensure a good electrical contact between the PTC components 8 respectively with the battery contact strip 2 and the first casing member 10.
  • the sub assembly is turned (actually rotated) through 180° and the same operation is repeated. This assembly process has the advantage of ensuring that each piece is well assembled and not forbidden.

Landscapes

  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Resistance Heating (AREA)
  • Cookers (AREA)

Abstract

An electrical heater element (1) comprises, a first electrical contact member (2) having opposed sides, at least one second electrical contact member (10, 10') providing at least two electrical contact plates (36,38), and at least one first frame member (4) on one with side of the first electrical contact member (2) and at least one second frame member (6) on the opposing side of the first electrical contact member (2). Each of the or each first and second frame members (4,6) is adapted to position at least one PTC component (8). At least one PTC component (8) is positioned by the or each frame member (4,6). The first electrical contact member (2), the or each first and second frame members (4,6) and the or each PTC components (8) are retained between the at least two electrical contact plates (36, 38).

Description

The present invention relates to an electrical heater element based on PTC (positive temperature co-efficient) components. The invention also relates to a method of assembling such a heater element.
An electrical heater based on PTC components is made in such a way that a pressure is applied on both faces of the PTC component to ensure a good electrical contact and a good thermal contact. Some such heaters elements have a design where the PTC component is enclosed in a tube with insulation devices and it requires a very accurate press-fit process. The good point of this latter assembly is that the tube is grounded and does provide insulation protection regarding, for example, a heating ventilating and air-conditioning (HVAC) module in a motor vehicle. Nevertheless, the draw back is that fitting the various components together can be difficult and can result in poor alignment of the PTC elements within the tube which may comprise thermal and electrical contact. In addition, the fins that transmit the heat to the air are stacked up and require a complex assembly process.
The aim of the present invention is to overcome one or more of the above disadvantages.
The invention provides an electrical heater as defined in claim 1.
An advantage of such a heater element is that it comprises a minimal number of pieces whilst still providing good retention, good electrical contact between the or each PTC component and the first and second electrical contact members, and good thermal contact. A further advantage of a minimal number of pieces is simplicity of assembly.
The electrical contact plates may be adapted to be urged into contact with the or each PTC component. For instance, the plates may be generally curved in the direction of the or each PTC component or shaped in a way such that they have an increased tendency to oppose a force that would act to reduce the retention and the electrical contact of the or each PTC component.
The second electrical contact member may comprise locking means for locking the electrical contact plates together.
The or each frame member may be adapted to position the or each PTC component by having apertures in which the or each PTC component may be received.
The invention also provides a method of assembling an electrical heater element as defined by claim 2.
A heater element according to the invention is particularly well suited to use in an HVAC module of a motor vehicle.
The invention will now be described, by way of example, with reference to the following drawings in which:
  • Figure 1 is a cross-sectional side view of a first embodiment of a heater element according to the invention, in the process of assembly;
  • Figure 2 is a perspective view of the grounded casing member shown in Figure 1, in the "broken" O-shaped position;
  • Figure 3 is an exploded perspective view of a second embodiment of a heater element according to the invention;
  • Figure 4 is an exploded perspective view of the embodiment shown in figure 3, partly assembled; and
  • Figure 5 is a perspective view of the embodiment shown in figures 3 and 4, fully assembled.
    • With reference to figures 1 and 2, a first embodiment of an electrical heater element 1 according to the invention comprises a first electrical contact member in the form of a battery contact strip 2, first and second frame members 4, 6, one on either of the opposing major sides 13, 15 of the battery contact strip 2, PTC elements 8 (only one of which is identifiable in figure 1), and a second electrical contact member in the form of a grounded casing member 10.
    The contact strip 2 may comprise any suitable electrically conductive material, such as brass with tin-silver coating. The first and second frame members 4,6 may comprise any suitable electrically insulating material, for instance plastic materials, such as PBT GF30. The casing member 10 may comprise any suitable electrically conductive material such as aluminium.
    The contact strip 2 is elongated in the sense that it extends along an axis perpendicular to the plane of figure 1 (as shown in figure 2). The first and second frame members 4, 6 similarly extend, and are so adapted, in this case with mating features 12, 14, so as to "click-fit" together around the contact strip 2. In the assembled electrical heater element 1, one purpose of the frame members 4, 6 is to space the casing member 10 from the contact strip 2. Also, each of the frame members 4, 6 is provided along its length with a series of apertures 16, 18; that is elongate rectangular openings extending from a side of the respective frame member 4, 6 adjacent the battery contact strip 2 to a side 24 26 opposite (the contact strip 2). Each of the apertures 16, 18 is sized to receive a PTC component 8 (in figure 1, only one of the left-hand apertures 16 is shown with a PTC element 8 slotted therein). PTC components 8 are slightly deeper than the apertures 16 so as to stand proud at A for the purpose of ensuring good electrical contact between the PTC components and the casing member 10.
    The casing member 10, which is shown in figure 1 during the process of assembling the heater element 1, is generally o-shaped in the assembled element 1, but is so adapted, in this case by being made of flexible, resilient material, as to enable the casing member 10 to be manipulated between an "open" o-shape and a "closed" o-shape positions. The casing member 10 has top arms 28, 30 that are adapted to overlap in the assembled heater element and are provided with a series of mating features 32, 34, in this case notches 32 and protrusions 34, for the purpose of locking the casing member 10 in the "closed" o-shape.
    An electrical contact plate is provided by each of the major sides 36, 38 of the casing member 10. In the "open" o-shape of the casing member 10, the contact strip 2 with the click fitted frame members 4, 6 therearound and the PTC components received in the frame members 4, 6, may be slidably received or inserted between the contact plates 36, 38. In the "closed" o-shape of the casing member 10, wherein the contact plates 36, 38 are in effect locked together, the contact strip 2, the frame members 4, 6 and the PTC components 8 are retained between the contact plates 36, 38.
    The contact plates 36, 38, in the assembled heater elements 1, tend to curve inwards, that is to say, away from the viewer, towards the PTC components 8 when looking side on at the contact plates 36, 38. This tendency to curve has the effect of urging the sides 36, 38 into contact with the respective PTC components 8 thereby to apply a transverse force on the PTC components 8 (in effect they are squeezed between the contact plates 36, 38) so as to retain them and prevent them from moving transversely, and so as to promote a good electrical contact with a contact strip 2 and the casing member 10, and good thermal contact. In other words, by being curved, the contact plates 36, 38 have an increased tendency to oppose a force that would act to reduce the retention, electrical contact, of the PTC components 8.
    With reference to figures 3, 4 and 5, a second embodiment of a heater element 1 according to the invention differs from the first embodiment in that there are two second electrical contact members 10, 10' and each of the members 10, 10' has a side 36, 38 providing a contact plate. The remaining parts of the same of those shown with reference to figure 1 and 2, and have been similarly numbered (although frame member 6 is hidden from view by the contact strip 2).
    In respect of assembly, the battery contact strip 2 with the frame member 4 thereon is first placed on a fixture (not shown) that is equipped to crimp the corresponding casing member 10. The PTC components 8 are then positioned, followed by the second casing member 10. Next, the first casing member 10 is crimped, controlling the pressure of the displacement to ensure a good electrical contact between the PTC components 8 respectively with the battery contact strip 2 and the first casing member 10. The sub assembly is turned (actually rotated) through 180° and the same operation is repeated. This assembly process has the advantage of ensuring that each piece is well assembled and not forbidden.

    Claims (3)

    1. An electrical heater element (1) comprising:
      a first electrical contact member (2) having opposed sides;
      at least one second electrical contact member (10, 10') providing at least two electrical contact plates (36,38);
      at least one first frame member (4) on one with side of the first electrical contact member (2) and at least one second frame member (6) on to the opposing side of the first electrical contact member (2), the or each first and second frame members (4,6) adapted to position at least one PTC component (8);
      at least one PTC component (8);
      wherein the first electrical contact member (2), the or each first and second frame members (4,6) and the or each PTC components (8) are retained between the at least two electrical contact plates (36, 38).
    2. A method of assembling an electrical heater element according to claim 1.
    3. An HVAC module of a motor vehicle comprising an electrical heater element according to claim 1 or assembled according to claim 2.
    EP04256795A 2003-11-03 2004-11-03 Electrical heater element Expired - Lifetime EP1528838B1 (en)

    Applications Claiming Priority (2)

    Application Number Priority Date Filing Date Title
    GBGB0325574.2A GB0325574D0 (en) 2003-11-03 2003-11-03 Electrical heater
    GB0325574 2003-11-03

    Publications (3)

    Publication Number Publication Date
    EP1528838A2 true EP1528838A2 (en) 2005-05-04
    EP1528838A3 EP1528838A3 (en) 2005-05-25
    EP1528838B1 EP1528838B1 (en) 2006-05-31

    Family

    ID=29725819

    Family Applications (1)

    Application Number Title Priority Date Filing Date
    EP04256795A Expired - Lifetime EP1528838B1 (en) 2003-11-03 2004-11-03 Electrical heater element

    Country Status (4)

    Country Link
    EP (1) EP1528838B1 (en)
    AT (1) ATE328458T1 (en)
    DE (1) DE602004001033T2 (en)
    GB (1) GB0325574D0 (en)

    Cited By (8)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    EP1916873A1 (en) * 2006-10-25 2008-04-30 Catem GmbH & Co.KG Heat-generating element for an electrical heating device and method for manufacturing the same
    US20090026194A1 (en) * 2007-07-18 2009-01-29 Catem Gmbh & Co. Kg Method of Manufacturing an Electric Heating Device and Electric Heating Devices
    WO2009027217A1 (en) * 2007-08-27 2009-03-05 Epcos Ag Flexible heating module and method for the production thereof
    US20090293857A1 (en) * 2005-06-29 2009-12-03 Bsh Bosch Und Siemens Hausgerate Gmbh Domestic Appliance and a Cookable Product Holding Device Therefor
    EP2346304A1 (en) * 2010-01-15 2011-07-20 Behr GmbH & Co. KG Heat exchanger
    EP2249618A4 (en) * 2008-01-30 2011-11-30 Koshiro Taguchi On-vehicle heater and its manufacturing method
    DE102017223785A1 (en) * 2017-12-22 2019-06-27 Eberspächer Catem Gmbh & Co. Kg Process for producing a heat-generating element
    EP3598847A1 (en) * 2018-07-18 2020-01-22 Eberspächer catem GmbH & Co. KG Heat-generating element and method for producing the same

    Families Citing this family (1)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    ITRM20120056A1 (en) 2012-02-20 2013-08-21 Bitron Spa HEATING DEVICE, IN PARTICULAR FOR THE HEATING OF THE EURO'S HABIT OF UN´EURO CAR, RADIANT ELEMENT AND ITS RELATED METHOD OF ASSEMBLY.

    Family Cites Families (4)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    DE3677603D1 (en) * 1986-10-01 1991-03-28 David & Baader Dbk Spezfab PTC PTC RADIATOR.
    JP2982327B2 (en) * 1991-02-14 1999-11-22 株式会社村田製作所 Heater device for fixing of copying machine
    DE19732010A1 (en) * 1997-07-25 1999-01-28 Behr Gmbh & Co Electric heating device, in particular for a motor vehicle
    DE20121115U1 (en) * 2001-12-21 2003-04-24 Fritz Eichenauer GmbH & Co. KG, 76870 Kandel Electrical heating arrangement used for heating corrosive liquid, especially a urea solution, in vehicle comprises heating element sealed by metallic housing coated with inorganic non-metallic layer containing boron, carbon and/or silicon

    Cited By (14)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    US20090293857A1 (en) * 2005-06-29 2009-12-03 Bsh Bosch Und Siemens Hausgerate Gmbh Domestic Appliance and a Cookable Product Holding Device Therefor
    WO2008049619A1 (en) * 2006-10-25 2008-05-02 Eberspächer Catem Gmbh & Co. Kg Heat-generating element for an electric heating device and method for the production thereof
    EP1916873A1 (en) * 2006-10-25 2008-04-30 Catem GmbH & Co.KG Heat-generating element for an electrical heating device and method for manufacturing the same
    US8395088B2 (en) 2006-10-25 2013-03-12 Catem Gmbh & Co., Kg Heat generating element and electric auxiliary heater for a motor vehicle with heat generating element
    US8362406B2 (en) * 2007-07-18 2013-01-29 Catem Gmbh & Co. Kg Method of manufacturing an electric heating device and electric heating devices
    US20090026194A1 (en) * 2007-07-18 2009-01-29 Catem Gmbh & Co. Kg Method of Manufacturing an Electric Heating Device and Electric Heating Devices
    WO2009027217A1 (en) * 2007-08-27 2009-03-05 Epcos Ag Flexible heating module and method for the production thereof
    US8338755B2 (en) 2008-01-30 2012-12-25 Koshiro Taguchi On-vehicle heater and its manufacturing method
    EP2249618A4 (en) * 2008-01-30 2011-11-30 Koshiro Taguchi On-vehicle heater and its manufacturing method
    EP2346304A1 (en) * 2010-01-15 2011-07-20 Behr GmbH & Co. KG Heat exchanger
    DE102017223785A1 (en) * 2017-12-22 2019-06-27 Eberspächer Catem Gmbh & Co. Kg Process for producing a heat-generating element
    EP3598847A1 (en) * 2018-07-18 2020-01-22 Eberspächer catem GmbH & Co. KG Heat-generating element and method for producing the same
    CN110740527A (en) * 2018-07-18 2020-01-31 埃贝赫卡腾有限两合公司 Heating element and method for manufacturing the same
    CN110740527B (en) * 2018-07-18 2022-08-30 埃贝赫卡腾有限两合公司 Heating element and method for manufacturing the same

    Also Published As

    Publication number Publication date
    EP1528838B1 (en) 2006-05-31
    ATE328458T1 (en) 2006-06-15
    DE602004001033T2 (en) 2006-12-07
    GB0325574D0 (en) 2003-12-03
    EP1528838A3 (en) 2005-05-25
    DE602004001033D1 (en) 2006-07-06

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