EP3295768B1 - Heating device for heating the vehicle interior of a motor vehicle - Google Patents

Description

The invention relates to a heating device with a plurality of heating modules for heating the vehicle interior of a motor vehicle. Finally, the invention relates to a motor vehicle with a vehicle interior and with at least one heating module explained above and / or with a heating device explained above.

In modern motor vehicles, internal combustion engines are frequently used with such high efficiency that the heat generated via the cooling water of the cooling system interacting with the internal combustion engine is insufficient to heat the vehicle interior of the motor vehicle in the desired manner. This is especially true at very low outdoor temperatures. In order to reduce such a deficit of available heating power, the prior art knows electric heating modules based on so-called PTC heating elements. Such PTC heating elements also increase with increasing temperature of the heating element electrical resistance ("Positive Temperature Coefficient"). Such heating modules with PTC heating elements are usually designed to be self-regulating, which means that the heating power provided by the PTC heating element automatically decreases in the event of a lack of heat dissipation into the vehicle interior due to the increasing electrical resistance. Nevertheless, the power electronics unit required to drive the PTC heating elements is typically designed in the manner of an electrical circuit board in such conventional heating modules.

The DE 10 2011 089 B3 describes a device for controlling an electric heater for vehicles. The device comprises a housing and a housed in this board, on which at least one component to be cooled is arranged.

The DE 100 28 446 B4 deals with an additional electric heater with PTC heating elements and with a semiconductor switch having an electrically insulating heat conductor. On the heat conductor an electrically conductive and heat-conducting plate and various electrical connections are arranged.

DE 100 15 905 A1 describes a device for heating passenger compartments of a motor vehicle, comprising a heating unit for heating flowing air with a heating element and heat emitting device for delivering the heat generated by the heating elements to the air flowing around the heat emitting devices.

DE 199 25 757 discloses a heating device according to the preamble of claim 1.

A disadvantage of such conventional heating modules proves the typically only consuming using plug and solder joints realized mechanical and electrical connection of the power electronics unit to the PTC heating elements.

The present invention therefore deals with the problem of providing an improved embodiment for a heating device for heating a vehicle interior of a motor vehicle, which is characterized in particular by improved electrical and thermal connection of the power electronics unit to the PTC power supply unit. Heating elements distinguishes.

This object is solved by the subject matter of the independent patent claims. Preferred embodiments are subject of the dependent claims.

The basic idea is accordingly to arrange the electrical / electronic components in modular form required for controlling / regulating the power supply of PTC heating elements - hereinafter referred to as "power electronics unit" - on a metal support plate on which said PTC heating elements are also provided ,

The support plate not only serves as a mechanical support for the PTC heating elements, but also functions as an electrical conduction path to electrically connect the power electronics unit to the PTC heating elements. Essential to the invention is provided on the metallic support plate, electrically insulating insulating layer, such as an oxide ceramic. On the electrically insulating insulating layer, in turn, an electrical conductor track of an electrically conductive material is arranged, which connects the power electronics unit electrically to the PTC heating elements. Elaborate alternative connection techniques for electrically connecting the PTC heating elements with the power electronics unit, such as electrical connectors can thus be omitted. At the same time, the metallic carrier plate can be used to transport waste heat generated by the PTC heating elements during operation. The additional provision of other suitable components for dissipating waste heat can thus be dispensed with or realized, at least in a simplified form, that is, with less constructive effort. This leads to considerable cost advantages in the production of the heating module according to the invention. Preferably, the electrically conductive material of the electrical conductor is a metal, particularly preferably copper.

A heating device according to the invention for heating the vehicle interior of a motor vehicle comprises at least one PTC heating element which, in particular sandwiched, is arranged between a first and a second carrier plate, each made of a metal. The first support plate has on a at least one PTC heating element side facing an electrically insulating insulation layer. On this insulating layer, an electrical conductor is formed, which is electrically connected to the at least one PTC heating element. On the first carrier plate, in turn, there is a power electronic unit electrically connected to the track for providing electric heating power to the PTC heating element. This power electronics unit is configured to control and / or regulate the propagation of electrical energy provided by an external electrical energy source to the PTC heating elements. For this purpose, the power electronics unit various electrical and / or electronic components known to the expert in the field of electrical engineering, such as power transistors or the like. include, which are realized in a compact modular design.

On a side facing away from the at least one PTC heating element side of the first support plate and / or on a side remote from the at least one PTC heating element side of the second support plate, a first or second rib structure is arranged. The first or second fin structure serves primarily for the effective dissipation of waste heat, which is generated by the PTC heating elements during operation of the heating module, to the external environment of the heating module.

On a side remote from the at least one PTC heating element side of the first rib structure, a first module end plate is arranged. Accordingly, a second heating module end plate is arranged on a side of the second rib structure facing away from the at least one PTC heating element. Both heating module end plates serve to stiffen the heating module. In addition, they can be used with the fin structures to remove waste heat from the PTC heating elements. In addition, the heating module end plates can be accessed via the rib structures electrically connected to the carrier plates and via these with the PTC heating elements. This provides the heating module plates with the characteristic of electrically conductive paths by means of which the PTC heating elements can be connected to an external power source, such as a battery of the motor vehicle.

However, associated with particularly low manufacturing costs is a further preferred embodiment, in which the first carrier plate and the first heating module end plate integrally formed on each other and formed as a U-shaped profile part. The first rib structure is arranged in this embodiment between the first support plate and the first Heizmodul- end plate and is supported for stiffening on the first support plate and on the first heating module end plate. Alternatively or additionally, according to this embodiment, the second support plate and the second heating module end plate are formed integrally with each other and formed as a first U-shaped profile part. The first support plate and the first heating module end plate are designed as legs of said first profile part. Alternatively or additionally, in this embodiment, the second support plate and the second Heizmodul- end plate integrally formed on each other and formed as a first U-shaped profile part. The second carrier plate and the second heating module end plate are formed in such a scenario as legs of the second profile part.

The first rib structure may preferably be arranged between the legs of the first support plate and the first heating module end plate, such that it is supported on the two plates. In an analogous manner, the second rib structure may preferably be arranged between the legs of the second carrier plate and the second heating module end plate, such that it is supported on the two plates. Both measures, taken alone or in combination, lead to an additional stiffening of the heating module.

In a further preferred embodiment, at least two PTC heating elements, preferably a plurality of PTC heating elements, can be present in the heating module, which are arranged adjacent to one another along a longitudinal direction of the heating module. Particularly preferably, the PTC heating elements along the longitudinal direction at a distance from each other. In this case, the first carrier plate points beyond the second carrier plate along the longitudinal direction. The projecting beyond the second support plate longitudinal portion of the first support plate is used to hold the power electronics unit of the heating module.

In another preferred embodiment, the second heating module end plate projects beyond the first heating module end plate in the longitudinal direction. In this variant, the longitudinal section of the second heating module end plate projecting beyond the first heating module end plate is designed as an electrical contact section for electrical connection to an electrical ground path.

In a particularly preferred embodiment, the second heating module end plate and the first carrier plate have substantially the same plate length in the longitudinal direction. Alternatively or additionally, the first heating module end plate and the second carrier plate may also have substantially the same plate length in the longitudinal direction. Thus, in this variant, the plates can be made with the same plate length as equal parts, thereby reducing the manufacturing cost of the heating module.

In order to improve the rigidity of the heating device, the first carrier plate and the first heating module end plate may in another preferred embodiment be formed integrally with each other and formed as a U-shaped first profile part. For the same purpose, in this variant, alternatively or In addition, the second support plate and the second heating module end plate integrally formed on each other and be formed as a U-shaped second profile part. For the purpose of further stiffening the structure, the first rib structure is arranged in a first intermediate space partially enclosed by the first U-shaped profile part. This is supported on the two opposite legs of the first U-shaped profile part. In this variant, the second rib structure, which is supported on the two opposite limbs of the second U-shaped profile part, can be arranged in a second intermediate space partially enclosed by the second U-shaped profile part.

Particularly preferably, the material of the electrically insulating insulation layer is a ceramic. Such a ceramic is particularly easy to apply to the first carrier plate.

The invention relates to a heating device with at least two heating modules presented above, preferably with a plurality of such heating modules. The at least two heating modules are stacked along a stacking direction adjacent to each other. In order to improve the heating power that can be provided by the heating device, in addition to the PTC heating elements present in the heating modules, PTC heating elements are additionally present between two adjacent heating modules. For this purpose, at least one PTC heating element, preferably a plurality of PTC heating elements, is sandwiched between two heating module end plates of adjacent heating modules adjacent in the stacking direction.

To produce the electrical connection to an electrical energy source required for operating the heating device, the electrical contact section is provided the second heating module end plates are electrically connected to a common electrical ground path of the heater.

Particularly suitably, the electrical ground path may be formed as a ground bus comprising an electrical mass sheet metal part. From this mass-sheet metal part are laterally contacting portions, with which the electrical contact portions of the second heating module end plates are materially connected, for example by means of a solder joint.

The power electronics units of the heating modules each have a contact area. The contact regions are connected to a common electrical supply path of the heater for electrical connection to an electrical energy source.

The electrical supply path is designed as a supply bus, which comprises a supply bus sheet metal part, with which in turn the contact areas of the power electronics units are materially connected. By providing such a supply bus eliminates an expensive and associated with high manufacturing costs electrical wiring of the individual heating modules with an electrical energy source.

A particularly effective electrical connection between the supply bus and the heating modules is achieved in that an electrical contact section which projects at an angle from the electrical supply bus sheet metal part is provided on the electrical supply bus sheet metal part for each heating module to be electrically contacted. The respective electrical contact section is by means of a cohesive connection flat with a corresponding electrical Contact area of the power electronics unit of the respective heating module connected.

In order to dissipate the waste heat generated by the PTC heating elements during operation effectively to the environment of the heating device, a thermal contact section is provided on the electrical supply bus sheet metal part for each electrically to be contacted heating module, each projecting at an angle from the supply bus sheet metal part. The thermal contact portions are connected by means of a cohesive connection areally with a corresponding thermal contact portion of the power electronics unit of the respective heating module. As such cohesive connection may be about a solder joint into consideration.

Finally, the invention relates to a motor vehicle with a vehicle interior and with at least one heating module explained above and / or with a heating device discussed above.

Other important features and advantages of the invention will become apparent from the dependent claims, from the drawings and from the associated figure description with reference to the drawings.

It is understood that the features mentioned above and those yet to be explained below can be used not only in the particular combination given, but also in other combinations or in isolation, without departing from the scope of the present invention.

Preferred embodiments of the invention are illustrated in the drawings and are explained in more detail in the following description, wherein the same reference numerals refer to the same or similar or functionally identical components.

Fig. 1

ein Beispiel eines erfindungsgemäßen Heizmoduls in einer perspektivischen Explosionsdarstellung,

Fig. 2

ein Beispiel einer erfindungsgemäßen Heizeinrichtung mit mehreren aufeinandergestapelten Heizmodulen gemäß Figur 1,

Fig. 3

eine separate Darstellung der in Form U-förmiger Profilteile realisierten Träger- bzw. Endplatten der Heizeinrichtung.

It show, each schematically

Fig. 1

an example of a heating module according to the invention in a perspective exploded view,

Fig. 2

an example of a heating device according to the invention with a plurality of stacked heating modules according to FIG. 1 .

Fig. 3

a separate representation of realized in the form of U-shaped profile parts support or end plates of the heater.

FIG. 1 Illustrates in an exploded perspective view an example of a heating module according to the invention 1. The heating module 1 for heating the vehicle interior of a motor vehicle comprises a plurality of PTC heating elements 2. The PTC heating elements 2 are sandwiched between a first and a second support plate 3, 4, respectively a metal, arranged. The individual PTC heating elements 2 are arranged adjacent to each other along a longitudinal direction L of the heating module 1 and at a distance from one another. In the assembled state of the heating module 1, the first carrier plate 3 is electrically connected to a lower side 16 of the PTC heating elements 2, for which purpose the first carrier plate 3 rests flat against the undersides 16 of the PTC heating elements 2. Accordingly, in the assembled state of the heating module 1, the second carrier plate 4 is electrically connected to an upper side 17 of the PTC heating elements 2. For this purpose, the second support plate 4 lies flat against the upper sides 17 of the PTC heating elements 2. The upper and lower sides 17, 16 thus serve as electrical Connections of the PTC heating elements 2. About the two support plates 3, 4, the PTC heating elements 2 with an electrical energy source (in FIG. 1 not shown) connected or connectable.

The first support plate 3 is in operation of the heating module 1 via a suitably designed electrical supply path 26 (only in FIG. 2 shown) electrically connected or connected to an electrical energy source. During operation of the heating module 1, the second carrier plate 4 is connected to an electrical ground path 21 (only in FIG FIG. 2 Not shown). connected to which said electrical energy source can be connected. The first support plate 3 has an electrically insulating insulation layer 6 on a side 5 facing the PTC heating elements 2. The material of the electrically insulating insulating layer may be a ceramic. On the electrically insulating insulating layer 6, an electrical conductor 7, for example made of copper, is formed. The electrical conductor 7 is electrically connected to the PTC heating elements 2. On the first support plate 3, a power electronics unit 8, which is likewise electrically connected to the track 7, is provided for providing electrical heating power to the PTC heating elements 2. On a side 9 of the first carrier plate 3 facing away from the PTC heating elements 2, a first rib structure 10 is arranged. Accordingly, a second ribbed structure 12 is arranged on a side 11 of the second carrier plate 4 facing away from the PTC heating elements 2. As FIG. 1 can be further seen, on a side facing away from the PTC heating elements 2 side of the first rib structure 10, a first module end plate 13 is arranged. In an analogous manner, a second heating module end plate 14 is arranged on a side of the second rib structure 12 facing away from the PTC heating elements 2. Preferably, the two rib structures 10, 12 and the two heating module end plates 13, 14 made of a metal or other suitable, electrically conductive material, so that the first support plate 3 via the first rib structure 10 electrically connected to the first heating module end plate 13th connected is. Accordingly, the second support plate 4 is then electrically connected via the second rib structure 12 to the second heating module end plate 14. For this purpose, the first rib structure 10 is supported with its ribs at the end on the first support plate 3 or on the first heating module end plate 13. Accordingly, the second rib structure 12 is supported with its ribs at the end on the second support plate 4 or the second heating module end plate 14. The two module end plates 13, 14, as well as the two support plates 3, 4 may be particularly preferably realized as sheet metal parts.

The representation of the FIG. 1 In addition, if the first carrier plate 3 protrudes beyond the second carrier plate 4 along the longitudinal direction L. The power electronics unit 8 is arranged in a projecting beyond the second support plate 4 longitudinal portion 15 of the first support plate 3 on this. In an analogous manner, the second heating module end plate 14 projects beyond the first heating module end plate 13. The second heating module end plate 14 and the first support plate 3 have substantially the same plate length in the longitudinal direction L. Preferably, the first heating module end plate 13 and the second support plate 4 in the longitudinal direction L have substantially the same plate length. The projecting beyond the first Heizmodul- end plate 13 longitudinal portion 18 of the second Heizmodul- end plate 14 is as electrical contact gate 19 for electrically connecting the second Heizmodul- end plate 14 and thus - via rib structure 12 and the second support plate 4 and the PTC heating elements 2 - with an electrical ground path 22 is formed.

The FIG. 2 shows an example of a heater 20 according to the invention with a plurality of heating modules 1, wherein in the example of the FIG. 2 for reasons of clarity, only two heating modules 1 are completely shown. The heating modules 1 are arranged adjacent to one another along a stacking direction S. Between adjacent in the stacking direction S heating module end plates 13, 14 adjacent Heating modules 1 is sandwiched a plurality of PTC heating elements 2 '. In the example scenario, these PTC heating elements 2 'are constructed, arranged and integrated into the heating device 20 identically to the PTC heating elements 2. The two heating module end plates 13, 14 lie flat against the lower or upper sides 16 ', 17' of the PTC heating elements 2 'and take over in this way the function of the support plates 3, 4 of the PTC heating elements 2, and Although the supply of the PTC heating elements 2 'with electrical energy from an electrical energy source.

The FIG. 3 shows to illustrate the geometric structure in a separate representation of the second carrier plates 4 and the second heating module end plates 14. It can be seen that they can be realized in the form of U-shaped profile parts: So takes the FIG. 3 in that the second carrier and heating module end plates 4, 14 can each be formed integrally with one another and formed as U-shaped second profile parts 31. In the in FIG. 2 shown, assembled state of the heater 20 is in the second U-shaped profile part 31 partially enclosed second spaces 33 each have a second rib structure 12 is arranged. The rib structures 12 are supported on the two opposite legs of the respective second U-shaped profile part 31. In an analogous manner, the first support plates 3 and the first heating module end plates 13 are each integrally formed on each other and each formed as a U-shaped first profile parts 30, which exclusively in the FIG. 2 is shown. Corresponding FIG. 2 In each case a first rib structure 10 is arranged in the first intermediate space 32 partially enclosed by the first U-shaped profile parts 30. The first rib structures 10 are each supported on the two opposite legs of the respective first U-shaped profile part 30.

The representation of the FIG. 3 Furthermore, it can be deduced that the electrical contact sections 19 of the second heating module end plates 14 can be electrically connected to a common electrical ground path 21 of the heating device 1. In the example scenario of FIG. 3 is such an electrical grounding path 21 is formed as a ground bus 22 having a, preferably one-piece, electrical mass sheet metal part 23. From the mass sheet metal part 23 are laterally contacting portions 24 from. These contacting portions 24 of the ground bus 22 are as in FIG. 2 shown connected by means of a solder connection or other suitable, preferably cohesive, connection with the electrical contact portions 19 of the second heating module end plates 14.

Also, the power electronics units 8 of the heating modules 1 each have an electrical contact region 25 (see. Fig. 1 and 2 ) connected to a common electrical supply path 26 of the heater 1 for electrical connection to an external electrical power source (not shown). The common electrical supply path 26 is in accordance with the Figures 2 and 3 formed as a supply bus 27, which in turn comprises a, preferably one-piece, supply bus sheet metal part 28, with which the electrical contact areas 25 of the power electronics units 8 are materially connected. This is according to the representation of Figures 2 and 3 from the electrical supply bus sheet metal part 28 for each electrically to be contacted heating module 1, an electrical contact portion 29 from. Each electrical contact section 29 is connected by means of a solder connection or another suitable, preferably cohesive, surface connection with a corresponding electrical contact region 25 of the power electronics unit 8.

Finally, the show Figures 2 and 3 also that a thermal contact section 34 projects from the electrical supply bus sheet-metal part 28 for each heating module 1 to be electrically contacted. Each such thermal contact section 34 is like in FIG. 3 shown connected by means of a cohesive connection surface with a corresponding thermal contact portion 35 of the power electronics unit 8 of the respective heating module 1.

Claims (10)

1. Heating device (20),

   - having at least two heating modules (1), preferably having a plurality of heating modules (1), which are arranged adjacent to each other along a stacking direction (S),

   - wherein between two heating module end plates (13, 14) of two adjacent heating modules (1), which heating module end plates are adjacent in the stacking direction (S), at least one PTC heating element (2') is arranged in a sandwich-like manner,

   - wherein the at least two heating modules (1) in each case comprise at least one PTC heating element (2), which is arranged between a first and a second carrier plate (3, 4), each composed of a metal,

   - wherein the first carrier plate (3) has an electrically insulating insulation layer (6) on a side (5) facing the at least one PTC heating element (2), on which insulation layer an electrical conducting track (7) is formed, which is electrically connected to the at least one PTC heating element (2),

   - wherein on the first carrier plate (3) a power electronics unit (8) electrically connected to the conducting track (7) is present on the first carrier plate (3) in order to provide electrical heating power to the at least one PTC heating element (2),

   - wherein at least two PTC heating elements (2) are present, which are arranged adjacent to each other along a longitudinal direction (L),

   - wherein the first carrier plate (3) protrudes along the longitudinal direction (L) beyond the second carrier plate (4), wherein the power electronics unit (8) is arranged in a longitudinal section (15) of the first carrier plate (3) protruding beyond the second carrier plate (4) on said first carrier plate,

   - wherein on a side (9) facing away from the at least one PTC heating element (2) and on a side of the second carrier plate (4) facing away from the at least one PTC hearing plate (2) a first or second rib structure (10, 12) is arranged,

   characterised in that

   - on a side of the first rib structure (10) facing away from the at least one PTC heating element (2) a first heating module end plate (13) and/or on a side of the second rib structure (12) facing away from the at least one PTC heating element (2) a second heating module end plate (14) is arranged,

   - the power electronics units (8) of the heating modules (1) in each case have an electrical contract region (25), which is connected to a common electrical supply path (26) of the heating device (20) for the electrical connection to an electrical energy source,

   - the electrical supply path (26) is designed as supply bus (27), which comprises a supply bus sheet metal part (28), to which the contact regions (25) of the power electronics units (8) are integrally connected.

   - from the electrical supply bus sheet metal part (28) for each heating module (1) to be electrically contacted an electrical contact section (19) projects angularly, which by means of an integral connection is connected in a planar manner to a corresponding electrical contact region (25) of the power electronics unit (8) of the respective heating module (1),

   - from the electrical supply bus sheet metal part (28) for each heating module (1) to be electrically contacted a thermal contact section (34) projects angularly, which by means of an integral connection is connected in a planar manner to a corresponding thermal contact section (35) of the power electronics unit (8) of the respective heating module (1).
2. Heating device according to claim 1,
   characterised in that

   - the first carrier plate (3) and the first heating module end plate (13) are integrally formed together and are designed as first U-shaped profile part (30), wherein the first carrier plate (3) and the first heating module end plate (13) are designed as limbs of the first profile part (30), and/or that

   - the second carrier plate (4) and the second heating module end plate (14) are integrally formed together and are designed as second U-shaped profile part (31), wherein the second carrier plate (4) and the second heating module end plate (14) are designed as limbs of the second profile part (31).
3. Heating device according to claim 1 or 2,
   characterised in that
   the second heating module end plate (14) protrudes in the longitudinal direction (L) beyond the first heating module end plate (13), wherein the longitudinal section (18) of the second heating module end plate (14), which longitudinal section protrudes beyond the first heating module end plate (13) is designed as electrical contact section (19) for the electrical connection to an electrical ground path (21).
4. Heating device according to any one of the preceding claims,
   characterised in that

   - the second heating module end plate (4) and the first carrier plate (13) have substantially the same plate length in the longitudinal direction and/or that

   - the first heating module end plate (3) and the second carrier plate (14) have substantially the same plate length in the longitudinal direction.
5. Heating device according to any one of the preceding claims,
   characterised in that

   - the first carrier plate (3) and the first heating module end plate (13) are integrally formed together and are designed as U-shaped first profile part (30),
   and/or that

   - the second carrier plate (4) and the second heating module end plate (14) are integrally formed together and are designed as U-shaped second profile part (31).
6. Heating device according to claim 5,
   characterised in that

   - in a first intermediate space (32) partially enclosed by the first U-shaped profile part (30) the first rib structure (10) is arranged and is supported on the two opposite limbs of the first U-shaped profile part (30), and/or that

   - in a second intermediate space (33) partially enclosed by the second U-shaped profile part (31) the second rib structure (12) is arranged and is supported on the two opposite limbs of the second U-shaped profile part (31).
7. Heating device according to any one of the preceding claims,
   characterised in that
   the material of the electrically insulating insulation layer (6) is a ceramic.
8. Heating device according to any one of the preceding claims,
   characterised in that
   the electrical contact section (19) of the second heating module end plates (14) is electrically connected to a common electrical ground path (21) of the heating device (20).
9. Heating device according to claim 8,
   characterised in that
   the electrical ground path (21) is designed as ground bus (22), which comprises an electrical ground sheet metal part (23), from which contacting sections (24) project angularly, with which the electrical contact section (19) of the second heating module end plates (14) are integrally connected.
10. Motor vehicle,

    - having a heating device (20) according to any one of the preceding claims.

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