EP3405001B1 - Procédé de fabrication d'un élément chauffant à coefficient de température positif (ptc) - Google Patents

Procédé de fabrication d'un élément chauffant à coefficient de température positif (ptc) Download PDF

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Publication number
EP3405001B1
EP3405001B1 EP18172444.4A EP18172444A EP3405001B1 EP 3405001 B1 EP3405001 B1 EP 3405001B1 EP 18172444 A EP18172444 A EP 18172444A EP 3405001 B1 EP3405001 B1 EP 3405001B1
Authority
EP
European Patent Office
Prior art keywords
contact
ptc element
ptc
contact plates
insulating layer
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.)
Active
Application number
EP18172444.4A
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German (de)
English (en)
Other versions
EP3405001A1 (fr
Inventor
Michael Niederer
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.)
Eberspaecher Catem GmbH and Co KG
Original Assignee
Eberspaecher Catem GmbH and Co KG
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
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Publication of EP3405001A1 publication Critical patent/EP3405001A1/fr
Application granted granted Critical
Publication of EP3405001B1 publication Critical patent/EP3405001B1/fr
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/20—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for assembling or disassembling contact members with insulating base, case or sleeve
    • H01R43/24—Assembling by moulding on contact members
    • 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
    • H05B3/02—Details
    • H05B3/04—Waterproof or air-tight seals for heaters
    • 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
    • H05B3/02—Details
    • H05B3/06—Heater elements structurally combined with coupling elements or holders
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
    • 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
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/017—Manufacturing methods or apparatus for heaters
    • 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 a method for producing a PTC heating element with a PTC element and contact surfaces for making electrical contact with the PTC element.
  • PTC heating elements such as those from EP 1 253 808 A1 or.
  • EP 1 395 098 A1 are known, an electrical conductor path on opposite main side surfaces of the PTC element.
  • the conductor track is usually formed from a contact plate which is connected to a positioning frame, for example, is sealed in the positioning frame.
  • EP 2 547 171 A2 shows further PTC elements from the prior art.
  • PTC elements have self-regulating properties. As the temperature increases, the power consumption decreases because the electrical resistance of the PTC element increases. Efforts have always been made to ensure good heat extraction from the PTC element. Furthermore, PTC heating elements for the automotive industry must be manufactured in a cost-effective manner. The structure of the PTC heating element must be scalable and reliably producible within predetermined tolerance limits even with large quantities.
  • the present invention is based on the problem of specifying a method for producing a PTC heating element in which the PTC element is reliably electrically contacted with contact surfaces on its end faces.
  • the present invention proposes a method having the features of claim 1.
  • the contact plates are connected to one another via electrically insulating bridge elements, leaving a receptacle for the PTC element free.
  • several bridge elements can be used to form several recordings. These bridge elements are usually provided at a distance from one another along elongated contact plates.
  • One or more PTC elements can be provided in each receptacle.
  • the PTC element is inserted into the receptacle and between the contact plates.
  • the contact plates are so far apart that the receptacle is dimensioned sufficiently large that the PTC element can be inserted into the receptacle without being influenced by the contact plates. Only then is each contact sheet deformed to form a contact projection resting against the end face of the PTC element.
  • the contact protrusion can be formed during forming.
  • the contact projection can usually already be formed by punching, but not yet reshaped in the direction of the PTC element for contact with the same. So it is conceivable to provide the contact plates with elongated slots through which the contact projections are cut free as strips at a boundary layer to the PTC element. During the subsequent reshaping, these thin webs are reshaped in the direction of the PTC element and placed against an end face of the PTC element in order to create solid electrical contact between the PTC element and the respective contact sheet.
  • the reshaping of the contact spring bar to rest it against the PTC element is preferably carried out by a conically widening tool, for example a pin, which is inserted into a slot is introduced between the contact spring bar and the remaining material of the contact plate in order to reshape the contact spring bar in the direction of the PTC element.
  • a conically widening tool for example a pin, which is inserted into a slot is introduced between the contact spring bar and the remaining material of the contact plate in order to reshape the contact spring bar in the direction of the PTC element.
  • a conically widening tool for example a pin, which is inserted into a slot is introduced between the contact spring bar and the remaining material of the contact plate in order to reshape the contact spring bar in the direction of the PTC element.
  • pins are provided on a tool for reshaping the contact spring bars in this way, and these pins are introduced into the corresponding slots at the same time.
  • the tool can, for example, be lowered in a force-controlled manner in order to ensure that the contact spring webs are in contact with the end face of the PTC element with a predetermined contact force.
  • care is also taken to ensure that identical contact is made with the PTC element on opposite end faces.
  • the contact plates are preferably received in a tool that rests on the outer surface of the contact plates. This counteracts the forces required for the deformation, so that the deformation is shown on the side of the contact plates that is to be brought into contact with the PTC element, but not on the opposite free outside of the contact plates. Also the reshaping of the contact spring bars controllable, since the possibly monitored force for deforming the contact spring projections leads exclusively to deformation in the direction of the PTC element.
  • the contact plates are overmolded after forming.
  • an insulating layer is preferably placed on the PTC element.
  • the PTC element is usually provided with an insulating layer on each of its main side surfaces, which can be a ceramic insulating layer.
  • the insulating layer is formed by an aluminum oxide plate.
  • the insulating layer is preferably glued to the PTC element with good thermal conductivity.
  • the insulating layer When the contact plates are overmolded, the insulating layer is sealed in with a plastic material at the edge. However, the predominant area of the insulating layer is left free, so that the finished PTC heating element with the encapsulation on its outside is essentially limited by the outer surface of the insulating layer, via which the heat generated by the PTC element can be discharged with a high heat density.
  • the bridge element or elements are usually also overmolded. These, in turn, can be connected to the contact plates by extrusion coating.
  • the contact plates can, however, also be inserted into receptacles in the bridge elements and thus connected to them.
  • the contact plates are preferably encapsulated with an elastic plastic material, for example TPE, elastomer or duomer.
  • One of the bridge elements which can be made of a hard plastic component such as polyamide, can be provided with a sealing collar which has a lamellar seal in order to form the PTC element as a plug-in heating element which can be inserted sealingly into a plug-in element receptacle of a partition which separates a circulation chamber through which the fluid to be heated flows from a connection chamber in which contact tongues of the PTC heating element are exposed for electrical connection.
  • the plastic material sealing the contact surface is preferably selected such that it has good wetting properties with respect to the surface of the insulating layer.
  • the Figure 1 shows a perspective side view of two sheet metal strips 2a, 2b, which are each designed identically and form contact tongues 4a, 4b.
  • the sheet metal strips 2a, 2b are stamped.
  • Each of the sheet metal strips 2a, 2b has two longitudinal slots 6 which form contact spring webs 8 which are formed as uniform segments on the sheet metal strips 2a, 2b and are each provided with a contact projection 9 which forms a convex contact surface 10.
  • the sheet metal strips 2a, 2b are connected to one another by an upper bridge element 12 and a lower bridge element 14.
  • the bridge elements 12, 14 are made of plastic. They are connected to the metal strips 2a, 2b by injection molding around them. During overmolding, bores 16 provided on sheet metal strips 2a, 2b are partially kept free by pins formed on the injection molding tool. Only the plastic material forming the lower bridge element 14 penetrates one in each case in the lower area (in Figure 1 , right) of the sheet metal strip 2a or 2b provided hole 16 so that an intimate, form-fitting connection between the plastic material of the bridge element 14 and the sheet metal strips 2a, 2b results.
  • the two sheet metal strips 2a, 2b are connected to one another in a predetermined manner and kept at a distance via the two plastic bridge elements 12, 14.
  • the bridge elements 12, 14 each form spacers 18 which protrude into a receptacle 20 formed between the two sheet metal strips 2a, 2b and the bridge elements 12, 14. This is to be inserted into the receptacle 20 and in Figure 4 provided PTC element 22 is positioned in a predetermined manner relative to the bridge elements 18, 20, whereby the air and creepage distances between the PTC element 22 and a holder for the PTC element formed by the sheet metal strips 2a, 2b and the bridge elements 12, 14 22 is adjustable and controllable.
  • This in Figure 2 intermediate product shown is in Figure 3 shown received in a tool 24.
  • This tool 24 is H-shaped and forms U-shaped receptacles for the lower bridge element 14 and the upper bridge element 12 together with the contact tongues 4a, 4b. These recordings of the tool 20 enclose the sheet metal strips 2a, 2b at the edge. Between the respective receptacles, a central web of the H-shaped tool 24 is provided, which has a support surface for an in Figure 3 Forms reproduced insulating layer, which is formed in the present case by an aluminum oxide plate 26. On this aluminum oxide plate 26 carried by the tool 24 is the in Figure 2 Intermediate product shown placed. The aluminum oxide plate 26 then partially covers the sheet metal strips 2a, 2b and is provided at a distance from the bridge elements 12, 14, like this Figure 6 can be found.
  • the insulating layer 28 placed there has identical dimensions to the insulating layer 26 in FIG Figure 3 .
  • the insulating layer 26 can be provided with an electrically highly conductive adhesive on its inner surface. This can be completely or partially filled with highly thermally conductive particles in order to improve the thermal conductivity of the adhesive.
  • the PTC element 22 is placed on the surface of the insulating layer 26 prepared in this way ( Figure 4 ). This is now located in the receptacle 20.
  • conical pins 30 engage in the longitudinal slots 6.
  • these each have an idealized circular extension 32, which is in the Figures 1 and 2 to be recognized and adapted to receive the conical end of the pin 30.
  • the pins 30 are held overall in a unitary holding element, not shown, which is movable relative to the tool 24.
  • the pins 30 penetrate with their tapered conical ends into the widening 32 in order to cause deformation of the contact spring bars 8. This is because the outside of the sheet metal side 2a, 2b is prevented by the tool 24 within its U-shaped receptacle from evading the outward deformation imposed by the pins 30.
  • the contact spring bars 8 are thus plastically deformed inward.
  • the contact surfaces 10 initially rest against the end face surfaces 34 of the PTC element 22. These are the end faces 34 on the long sides of the PTC element 22.
  • the end faces provided on the broad side, via which this electrical contact is made, are held at a distance from the bridge elements 12, 18 by the spacers 18.
  • the contact spring bars 8 As the insertion movement progresses and after the contact spring bars 8 have been placed against the end faces 34, there is an elastic deformation of the contact spring bars 8, so that at the end of the deformation of the contact spring bars 8 the contact surfaces 10 rest against the PTC elements 22 at the end face with a certain elastic pretension. Thereafter, the PTC element 22 is electrically connected to the respective sheet metal strips 2a, 2b via the contact surfaces 10.
  • the PTC element 22 is also held by this pressing inside a housing 36 formed by the sheet metal strips 2a, 2b and the bridge elements 12, 14 (cf. Figure 5 ). During this deformation step, the PTC element 22 is supported on the underside by a support formed by the tool 24 with the insulating layer 26 interposed. In this way, the PTC element 22 is clamped in the vertical direction between the contact spring bars 8.
  • This plastic material can be a TPE, silicone, a duromer or an elastomer.
  • the plastic material is overmolded, essentially omitting the main side surfaces of the insulating layer 26, 28.
  • the overmolded plastic material thus produces a plastic frame which essentially leaves the main side surfaces of the insulating layers 26, 28 free and forms a window 40 in which the insulating layers 26, 28 are exposed.
  • the circumferential edges of the insulating layers 26, 28 are, however, sealed in by the material of the plastic frame and accordingly the insulating layers 26, 28 are sealed against the plastic frame 38
  • Figure 7 shows, only the contact tongues 4a, 4b protrude beyond the product produced in this way.
  • the bridge elements 12, 14 are only partially enveloped by the elastic material of the plastic frame 38.
  • the lower bridge element 14 projects beyond the plastic frame 38 and forms a holder from the engineering plastic of the bridge element 14, via which the in Figure 7 PTC heating element 42 shown can be positioned on the underside in a heater housing.
  • the plastic material of the plastic frame 38 forms a sealing collar 44 which has several circumferential sealing beads 46 which can be pressed into a female receptacle of a partition wall as male plug-in and sealing elements in order to hold the PTC heating element 42 in a plug-in connection and to seal in this.
  • the plug connection is usually provided in a partition that separates a circulation chamber, through which the fluid to be heated flows and in which the PTC heating element 42 is essentially provided, from a connection chamber in which the contact tongues 4a, 4b are electrically connected.
  • the connection chamber can have a printed circuit board, by means of which various PTC heating elements of the heater are combined to form a heating circuit and / or are supplied with power in a controlled manner.
  • the control can also be provided within the connection chamber.
  • the sealing beads 46 are provided around the circumference of the plastic of the upper bridge element 12. This improves the contact pressure within the female plug-in element receptacle.
  • the product according to the invention is characterized in that the PTC element 22 is reliably contacted with its opposite end faces 34.
  • the contact surfaces 10 of the sheet metal strips 2a, 2b are not only pressed against the PTC element 22. Rather, the lateral distance between the convex contact surface 10 and the extension 32, which receives the pin 30, imposes an elastic deformation on the contact spring bar 8, by means of which any settling amounts and / or thermal expansions within the PTC heating element 42 can be compensated for during operation .
  • the bridge elements 12, 14 can also be connected to the sheet metal strips 2a, 2b by being pushed on.
  • the attachment between the bridge elements 12, 14 and the sheet metal strips 2a, 2b can be done for example by welding or gluing. Positive connections are also conceivable.
  • the bridge elements 12, 14 can each be formed in several parts, with the several parts of an individual bridge element being able to be joined to one another, including the sheet metal strips 2a, 2b.
  • the sheet metal strips 2a, 2b are preferably secured in a form-fitting manner within the bridge element or elements during this joining.
  • the sheet metal strips are each provided with a plurality of bridge elements in the longitudinal direction, a receptacle being provided between adjacent bridge elements.
  • the PTC heating element 42 shown is suitable as a PTC heating element in a fluid heater. Due to the plastic frame 38, there is no risk of fluid to be heated reaching the PTC element. In this case, the sealing bead 46 is sealingly accommodated in a partition wall and the lower bridge element 14 protruding beyond the plastic frame 38 can be accommodated in a recess which is cut out in the bottom of the circulation chamber. As a result, the PTC heating element 42 can be held in a predetermined arrangement and orientation within a fluid heater, as it is basically from the EP 2 607 121 B1 , EP 2 440 004 B1 or EP 1 921 896 is known to the applicant.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Resistance Heating (AREA)
  • Thermistors And Varistors (AREA)

Claims (8)

  1. Procédé de fabrication d'un élément chauffant CTP, comprenant un élément CTP (22) et des plaques de contact (2a, 2b) qui sont en contact électriquement conducteur avec les faces frontales (34) de l'élément CTP (22), procédé dans lequel les plaques de contact (2a, 2b) sont d'abord reliées à l'élément CTP (22) par l'intermédiaire d'éléments de pont (12) électriquement isolants, 14) tout en laissant libre un réceptacle (20) pour l'élément PTC (22), puis l'élément PTC (22) est inséré dans le réceptacle (20) et enfin les plaques de contact (2a, 2b) sont façonnées pour former une saillie de contact (9) qui s'appuie contre la face frontale (34) de l'élément PCT (22).
  2. Procédé selon la revendication 1, caractérisé en ce qu'avant l'insertion de l'élément PTC (22) dans le réceptacle (20), la feuille de contact (2a, 2b) est pourvue d'une âme de ressort de contact (8) et en ce qu'après l'insertion de l'élément PTC (22), l'âme de ressort de contact (8) est déformée en direction de l'élément PTC (22).
  3. Procédé selon les revendications 1 ou 2, caractérisé en ce que, pendant la formation de la saillie de contact (9), les feuilles de contact (2a, 2b) sont reçues dans un outil (24) qui vient en butée contre la surface extérieure des feuilles de contact.
  4. Procédé selon l'une des revendications précédentes, caractérisée en ce que les plaques de contact (2a, 2b) sont surmoulées après le formage.
  5. Procédé selon l'une des revendications précédentes, caractérisé en ce qu'une couche isolante (26, 28) est placée sur l'élément PTC (22) avant le surmoulage, et en ce que, pendant le surmoulage, les plaques de contact (2a, 2b) et la couche isolante (26, 28) sont entourées sur les bords par un cadre en plastique (38).
  6. Procédé selon l'une des revendications précédentes, caractérisé en ce que les éléments de pont (12, 14) sont reliés aux plaques de contact (2a, 2b) par surmoulage.
  7. Procédé selon l'une des revendications précédentes, caractérisé en ce que les plaques de contact (2a, 2b) sont prolongées d'un côté au-dessus de l'un des éléments de pont (12, 14) pour former des languettes de contact (4a, 4b).
  8. Procédé selon l'une des revendications précédentes, caractérisé en ce que l'élément PTC (22) est soutenu sur la face inférieure pendant le formage par un support formé par l'outil (24).
EP18172444.4A 2017-05-16 2018-05-15 Procédé de fabrication d'un élément chauffant à coefficient de température positif (ptc) Active EP3405001B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102017208253.4A DE102017208253A1 (de) 2017-05-16 2017-05-16 Verfahren zum Herstellen eines PTC-Heizelementes

Publications (2)

Publication Number Publication Date
EP3405001A1 EP3405001A1 (fr) 2018-11-21
EP3405001B1 true EP3405001B1 (fr) 2020-10-07

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP18172444.4A Active EP3405001B1 (fr) 2017-05-16 2018-05-15 Procédé de fabrication d'un élément chauffant à coefficient de température positif (ptc)

Country Status (4)

Country Link
US (1) US10892590B2 (fr)
EP (1) EP3405001B1 (fr)
CN (1) CN108882399B (fr)
DE (1) DE102017208253A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102022205705A1 (de) 2022-06-03 2023-12-14 Mahle International Gmbh Heizeinrichtung zum Heizen eines Fluids

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DE102019204401A1 (de) * 2019-03-28 2020-10-01 Eberspächer Catem Gmbh & Co. Kg PTC-Heizelement und elektrische Heizvorrichtung umfassend ein solches
DE102019217234A1 (de) * 2019-11-07 2021-05-12 Eberspächer Catem Gmbh & Co. Kg PTC-Heizeinrichtung und elektrische Heizvorrichtung mit einer solchen PTC- Heizeinrichtung und Verfahren zur Herstellung einer elektrischen Heizvorrichtung

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102022205705A1 (de) 2022-06-03 2023-12-14 Mahle International Gmbh Heizeinrichtung zum Heizen eines Fluids

Also Published As

Publication number Publication date
US10892590B2 (en) 2021-01-12
DE102017208253A1 (de) 2018-11-22
CN108882399A (zh) 2018-11-23
CN108882399B (zh) 2020-08-18
US20180337506A1 (en) 2018-11-22
EP3405001A1 (fr) 2018-11-21

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