EP4351273A1 - Ptc heating device and method for producing same - Google Patents
Ptc heating device and method for producing same Download PDFInfo
- Publication number
- EP4351273A1 EP4351273A1 EP23201142.9A EP23201142A EP4351273A1 EP 4351273 A1 EP4351273 A1 EP 4351273A1 EP 23201142 A EP23201142 A EP 23201142A EP 4351273 A1 EP4351273 A1 EP 4351273A1
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- European Patent Office
- Prior art keywords
- frame
- ptc
- heating device
- contact
- mass
- Prior art date
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- 238000010438 heat treatment Methods 0.000 title claims abstract description 72
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 11
- 229910010293 ceramic material Inorganic materials 0.000 claims abstract description 11
- 238000001465 metallisation Methods 0.000 claims abstract description 11
- 238000000034 method Methods 0.000 claims abstract description 5
- 238000005485 electric heating Methods 0.000 claims description 6
- 230000002093 peripheral effect Effects 0.000 claims description 6
- 239000000463 material Substances 0.000 description 6
- 239000000919 ceramic Substances 0.000 description 3
- 238000005192 partition Methods 0.000 description 3
- 210000002105 tongue Anatomy 0.000 description 3
- 239000004020 conductor Substances 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 125000006850 spacer group Chemical group 0.000 description 2
- 238000004544 sputter deposition Methods 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 238000004512 die casting Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000010292 electrical insulation Methods 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- 238000007650 screen-printing Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
Images
Classifications
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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
- H05B3/02—Details
- H05B3/03—Electrodes
-
- 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
-
- 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
-
- 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
- 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
-
- 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
- H05B3/141—Conductive ceramics, e.g. metal oxides, metal carbides, barium titanate, ferrites, zirconia, vitrous compounds
-
- 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
- H05B3/18—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor the conductor being embedded in an insulating material
-
- 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
-
- 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
- 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
- H05B3/52—Apparatus or processes for filling or compressing insulating material in tubes
-
- 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
- F24H2250/00—Electrical heat generating means
- F24H2250/04—Positive or negative temperature coefficients, e.g. PTC, NTC
-
- 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
-
- 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
Definitions
- the present invention relates to a PTC heating device and a method for producing the same.
- the present invention is based on a PTC heating device with a frame in which a heating cell comprising at least one PTC element made of a ceramic material and contact elements assigned to different polarities are accommodated.
- the PTC element has contact surfaces formed by metallization. The contact elements are electrically contacted with these contact surfaces.
- the present invention relates in particular to such a PTC heating device for heat management in a motor vehicle.
- PTC heating devices of the type mentioned at the beginning are sometimes operated with higher voltages than 12 V, which places special demands on the electrical safety that must be observed. From this point of view, not only must a safe electrical insulation of the parts of the heating cell that carry the power current be ensured from the outside. Rather, air and creepage distances must also be designed accordingly.
- the PTC heating device must be able to be manufactured in a process-reliable manner, whereby a component in a vehicle has to meet particularly economic requirements with regard to production. It is known to completely or partially surround a heating cell with a hardening mass in order, for example, to replace air present in the frame with a material that conducts heat better.
- a particularly electrically insulating mass is sometimes also used to completely or partially electrically enclose the PTC heating cell, with the result that at least the parts carrying the power current are also covered by the electrically insulating mass inside the heating cell.
- the present invention is based on the object of providing a PTC heating device which provides good electrical safety and can be produced economically.
- the present invention proposes a PTC heating device with a frame in which a heating cell is arranged.
- This comprises a PTC element made of a ceramic material.
- Metallization is provided on opposite sides, usually main side surfaces of the PTC element. This is usually by sputtering an electrically conductive material onto the ceramic surface of the PTC element.
- Contact elements are electrically conductive against the regularly opposing contact surfaces formed by the metallization, which serve to supply the power current to the PTC element.
- These contact elements can be formed by contact plates.
- the contact elements can also be formed by other electrically conductive structures that can consist of one or more materials that do not necessarily have to be electrically conductive.
- the frame can be made of plastic or ceramic. Usually, a material is selected that has very good electrically insulating properties.
- the frame can only have bars that surround the PTC element.
- the frame can be made of one or more parts.
- the frame can be made in one piece with the contact element by itself or by a segment of the frame, in particular by molding the contact element with plastic.
- the frame is usually surmounted on one side by connection lugs that are electrically conductively connected to the respective contact elements, preferably made in one piece by them.
- an electrically insulating mass which can be made of silicone, for example, is located between the inner circumference of the frame and the outer circumference of the heating cell.
- the mass is hardened and therefore dimensionally stable.
- the mass serves to fix the heating cell within the frame.
- the mass can only be located between the outer circumference of the PTC element and the inner circumference of the frame. However, it can also be connected to the opposite inner surfaces of the contact elements.
- the contact elements preferably protrude beyond the main side surfaces of the PTC element provided with the metallization. This results in an edge-side, possibly circumferential, overhang of the PTC element due to the two contact elements.
- the hardened mass is located in particular in the gap formed between the overhangs.
- an edge formed by the ceramic material of the PTC element is located between the contact surface and the hardened mass.
- This edge can only be partially formed on one long side of the PTC element, which is usually provided in a cuboid shape.
- the edge can extend over an entire long side of the PTC element.
- the edge is usually provided as a peripheral edge on the main side surface of the PTC element.
- the edge creates a distance of at least 0.1 mm between the outer peripheral surface of the PTC element and the metallization.
- the edge distances the conductor path for the power current provided on the PTC element in the form of the contact surfaces from the outer contour of the PTC element.
- the hardened mass provided adjacent to the edge does not directly contact the metallization.
- the mass is only located at discrete locations on the outer circumference of the heating cell.
- discrete dosages of the hardened mass are preferably provided on the outer circumference of the heating cell. These discrete dosages do indeed adequately fix the heating cell in the frame. However, the dosage is also carried out with a view to using as little mass as possible to produce the PTC heating device. This not only saves material from the mass, but also shortens the time required for the mass to harden during the production of the PTC heating device.
- mass is usually introduced into the frame on opposite sides between the heating cell and the frame.
- the mass is usually introduced into the frame, which is still open on one side.
- the frame or a segment of the frame is usually closed on one side, for example by attaching and connecting one of the contact elements to the frame. During assembly, this side forms the underside of the frame or frame segment.
- the term frame is also used as a synonym for the frame segment.
- the PTC element is then inserted into the frame or frame segment, which is open at the top.
- the contact surface is placed against the contact element in an electrically conductive manner.
- the mass is then metered into the gap between the PTC element and the frame.
- the metering is carried out in such a way that no mass protrudes onto the main side surface of the PTC element.
- Appropriate volumetric metering ensures that the mass stays within the gap and does not protrude beyond the frame.
- the mass is usually introduced up to the height of the contact surface that has not yet been covered with a contact element. When the other contact element is subsequently placed on the PTC element, this can result in a slight displacement of the mass, which also applies the mass against both inner surfaces of the contact elements and, if necessary, slightly pressed in the area of the overhang. In this way, the other contact element is usually fixed to the PTC element and the frame using the mass.
- the contact element can be adapted to the dimensions of the contact surface and can be made smaller than usual. It is usual for the PTC element to be overhanged by the contact elements on its entire outer circumference.
- the contact element, which is placed later, can also be joined beforehand with another segment of the frame to form a pre-assembled unit, for example by overmolding a plastic that forms the segment around the contact element.
- the PTC heating device is usually part of an electric heating device of a motor vehicle.
- This heating device has a heater housing with inlet and outlet openings for a medium to be heated.
- the housing accommodates at least one, usually several PTC heating devices according to the present invention. These are coupled in a heat-conducting manner to the medium to be heated.
- the medium to be heated can be a liquid or gaseous medium.
- insulating layers are usually located on the outside of the respective contact elements, against which corrugated fin layers rest on the outside.
- the electrical heating device usually comprises several layers of corrugated fins and PTC heating devices. This layering is fixed in a frame-shaped heater housing, usually under pre-tension from a spring; cf. EP 2 298 582 B1 .
- the PTC heating device of the type mentioned above can also be arranged in a metallic housing which forms a type of pocket into which the PTC heating device is inserted (cf. EP 3 101 364 A1 ).
- an insulating layer is usually applied to the outer surfaces of the contact elements beforehand so that there is no direct electrical contact between the elements of the PTC heating device that carry the power current and the housing.
- the connection lugs protrude above the housing.
- connection chamber usually also houses a control system for the electrical heating device.
- the present invention offers a number of advantages. By reducing the total mass used, not only is material saved, but also the time required for the mass to harden is reduced. By using a smaller volume of hardened mass and discretely dosing mass at predetermined locations, excess mass is prevented. In particular, it is prevented that the mass in the During production, the dirt spreads over areas of the contact surface, contaminating it and preventing the power current from being introduced onto the PTC element over as wide an area as possible. In particular, a surrounding edge prevents contact between the ground and the contact surface and also edge flashovers of the power current.
- the Figure 1 shows an embodiment of an electric heating device 2 with a multi-part heater housing, which comprises a lower housing part 4 made of plastic and a housing upper part 6 made of metal by means of die casting.
- the housing base 4 is trough-shaped and encloses a heating chamber 8 and forms inlet and outlet nozzles 10 that communicate with the heating chamber 8. These inlet and outlet nozzles 10 are formed as one piece with the housing base 4 by means of injection molding. Between the housing top 6 and the housing base 4, several PTC heating devices 12 are shown.
- these PTC heating devices 12 each have at least one PTC element 14, against which contact elements 16.1; 16.2 rest, forming contact tongues 18 which protrude beyond a metallic housing 20.
- the PTC element 14 is accommodated in a frame 22 and between the contact elements 16.1; 16.2.
- Insulating layers 26 are provided between the metallic housing 20 and a heating cell 24 formed by the two contact elements 16.1; 16.2 and the PTC element 14.
- the PTC heating devices 12 are plugged into a receptacle 28 provided for this purpose in a partition wall 30 of the upper housing part 6 and are electrically connected and controlled in a connection chamber 29 of a control device 31. Details of this design are described in the applicant's EP 3 334 242 A1 described.
- FIG.3 shows details of the frame 22, which comprises longitudinal and transverse beams 32; 34, from which spacer webs 36 protrude inwards, which allow pre-positioning of the PTC element 14 in the frame 22.
- the Fig.3 The upper cross member 34 is surmounted by the contact tongues 18.
- Fig.5 As shown in Fig.3 lower boundary of the receiving space for the PTC element 14 in the frame 22 is formed by the lower contact element 16.1, which is connected to the frame 22 by overmolding.
- the Fig. 3 and 5 also reveal a metallization 38 which is applied to the ceramic material of the PTC element 14 by sputtering or printing a metallic layer using screen printing and which forms a contact surface 40 on opposite sides of the PTC element 14.
- the ceramic surface of the PTC element 14 is exposed between the contact surface 40 and a peripheral surface of the PTC element 14 identified by reference numeral 42. As a result, an edge 44 which circumferentially delimits the contact surface 40 is formed on the main side surface of the PTC element 14 (cf. Fig.3 ).
- the Fig. 3 and 5 also reveal plugs of a hardened electrically insulating mass 46.
- the mass 46 is provided between one of the cross members 34 and the heating cell 24. Otherwise, a gap 48 remaining between the PTC element 14 and an inner circumferential surface of the frame 22 is free of material of the mass 46.
- the frame 22 with the lower contact element 16.1 is first produced by overmolding this contact element with a plastic that forms the frame 22.
- the PTC element 14 is then placed in the frame 22 with the first contact element 16.1 facing downwards, as can be seen.
- the discrete doses of the mass 46 are then introduced between the outer peripheral surface 42 and the frame 22.
- the second contact element 16.2 is then placed on top. This further contact element 16.2 lies against the mass 46, which is then cured by energizing the PTC element 14. Curing by means of an oven process is also possible.
- the two contact elements 16.1 and 16.2 are then connected to the PTC element 14 and the frame 22.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Resistance Heating (AREA)
Abstract
Die vorliegende Erfindung betrifft eine PTC-Heizvorrichtung (12) und ein Verfahren zu deren Herstellung mit einem Rahmen (22), in dem eine Heizzelle (24) umfassend zumindest ein PTC-Element (14) aus einem keramischen Material und unterschiedlicher Polarität zuzuordnende Kontaktelemente (16.1; 16.2) aufgenommen sind, wobei das PTC-Element (14) durch eine Metallisierung (38) gebildete Kontaktflächen (40) aufweist und die Kontaktelemente (16.1; 16.2) jeweils mit einer der Kontaktflächen (40) elektrisch kontaktiert sind. Eine wirtschaftlich herstellbare und im Hinblick auf die elektrische Sicherheit verbesserte PTC-Heizvorrichtung (14) nach der vorliegenden Erfindung hat eine elektrisch isolierende ausgehärtete Masse (46), die zwischen dem Außenumfang der Heizzelle (24) und dem Innenumfang des Rahmens (22) angeordnet ist und die die Heizzelle (24) in dem Rahmen (22) festlegt, wobei zwischen der Masse (46) und der Kontaktfläche (40) ein durch das keramische Material des PTC-Elementes (14) gebildeter Rand (44) vorgesehen ist. Bei dem erfindungsgemäßen Verfahren wird nach Einbringen des PTC-Elementes (14) in den Rahmen (22) auf Höhe des Randes (44) eine elektrisch isolierende Masse (46) eingebracht, durch die das PTC-Element (14) nach dem Aushärten des Rahmens (22) festgelegt ist.The present invention relates to a PTC heating device (12) and a method for producing the same, having a frame (22) in which a heating cell (24) comprising at least one PTC element (14) made of a ceramic material and contact elements (16.1; 16.2) assigned to different polarities are accommodated, wherein the PTC element (14) has contact surfaces (40) formed by a metallization (38) and the contact elements (16.1; 16.2) are each electrically contacted with one of the contact surfaces (40). A PTC heating device (14) according to the present invention which can be produced economically and is improved with regard to electrical safety has an electrically insulating hardened mass (46) which is arranged between the outer circumference of the heating cell (24) and the inner circumference of the frame (22) and which fixes the heating cell (24) in the frame (22), wherein an edge (44) formed by the ceramic material of the PTC element (14) is provided between the mass (46) and the contact surface (40). In the method according to the invention, after the PTC element (14) has been introduced into the frame (22), an electrically insulating mass (46) is introduced at the level of the edge (44), by means of which the PTC element (14) is fixed after the frame (22) has hardened.
Description
Die vorliegende Erfindung betrifft eine PTC-Heizeinrichtung und ein Verfahren zur Herstellung einer solchen.The present invention relates to a PTC heating device and a method for producing the same.
Die vorliegende Erfindung geht von einer PTC-Heizeinrichtung mit einem Rahmen aus, in dem eine Heizzelle umfassend zumindest ein PTC-Element aus einem keramischen Material und unterschiedlicher Polarität zuzuordnende Kontaktelemente aufgenommen sind. Das PTC-Element hat durch eine Metallisierung gebildete Kontaktflächen. Mit diesen Kontaktflächen sind die Kontaktelemente elektrisch kontaktiert.The present invention is based on a PTC heating device with a frame in which a heating cell comprising at least one PTC element made of a ceramic material and contact elements assigned to different polarities are accommodated. The PTC element has contact surfaces formed by metallization. The contact elements are electrically contacted with these contact surfaces.
Die vorliegende Erfindung betrifft insbesondere eine derartige PTC-Heizvorrichtung für das Wärmemanagement in einem Kraftfahrzeug. Hier werden PTC-Heizvorrichtungen der eingangs genannten Art mitunter mit höheren Spannungen als 12 V betrieben, was besondere Anforderungen an die einzuhaltende elektrische Sicherheit stellt. Unter diesem Gesichtspunkt muss nicht nur eine sichere elektrische Isolierung der den Leistungsstrom führenden Teile der Heizzelle nach außen gewährleistet werden. Vielmehr müssen auch Luft- und Kriechstrecken entsprechend ausgelegt werden.The present invention relates in particular to such a PTC heating device for heat management in a motor vehicle. Here, PTC heating devices of the type mentioned at the beginning are sometimes operated with higher voltages than 12 V, which places special demands on the electrical safety that must be observed. From this point of view, not only must a safe electrical insulation of the parts of the heating cell that carry the power current be ensured from the outside. Rather, air and creepage distances must also be designed accordingly.
Die PTC-Heizvorrichtung muss sich prozesssicher herstellen lassen, wobei an ein Bauteil in einem Fahrzeug insbesondere wirtschaftliche Anforderungen hinsichtlich der Herstellung gestellt werden. Es ist bekannt, eine Heizzelle ganz oder teilweise mit einer aushärtenden Masse zu umgeben, um beispielsweise in dem Rahmen vorhandene Luft durch ein besser wärmeleitendes Material zu ersetzen.The PTC heating device must be able to be manufactured in a process-reliable manner, whereby a component in a vehicle has to meet particularly economic requirements with regard to production. It is known to completely or partially surround a heating cell with a hardening mass in order, for example, to replace air present in the frame with a material that conducts heat better.
Eine insbesondere elektrisch isolierende Masse wird mitunter auch genutzt, um die PTC-Heizzelle ganz oder teilweise elektrisch einzuhausen mit dem Ergebnis, dass zumindest die den Leistungsstrom führenden Teile auch im Inneren der Heizzelle von der elektrisch isolierenden Masse bedeckt sind.A particularly electrically insulating mass is sometimes also used to completely or partially electrically enclose the PTC heating cell, with the result that at least the parts carrying the power current are also covered by the electrically insulating mass inside the heating cell.
Es ist zwar bekannt, die für das Aushärten der Masse notwendige Zeit dadurch zu verringern, dass diese erhitzt wird, beispielsweise durch Betrieb der Heizzelle im Rahmen der Herstellung oder durch einen Ofenprozess. Allerdings bieten die derzeitigen Lösungen noch Raum für eine Verschlankung des Herstellungsverfahrens.Although it is known that the time required for the mass to harden can be reduced by heating it, for example by operating the heating cell during production or by using an oven process, current solutions still offer scope for streamlining the production process.
Der vorliegenden Erfindung liegt die Aufgabe zugrunde, eine PTC-Heizvorrichtung anzugeben, die eine gute elektrische Sicherheit bereitstellt und sich wirtschaftlich herstellen lässt.The present invention is based on the object of providing a PTC heating device which provides good electrical safety and can be produced economically.
Zur Lösung dieses Problems wird mit der vorliegenden Erfindung eine PTC-Heizvorrichtung mit einem Rahmen vorgeschlagen, in dem eine Heizzelle angeordnet ist. Diese umfasst ein PTC-Element aus einem keramischen Material. Auf gegenüberliegenden Seiten, üblicherweise Hauptseitenflächen des PTC-Elementes, ist eine Metallisierung vorgesehen. Diese wird üblicherweise durch Sputtern eines elektrisch leitenden Materials auf die keramische Oberfläche des PTC-Elementes erzeugt. Gegen die durch die Metallisierung gebildeten, sich regelmäßig gegenüberliegenden Kontaktflächen liegen Kontaktelemente elektrisch leitend an, die der Zuleitung des Leistungsstromes zu dem PTC-Element dienen. Diese Kontaktelemente können durch Kontaktbleche gebildet sein. Die Kontaktelemente können aber auch durch andere elektrisch leitenden Strukturen gebildet sein, die aus einem oder mehreren Werkstoffen bestehen können, die nicht notwendigerweise jeweils elektrisch leitend sein müssen. So ist es bekannt, Streckmetall oder auch ein Drahtgitter als Kontaktelement zu verwenden, dessen Freiräume durch einen gut wärmeleitenden Kleber ausgefüllt sind (
Der Rahmen kann aus einem Kunststoff oder einer Keramik gebildet sein. Üblicherweise wird jedenfalls ein Material ausgewählt, welches sehr gute elektrisch isolierende Eigenschaften hat. Der Rahmen kann lediglich das PTC-Element umfänglich umgebende Holme aufweisen. Der Rahmen kann ein- oder mehrteilig ausgebildet sein. Der Rahmen kann für sich oder durch ein Segment des Rahmens einteilig mit dem Kontaktelement ausgebildet, insbesondere durch Umspritzen des Kontaktelementes mit Kunststoff gebildet sein. Der Rahmen ist üblicherweise an einer Seite von Anschlussfahnen überragt, die elektrisch leitend mit den jeweiligen Kontaktelementen verbunden, bevorzugt einteilig durch diese ausgebildet, sind.The frame can be made of plastic or ceramic. Usually, a material is selected that has very good electrically insulating properties. The frame can only have bars that surround the PTC element. The frame can be made of one or more parts. The frame can be made in one piece with the contact element by itself or by a segment of the frame, in particular by molding the contact element with plastic. The frame is usually surmounted on one side by connection lugs that are electrically conductively connected to the respective contact elements, preferably made in one piece by them.
Zwischen dem Innenumfang des Rahmens und dem Außenumfang der Heizzelle befindet sich gemäß der vorliegenden Erfindung eine elektrisch isolierende Masse, die beispielweise durch Silikon gebildet sein kann. Die Masse ist ausgehärtet und dadurch formsteif. Die Masse dient dazu, die Heizzelle innerhalb des Rahmens festzulegen. Die Masse kann sich lediglich zwischen dem Außenumfang des PTC-Elementes und dem Innenumfang des Rahmens befinden. Sie kann aber auch an den einander gegenüberliegenden Innenflächen der Kontaktelemente angebunden sein. Bevorzugt überragen die Kontaktelemente die mit der Metallisierung vorgesehenen Hauptseitenflächen des PTC-Elementes. So ergibt sich ein randseitiger ggf. umfänglicher Überhang des PTC-Elementes aufgrund der beiden Kontaktelemente. Zur Festlegung der Heizzelle befindet sich die ausgehärtete Masse insbesondere in dem zwischen den Überhängen gebildeten Spalt.According to the present invention, an electrically insulating mass, which can be made of silicone, for example, is located between the inner circumference of the frame and the outer circumference of the heating cell. The mass is hardened and therefore dimensionally stable. The mass serves to fix the heating cell within the frame. The mass can only be located between the outer circumference of the PTC element and the inner circumference of the frame. However, it can also be connected to the opposite inner surfaces of the contact elements. The contact elements preferably protrude beyond the main side surfaces of the PTC element provided with the metallization. This results in an edge-side, possibly circumferential, overhang of the PTC element due to the two contact elements. To fix the heating cell, the hardened mass is located in particular in the gap formed between the overhangs.
Gemäß der vorliegenden Erfindung befindet sich zwischen der Kontaktfläche und der ausgehärteten Masse ein durch das keramische Material des PTC-Elementes gebildeter Rand. Dieser Rand kann an einer Längsseite des üblicherweise quaderförmig vorgesehenen PTC-Elementes nur teilweise ausgebildet sein. Der Rand kann sich über eine gesamte Längsseite des PTC-Elementes erstrecken. Der Rand ist üblicherweise als umlaufender Rand auf der Hauptseitenfläche des PTC-Elementes ausgebildet. Der Rand schafft einen Abstand zwischen der Außenumfangsfläche des PTC-Elementes und der Metallisierung von zumindest 0,1 mm. Der Rand beabstandet die an dem PTC-Element vorgesehene Leitungsbahn für den Leistungsstrom in Form der Kontaktflächen von der äußeren Kontur des PTC-Elementes. Die benachbart zu dem Rand vorgesehene ausgehärtete Masse kontaktiert nicht direkt die Metallisierung. Durch diese Maßnahmen wird die elektrische Sicherheit der PTC-Heizvorrichtung erhöht.According to the present invention, an edge formed by the ceramic material of the PTC element is located between the contact surface and the hardened mass. This edge can only be partially formed on one long side of the PTC element, which is usually provided in a cuboid shape. The edge can extend over an entire long side of the PTC element. The edge is usually provided as a peripheral edge on the main side surface of the PTC element. The edge creates a distance of at least 0.1 mm between the outer peripheral surface of the PTC element and the metallization. The edge distances the conductor path for the power current provided on the PTC element in the form of the contact surfaces from the outer contour of the PTC element. The hardened mass provided adjacent to the edge does not directly contact the metallization. These measures increase the electrical safety of the PTC heating device.
Nach der vorliegenden Erfindung wird nicht der gesamte zwischen dem Rahmen und der Heizzelle vorgesehene Freiraum mit der Masse ausgefüllt. Vielmehr befindet sich die Masse lediglich an diskreten Stellen am Außenumfang der Heizzelle. Nach der vorliegenden Erfindung werden bevorzugt diskrete Dosierungen der ausgehärteten Masse an dem Außenumfang der Heizzelle vorgesehen. Durch diese diskreten Dosierungen wird zwar die Heizzelle in dem Rahmen angemessen festgelegt. Die Dosierung erfolgt aber auch mit Blick auf eine möglichst geringe Menge der zur Herstellung der PTC-Heizeinrichtung verwendeten Masse. Dadurch lässt sich nicht nur Material der Masse einsparen. Vielmehr kann auch die Zeit für das Aushärten der Masse im Rahmen der Herstellung der PTC-Heizvorrichtung verkürzt werden.According to the present invention, not all of the free space provided between the frame and the heating cell is filled with the mass. Rather, the mass is only located at discrete locations on the outer circumference of the heating cell. According to the present invention, discrete dosages of the hardened mass are preferably provided on the outer circumference of the heating cell. These discrete dosages do indeed adequately fix the heating cell in the frame. However, the dosage is also carried out with a view to using as little mass as possible to produce the PTC heating device. This not only saves material from the mass, but also shortens the time required for the mass to harden during the production of the PTC heating device.
Zur Festlegung der Heizzelle wird Masse üblicherweise auf gegenüberliegenden Seiten zwischen der Heizzelle und dem Rahmen in diesen eingebracht. Das Einbringen der Masse erfolgt üblicherweise an dem einseitig noch offenen Rahmen. Mit anderen Worten wird üblicherweise der Rahmen oder ein Segment des Rahmens einseitig verschlossen, beispielsweise durch Anbringen und Verbinden eines der Kontaktelemente mit dem Rahmen. Diese Seite bildet im Rahmen der Montage die Unterseite des Rahmens bzw. Rahmensegments. Im Folgenden wird der Begriff Rahmen auch als Synonym für das Rahmensegment verwendet. In den oben offenen Rahmen bzw. das oben offene Rahmensegment wird danach das PTC-Element eingelegt.To secure the heating cell, mass is usually introduced into the frame on opposite sides between the heating cell and the frame. The mass is usually introduced into the frame, which is still open on one side. In other words, the frame or a segment of the frame is usually closed on one side, for example by attaching and connecting one of the contact elements to the frame. During assembly, this side forms the underside of the frame or frame segment. In the following, the term frame is also used as a synonym for the frame segment. The PTC element is then inserted into the frame or frame segment, which is open at the top.
Dabei wird die Kontaktfläche elektrisch leitend gegen das Kontaktelement angelegt. Danach erfolgt das Dosieren der Masse in den Spalt zwischen dem PTC-Element und dem Rahmen. Das Dosieren erfolgt so, dass sich kein auf die Hauptseitenfläche des PTC-Elementes erstreckender Überstand der Masse ergibt. Durch angemessene volumetrische Dosierung wird sichergestellt, dass die Masse innerhalb des Spaltes bleibt und auch nicht nach außen über den Rahmen hinaustritt. Die Masse wird aber üblicherweise bis auf die Höhe der noch nicht mit einem Kontaktelement belegten Kontaktfläche eingebracht. Beim nachfolgenden Auflegen des anderen Kontaktelementes auf das PTC-Element kann sich so eine geringfügige Verdrängung der Masse ergeben, durch die die Masse auch gegen beide Innenflächen der Kontaktelemente angelegt und ggf. im Bereich des Überhangs geringfügig verpresst wird. So werden regelmäßig das andere Kontaktelement über die Masse gegenüber dem PTC-Element und dem Rahmen fixiert.The contact surface is placed against the contact element in an electrically conductive manner. The mass is then metered into the gap between the PTC element and the frame. The metering is carried out in such a way that no mass protrudes onto the main side surface of the PTC element. Appropriate volumetric metering ensures that the mass stays within the gap and does not protrude beyond the frame. However, the mass is usually introduced up to the height of the contact surface that has not yet been covered with a contact element. When the other contact element is subsequently placed on the PTC element, this can result in a slight displacement of the mass, which also applies the mass against both inner surfaces of the contact elements and, if necessary, slightly pressed in the area of the overhang. In this way, the other contact element is usually fixed to the PTC element and the frame using the mass.
Für diese Festlegung ist es lediglich gewünscht, dass das weitere, später aufgelegte Kontaktelement jedenfalls die Masse mit einem Überhang überragt. Das Kontaktelement kann ansonsten auf die Abmessung der Kontaktfläche angepasst und dementsprechend kleiner als üblich ausgebildet werden. Üblich ist, dass das PTC-Element an seinem gesamten Außenumfang jeweils von den Kontaktelementen überragt wird. Das später aufgelegte Kontaktelement kann auch zuvor mit einem anderen Segment des Rahmens zu einer vormontierten Einheit gefügt werden, beispielsweise durch Umspritzen eines das Segment ausbildenden Kunststoffs um das Kontaktelement.For this purpose, it is only necessary that the additional contact element, which is placed later, overhangs the mass. Otherwise, the contact element can be adapted to the dimensions of the contact surface and can be made smaller than usual. It is usual for the PTC element to be overhanged by the contact elements on its entire outer circumference. The contact element, which is placed later, can also be joined beforehand with another segment of the frame to form a pre-assembled unit, for example by overmolding a plastic that forms the segment around the contact element.
Die erfindungsgemäße PTC-Heizvorrichtung ist üblicherweise Teil einer elektrischen Heizvorrichtung eines Kraftfahrzeuges. Diese Heizvorrichtung hat ein Heizergehäuse mit Ein- und Auslassöffnungen für ein zu erwärmendes Medium. Das Gehäuse nimmt zumindest eine, üblicherweise mehrere PTC-Heizvorrichtungen gemäß der vorliegenden Erfindung in sich auf. Diese sind wärmeleitend mit dem zu erwärmenden Medium gekoppelt. Das zu erwärmende Medium kann ein flüssiges oder gasförmiges Medium sein.The PTC heating device according to the invention is usually part of an electric heating device of a motor vehicle. This heating device has a heater housing with inlet and outlet openings for a medium to be heated. The housing accommodates at least one, usually several PTC heating devices according to the present invention. These are coupled in a heat-conducting manner to the medium to be heated. The medium to be heated can be a liquid or gaseous medium.
Im Falle eines gasförmigen Mediums befinden sich an der Außenseite der jeweiligen Kontaktelemente üblicherweise isolierende Lagen, gegen die außen Wellrippenlagen anliegen. Üblicherweise umfasst die elektrische Heizvorrichtung mehrere Schichten von Wellrippen und PTC-Heizvorrichtungen. Diese Schichtung ist in einem rahmenförmig ausgebildeten Heizergehäuse üblicherweise unter Vorspannung einer Feder fixiert; vgl.
Für den Einbau in der elektrischen Heizvorrichtung kann die PTC-Heizvorrichtung der eingangs genannten Art auch in einem metallischen Gehäuse angeordnet sein, das eine Art Tasche ausbildet, in welche die PTC-Heizvorrichtung eingebracht wird (vgl.
Die vorliegende Erfindung bietet eine Vielzahl von Vorteilen. Durch Reduzieren der insgesamt verwendeten Masse wird nicht nur Material eingespart. Vielmehr wird auch die Zeit, die für das Aushärten der Masse erforderlich ist, reduziert. Durch ein geringeres Volumen der verwendeten ausgehärteten Masse und das diskrete Dosieren von Masse an vorbestimmten Stellen wird ein Überstand der Masse verhindert. Es wird insbesondere verhindert, dass sich die Masse im Rahmen der Herstellung auf Bereiche der Kontaktfläche ausbreitet, diese verschmutzt und die möglichst flächige Einleitung des Leistungsstromes auf das PTC-Element verhindert. Insbesondere durch einen umlaufenden Rand wird ein Kontakt der Masse mit der Kontaktfläche und auch Randüberschläge des Leistungsstromes vermieden.The present invention offers a number of advantages. By reducing the total mass used, not only is material saved, but also the time required for the mass to harden is reduced. By using a smaller volume of hardened mass and discretely dosing mass at predetermined locations, excess mass is prevented. In particular, it is prevented that the mass in the During production, the dirt spreads over areas of the contact surface, contaminating it and preventing the power current from being introduced onto the PTC element over as wide an area as possible. In particular, a surrounding edge prevents contact between the ground and the contact surface and also edge flashovers of the power current.
Weitere Einzelheiten und Vorteile der vorliegenden Erfindung ergeben sich aus der nachfolgenden Beschreibung eines Ausführungsbeispiels in Verbindung mit der Zeichnung. In dieser zeigen:
- Fig. 1
- eine perspektivische Explosionszeichnung eines Ausführungsbeispiels einer elektrischen Heizvorrichtung;
- Fig. 2
- eine Längsschnittansicht einer PTC-Heizeinrichtung der Heizvorrichtung nach Figur 1;
- Fig. 3
- eine Draufsicht auf Teile des Ausführungsbeispiels der PTC-Heizvorrichtung im Rahmen der Montage nach dem Einbringen der Masse;
- Fig. 4
- eine Ansicht gemäß
Fig. 3 nach dem Aufbringen des weiteren Kontaktelementes und - Fig. 5
- eine Querschnittsansicht entlang der Linie V-V gemäß
Fig. 3 .
- Fig.1
- an exploded perspective view of an embodiment of an electric heating device;
- Fig.2
- a longitudinal sectional view of a PTC heating device of the heating apparatus according to Figure 1;
- Fig.3
- a plan view of parts of the embodiment of the PTC heating device during assembly after the introduction of the mass;
- Fig.4
- a view according to
Fig.3 after applying the additional contact element and - Fig.5
- a cross-sectional view along the line VV according to
Fig.3 .
Die
Das Gehäuseunterteil 4 ist wannenförmig ausgebildet und umschließt eine Heizkammer 8 und bildet Ein- und Auslassstutzen 10 aus, die mit der Heizkammer 8 kommunizieren. Diese Ein- und Auslassstutzen 10 sind einteilig mit dem Gehäuseunterteil 4 mittels Spritzgießen ausgeformt. Zwischen dem Gehäuseoberteil 6 und dem Gehäuseunterteil 4 sind mehrere von PTC-Heizeinrichtungen 12 dargestellt.The
Wie
Die PTC-Heizvorrichtungen 12 sind steckkontaktiert in dazu vorgesehenen Aufnahme 28 einer Trennwand 30 des Gehäuseoberteils 6 gehalten und in einer Anschlusskammer 29 eines Steuereinrichtung 31 elektrisch angeschlossen und gesteuert. Details dieser Ausgestaltung sind in der auf die Anmelderin zurückgehenden
Die Draufsicht nach
Die
Im Rahmen der Herstellung wird zunächst der Rahmen 22 mit dem unteren Kontaktelement 16.1 durch Umspritzen dieses Kontaktelements mit einem den Rahmen 22 bildenden Kunststoff hergestellt. In der in
Es können weitere Fertigungsschritte folgen, bei welchen der PTC-Heizvorrichtung 12 noch weitere Komponenten hinzugefügt werden, die unter Bezugnahme auf
- 22
- HeizvorrichtungHeating device
- 44
- GehäuseunterteilHousing base
- 66
- GehäuseoberteilHousing top
- 88th
- HeizkammerHeating chamber
- 1010
- Ein- und AuslassstutzenInlet and outlet nozzles
- 1212
- PTC-HeizvorrichtungPTC heater
- 1414
- PTC-ElementPTC element
- 1616
- KontaktelementContact element
- 16.116.1
- unteres Kontaktelementlower contact element
- 16.216.2
- oberes Kontaktelementupper contact element
- 1818
- KontaktzungeContact tongue
- 2020
- GehäuseHousing
- 2222
- RahmenFrame
- 2424
- HeizzelleHeating cell
- 2626
- IsolierlageInsulation layer
- 2828
- AufnahmeRecording
- 2929
- AnschlusskammerConnection chamber
- 3030
- Trennwandpartition wall
- 3131
- SteuereinrichtungControl device
- 3232
- LängsholmLongitudinal beam
- 3434
- QuerholmCrossbar
- 3636
- AbstandsstegSpacer bar
- 3838
- MetallisierungMetallization
- 4040
- KontaktflächeContact surface
- 4242
- UmfangsflächeCircumferential area
- 4444
- Randedge
- 4646
- MasseDimensions
- 4848
- Spaltgap
Claims (9)
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EP (1) | EP4351273A1 (en) |
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Citations (7)
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US20070068913A1 (en) * | 2005-09-23 | 2007-03-29 | Catem Gmbh & Co. Kg | Heat-Generating Element of a Heating Device |
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US20160360573A1 (en) * | 2015-06-02 | 2016-12-08 | Eberspacher Catem Gmbh & Co. Kg | PTC Heating Element and Electric Heating Device Comprising Such a PTC Heating Element and Method for Producing an Electric Heating Device |
EP3334242A1 (en) | 2016-12-06 | 2018-06-13 | Eberspächer catem GmbH & Co. KG | Electric heating device |
EP3515152A2 (en) | 2017-12-22 | 2019-07-24 | Eberspächer catem GmbH & Co. KG | Heating element of an electric heating device |
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DE3583932D1 (en) | 1984-12-18 | 1991-10-02 | Matsushita Electric Ind Co Ltd | SELF-REGULATING HEATING ITEM WITH ELECTRODES THAT ARE DIRECTLY CONNECTED TO A PTC LAYER. |
JPH05114466A (en) | 1991-10-22 | 1993-05-07 | Matsushita Electric Ind Co Ltd | Heating body having positive resistance temperature coefficient and manufacture thereof |
DE102018209777A1 (en) | 2018-06-18 | 2019-12-19 | Mahle International Gmbh | PTC heating module |
DE102018218667A1 (en) | 2018-10-31 | 2020-04-30 | Mahle International Gmbh | PTC heating module and a method for manufacturing the PTC heating module |
-
2022
- 2022-10-05 DE DE102022125637.5A patent/DE102022125637A1/en active Pending
-
2023
- 2023-09-27 CN CN202311287392.XA patent/CN117858283A/en active Pending
- 2023-10-02 EP EP23201142.9A patent/EP4351273A1/en active Pending
- 2023-10-04 US US18/376,550 patent/US20240121864A1/en active Pending
Patent Citations (7)
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US20070068913A1 (en) * | 2005-09-23 | 2007-03-29 | Catem Gmbh & Co. Kg | Heat-Generating Element of a Heating Device |
EP2298582B1 (en) | 2009-09-22 | 2011-11-16 | Eberspächer catem GmbH & Co. KG | Electric heating device and method for its production |
EP3101364A1 (en) | 2015-06-02 | 2016-12-07 | Eberspächer catem GmbH & Co. KG | Electric heating device |
US20160360573A1 (en) * | 2015-06-02 | 2016-12-08 | Eberspacher Catem Gmbh & Co. Kg | PTC Heating Element and Electric Heating Device Comprising Such a PTC Heating Element and Method for Producing an Electric Heating Device |
EP3334242A1 (en) | 2016-12-06 | 2018-06-13 | Eberspächer catem GmbH & Co. KG | Electric heating device |
EP3515152A2 (en) | 2017-12-22 | 2019-07-24 | Eberspächer catem GmbH & Co. KG | Heating element of an electric heating device |
EP3584808B1 (en) * | 2018-06-18 | 2021-10-06 | Mahle International GmbH | Ptc heating module for heating a fluid |
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