WO2006073264A1

WO2006073264A1 - Ptc rod assembly and pre-heater including the same

Info

Publication number: WO2006073264A1
Application number: PCT/KR2006/000025
Authority: WO
Inventors: Sung Mok Hong
Original assignee: Modine Korea, Llc
Priority date: 2005-01-08
Filing date: 2006-01-04
Publication date: 2006-07-13
Also published as: DE112006000165T5; CN101102912A; KR100492374B1

Abstract

The present invention provides a PTC rod assembly, including PTC elements, for use in a pre-heater for a vehicle, and a pre-heater for a vehicle including the same. The PTC rod assembly comprises a lower PTC rod constructed in the form of an elongated channel with an open side; an anode terminal placed within the lower PTC rod while being enclosed by an insulator made of an insulating material such that the anode terminal is not in contact with the lower PTC rod; PTC elements constructed to generate heat upon application of electric power thereto and coupled to be in contact with one side of the anode terminal; heat transfer blocks made of a material with high thermal conductivity and brought into contact with the other side surface of the anode terminal; and an upper PTC rod coupled to cover the open side of the lower PTC rod. According to the PTC rod assembly and the pre-heater for a vehicle including the same, the insulator for fixing the anode terminal has a more simplified structure and is conveniently manufactured and the efficiency of transferring the heat generated by the PTC elements is improved.

Description

PTC ROD ASSEMBLY AND PRE-HEATER INCLUDING THE

SAME

Technical Field

[1] The present invention relates to a positive temperature coefficient (PTC) rod assembly and a pre-heater for a vehicle including the same, and more particularly, to a PTC rod assembly configured such that the structure of an insulator used for fixing an anode terminal is more simplified and PTC elements can be stably mounted thereon, and a pre-heater for a vehicle including the same. Background Art

[2] A general vehicle has a heating apparatus for heating the interior of the vehicle or removing moisture or frost on a windshield of the vehicle using thermal energy of cooling water heated by heat generated from an engine of the vehicle.

[3] In the heating apparatus, since the cooling water, which flows around the engine after the engine is started, is introduced into a heater, it takes a great deal of time to heat the cooling water and to subsequently heat the interior of the vehicle. Accordingly, there is a problem in that a driver and/or passenger(s) should stay in the cold interior of the vehicle for a certain period of time after the engine is started.

[4] To solve such a problem, Korean Patent Publication No. 10-0445722 discloses a heat rod assembly and a pre-heater, wherein pre-heating is performed using PTC elements.

[5] Hereinafter, the structure of the convention pre-heater will be briefly described below with reference to the accompanying drawings.

[6] Fig. 1 is an exploded perspective view of the conventional pre-heater.

[7] As shown in Fig. 1, the conventional pre-heater for a vehicle comprises PTC rod assemblies 10 each of which includes PTC elements; heat fin assemblies 20 disposed at both sides of each of the PTC rod assemblies 10 in parallel to each other; anode terminals 30 disposed in parallel to the heat fin assemblies 20; frames 40 and 50 coupled respectively to both lateral ends of a combination of the PTC rod assemblies 10, the heat fin assemblies 20 and the anode terminals 30; and housings 60 and 70 coupled respectively to both longitudinal ends of a combination of the PTC rod assemblies 10, the heat fin assemblies 20 and the anode terminals 30 with the frames 40 and 50.

[8] Further, it is preferred that fin protecting members 80 be provided on inner surfaces of the frames 40 and 50 so as to protect the fin assemblies 20.

[9] Fig. 2 is an exploded perspective view of the conventional PTC rod assembly, and Fig. 3 is a cross-sectional view of the conventional PTC rod assembly.

[10] As shown in Figs. 2 and 3, a lower PTC rod 11 is constructed in the form of a channel to serve as a kind of receiving part.

[11] An insulator 12 is disposed on a floor portion of the lower PTC rod 11 to prevent an electric leakage. The insulator 12 is made of a nonconductive material such as nylon with good thermal conductivity.

[12] Moreover, an anode terminal 17 made of carbon steel or the like is fixedly coupled on the insulator 12 in a longitudinal direction. A floor groove 16 is formed in a floor surface of the insulator 12 so that the relatively thin anode terminal 17 can be received and securely fixed in the groove 16. In addition, the PTC elements 18 that generate heat by applying electric power thereto are seated in step-like recesses 15 formed at sides of the floor groove 16 and are then fixed by fitting protrusions 14 formed at lateral side ends of the step-like recesses 15.

[13] However, there are problems in that it is difficult to form the step-like recesses 15 and the fitting protrusions 14 for fixing the PTC elements 18 in view of manufacture thereof and production costs increase.

[14] Further, a plurality of openings 13 are formed in the floor of the insulator 12 so that heat generated by the PTC elements 18 can be transferred to the lower PTC rod 11 therethrough. However, since air existing in the openings 13 has very low thermal conductivity, there is a disadvantage in that a heat transfer efficiency with which the heat generated by the PTC elements 18 is transferred to the lower PTC rod 11 is remarkably lowered.

Disclosure of Invention Technical Problem

[15] The present invention is conceived to solve the aforementioned problems. An object of the present invention is to provide a PTC rod assembly, wherein an insulator for fixing an anode terminal has a more simplified structure and is conveniently manufactured and the heat transfer efficiency of PTC elements is improved, and a pre- heater for a vehicle including the PTC rod assembly. Technical Solution

[16] A PTC rod assembly of the present invention for solving the problems is a PTC rod assembly including PTC elements for use in a pre-heater for a vehicle. The PTC rod assembly comprises a lower PTC rod constructed in the form of a channel with an open side; an anode terminal placed within the lower PTC rod; an insulator that is made of an insulating material, coupled to enclose the anode terminal and formed with first exposure openings for exposing a portion of one side surface of the anode terminal therethrough and second exposure openings for exposing a portion of the other side surface of the anode terminal therethrough; PTC elements fitted respectively into the first exposure openings of the insulator so that the PTC elements can be brought into contact with the anode terminal; heat transfer blocks fitted respectively into the second exposure openings of the insulator so that the heat transfer blocks can be brought into contact with the anode terminal; and an upper PTC rod coupled to cover the open side of the lower PTC rod.

[17] The anode terminal and the insulator is preferably formed integrally with each other through a dual-injection molding process, and the insulator is preferably spaced apart by certain distances from a floor surface of the lower PTC rod and a bottom surface of the upper PTC rod.

[18] The insulator may have protruding steps formed at both ends thereof, and the protruding steps may be brought into close contact with inner surfaces of the lower PTC rod and the upper PTC rod, i.e., inner sidewall surfaces and the floor surface of the lower PTC rod and the bottom surface of the upper PTC rod. Each of the first and second exposure openings may be formed to have a rectangular shape and have notches formed at respective corners thereof.

[19] The heat transfer blocks are preferably made of alumina to have a thickness smaller than that of the PTC elements.

[20] Further, a pre-heater for a vehicle according to the present invention comprises the

PTC rod assembly constructed as above. Advantageous Effects

[21] The PTC rod assembly of the present invention has advantages in that the insulator for fixing the anode terminal has a more simplified structure and is conveniently manufactured, resulting in lowered production costs, and heat generated by the PTC elements is transferred with a high heat transfer efficiency.

[22] Furthermore, the pre-heater for a vehicle according to the present invention has an advantage in that the performance of the pre-heater capable of heating the interior of the vehicle can be remarkably improved. Brief Description of the Drawings

[23] Fig. 1 is an exploded perspective view of a conventional pre-heater.

[24] Fig. 2 is an exploded perspective view of a conventional PTC rod assembly.

[25] Fig. 3 is a cross-sectional view of the conventional PTC rod assembly.

[26] Fig. 4 is an exploded perspective view of a PTC rod assembly according to the present invention.

[27] Fig. 5 is a side view showing a state where an anode terminal and an insulator are coupled to each other.

[28] Fig. 6 is a sectional view of the anode terminal and the insulator taken along line A- A shown in Fig. 5.

[29] Fig. 7 is a perspective view of the PTC rod assembly according to the present invention.

[30] Fig. 8 is a sectional view of the PTC rod assembly taken along line B-B shown in

Fig. 7.

[31] Fig. 9 is a sectional view of the PTC rod assembly taken along line C-C shown in

Fig. 7. Best Mode for Carrying Out the Invention

[32] Hereinafter, preferred embodiments of a PTC rod assembly and a pre-heater for a vehicle including the same according to the present invention will be described in detail with reference to the accompanying drawings.

[33] Fig. 4 is an exploded perspective view of a PTC rod assembly according to the present invention.

[34] As shown in Fig. 4, the PTC rod assembly with PTC elements 400 for a vehicle according to the present invention comprises a lower PTC rod 100 constructed in the form of an elongated channel with an open side; an anode terminal 200 placed within the lower PTC rod 100 while being enclosed by an insulator 300 made of an insulating material such that the anode terminal is not in contact with the lower PTC rod 100; the PTC elements 400 placed between one surface of the anode terminal 200 and an upper PTC rod 600; heat transfer blocks 500 made of a material with high thermal conductivity and brought into contact with the other side surface of the anode terminal 200; and the upper PTC rod 600 coupled to cover the open side of the lower PTC rod 100.

[35] Each of the PTC elements 400 is coupled such that one surface thereof is in contact with the anode terminal 200 and the other surface thereof is in contact with the upper PTC rod 600 acting as a cathode terminal. The PTC elements generate heat when electric power is applied thereto. At this time, since the upper PTC rod 600 and the lower PTC rod 100 are brought into contact with each other, the lower PTC rod 100 also acts as a cathode terminal in the same manner as the upper PTC rod 600.

[36] Further, protruding steps 330 are formed at both ends of the insulator 300. When the upper PTC rod 600 and the lower PTC rod 100 are coupled to each other, the protruding steps are brought into close contact with inner surfaces of the upper PTC rod 600 and the lower PTC rod 100, i.e., inner sidewall surfaces and a floor surface of the lower PTC rod 100 and a bottom surface of the upper PTC rod 600 (see Fig. 8). Accordingly, since an inner space defined by the upper PTC rod 600 and the lower PTC rod 100 is sealed by the protruding steps 330, there is no case where a fire breaks out due to contact of dust or other foreign substances with the PTC elements 400. [37] Fig. 5 is a side view showing a state where the anode terminal and the insulator are coupled to each other, and Fig. 6 is a sectional view of the anode terminal and the insulator taken along line A-A shown in Fig. 5.

[38] As shown in Figs. 5 and 6, the insulator 300 encloses the anode terminal 200 and has first exposure openings 310 and second exposure openings 320 so that some portions of one and the other side surfaces of the anode terminal 200 can be exposed therethrough. At this time, the insulator 300 and the anode terminal 200 may be separately manufactured and then coupled to each other or may be manufactured integrally with each other through a dual-injection molding process. In the case where the anode terminal 200 and the insulator 300 are manufactured integrally with each other through the dual-injection molding process, the numbers of manufacturing processes and assembling processes are reduced. Thus, there is an advantage in that production costs of the PTC rod assembly are remarkably reduced.

[39] Upon manufacture of the insulator 300 through an injection molding process, if each of the first exposure openings 310 is formed to have a simple rectangular shape, cases where respective corners of each of the first exposure openings 310 do not form a right angle may frequently occur due to characteristics of the injection molding process. If the corners of each of the first exposure openings 310 do not form a right angle as described above, the PTC elements 400 cannot be brought into close contact with the anode terminal 200. Thus, a heat generating function is degraded.

[40] To solve this problem, each of first exposure openings 310 in the present invention is formed to have a rectangular shape, and has notches 312 formed at respective corners of the first exposure opening 310. When the notches 312 are formed at the respective corners as described above, the PTC elements 400 can be completely brought into close contact with the anode terminal 200 even though a slight dimensional error exists at the corners of the first exposure opening 310.

[41] Further, like the first exposure openings 310, notches may also be formed at respective corners of each of the second exposure openings 320 to improve close contact of the heat transfer blocks 500 with the anode terminal 200.

[42] Fig. 7 is a perspective view of the PTC rod assembly according to the present invention, Fig. 8 is a sectional view of the PTC rod assembly taken along line B-B shown in Fig. 7, and Fig. 9 is a sectional view of the PTC rod assembly taken along line C-C shown in Fig. 7.

[43] As shown in Fig. 8, the both ends of the insulator 300, i.e., the protruding steps 330, are brought into close contact with the inner surfaces of the upper PTC rod 600 and the lower PTC rod 100, i.e., the bottom surface of the upper PTC rod 600 and the inner sidewall surfaces and the floor surface of the lower PTC rod 100. Further, as shown in Fig. 9, an intermediate portion of the insulator 300 is introduced into a space between the both sidewall surfaces of the lower PTC rod 100 and preferably spaced apart by certain distances from the floor surface of the lower PTC rod 100 and the bottom surface of the upper PTC rod 600 so as not to interfere the coupling of the lower PTC rod 100 with the upper PTC rod 600.

[44] At this time, the PTC elements 400 are fitted into the first exposure openings 310 and the heat transfer blocks 500 are fitted into the second exposure openings 320. Thus, the PTC elements 400 and the heat transfer blocks 500 can be maintained in a state where they are in contact with the anode terminal 200, without an additional fixing means.

[45] The lower PTC rod 100, the anode terminal 200, the upper PTC rod 600 and the heat transfer blocks 500 are made of materials with high thermal conductivity so that heat generated by the PTC elements can be transferred to the outside. In particular, since the heat transfer blocks 500 are intended to transfer heat, it is desirable to manufacture the heat transfer blocks out of a material with high thermal conductivity, such as alumina.

[46] Since the PTC elements 400 are in direct contact with the upper PTC rod 600 and in indirect contact with the lower PTC rod 100 via the anode terminal 200 and the heat transfer blocks 500, heat generated by the PTC elements through application of electric power thereto is conducted to the upper PTC rod 600 and the lower PTC rod 100. Accordingly, as compared with a conventional PTC rod assembly in which an anode terminal is spaced apart by a certain distance from a lower PTC rod, the PTC rod assembly of the present invention has remarkably improved thermal conductivity. At this time, it is preferred that each of the heat transfer blocks 500 have a thickness smaller than that of each of the PTC elements 400 so that the heat generated by the PTC elements can be effectively transferred to the lower PTC rod 100.

[47] Although this embodiment is implemented such that the PTC elements 400 are in contact with an upper surface of the anode terminal 200 while the heat transfer blocks 500 are in contact with a lower surface of the anode terminal 200, the contact locations of the PTC elements 400 and the heat transfer blocks 500 with the anode terminal 200 may be interchanged with each other.

[48] Moreover, in a pre-heater for a vehicle including the PTC rod assembly constructed as above, the heat generated by the PTC elements is rapidly transferred to the outside. Thus, the performance of the pre-heater capable of heating the interior of the vehicle is remarkably improved.

[49] The pre-heater including the PTC rod assembly according to the present invention differs from a conventional pre-heater only in view of the inner structures of their PTC rod assemblies and is identical with the conventional pre-heater in view of the structures of their heat fin assemblies and housings. Detailed descriptions of the identical parts will be omitted.

[50] Although the present invention has been described in connection with the preferred embodiments, the scope of the present invention is not limited by the specific embodiments but should be construed by the appended claims. Further, it should be understood by those skilled in the art that various changes and modifications can be made thereto without departing from the scope of the present invention.

[51]

Claims

[1] L A positive temperature coefficient (PTC) rod assembly, including PTC elements, for use in a pre-heater for a vehicle, comprising: a lower PTC rod constructed in the form of a channel with an open side; an anode terminal placed within the lower PTC rod; an insulator made of an insulating material and coupled to enclose the anode terminal, the insulator being formed with first exposure openings for exposing a portion of one side surface of the anode terminal therethrough and second exposure openings for exposing a portion of the other side surface of the anode terminal therethrough; the PTC elements being fitted respectively into the first exposure openings of the insulator so that the PTC elements can be brought into contact with the anode terminal; heat transfer blocks fitted respectively into the second exposure openings of the insulator so that the heat transfer blocks can be brought into contact with the anode terminal; and an upper PTC rod coupled to cover the open side of the lower PTC rod. [2] 2. The PTC rod assembly as claimed in claim 1, wherein the anode terminal and the insulator are formed integrally with each other through a dual-injection molding process. [3] 3. The PTC rod assembly as claimed in claim 1 or 2, wherein the insulator is spaced apart by certain distances from a floor surface of the lower PTC rod and a bottom surface of the upper PTC rod. [4] 4. The PTC rod assembly as claimed in claim 1 or 2, wherein the insulator has protruding steps formed at both ends thereof, and the protruding steps are brought into close contact with inner surfaces of the lower PTC rod and the upper PTC rod. [5] 5. The PTC rod assembly as claimed in claim 1 or 2, wherein each of the first and second exposure openings is formed to have a rectangular shape and has notches formed at respective corners thereof. [6] 6. The PTC rod assembly as claimed in claim 1 or 2, wherein the heat transfer blocks have a thickness smaller than that of the PTC elements. [7] 7. The PTC rod assembly as claimed in claim 1 or 2, wherein the heat transfer blocks comprise alumina. [8] 8. A pre-heater for a vehicle, comprising the PTC rod assembly according to claim 1 or 2.