Description PRE-HEATER FOR VEHICLE
Technical Field
[1] The present invention relates to a pre-heater for a vehicle, and more particularly, to a pre-heater for a vehicle constructed such that heat generated from positive temperature coefficient (PTC) elements contained in the pre-heater does not escape to the outside but is uniformly transferred only to a heat radiation fin assembly and close contact between a PTC rod assembly and the heat radiation fin assembly is improved.
[2]
Background Art
[3] 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.
[4] 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 penod of time after the engine is started.
[5] To solve such a problem, Korean Patent No. 445722 discloses a pre-heater using
PTC elements.
[6] The pre-heater will be briefly described below with reference to Figs. 1 and 2.
[7] As shown in Fig. 1 , the conventional pre-heater for a vehicle comprises heat rod assemblies 10 each of which includes PTC elements; heat fin assemblies 20 disposed at both sides of each of the heat rod assemblies 10 m parallel to each other; cathode terminals 30 disposed in parallel to the heat fin assemblies 20; frames 60 and 90 coupled respectively to both lateral ends of a combination of the heat rod assemblies 10, the heat fin assemblies 20 and the cathode terminals 30; and front and rear housings 40 and 80 coupled respectively to both longitudinal ends of a combination of the heat rod assemblies 10, the heat fin assemblies 20 and the cathode terminals 30 with the frames 60 and 90.
[8] At this time, each of the heat rod assemblies 10 comprises a channel-shaped lower heat rod, and insulator placed on a floor portion of the lower heat rod, an anode terminal longitudinally placed on and fixedly coupled to the insulator, PTC elements coupled to the insulator with the anode terminal interposed therebetween, and an upper heat rod for covering an open portion of the lower heat rod. However, it will be apparent that the heat rod assembly can have a variety of structures in addition to the
aforementioned structure.
[9] Meanwhile, since the front and rear housings 40 and 80 are simply coupled in a press-fit manner to the longitudinal ends of the combination of the heat rod assemblies 10, the heat fin assemblies 20, the anode terminals 30 and the frames 60 and 90, which are disposed in parallel, in the conventional pre-heater 1 for a vehicle, as shown in Fig. 2, there is a disadvantage of lack of coupling strength.
[10] Specifically, front ends of the anode and cathode terminals 12 and 30 are fitted into and installed in an insulating plate and then directly fixed to the front housing 40. Further, rear ends of the heat rod assemblies 10, the heat fin assemblies 20, the cathode terminals 300 and the frames 60 and 90 are aligned in a line and then directly fitted into the rear housing 80. In particular, the rear ends of the frames 60 and 90 are adapted to be fitted into a groove 82 formed in the rear housing 80.
[11] As such, the prior art has a disadvantage of lack of a structure for ensuring strong lateral coupling of the combination of the cathode terminals 30 or the heat rod assemblies 10 and the heat fin assemblies 200. Thus, there is a risk that the components of the combination may be separated from the housings 40 and 80 in use. Although the housings 40 and 80 apparently have inner structures for ensuring close contact with the ends of the combination, it is impossible to sufficiently exhibit their effects since the coupling lengths of the housings are small. Moreover, if air gaps are produced due to deterioration of close contact among the heat rod assemblies 10, the heat fin assemblies 20, the cathode terminals 30 and the frames 60 and 90, which are disposed in parallel, there is a disadvantage in that the overall performance of the pres- heater may be lowered accordingly
[12]
Disclosure of Invention Technical Problem
[13] The present invention is conceived to solve the aforementioned problems. An object of the present invention is to provide a pre-heater for a vehicle constructed such that heat generated from PTC elements contained in the pre-heater does not escape to the outside but is uniformly transferred only to a heat radiation fin assembly and close contact between a PTC rod assembly and the heat radiation fm assembly is improved.
[14]
Technical Solution
[15] A pre-heater for a vehicle according to the present invention for achieving the object includes PTC rod assemblies, one or more heat radiation fm assemblies coupled to be in close contact with bothsurfaces of each of the PTC rod assemblies, a pair of frames coupled to outer side surfaces of the outermost heat radiation fin assemblies,
and a first housing and a second housing having housing terminals serving as cathode terminals therein and coupled to both longitudinal ends of a combination of these respective components.
[16] At this time, the pair of frames are formed to be curved so that these respective components can be in close contact with one another, and have reinforcing grooves formed on surfaces thereof brought into contact with the heat radiation fm assemblies in a longitudinal direction of the contact surfaces with the heat radiation fin assemblies.
[17] Further, facing surfaces of the first and second housings are formed with a plurality of protruding pieces that protrude in opposite directions are formed, respectively. Both ends of each of the frames are formed with spaces for receiving the protruding pieces.
[18]
Advantageous Effects
[19] In the pre-heater for a vehicle according to the present invention, heat generated from the PTC elements does not escape to the outside but is uniformly transferred withm the pre-heater. Further, there are advantages in that coupling forces of respective components placed between the frames can be increased, and close contact between the PTC rod assemblies and the heat radiation fin assemblies can be improved
[20] Moreover, in the pre-heater for a vehicle according to the present invention, a pair of protruding pieces are formed in the first and second housings for use m coupling the respective components to one another, and both ends of each of the frames corresponding to the protruding pieces are formed with spaces for receiving the protruding pieces. Therefore, there is an advantage in that an assembling process can be easily performed.
[21]
Brief Description of the Drawings
[22] Fig. 1 is a perspective view showing a conventional pre-heater for a vehicle.
[23] Fig. 2 is an exploded perspective view of the pre-heater of Fig. 1.
[24] Fig 3 is a perspective view showing an exploded state of a pre-heater for a vehicle according to the present invention
[25] Fig. 4 is a sectional view showing coupling structures of a first housing and PTC rod assemblies included m the pre-heater for a vehicle according to the present invention.
[26] Fig 5 is a sectional perspective view showing the housing employed in the pre- heater for a vehicle according to the present invention.
[27] Fig. 6 is a sectional view of the housing, showing a coupling structure of one of housing terminals.
[28] Fig. 7 is a perspective view showing a PTC rod assembly employed in the pre- heater for a vehicle according to the present invention.
[29] Fig. 8 is an exploded perspective view of the PTC rod assembly of Fig. 7.
[30] Fig. 9 is a perspective view showing an exploded state of the PTC rod assembly including an insulator formed with discharge grooves.
[31] Fig. 10 is a perspective view showing a modified embodiment of the PTC rod assembly employed in the pre-heater for a vehicle according to the present invention.
[32] Fig. 11 is a perspective view showing another modified embodiment of the PTC rod assembly employed in the pre-heater for a vehicle according to the present invention.
[33]
[34] <Explanation of Reference Numerals for Main Portions in Drawings>
[35] 1000: PTC rod assembly 2000: Heat radiation fin assembly
[36] 3000: Cathode terminal 4000, 5000: Frame
[37] 5000, 7000: First and second housings
[38] 100: First PTC rod 200: Second PTC rod
[39] 300: Electrode terminal 400: Insulator
[40] 500: PTC element 600: Heat transfer block
[41]
Best Mode for Carrying Out the Invention
[42] Hereinafter, preferred embodiments according to the present invention will be described in detail with reference to the accompanying drawings.
[43] Fig. 3 is a perspective view showing an exploded state of a pre-heater for a vehicle according to the present invention.
[44] As shown in Fig. 3, the pre-heater for a vehicle according to the present invention comprises a plurality of PTC rod assemblies 1000 disposed in parallel to one another in a longitudinal direction; heat radiation fin assemblies 2000 brought into contact with and coupled to both sides of each of the PTC rod assemblies 1000; cathode terminals 3000 each of which is placed between adjacent heat radiation fin assemblies 2000; a pair of frames 4000 and 5000 coupled to outer side surfaces of the outermost heat radiation fin assemblies 2000, respectively; and a first housing 6000 and a second housing 7000 coupled respectively to both longitudinal ends of a combination of the PTC rod assemblies 1000, the heat radiation fin assemblies 2000, the cathode terminals 3000 and the frames 4000 and 5000.
[45] At this time, heat generated from PTC elements (not shown) installed within the
PTC rod assemblies 1000 is transferred to the heat radiation fin assemblies 2000 so as to heat air that passes through the heat radiation fin assemblies 2000.
[46] Further, in order to prevent heat transferred to the heat radiation fin assemblies
2000 from being transferred to the outside through the frames 4000 and 5000, reinforcing grooves 4100 and 5100 are longitudinally formed on contact surfaces of the frames 4000 and 5000 and the heat radiation fin assemblies 2000 to minimize a contact area between each of the frames 4000 and 5000 and the corresponding heat radiation fin assembly 2000.
[47] When the reinforcing grooves 4100 and 5100 are formed as described above, the contact area between each of the frames 4000 and 5000 and the corresponding heat radiation fin assembly 2000 is reduced, resulting in a lowered heat transfer rate At this time, since the interiors of the reinforcing grooves 4100 and 5100 are filled with air, some of heat in the heat radiation fin assemblies 2000 is transferred to the frames 4000 and 5000 through the air. However, since air has a very low heat transfer rate, the amount of heat transferred through air can be regarded as a negligible quantity.
[48] The PTC rod assemblies 1000 and the heat radiation fin assemblies 2000 heated by heat generated from the PTC elements (not shown) installed therein are increased in volume and then push outward the frames 4000 and 5000 coupled to both lateral outer sides of the combination thereof. As a result, the frames 4000 and 5000 of which the longitudinal ends are coupled to the housings 6000 and 7000 may be bulged outward at intermediate portions thereof. If the frames 4000 and 5000 are bulged, there is a problem in that the coupling state of respective components disposed between the frames 4000 and 5000 may be strayed
[49] Accordingly, the frames 4000 and 5000 employed in the present invention are formed such that intermediate portions of the surfaces thereof brought into contact with the heat radiation fin assemblies 2000 slantly protrude toward the corresponding heat radiation fin assemblies 2000. As compared with a conventional straight frame, the frames 4000 and 5000 of which the intermediate portions slantly protrude inward are much less bulged even though they are subjected to pressure resulting from expansion of the PTC rod assemblies 1000 and the heat radiation fin assemblies 2000. Further, since the reinforcing grooves 4100 and 5100 serve as ribs for preventing the bulging in the frames 4000 and 5000 employed in the present invention, there is an advantage in that the frames hardly undergo deformation in shape due to an external force.
[50] At this time, since the longitudinal ends of the frames 4000 and 5000 are coupled to the housings 6000 and 7000 as described above, the housings 6000 and 7000 are provided with coupling grooves (6020 in Fig. 8 , 7020 in Fig. 3) into which the longitudinal ends of the frames 4000 and 5000 are to be inserted The longitudinal ends 4200 and 5200 of the frames 4000 and 5000 are tapered toward their tips so that they can be easily inserted into the coupling grooves 6020 and 7020.
[51] Moreover, although the additional cathode terminals 3000 are provided between the heat radiation fin assemblies 2000 in this embodiment, the frames 4000 and 5000 may
be constructed to perform the function of a cathode terminal 3000 without the cathode terminal 3000. When the frames 4000 and 5000 serve as cathode terminals 3000, there are advantages in that the inner structure of the pre-heater for a vehicle is simplified and production costs can be reduced.
[52] The heat radiation fin assemblies 2000 are coupled to both side surfaces of each of the PTC rod assemblies 1000. Since the amount of heat generated from one side of the PTC rod assembly where the PTC elements are mounted is higher than the amount of heat generated from the other side of the PTC rod assembly where the heat transfer blocks are mounted, a plurality of heat radiation fin assemblies 2000 are stacked laterally at the side of the PTC rod assembly where the PTC elements are mounted, and heat radiation fin assemblies 2000 of which the number is smaller than the number of the heat radiation fin assemblies 2000 coupled to the side of the PTC rod assembly where the PTC elements are mounted are coupled to the other side of the PTC rod assembly where a PTC element is not mounted. In this embodiment, two heat radiation fin assemblies 2000 are coupled to one side of the PTC rod assembly where the PTC elements are mounted and one heat radiation fin assembly 2000 is coupled to the other side of the PTC rod assembly where the heat transfer blocks are mounted. However, the number of heat radiation fin assemblies 2000 to be coupled to a side of each of the PTC rod assemblies 1000 is not limited thereto but may be changed variously according to user s selection.
[53] Fig. 4 is a sectional view showing coupling structures of the first housing and the
PTC rod assemblies included in the pre-heater for a vehicle according to the present invention.
[54] The respective PTC rod assemblies 1100, 1200 and 1300 of the pre-heater for a vehicle according to the present invention have different locations of the PTC elements and the heat transfer blocks therein. Thus, if the PTC rod assemblies are coupled to the first housing 6000 at different positions, there are several problems in that the efficiency of the pre-heater is lowered or the pre-heater is out of order.
[55] In order to avoid these problems, the PTC rod assemblies 1100, 1200 and 1300 are formed such that the lengths of bent portions of the terminals 1160, 1260 and 1360 thereof differ from one another. Accordingly, in the first housing 6000, the distance between each of coupling terminals 6100, 6200 and 6300 to which the terminals 1160, 1260 and 1360 are to be coupled and each of seating recesses 6400, 6500 and 6600 for receiving respective insulating members 1180, 1280 and 1380 is determined to conform to the length of the bent portion of each of the terminals 1160, 1260 and 1360.
[56] Accordingly, each of the PTC rod assemblies 1100, 1200 and 1300 can be coupled at only a designated position, thereby avoiding the occurrence of a confusion in assembling the PTC rod assemblies 1100, 1200 and 1300. At this time, each of the
PTC rod assemblies 1100, 1200 and 1300 is coupled in such a manner that each of the insulating members 1180, 1280 and 1380 is completely inserted into the housing 6000.
[57] Fig. 5 is a sectional perspective view showing the housing employed in the pre- heater for a vehicle according to the present invention, and Fig. 6 is a sectional view of the housing, showing a coupling structure of one of housing terminals.
[58] As shown in Figs. 5 and 6, the first housing 6000 employed in the present invention comprises housing terminals 6700 each of which has one end embedded in the first housing 6000 and also has bent plates 6800 to be brought into contact with one end of each of the PTC rod assemblies (1100, 1200 and 1300 in Fig. 3) introduced into the first housing 6000. When the housing terminals 6700 to be brought into contact with the respective PTC rod assemblies 1100, 1200 and 1300 are provided as such, the entire PTC rod assemblies 1100, 1200 and 1300 serve as cathode terminals, and thus, there is an advantage in that it is not necessary to provide an additional cathode terminal.
[59] At this time, a portion of each of the housing terminals 6700, which is embedded in the first housing 6000, is formed with locking protrusions 6900 to be caught in the first housing 6000 so that the housing terminal 6700 cannot come out from the housing 6000. At this time, it is preferred that each of the locking protrusions 6900 be formed to have a pointed tip and to be inclined in a direction in which the housing terminal 6700 is withdrawn.
[60] Fig. 7 is a perspective view showing a PTC rod assembly employed in the pre- heater for a vehicle according to the present invention, and Fig. 8 is an exploded perspective view of the PTC rod assembly of Fig. 7.
[61] As shown in Figs. 7 and 8, a PTC rod assembly 1000 according to a first embodiment of the present invention comprises a first PTC rod 100 constructed in the form of a channel in cross section and having a predetermined length, and a second PTC rod 200 having the same length as the first PTC rod 100 and coupled to the first PTC rod 100 so as to cover an open portion of the first PTC rod 100. At this time, when the first and second PTC rods 100 and 200 are coupled to each other, a space 110 having a rectangular cross section is provided to be elongated in a longitudinal direction therebetween, and an electrode terminal 300, an insulator 400, PTC elements 500 and heat transfer blocks 600 are accommodated in the space 110.
[62] The electrode terminal 300 of the components provided in the space 110 is an anode terminal having a predetermined length, and has a terminal 310 formed at one end of the electrode terminal and a plurality of through-holes (not shown) formed at a predetermined interval in the longitudinal direction in the electrode terminal. At this time, the width of the one end of the electrode terminal 300 where the terminal 310 is formed is larger than that of an intermediate portion of the electrode terminal. Upper
and lower sides of the one end of the electrode terminal are folded inward, and the folded end of the electrode terminal is then bent in the form of a crank. The thickness of the terminal 310 constructed as above is twice as larger as that of the intermediate portion of the electrode terminal 300, so that the strength of the terminal 310 can be increased. Accordingly, there is an advantage in that the terminal can more stably transmit an electric current in a state where the terminal is connected to a connector or housing.
[63] Here, the electrode terminal 300 is preferably made of alloy steel such as carbon steel having high electrical conductivity and certain strength so that electric power supplied from a power source of a vehicle can be smoothly applied therethrough. The through-holes are preferably formed as elongated holes to increase a coupling force between the electrode terminal 300 and the insulator 400 and to facilitate injection and flow of an injection molding material when a dual injection molding process is carried out.
[64] The insulator 400 is to prevent the electrode terminal 300 from being in contact with the first and second PTC rods 100 and 200, and is formed integrally with the electrode terminal 300 by means of dual injection molding.
[65] As for the shape of the insulator, the insulator 400 is formed to surround the electrode terminal 300 and has first and second seating portions 410 and 420 at both sides thereof such that the electrode terminal 300 is partially exposed The first and second seating portions 410 (not shown) are formed with first and second supporting members 430 (not shown) at an identical interval in a longitudinal direction of the insulator 400 so as to partition the first and second seating portions into a plurality of regions. The PTC elements 500 and the heat transfer blocks 600 are mounted in the partitioned regions of the first and second seating portions 410 (not shown).
[66] Meanwhile, as shown in Fig. 9, both longitudinal ends of the insulator 400 are provided with insulating members 460 and 470 having a cross sectional shape in the form of a rectangle having a length larger than a width in a state where the first and second PTC rods 100 and 200 are coupled to each other. At this time, the pair of insulating members 460 and 470 are adapted to be in close contact with both ends of each of the first and second PTC rods 100 and 200. The insulating members 460 and 470 prevent deformation of the electrode terminal, the occurrence of a short circuit due to contact thereof with peπpheral components, and play of the first and second PTC rods 100 and 200 coupled between the pair of insulating members. Further, the insulating members can prevent introduction of dust or other foreign substances into the inner space 110 through the both open ends of each of the first and second PTC rods 100 and 200. At this time, one end of the electrode terminal 300 outwardly protrudes beyond the insulating member 460 of the pair of insulating members, which
is formed at one end of the insulator. Moreover, the terminal 310 is formed at the end of the electrode terminal 300, which outwardly protrudes beyond the insulating member 460.
[67] One or more discharge grooves 462 or 472 are formed at both sides of each of the insulating members 460 and 470. The discharge grooves 462 and 472 communicate with the space 110 defined by the coupling of the first and second PTC rods, so that gas generated from the electrode terminal 300, the PTC elements 500 and the heat transfer blocks 600 upon generation of heat from the PTC elements 500 can be discharged to the outside. By doing this, it is possible to prevent the insulator 400 from being deformed due to the gas. Further, discharge grooves 432 are also formed at the first and second supporting members 430 and 440, thereby more improving gas discharging efficiency.
[68] Fig. 10 is a perspective view showing a modified embodiment of the PTC rod assembly employed in the pre-heater for a vehicle according to the present invention, and Fig. 11 is a perspective view showing another modified embodiment of the PTC rod assembly employed in the pre-heater for a vehicle according to the present invention.
[69] In the modified embodiment of the PTC rod assembly, any one of first and second supporting members 430 (not shown) of the insulator 400, i.e., the first supporting members 430, are in pairs as shown in Fig 10 The pair of first supporting members are formed to protrude toward each other at upper and lower ends of the first seating portion 410. If the first supporting members 430 are in pairs and positioned to be spaced apart from each other as described above, respective corners of the PTC elements (not shown) mounted in the first seating portion 410 can be coupled thereto while coming into close contact with the first seating portion 410. At this time, it is preferred that the through-holes (not shown) formed in the electrode terminal 300 be provided at locations where the pairs of first supporting members 340 are formed.
[70] In the other modified embodiment of the PTC rod assembly, as shown in Fig. 11, insulating members 460 and 470 are formed at both longitudinal ends of the electrode terminal 300, and the both longitudinal ends of the insulator 400 corresponding to the insulating members 330 are formed with receiving portions 480 in which the insulating members 330 are accommodated. Further, any one of the insulating member 330 and the receiving portion 480, i.e., the insulating member 330 in this embodiment, is formed with a coupling hole 332, and the receiving portion 480 is formed with a coupling protrusion 482 to be inserted into the coupling hole 332. At this time, the first supporting members 430 of the insulator 400 are in pairs in the same manner as the second embodiment and formed to protrude toward each other at upper and lower ends of the first seating portion 410.
[71] Meanwhile, if at least one discharge groove (not shown) is provided in each of the insulating members 460 and 330 in the embodiments shown in Figs. 10 and 11, gas generated from the electrode terminal, the PTC elements and the heat transfer blocks upon generation of heat from the PTC elements can be discharged to the outside. Particularly, since the first supporting members 430 are in pairs and positioned to be spaced apart from each other in each of the embodiments, gas can be smoothly discharged without additionally providing a discharge groove at the first supporting members.
[72] Although the constitutions and coupling structures of the pre-heater for a vehicle and the PTC rod assembly provided therein according the preferred embodiments of the present invention have been described above with reference to the drawings, they are only for illustrative purposes. 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
[73]