PTC HEATING MODULE

Abstract

A PTC heating module may include at least one cuboid PTC thermistor element with two opposing main surfaces, which may be connected to one another via two opposing lateral surfaces. The PTC heating module may also include two contact elements each lying against one of the lateral surfaces and via which the PTC thermistor element may be electrically contactable, a housing in which the at PTC thermistor element and the contact elements may be arranged, and two insulating boards each lying against one of the main surfaces and electrically insulating the PTC thermistor element from the housing and connecting the PTC thermistor element to the housing in a heat-transferring manner. Each contact element may be electroconductively fixed on one side on one of the lateral surfaces and on another side on one of two contacting tracks, each of which may be arranged on one of the insulating boards.

Claims

1. A PTC heating module for heating a fluid, comprising: at least one cuboid PTC thermistor element with two main surfaces located opposite one another, which are connected to one another via two lateral surfaces located opposite one another; two contact elements each lying against a respective one of the two lateral surfaces, and via which the at least one cuboid PTC thermistor element is electrically contactable; a housing in which the at least one cuboid PTC thermistor element and the two contact elements are arranged; and two insulating boards in each lying against a respective one of the two main surfaces of the at least one cuboid PTC thermistor element in a heat-transferring manner, each insulating board electrically insulating the at least one cuboid PTC thermistor element from the housing and connecting the at least one cuboid PTC thermistor element to the housing in a heat-transferring manner; wherein each contact element is electroconductively fixed on one side on the respective one of the two lateral surfaces and on another side on a respective one of two contacting tracks, wherein each contacting track is arranged on a respective one of the insulating boards.

2. The PTC heating module according to claim 1, wherein each contacting track is formed as one of an electroconductive solder layer or an electroconductive adhesive layer, by way of which the respective contact element is soldered or glued on the respective one of the insulating boards.

3. The PTC heating module according to claim 1, wherein each contacting track is formed as a conductor that is fixed to the respective one of the insulating boards in a firmly bonded manner and on which a respective one of the contact elements is fixed in a firmly bonded manner.

4. The PTC heating module according to claim 1, wherein each contacting track is formed as a circuit board with at least one conductor, wherein the circuit board is fixed to the respective one of the insulating boards and a respective one of the contact elements is fixed to the at least one conductor in a firmly bonded manner.

5. The PTC heating module according to claim 4, wherein the at least one conductor is fixed on the circuit board in a firmly bonded manner.

6. The PTC heating module according to claim 1, wherein each insulating board is ceramic.

7. The PTC heating module according to claim 1, wherein each contact element is formed as a resilient S- or C- or L- or O-shaped metal element.

8. The PTC heating module according to claim 1, further comprising at least one rib structure for the discharge of heat, which lies against the housing in a heat-transferring manner and is located opposite a respective one of the two main surfaces of the at least one PTC thermistor element.

9. The PTC heating module according to claim 1, wherein the housing is metallic.

10. The PTC heating module according to claim 1, wherein the at least one PTC thermistor element is electrically contactable by one of the contact elements with a negative terminal and the other of the contact elements with a positive terminal.

11. A method for producing a PTC heating module, comprising: fixing each of two contacting tracks to a respective one of two insulating boards; fixing each of two contact elements to a respective one of the two contacting tracks of the respective one of the two insulating boards; at least one PTC thermistor element with one of two main surfaces to one of the two insulating boards between the two contact elements, wherein each contact element electrically contacts the at least one PTC thermistor element on a respective one of two lateral surfaces of the at least one PTC thermistor element that are arranged opposite one another and connect the two main surfaces; fixing the other of the two insulating boards to the other of the two main surfaces of the at least one PTC thermistor element that is arranged opposite the one of the two main surfaces; and arranging the at least one PTC thermistor element and the two insulating boards in a housing.

12. The method according to claim 11, wherein each contacting track is an electroconductive solder layer or an electroconductive adhesive layer.

13. The method according to claim 11, wherein each contacting track is a conductor that is fixed to the respective one of the insulating boards in a firmly bonded manner.

14. The method according to claim 11, wherein each contacting track is a circuit board with at least one conductor, wherein a respective one of the contact elements is fixed to the at least one conductor in a firmly bonded manner.

15. The method according to claim 14, wherein the at least one conductor is fixed on the circuit board in a firmly bonded manner.

16. The method according to claim 11, wherein each insulating board is ceramic.

17. The method according to claim 11, wherein each contact element is a resilient S- or C- or L- or O-shaped metal element.

18. The method according to claim 11, further comprising laying at least one rib structure against the housing in a heat-transferring manner opposite a respective one of the two main surfaces of the at least one PTC thermistor element.

19. The method according to claim 11, wherein the housing is metallic.

20. A PTC heating module for heating a fluid, comprising: at least one cuboid PTC thermistor element with two main surfaces located opposite one another, which are connected to one another via two lateral surfaces arranged located opposite one another; two contact elements each lying against a respective one of the two lateral surfaces and via which the at least one cuboid PTC thermistor element is electrically contactable; a housing in which the at least one cuboid PTC thermistor element and the two contact elements are arranged; two insulating boards each lying against a respective one of the two main surfaces of the at least one cuboid PTC thermistor element in a heat-transferring manner, each insulating board electrically insulating the at least one cuboid PTC thermistor element from the housing and connecting the at least one cuboid PTC thermistor element to the housing in a heat-transferring manner; and at least one rib structure for the discharge of heat, which lies against the housing in a heat-transferring manner and is located opposite a respective one of the two main surfaces of the at least one PTC thermistor element; wherein each contact element is electroconductively fixed on one side on the respective one of the two lateral surfaces and on another side on a respective one of two contacting tracks, wherein each contacting track is arranged on a respective one of the insulating boards; and wherein each contacting track is a circuit board with at least one conductor, wherein a respective one of the contact elements is fixed to the at least one conductor in a firmly bonded manner, and the at least one conductor is fixed on the circuit board in a firmly bonded manner.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Preferred exemplary embodiments of the invention are shown in the drawings and are explained in more detail in the following description, wherein same reference numbers relate to same or similar or functionally same components.

[0023] It shows, in each case schematically

[0024] FIG. 1 a sectional view of a PTC heating module according to the invention in a first embodiment;

[0025] FIG. 2 a plan view of individual PTC thermistor elements in the PTC heating module shown in FIG. 1;

[0026] FIG. 3 an exploded view of the PTC heating module shown in FIG. 1;

[0027] FIG. 4 a sectional view of a PTC heating module according to the invention in a second embodiment;

[0028] FIG. 5 a plan view of individual PTC thermistor elements in the PTC heating module shown in FIG. 4;

[0029] FIG. 6 an exploded view of the PTC heating module shown in FIG. 4.

DETAILED DESCRIPTION

[0030] FIG. 1 shows a sectional view of a PTC heating module 1 according to the invention in a first embodiment. The PTC heating module 1 comprises multiplehowever only one visible herecuboid PTC thermistor elements 2 each with two main surfaces 3a and 3b and each with two lateral surfaces 4a and 4b. The main surfaces 3a and 3b are arranged located opposite one another and connected to one another via the lateral surfaces 4a and 4b arranged located opposite one another. On the main surfaces 3a and 3b of the respective PTC thermistor element 2, a for example ceramic insulating board 5a and 5b each is arranged lying against the same, which electrically insulates the respective PTC thermistor element 2 from a housing 6 and connects the same to the housing 6 in a heat-transferring manner.

[0031] The heat exchanged between the PTC thermistor element 2 and a fluidfor example airsurrounding the PTC heating module 1 takes place on the main surfaces 3a and 3b of the respective PTC thermistor element 2 via the respective insulating boards 5a and 5b and via the housing 6. In this way, the heat generated in the respective PTC thermistor element 2 can be discharged to the fluid to be heated. The PTC heating module 1, furthermore, comprises rib structures 6a and 6b which lie against the housing 6 in a heat-transferring manner. The rib structures 6a and 6b are arranged located opposite the respective main surfaces 3a and 3b of the respective PTC thermistor element 2 and enlarged a heat-emitting surface of the housing 6 to be contacted with the fluid to be heated. The housing 6 and the rib structure 6a and 6b can be metallic, for example made of aluminium, in order to intensify the heat exchange between the fluid to be heated and the respective PTC thermistor element 2.

[0032] The respective PTC thermistor element 2 is electrically contacted to the outside on its lateral surfaces 4a and 4b via a contact element 7a and 7b lying against the respective lateral surface 4a and 4b in each case. The respective contact element 7a and 7b in this case is electroconductively fixed on the one side on the respective lateral surface 4a and 4b of the respective PTC thermistor element 2 and on the other side on a contacting track 8a and 8b. The respective contracting track 8a and 8b in this case is arranged on the insulating board 5a and in this first embodiment of the PTC heating module 1 an electroconductive solder layer 14 or an electroconductive adhesive layer 15. Accordingly, the respective contact element 7a and 7b is soldered or glued to the respective contacting track 8a and 8b. The respective PTC thermistor element 2 is thus electrically contactable to a negative terminal and to a positive terminal by the one contact element 7a or 7b and via the other contact element 7b or 7a respectively. To this end, an external voltage can be applied to the respective contacting track 8a and 8b and thus to the respective PTC thermistor element 2 and heat generated in the respective PTC thermistor element 2.

[0033] In the first embodiment of the PTC heating module 1 shown here, the respective contact element 7a and 7b is a C-shaped metal element 9a and 9b. The respective C-shaped metal element 9a and 9b is electroconductive and resilient by way of its shape so that the respective PTC thermistor element 2 remains mechanically stable and securely contacted even in the case of a major heat expansion of the individual components in the PTC heating module 1, such as for example of the housing 6 or of the insulating boards 5a and 5b. Furthermore, the contacting of the respective PTC thermistor element 2 and the overall construction of the PTC heating module 1 is significantly simplified by the respective contacting track 8a and 8b on the insulating board.

[0034] FIG. 2 shows a plan view of the individual PTC thermistor elements 2 of the PTC heating module 1 in the first embodiment. In the PTC heating module 1, a total of six PTC thermistor elements 2 are arranged on the insulating board 5a next to one another and electrically contactable with one another and to the outside via the respective joint contacting track 8a and 8b. The respective contact elements 7a and 7b are fixed to the respective contacting track 8a and 8b in a firmly bonded manner. In this first embodiment of the PTC heating module, the contact element 7a and 7b are the C-shaped metal elements 9a and 9b, which are soldered or glued to the contacting track 8a and 8b in the form of the electroconductive solder layer 14 or of the electroconductive adhesive layer 15.

[0035] FIG. 3 shows an exploded view of the PTC heating module 1 in the first embodiment. In a method 10 according to the invention, the respective contacting tracks 8a and 8b are fixed in the form of the electroconductive solder layer 14 or the electroconductive adhesive layer 15 and the C-shaped metal elements 9a and 9b are soldered or glued to the respective contacting track 8a and 8b. The respective contacting track 8a and 8b is arranged on the insulating board 5a so that an installation space that is available for the contacting is not limited by the thickness of the PTC thermistor elements 2 in the PTC heating module 1. In this advantageous manner, the expenditure for the usually technically elaborate contacting of the PTC thermistor elements 2 can be significantly reduced. The PTC thermistor elements 2 are fixed with the main side 3a on the insulating board 5a between the respective metal elements 9a and 9b. Here, the metal elements 9a and 9b are electrically contacted with the PTC thermistor elements 2 on the respective lateral surfaces 4a and 4b. Following this, the other insulating board 5b can be fixed to the main surface 3b of the PTC thermistor elements 2 and the PTC thermistor elements 2 and the adjacent insulating boards 5a and 5b can be arranged in the housing 6 of the PTC heating module 1. Here, the respective rib structure 6a and 6b can be fixed to the housing 6 before or after the arranging of the PTC thermistor elements 2 and the adjacent insulating boards 5a and 5b in the housing 6.

[0036] FIG. 4 shows a sectional view of the PTC heating module 1 according to the invention in a second embodiment. In the following, the differences between the first embodiment and the second embodiment of the PTC heating module 1 according to the invention are discussed separately. Otherwise, the construction of the PTC heating module 1 in the second embodiment corresponds to the construction of the PTC heating module 1 in the first embodiment. In the second embodiment of the PTC heating module 1, the respective contacting track 8a and 8b is formed in each case by an elongated circuit board 11a and 11b each with a conductor 12a and 12b. The respective circuit board 11a and 11b is fixed on the insulating board 5a in a firmly bonded manner, preferably by soldering or gluing. The respective contact element 7a and 7b in this second embodiment of the PTC heating module 1 is an L-shaped metal element 13a and 13b which is fixed to the conductor 12a and 12b of the respective circuit board 11a and 11b in a firmly bonded manner preferably by soldering or gluing.

[0037] FIG. 5 shows a top view of the individual PTC thermistor elements 2 of the PTC heating module 1 in the second embodiment. In the PTC heating module 1 a total of six PTC thermistor elements 2 are arranged on the insulating board 5a next to one another and electrically contacted with one another and to the outside via the respective joint contacting track 8a and b. On the respective contacting track 8a and 8b, the respective contact elements 7a and 7b are fixed in a firmly bonded manner. In this second embodiment of the PTC heating module, the contact elements 7a and 7b are the L-shaped metal elements 13a and 13b, which are soldered or glued to the respective contacting track 8a and 8b in the form of the circuit board 11a and 11b with the conductor 12a and 12b.

[0038] FIG. 6 shows an exploded view of the PTC heating module 1 in the second embodiment. In the method 10 according to the invention, the circuit boards 11a and 11b are fixed on the insulating board 5a in a firmly bonded manner, preferably by soldering or gluing and the L-shaped metal elements 13a and 13b are soldered or glued to the respective conductor 12a and 12b of the respective circuit board 11a and 11b. The respective circuit board 11a and 11b in this case is arranged on the insulating board 5a and an installation space that is available for the contacting is not limited by the thickness of the PTC thermistor elements 2 in the PTC heating module 1. Because of this, the effort for the usually technically elaborate contacting of the PTC thermistor elements 2 can be significantly reduced. The PTC thermistor elements 2 are fixed with the main side 3a to the insulating board 5a between the respective metal elements 13a and 13b and electrically contacted with these on the respective lateral surfaces 4a and 4b. The other insulating board 5b is fixed to the main surface 3b of the PTC thermistor elements 2 and the PTC thermistor elements 2 and the adjacent insulating boards 5a and 5b are arranged in the housing 6 of the PTC heating module 1. The respective rib structure 6a and 6b in this case can be fixed to the housing 6 before or after the arranging of the PTC thermistor elements 2 and the adjacent insulating boards 5a and 5b in the housing 6.

[0039] In summary, the contacting of the respective PTC thermistor element 2 in the PTC heating module 1 according to the invention and the overall construction of the PTC heating module 1 according to the invention is significantly simplified. The contacting of the at least one PTC thermistor element 2 usually involving major technical expenditure is limited by the method 10 according to the invention to a fixing of the respective contact element 7a and 7b on the contacting track 8a and 8b on the respective insulating board 5a. Here, an installation space that is available for the contacting is not limited by the thickness of the PTC thermistor elements 2 in the PTC heating module 1. Because of this, the production effort and also the production costs can be reduced.