TEMPERATURE CONTROL DEVICE WITH PTC MODULE

Abstract

A PTC module for a temperature control device may include at least one PTC element, having a flat element cross section transverse to a longitudinal direction, and two large outer surfaces along the longitudinal direction facing away from each other, and two small outer surfaces facing away from each other and joining together the two large outer surfaces. The PTC module may also have an envelope body enclosing the PTC element at least in a circumferential direction, two electrical conductors extending in the longitudinal direction and spaced apart from each other in the flat element cross section and electrically conductively connected to the PTC element, and two electrically isolating insulator plates extending in the longitudinal direction and each of which may be connected in a heat transfer manner to one of the large outer surfaces. Each electrical conductor may be formed by an electrically conducting conductor coating on a respective one of the insulator plates, where one conductor coating may be arranged on one insulator plate only in a first edge region, which borders on one small outer surface, and the other conductor coating may be arranged on the other insulator plate only in a second edge region, which borders on the other small outer surface.

Claims

1. A PTC module for a temperature control device, comprising: at least one PTC element, having a flat element cross section transverse to a longitudinal direction of the PTC module, and two large outer surfaces along the longitudinal direction, facing away from each other, and two small outer surfaces facing away from each other and joining together the two large outer surfaces; an envelope body, which encloses the at least one PTC element at least in a circumferential direction; two electrical conductors, which extend in the longitudinal direction and are spaced apart from each other in the flat element cross section and electrically conductively connected to the at least one PTC element; and two electrically isolating insulator plates, which extend in the longitudinal direction and each of which is connected in a heat transfer manner to one of the large outer surfaces of the at least one PTC element; wherein each electrical conductor is formed by an electrically conducting conductor coating on a respective one of the insulator plates; wherein the conductor coating of one of the electrical conductors is arranged on the one of the insulator plates only in a first edge region, which borders on one of the two small outer surfaces; and wherein the conductor coating of the other of the electrical conductors is arranged on the other of the insulator plates only in a second edge region, which borders on the other of the two small outer surfaces.

2. The PTC module according to claim 1, wherein the two conductor coatings have a spacing from each other along the large outer surfaces which is larger than an element thickness of the at least one PTC element measured between the large outer surfaces.

3. The PTC module according to claim 1, wherein each conductor coating has in the element cross section a conductor width measured along a respective one of the large outer surfaces which is less than 50%, of an element width of the at least one PTC element, measured between the small outer surfaces.

4. The PTC module according to claim 1, wherein each conductor coating has in the element cross section a conductor width measured along a respective one of the large outer surfaces that is larger than an element thickness of the at least one PTC element, measured between the large outer surfaces.

5. The PTC module according to claim 1, wherein the at least one PTC element has an electrically conducting metal coating on each large outer surface at least in a region of a respective one of the conductors, which is electrically conductively connected to the conductor coating.

6. The PTC module according to claim 5, wherein each conductor coating is soldered to a respective metal coating.

7. The PTC module according to claim 1, wherein: the at least one PTC element includes a plurality of PTC elements arranged in succession in the longitudinal direction; the envelope body encloses all PTC elements in the circumferential direction; and the two insulator plates extend across all PTC elements so that the two conductor coatings are electrically conductively connected to all the PTC elements.

8. The PTC module according to claim 1, wherein each insulator plate is thermally conductive and is connected in a sheet-like and heat transfer manner by a plate outer side facing away from the at least one PTC element to a body inner side of the envelope body facing toward the at least one PTC element.

9. The PTC module according to claim 1, wherein the envelope body is connected in a heat transfer manner to cooling fins at least on one body outer side facing away from the at least one PTC element.

10. A temperature control device for controlling the temperature of a fluid, comprising at least one PTC module and a control device for the electrical actuation of the at least one PTC module, each PTC module including: at least one PTC element, having a flat element cross section transverse to a longitudinal direction of the PTC module, and two large outer surfaces along the longitudinal direction facing away from each other, and two small outer surfaces facing away from each other and joining together the two large outer surfaces; an envelope body, which encloses the at least one PTC element at least in a circumferential direction: two electrical conductors, which extend in the longitudinal direction and are spaced apart from each other in the flat element cross section and electrically conductively connected to the at least one PTC element; and two electrically isolating insulator plates, which extend in the longitudinal direction and each of which is connected in a heat transfer manner to one of the large outer surfaces of the at least one PTC element wherein each electrical conductor is formed by an electrically conducting conductor coating on a respective one of the insulator plates; wherein the conductor coating of one of the electrical conductors is arranged on the one of the insulator plates only in a first edge region, which borders on one of the two small outer surfaces; and wherein the conductor coating of the other of the electrical conductors is arranged on the other of the insulator plates only in a second edge region, which borders on the other of the two small outer surfaces.

11. The temperature control device according to claim 10, wherein the at least one PTC module includes a plurality of PTC modules, which are arranged alongside each other in a heat transfer region through which the fluid whose temperature is to be controlled is flowable.

12. The temperature control device according to claim 11, wherein the plurality of PTC modules form a heat transfer block, through which the fluid whose temperature is to be controlled is flowable, while the control device is mounted at a side on the heat transfer block.

13. The temperature control device according to claim 10, wherein the two conductor coatings have a spacing from each other along the large outer surfaces which is larger than an element thickness of the at least one PTC element measured between the large outer surfaces.

14. The temperature control device according to claim 10, wherein each conductor coating has in the element cross section a conductor width measured along a respective one of the large outer surfaces which is less than 50% of an element width of the at least one PTC element, measured between the small outer surfaces.

15. The temperature control device according to claim 10, wherein each conductor coating has in the element cross section a conductor width measured along a respective one of the large outer surfaces that is larger than an element thickness of the at least one PTC element, measured between the large outer surfaces.

16. The temperature control device according to claim 10, wherein the at least one PTC element has an electrically conducting metal coating on each large outer surface at least in a region of a respective one of the conductors, which is electrically conductively connected to the conductor coating.

17. The temperature control device according to claim 16, wherein each conductor coating is soldered to a respective metal coating.

18. The temperature control device according to claim 10, wherein: the at least one PTC element includes a plurality of PTC elements arranged in succession in the longitudinal direction; the envelope body encloses all PTC elements in the circumferential direction; and the two insulator plates extend across all PTC elements so that the two conductor coatings are electrically conductively connected to all the PTC elements.

19. The temperature control device according to claim 10, wherein each insulator plate is thermally conductive and is connected in a sheet-like and heat transfer manner by a plate outer side facing away from the at least one PTC element to a body inner side of the envelope body facing toward the at least one PTC element.

20. A PTC module for a temperature control device, comprising: at least one PTC element, having a flat element cross section transverse to a longitudinal direction of the PTC module, and two large outer surfaces along the longitudinal direction facing away from each other, and two small outer surfaces facing away from each other and joining together the two large outer surfaces; an envelope body, which encloses the at least one PTC element at least in a circumferential direction; two electrical conductors, which extend in the longitudinal direction and are spaced apart from each other in the flat element cross section and electrically conductively connected to the at least one PTC element; and two electrically isolating insulator plates, which extend in the longitudinal direction and each of which is connected in a heat transfer manner to one of the large outer surfaces of the at least one PTC element; wherein each electrical conductor is formed by an electrically conducting conductor coating on a respective one of the insulator plates; wherein the conductor coating of one of the electrical conductors is arranged on the one of the insulator plates only in a first edge region, which borders on one of the two small outer surfaces; wherein the conductor coating of the other of the electrical conductors is arranged on the other of the insulator plates only in a second edge region, which borders on the other of the two small outer surfaces; and wherein each conductor coating has in the element cross section a conductor width measured along a respective one of the large outer surfaces which is less than 50% of an element width of the at least one PTC element, measured between the small outer surfaces, and which is larger than an element thickness of the at least one PTC element, measured between the large outer surfaces.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Preferred exemplary embodiments of the invention are represented in the drawings and shall be discussed more closely in the following description, where the same reference numbers pertain to the same or similar or functionally equal components.

[0025] There are shown, each time schematically,

[0026] FIG. 1 an isometric view of a temperature control device with a plurality of PTC modules,

[0027] FIG. 2 an isometric view of a single PTC module with an envelope body and two insulator plates,

[0028] FIG. 3 an isometric view of the PTC module of FIG. 2, but omitting the envelope body and one of the insulator plates,

[0029] FIG. 4a cross section of the PTC module along sectioning lines IV in FIG. 2, where in addition there are arranged on the envelope body cooling fins which are absent from FIG. 2.

DETAILED DESCRIPTION

[0030] According to FIG. 1, a temperature control device 1 comprises a plurality of PTC modules 2, which are assembled into a heat transfer block 3. For this purpose, the PTC modules 2 are arranged next to each other in a heat transfer region 4, through which a fluid 5 whose temperature is to be controlled can flow. The ability of the fluid 5 to flow through the heat exchanger 4 and also the heat transfer block 3 is indicated by arrows in FIG. 1. Moreover, cooling fins 6 are provided in the heat transfer block 3, which on the one hand can have the fluid 5 flowing through them and on the other hand are connected in heat transfer manner to the PTC modules 2. The cooling fins 6 each extend between neighbouring PTC modules 2 and outwardly against the outer situated PTC modules 2.

[0031] The temperature control device 1 is furthermore outfitted with a control device 7, by means of which the PTC modules 2 can be electrically actuated. In particular, it may be provided that the control device 7 can individually activate and deactivate the individual PTC modules 2, so as to control the heating power of the heat transfer block 3. Likewise, a zone control may be realized. For the electrical connection to the control device 7, the respective PTC module 2 has corresponding electrical leads 8.

[0032] According to FIGS. 2 to 4, the respective PTC module 2 has at least one PTC element 9. Preferable are designs in which a plurality of such PTC elements 9 are provided, which are arranged in succession in a longitudinal direction 10 of the module 2, hereafter also called the module longitudinal direction 10. The PTC elements 9 consist of PTC material, and are thus PTC elements.

[0033] According to FIG. 4, the respective PTC element 9 has a flat element cross section 11 transversely to the module longitudinal direction 10, which runs in FIG. 4 perpendicular to the plane of the drawing, which in the preferred example shown here is rectangular in configuration. Along the module longitudinal direction 10 the respective PTC element 9 thus has two large outer surfaces 12, 13, namely, a first large outer surface 12 and a second large outer surface 13, as well as two small outer surfaces 14, 15, namely a first small outer surface 14 and a second small outer surface 15. The two large outer surfaces 12, 13 face away from each other. The two small outer surfaces 14, 15 are also facing away from each other. Moreover, the two small outer surfaces 14, 15 join the two large outer surfaces 12, 13. In the example shown, the large and small outer surfaces 12, 13, 14, 15 are configured flat each time, so that the respective PTC element 9 is also flat in configuration.

[0034] The PTC module 2 furthermore comprises an envelope body 16, which encloses the respective PTC element 9 at least in a circumferential direction 17. The circumferential direction 17 is indicated in FIGS. 2 to 4 by a double arrow and runs around the module longitudinal direction 10 or a module longitudinal centre axis 18. The envelope body 16 is expediently made of a metal, having on the one hand a good thermal conductivity and on the other hand a good electrical conductivity.

[0035] The respective PTC module 2 has electrically isolating insulator plates 19, 20, namely, a first insulator plate 19 and a second insulator plate 20. The two insulator plates 19, 20 each extend in the module longitudinal direction 10 and are each connected in heat transfer manner to one of the large outer surfaces 12, 13 of the respective PTC element 9. Expediently, the respective insulator plate 19, 20 lies flat against the entire respective large outer surface 12, 13 of the respective PTC element 9. For improved heat transfer, a thermal conduction material may be arranged between the respective large outer surface 12, 13 and a plate inner side 21 facing the respective PTC element 9, such as one in the form of a paste or in the form of a film.

[0036] Furthermore, two electrical conductors 22, 23 are provided for the electrical power supply and the actuation of the respective PTC element 9, namely, a first electrical conductor 22 and a second electrical conductor 23. The two electrical conductors 22, 23 extend each time in the module longitudinal direction 10 and are each electrically conductively connected to a contact region 24 or 25 of the respective PTC element 9. The two contact regions 24, 25, which are also called in the following the first contact region 24 and second contact region 25, are arranged on the respective PTC element 9, spaced apart from each other in the element cross section 11. In this way, the two conductors 22, 23 are also arranged on the respective PTC element 9 spaced apart from each other.

[0037] In the PTC module 2 presented here, the two electrical conductors 22, 23 are formed each time by an electrically conducting conductor coating 26, 27, which is also called in the following the first conductor coating 26 and second conductor coating 27. The first conductor coating 26 is formed on the first insulator plate 19, namely on its plate inner side 21. The second conductor coating 27 on the other hand is formed on the second insulator plate 20, likewise on its plate inner side 21. Furthermore, the arrangement of the conductor coatings 26, 27 on the respective insulator plate 19, 20 is done each time only in an edge region 28 or 29 of the respective insulator plate 19, 20. Accordingly, there is located on the first insulator plate 19 a first edge region 28, while the second insulator plate 20 has a second edge region 29. The edge regions 28, 29 are indicated in FIG. 4 by a curly brace each time. Accordingly, the first conductor coating 26 is arranged in the first edge region 28, while the second conductor coating 27 is arranged in the second edge region 29. The first edge region 28 borders on the first small outer surface 14, while the second edge region 29 borders on the second small outer surface 15. In this way, the two edge regions 28, 29 and thus also the two conductor coatings 26, 27 are arranged almost diagonally or diametrically opposite each other in the element cross section 11. This results in a substantially diagonal electrical pathway 30 inside the element cross section 11, which is taken by the electric current when the respective PTC element 9 is energized. This electrical pathway 30 is comparatively long, so that an efficient thermoelectric conversion occurs.

[0038] The two conductor coatings 26, 27 have a spacing 31 in the element cross section 11 along the large outer surfaces 12, 13. Insofar as the large outer surfaces 12, 13 are flat and run parallel to each other, as in the example shown, the spacing 31 also extends parallel to the large outer surfaces 12, 13. This spacing 31 is demonstrably larger than an element thickness 32 of the respective PTC element 9, the element thickness 32 being measured between the two large outer surfaces 12, 13. When the outer surfaces 12, 13 are flat, the element thickness 32 extends perpendicular to the large outer surfaces 12, 13. For example, the spacing 31 is at least twice as large as the element thickness 32.

[0039] Furthermore, the respective conductor coating 26 or 27 has in the element cross section 11 an effective conductor width 33 or 34, measured along the respective large outer surface 12, 13. One measures in this case only that region of the respective conductor coating 26, 27 which is directly electrically conductively connected to the respective large outer surface 12, 13 of the PTC element 9. In the example of FIG. 4, the conductor coating 26, 27 projects beyond the respective small outer surface 14, 15 along the respective insulator plate 19, 20 and thus protrudes out from the element cross section 11. This partial overhanging region of the respective conductor coating 26, 27 does not stand in direct electrical connection to the respective large outer surface 12, 13 of the PTC element 9. No such overhang is present in the example of FIG. 3.

[0040] The first conductor coating 26 has the first conductor width 23, while the second conductor coating 27 has the second conductor width 34. Expediently, the two conductor widths 33, 34 are the same size. Expediently, it may now be provided that the respective conductor width 33, 34 is less than half of an element width 35, measured between the small outer surfaces 14, 15. Preferably, the respective conductor width 33, 34 is less than a quarter of the element width 35.

[0041] Furthermore, the respective conductor width 33, 34 may be larger than the element thickness 32. This is not recognizable in the representation shown in FIG. 4, not drawn to scale, but can be seen from FIG. 3.

[0042] The respective PTC element 9 may now have an electrically conducting metal coating 36 on the respective large outer surface 12, 13, at least in the region of the respective conductor 22, 23. The respective metal coating 36 is also recognizable in FIG. 3. The respective metal coating 36 is electrically conductively connected to the respective conductor coating 26, 27. For example, the conductor coatings 26, 27 may be soldered to the metal coatings 36.

[0043] According to FIGS. 2 and 3, the two insulator plates 19, 20 extend across all the PTC elements 9, so that the two conductors 22, 23 or the two conductor coatings 26, 27 are electrically conductively connected to all the PTC elements 9. The envelope body 16 recognizable in FIG. 2 is also jointly provided for all PTC elements 9, so that it encloses all the PTC elements 9 in the circumferential direction 17.

[0044] According to FIG. 4, the thermally conductive insulator plates 19, 20 are connected in heat transfer manner to the envelope body 16. For this purpose, each time a plate outer side 37 facing away from the respective PTC element 9 is connected in sheetlike and heat transfer manner to a body inner side 38 facing toward the respective PTC element 9. This can be accomplished by a direct contact or by a thermal conduction material, which may be provided as a paste or film. The envelope body 16 according to FIGS. 1 and 4 may be connected in heat transfer manner to the cooling fins 6 at its body outer side 39 facing away from the respective PTC element 9. For example, the cooling fins 6 may be soldered to the envelope body 16.