Electric heating device, in particular for a vehicle heating and/or air-conditioning apparatus

• US 7,200,327 B2
• Filed: 02/10/2006
• Issued: 04/03/2007
• Est. Priority Date: 04/11/2002
• Status: Active Grant

• Current Assignee: Valeo Climatisation
• Original Assignee: Valeo Climatisation
• Inventors: Terranova, Gilbert, Colette, Olivier, Marange, Christophe, Pierron, Free
• Primary Examiner(s): Evans; Robin
• Assistant Examiner(s): PATEL, VINOD D
• Application Number:
  US11/351,916
• Publication Number:
  US 20060222346A1
• Time in Patent Office: 417 Days
• Field of Search: 392/350, 392/485, 219/541, 219/530, 219/540, 219/202, 219/486, 219/492, 219/205, 165/148
• US Class Current: 392/350
• CPC Class Codes: B60H 1/2225 arrangements of electric heaters for heating air
• CPC Class Codes: F24H 3/0405 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 F24H3/06, F24H3/08, F24H3/10 take precedence
• CPC Class Codes: F24H 3/0429 For vehicles
• CPC Class Codes: F24H 3/0435 Structures comprising heat spreading elements in the form of fins
• CPC Class Codes: F24H 3/0441 Interfaces between the electrodes of a resistive heating element and the power supply means
• CPC Class Codes: F24H 3/0447 Forms of the electrode terminals, e.g. tongues or clips
• CPC Class Codes: F24H 3/0458 One-piece frames
• CPC Class Codes: F24H 9/1872 PTC
• CPC Class Codes: H05B 1/0236 for vehicles
• CPC Class Codes: H05B 2203/02 Heaters using heating elements having a positive temperature coefficient
• CPC Class Codes: H05B 3/16 the conductor being mounted on an insulating base

Abstract

Electric heating device comprising an electric radiator (10) for heating the air passing through it, said radiator comprising a casing (12), at least one resistive element mounted in the casing and constituted by at least one zigzag metal strip (22) which is disposed so as to be directly exposed to the air passing through the casing, and a circuit (30) for controlling the electrical supply of the resistive element or elements connected to a power supply.

The electric radiator (10) comprises a set of individual heating modules (20) disposed parallel to one another in the casing (12) and so as to be directly exposed to the air passing through the casing, each heating module (20) comprising a pleated or corrugated metal strip (22) and an electronic switch controlled by the control circuit (30) intended to selectively inhibit the electrical supply of the metal strip (22).

Claims

1. An electric heating device comprising:

an electric radiator comprising a set of individual heating modules and a casing;

at least one resistive element constituted by at least one zigzag metal strip mounted in the casing;

a power supply;

a resistive element or elements connected to the power supply;

a control circuit for controlling the electrical supply of the resistive element or elements;

wherein each heating module (20) comprise a pleated or corrugated metal strip (22) and an electronic switch (25) controlled by the control circuit, wherein the pleated or corrugated metal strip (22) and the electronic switch (25) selectively inhibit the electrical supply of the metal strip (22), wherein each heating module (20) also comprises an insulating support (40), and the insulating support (40) comprises a molded rail (45) to hold the metal strip (22) in position, and

wherein when air passes through the radiator the at least one zigzag metal strip is disposed so as to be directly exposed to the air passing through the radiator and wherein the in individual heating modules (20) are disposed parallel to one another in the casing.

2. An electric heating device according to claim 1, wherein the molded rail (45) has flanges (45a, 45b) and separations (46) to hold the pleats or corrugations of the metal strip laterally and to maintain a certain regularity of the pitch of the corrugated or pleated metal strip (22).

3. Device according to claim 2, wherein each metal strip (22) of each heating module (20) has a corrugation period with a length of between 1.8 mm and 6 mm.

4. Device according to claim 2, wherein each metal strip (22) of each heating module has a peak-to-peak amplitude between corrugation tops of between 5 mm and 20 mm.

5. An electric heating device according to claim 1, wherein the heating module comprises at least one thermal and electrical protection element directly exposed to the air passing through the heating module and in series with the metal strip (22).

6. An electric heating device according to claim 5, wherein the protection element comprises at least one hot-melt link (58) in series with a metal strip (22).

7. Device according to claim 6, wherein the brazed joint of the hot-melt link (58) has a melting point matching an upper temperature limit.

8. Device according to claim 7, wherein the brazed joint of the hot-melt link (58) is formed by a eutectic solder joint.

9. Device according to claim 5, wherein the protection element comprises a spring blade (57) and a hot-melt link (58) formed by a brazed joint between one end of the metal strip (22) and one end of the spring blade (57), the other end of the spring blade being immovably attached to the support (40) and electrically connected to a terminal 56.

10. Device according to claim 9, wherein the spring blade (57) is directly exposed to the air passing through the heating module (20) and openings in the form of louvres are formed in the spring blade (57).

11. Device according to claim 9, wherein the spring blade (57) has a cross-section smaller than or equal to that of the metal strip (22).

12. Device according to claim 9, wherein the spring blade (57) has a resistivity greater than or equal to that of the metal strip (22).

13. Device according to claim 9, wherein the end of the spring blade (57) immovably attached to the insulating support (40) is soldered permanently to the connection terminal (56) electrically independent of the metal connection support (50) and the strip or the spring blade is electrically connected to an external terminal or busbar (35).

14. Device according to claim 9, wherein the spring blade (57) has a PTC effect thus providing the function of a thermal sensor.

15. Device according to claim 1, wherein a metal connection support (50) connected to the electrical power supply is integrated into the insulating support (40) allowing the electrical supply of the metal strip (22).

16. Device according to claim 15, wherein the electronic switch (25) is integrated onto the metal connection support (50) through tracks formed by said support.

17. Device according to claim 16, wherein flanges (52) are formed in the metal connection support (50) facilitating the heat dissipation of the electronic switch (25) by the air passing through the heating module (20).

18. Device according to claim 15, wherein flanges (52) are formed in the metal connection support (50) facilitating the heat dissipation of the electronic switch (25) by the air passing through the heating module (20).

19. Device according to claim 1, wherein each heating module (20) also comprises at least one reversible or resettable protection mechanism (61) connected directly or indirectly to the metal strip (22), thereby preventing excessive heating.

20. Device according to claim 19, wherein the reversible protection mechanism (61) is a thermal sensor or detector delivering information to the control circuit (30), matching the temperature of the metal strip (22) or of the spring blade (57) in order that the control circuit (30) disconnects the electrical supply in the case of excessive heating.

21. Device according to claim 20, wherein the thermal sensor or detector is connected thermally to the spring blade (57).

22. Device according to claim 20, wherein the thermal sensor or detector comprises an element chosen from the group consisting of an NTC resistor, a PTC resistor, a bimetallic strip and a PTC effect polymer switch.

23. Device according to claim 1, wherein each heating module (20) has a heating power of between 0 and 500 W.

24. Device according to claim 1, wherein the casing (12) comprises a set of cells (14) intended to accommodate and hold in place each heating module (20).

25. Device according to claim 24, wherein the casing (12) has a cover (39).

26. Device according to claim 1, wherein the control circuit (30) comprises means of varying the power supplied by the radiator by modulating the supply voltage delivered to each heating module (20).

27. Device according to claim 26, wherein the control circuit (30) comprises means of varying the supplied power by pulse width modulation.

28. Device according to claim 1, wherein the different heating modules (20) comprise metal strips (22) having substantially identical resistances.

29. Device according to claim 1, wherein each metal strip (22) of each heating module has a width of between 5 mm and 20 mm.

30. Device according to claim 1, wherein each metal strip (22) of each heating module has a thickness of between 50 μ

m and 250 μ

m.

31. Device according to claim 1, wherein each metal strip (22) of each heating module is made of a material chosen from amongst an iron-based alloy and a copper-based alloy.

32. Device according to claim 31, wherein the copper-based alloy is an alloy chosen from amongst CuNi30, CuNi45 and CuNi18Zn20.

33. Device according to claim 31, wherein the material is an alloy having a positive temperature coefficient resistance effect.

34. Device according to claim 1, wherein openings in the form of louvres (26) are formed in each strip (22).

35. Device according to claim 34, wherein the louvres (26) comprise fins (26a) which form an angle of between 20°

and 35°

with respect to the plane of the strip (22).

36. Device according to claim 1, wherein each strip (22) is provided with an electrically insulating or corrosion protection covering.

37. Device according to claim 1, wherein each metal strip (22) has a profile chosen from amongst a sinusoidal profile, a triangular profile, a rectangular profile and a trapezoidal profile.

38. Device according to claim 1, also comprising an air flow generator (7), wherein the electronic switches (25) driven by the control circuit (30) inhibit the electrical supply of the heating modules (20) when the air flow rate passing through the radiator (10) is below a minimum value.

39. Device according to claim 38, in which the air flow generator (7) comprises a fan (3), wherein means are provided for supplying the control circuit (30) with a signal representing the speed of rotation of the fan in order to inhibit the electrical supply of the healing modules when the speed of rotation of the fan is below a predetermined threshold.

40. Heating or air-conditioning apparatus for a motor vehicle comprising a heating device according to claim 1.

41. Apparatus according to claim 40, comprising a liquid heat exchanger and an air circulation channel wherein the electric radiator is disposed downstream of the liquid heat exchanger in the air circulation channel.

42. Apparatus according to claim 41, further Comprising an air outlet aperture wherein the electric radiator is disposed in proximity to the air outlet aperture.