Convective heater

• US 8,575,518 B2
• Filed: 01/28/2010
• Issued: 11/05/2013
• Est. Priority Date: 01/28/2009
• Status: Active Grant

• Current Assignee: Gentherm Incorporated
• Original Assignee: Gentherm Incorporated
• Inventors: Walsh, Ryan
• Primary Examiner(s): Pizarro, Marcos D.
• Assistant Examiner(s): TANG, SUIAN
• Application Number:
  US12/695,602
• Publication Number:
  US 20100193498A1
• Time in Patent Office: 1,377 Days
• Field of Search: 219/217, 219/540
• US Class Current: 219/217
• CPC Class Codes: F24H 3/002 using electric energy supply
• 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 3/0482 Frames with integrated fan
• CPC Class Codes: F24H 9/2071 using electrical energy supply
• CPC Class Codes: F28D 1/024 with an air driving element
• CPC Class Codes: F28F 3/02 Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations F28F3/08 takes precedence
• CPC Class Codes: F28F 3/025 the means being corrugated, plate-like elements

Abstract

A heating device comprises a heater having a first surface and a second surface, with the second surface being generally opposite of the first surface. The heater is configured to receive an electrical current and convert it to heat. The heating device additionally includes at least one heat transfer assembly positioned along the first and/or second surface of the heater. In one embodiment, the heat transfer assembly includes a plurality of fins that generally define a plurality of fin spaces through which fluids may pass. In some arrangements, the heating device comprises an outer housing that at least partially surrounds the heater and one or more of the heat transfer assemblies. Heat generated by the heater is transferred to the fins of the heat transfer assembly. In addition, fluids passing through the fin spaces are selectively heated when electrical current is provided to the heater.

Claims

1. A heating device for convectively heating a fluid, said heating device comprising:

a first heat transfer assembly comprising a plurality of fins, said fins defining a plurality of fin spaces therebetween through which fluids are selectively passed;

a base having a first side and a second side, said first side being generally opposite of said second side;

wherein said base comprises a first end and a second end, said first end being located opposite of said second end;

wherein the plurality of fins extend from and are adjacent the first side of the base;

at least one electrical conducting member positioned along at least a portion of the second side of the base, said at least one electrical conducting member beginning and terminating along the first end of the base and extending at least partially along or near a periphery of said base;

wherein the at least one electrical conducting member is configured to receive electrical current and convert said electrical current to heat;

an outer housing at least partially surrounding the first heat transfer member and said base, wherein said outer housing defines at least one partially enclosed space through which fluids are selectively passed;

an electrical coupling for electrically connecting a first end and a second end of said at least one electrical conducting member, said electrical coupling extending, at least partially, to an exterior of the outer housing;

wherein heat generated at or near the at least one electrical conducting member is transferred to the plurality of fins of the first heat transfer assembly; and

wherein fluids directed through the fin spaces within the at least one partially enclosed space are selectively heated when electrical current is provided to the heating device.

2. The heating device of claim 1, wherein the first heat transfer assembly and the at least one electrical conducting member comprise a generally unitary structure.

3. The heating device of claim 1, wherein the at least one electrical conducting member is formed directly on the base of the first heat transfer assembly.

4. The heating device of claim 1, wherein the at least one electrical conducting member is part of a heater secured to the base of the first heat transfer assembly.

5. The heating device of claim 4, wherein the heater comprises a thick film heater.

6. The heating device of claim 1, wherein the at least one electrical conducting member comprises a conductive material positioned on the base of the first heat transfer assembly.

7. The heating device of claim 6, wherein the conductive material comprises a metal.

8. The heating device of claim 6, wherein the conductive material comprises an electrically conductive carbon material.

9. The heating device of claim 6, wherein the conductive material comprises a conductive ink.

10. The heating device of claim 6, wherein the conductive material is deposited on the base using at least one of spraying, coating and printing.

11. The heating device of claim 1, wherein the first heat transfer assembly comprises an electrically non-conductive material.

12. The heating device of claim 1, further comprising an electrical connector in electrical communication with at least one electrical conducting member, said connector being configured to connect to a coupling for the selective delivery of electrical current to the heating device.

13. The heating device of claim 1, further comprising a second heat transfer assembly, said second heat transfer assembly extending in a direction generally away from the second side of the base.

14. The heating device of claim 4, wherein the heater and the first heat transfer assembly are attached using adhesives or thermal grease.

15. The heating device of claim 4, wherein the heater and the first heat transfer assembly are attached using at least one mechanical fastener.

16. The heating device of claim 1, wherein a Temperature Coefficient of Resistance (TCR) of the at least one electrical conducting member is between about 1,500 and 3,500 ppm/°

C.

17. A heating device comprising:

a heater having a first surface and a second surface, said second surface being generally opposite of said first surface, said heater being configured to receive an electrical current and convert such electrical current to heat;

at least one heat transfer assembly positioned along and adjacent the first surface of the heater, said heat transfer assembly comprising a plurality of fins, said fins defining a plurality of fin spaces therebetween through which fluids may pass;

an electrically conductive portion positioned along the second surface of the heater, said electrically conductive portion having first and second terminals, said first and second terminals positioned along one end of the heater;

an outer housing at least partially surrounding the heater and the at least one heat transfer assembly; and

an electrical coupling for electrically connecting the first and second terminals of the electrically conductive portion, said electrical coupling extending, at least partially, to an exterior of the outer housing;

wherein heat generated by the heater is transferred to the fins of the heat transfer assembly; and

wherein fluids passing through the fin spaces are selectively heated when electrical current is provided to the heater.

18. The heating device of claim 17, wherein a Temperature Coefficient of Resistance (TCR) of the electrically conducting portion is between about 1,500 and 3,500 ppm/°

C.

19. The heating device of claim 17, wherein the heater comprises a thick film heater.

20. The heating device of claim 17, wherein the electrically conductive portion comprises a conductive material positioned on the base of the first heat transfer assembly.

21. The heating device of claim 20, wherein the conductive material comprises at least one of a metal and an electrically conductive carbon.

22. A seating assembly comprising a support member with at least one fluid passageway, wherein the at least one fluid passageway is in fluid communication with a heating device of claim 17 so as to selectively provide heated air toward a seated occupant of the seating assembly.

23. The seating assembly of claim 22, wherein the seating assembly comprises at least one of a seat and a bed.

24. A heating device comprising:

a heater configured to receive an electrical current to produce heat;

at least one heat transfer assembly adjacent the heater, the heat transfer assembly comprising a plurality of heat transfer members, wherein the heat transfer members define a plurality of spaces therebetween through which fluid may pass;

at least one electrically conductive member positioned on or within the heater, the at least one electrically conductive member terminating along one end of the heater;

wherein the at least one electrically conductive member is configured to produce heat when electrically energized;

an outer housing at least partially surrounding the heater and the at least one heat transfer assembly; and

an electrical coupling electrically connecting the at least one electrically conductive member, wherein the electrical coupling extends at least partially to an exterior of the outer housing;

wherein heat generated by the heater is transferred to the at least one heat transfer assembly; and

wherein fluid passing through the spaces is selectively heated when electrical current is provided to the heater.

25. A seating assembly comprising a support member with at least one fluid passageway, wherein the at least one fluid passageway is in fluid communication with a heating device of claim 24 so as to selectively provide convectively heated air toward a seated occupant of the seating assembly.

26. The seating assembly of claim 25, wherein the seating assembly comprises a seat or a bed.