PTC heating module and a method for producing the PTC heating module

• US 11,765,792 B2
• Filed: 10/30/2019
• Issued: 09/19/2023
• Est. Priority Date: 10/31/2018
• Status: Active Grant

• Current Assignee: Mahle International GmbH (MAHLE-STIFTUNG GmbH)
• Original Assignee: Mahle International GmbH (MAHLE-STIFTUNG GmbH)
• Inventors: Daniel, Alexander, Kohl, Michael, Schwenzer, Jonas Caspar, Seewald, Wolfgang, Viehrig, Falk
• Primary Examiner(s): Ross, Dana
• Assistant Examiner(s): Chen, Kuangyue
• Application Number:
  US16/669,497
• Publication Number:
  US 20200137837A1
• Time in Patent Office: 1,420 Days
• CPC Class Codes: H05B 1/0297 Heating of fluids for non specified applications
• CPC Class Codes: H05B 2203/017 Manufacturing methods or apparatus for heaters
• CPC Class Codes: H05B 2203/02 Heaters using heating elements having a positive temperature coefficient
• CPC Class Codes: H05B 2203/021 Heaters specially adapted for heating liquids
• CPC Class Codes: H05B 2203/023 Heaters of the type used for electrically heating the air blown in a vehicle compartment by the vehicle heating system
• CPC Class Codes: H05B 3/22 non-flexible

Abstract

The disclosure relates to a PTC heating module for heating a fluid and a method for producing such a PTC heating module. The PTC heating module includes a plurality of PTC thermistors having main surfaces disposed opposite to one another and spaced apart relative to one another in a thickness direction. The PTC thermistors are arranged between two contact plates next to one another transversely to the thickness direction and spaced apart relative to one another. The main surfaces of the PTC thermistors are electrically contacted with a contact surface of the two contact plates. At least one dielectric function element is arranged between the two contact plates and laterally sealingly engages about the respective PTC thermistors to at least partially fill a hollow space between the two contact plates and facilitate enlarging a creepage distance between the two contact plates within the hollow space.

Claims

1. A PTC heating module for heating a fluid, comprising:

a plurality of PTC thermistors each having two main surfaces, wherein the two main surfaces of the plurality of PTC thermistors are located opposite to one another and spaced apart relative to one another in a thickness direction,

two contact plates each provided with a contact surface, between which the plurality of PTC thermistors are arranged transversely to the thickness direction next to one another and spaced apart relative to one another,

wherein the two main surfaces of the plurality of PTC thermistors are electrically contacted with the contact surface of a respective one of the two contact plates, and

at least one dielectric function element, arranged between the two contact plates and laterally sealingly engaged about and sealingly adjoins the plurality of PTC thermistors, such that a hollow space between the two contact plates in the thickness direction is at least partly filled out with the at least one dielectric function element and a creepage distance between the two contact plates within the hollow space is enlarged, and

wherein the at least one dielectric function element is a dielectric coating, and the hollow space is at least partially filled out with the dielectric coating in the thickness direction.

2. The PTC heating module according to claim 1, further comprising an insulation plate.

3. The PTC heating module according to claim 2, wherein the insulation plate, transversely to the thickness direction, projects out of the hollow space towards an outside such that in an edge region of the two contact plates an air gap between the two contact plates is enlarged.

4. The PTC heating module according to claim 1, wherein the dielectric coating is fixed on each of the contact surfaces of the two contact plates around the plurality of PTC thermistors, and wherein the hollow space between the two contact plates in the thickness direction is partly filled out by the dielectric coating such that an air gap is defined transversely to the thickness direction in the hollow space.

5. The PTC heating module according to claim 1, wherein:

the dielectric coating is fixed on each of the contact surfaces of the two contact plates around the plurality of PTC thermistors, wherein the hollow space between the two contact plates in the thickness direction is partly filled out such that the dielectric coating at least partially covers the plurality of PTC thermistors in the thickness direction, or

the dielectric coating is fixed on each of the contact surfaces of the two contact plates around the plurality of PTC thermistors, wherein the hollow space between the two contact plates in the thickness direction is completely filled out, or

the dielectric coating is fixed on each of the contact surfaces of the two contact plates around the plurality of PTC thermistors, wherein the hollow space between the two contact plates in the thickness direction is partly filled out and the plurality of PTC thermistors are cladded by the dielectric coating transversely to the thickness direction.

6. The PTC heating module according to claim 1, wherein the dielectric coating laterally dads the at least one contact plate and is disposed outside of the contact surface at least in one region, such that in an edge region of the two contact plates an air gap between the two contact plates is enlarged.

7. The PTC heating module according to claim 4, wherein the dielectric coating completely dads the at least one contact plate around the plurality of PTC thermistors and the two contact plates are electrically insulated towards an outside.

8. The PTC heating module according to claim 1, further comprising:

a dielectric basic coating fixedly bonded on an end face of at least one of the two contact plates, the end face located opposite to the contact surface of the at least one contact plate, wherein the dielectric basic coating electrically insulates the at least one contact plate towards an outside, or

a dielectric insulation cladding structured and arranged to clad the two contact plates on a plurality of sides and electrically insulate the two contact plates towards an outside.

9. The PTC heating module according to claim 1, further comprising an electrically conductive contact base arranged between a respective one of the plurality of PTC thermistors and at least one of the two contact plates, the electrically conductive contact base having a support face that is smaller than the two main surfaces of the respective PTC thermistor, and wherein the respective PTC thermistor projects from the electrically conductive contact base transversely to the thickness direction.

10. The PTC heating module according to claim 9, wherein the electrically conductive contact base has a thickness defined in the thickness direction that is smaller than a layer thickness of a dielectric coating of the at least one dielectric function element defined in the thickness direction on at least one of the two contact plates, and wherein the electrically conductive contact base, transversely to the thickness direction, is completely cladded by the dielectric coating on the at least one contact plate.

11. The PTC heating module according to claim 1, further comprising a dielectric basic coating disposed on a respective end face of the two contact plates disposed opposite to the contact surface, wherein the dielectric basic coating electrically insulates the two contact plates towards an outside.

12. The PTC heating module according to claim 1, wherein the dielectric coating, transversely to the thickness direction, projects out of the hollow space towards an outside such that in an edge region of the two contact plates an air gap between the two contact plates is enlarged.

13. The PTC heating module according to claim 2, wherein the insulation plate is composed of ceramic.

14. The PTC heating module according to claim 9, wherein the dielectric coating is disposed on the contact surface of the at least one contact plate, and wherein the electrically conductive contact base has a thickness in the thickness direction that is smaller than a layer thickness of the dielectric coating in the thickness direction.

15. A method for producing a PTC heating module, comprising:

providing a plurality of PTC thermistors each having two main surfaces disposed opposite to one another and spaced apart from one another in a thickness direction of the plurality of PTC thermistors;

arranging the plurality of PTC thermistors between two contact plates next to one another transversely to the thickness direction and spaced apart relative to one another;

joining the plurality of PTC thermistors with the two contact plates, wherein the plurality of PTC thermistors are joined simultaneously with the two contact plates or are joined first with one of the two contact plates and then with the other of the two contact plates, such that the two main faces of the plurality of PTC thermistors are indirectly or directly electrically contacted with a respective contact surface of the two contact plates, and

wherein prior to the joining or after the joining of the plurality of PTC thermistors with the two contact plates, applying at least one dielectric function element comprising a dielectric coating onto the respective contact surface of at least one of the two contact plates, wherein applying the at least one dielectric function element comprising the dielectric coating includes at least partially filling a hollow space between the two contact plates in the thickness direction and laterally sealingly engaged about and sealingly adjoins the plurality of PTC thermistors with the dielectric coating.

16. The method according to claim 15, wherein applying the dielectric coating further includes:

applying the dielectric coating on the at least one contact plate in at least one region outside of the respective contact surface such that the at least one contact plate is laterally or completely cladded by the dielectric coating, or

applying a dielectric basic coating onto an end face of the at least one contact plate located opposite to the respective contact surface, or

applying a dielectric insulation cladding onto the two contact plates to clad the two contact plates on a plurality of sides.

17. The method according to claim 15, wherein the dielectric coating is applied after the joining of the plurality of PTC thermistors with the two contact plates, and wherein applying the dielectric coating includes injecting or over-moulding or spraying-in a dielectric material in the hollow space or by dipping into a dielectric material or by anodizing with a dielectric material.

18. The method according to claim 15, wherein:

the dielectric coating is applied by over-moulding or spraying-on a dielectric material or by dipping into a dielectric material or by anodizing with a dielectric material or by gluing on a film of a dielectric material around the plurality of PTC thermistors after the joining of the plurality of PTC thermistors with a respective one of the two contact plates, or

the dielectric coating is applied by over-moulding or by spraying-on a dielectric material or by anodizing with a dielectric material or by dipping into a dielectric material or by gluing-on a film of a dielectric material around a plurality of place holder elements prior to the joining of the plurality of PTC thermistors with the two contact plates, and thereafter removing the plurality of place holder elements and then the plurality of PTC thermistors are placed in positions kept by the plurality of place holder elements and joined with the two contact plates.

19. The method according to claim 15, further comprising arranging an electrically conductive contact base between a respective one of the plurality of PTC thermistors and at least one of the two contact plates, wherein the electrically conductive contact base has a support face that is smaller than a corresponding one of the two main faces of the respective PTC thermistor such that the respective PTC thermistor projects outwardly from the electrically conductive contact base transversely to the thickness direction.

20. A PTC heating module for heating a fluid, comprising:

a plurality of PTC thermistors respectively having two main surfaces disposed opposite to one another and spaced apart relative to one another in a thickness direction;

two contact plates arranged spaced apart from one another in the thickness direction, the plurality of PTC thermistors arranged between the two contact plates next to and spaced apart from one another transversely to the thickness direction, wherein the two main surfaces of the plurality of PTC thermistors are electrically contacted with a respective contact surface of the two contact plates; and

a dielectric coating arranged between the two contact plates and laterally sealingly engaged about and sealingly adjoins the plurality of PTC thermistors, wherein the dielectric coating is fixed on the contact surface of at least one of the two contact plates and at least partially fills a hollow space between the two contact plates to facilitate increasing a creepage distance between the two contact plates within the hollow space.