EP3728962A1

EP3728962A1 - Electric heating device with electrode housing station

Info

Publication number: EP3728962A1
Application number: EP18839826.7A
Authority: EP
Inventors: Yann COUAPEL; Erwan Gogmos
Original assignee: Valeo Systemes Thermiques SAS
Current assignee: Valeo Systemes Thermiques SAS
Priority date: 2017-12-19
Filing date: 2018-12-13
Publication date: 2020-10-28
Anticipated expiration: 2038-12-13
Also published as: FR3075554A1; EP3728962B1; CN111742183B; JP6999815B2; JP2021507197A; CN111742183A; US12092367B2; WO2019122616A1; US20200309410A1; FR3075554B1

Abstract

Heating device 1 for an air conditioning unit, the said heating device 1 comprising a heating body 2 powered with current via a distribution unit 3 to heat a flow of air passing through the said heating body 2, the heating body 2 comprising an alignment of tubes 4 in which there are: – heating elements 8 through which the said current passes; – electrodes 9 situated on each side of the heating elements 8 in order to supply them with electrical current. This heating device 1 is characterised in that the distribution units 3 comprises an electrode housing station 6 housing the electrodes 9, the said housing station 6 having a plurality of housings 17 to house the electrodes 9 and in which there are means for mechanically and electrically connecting the electrodes 9 to the distribution unit 3.

Description

ELECTRICAL HEATING DEVICE WITH RECEPTION STATION

PADS

Field of the invention

The invention relates to a heating device for an air conditioning unit, comprising a docking station for the heating electrodes. The invention also relates to an air conditioning unit comprising such a heating device. Finally, the invention relates to a method of mechanical and electrical connection of the electrodes of the heating device.

The invention will find applications, particularly in the field of motor vehicles.

State of the art

Electric heating devices are known to be integrated in vehicle air conditioning units. These are either additional radiators, combined with heating radiators covered by a heat transfer fluid, in vehicles with a combustion engine or main radiators, in electric or hybrid vehicles.

Such heating devices comprise a heating body accommodating heating units provided with heating elements supplied with electric current by electrodes. For reasons of electrical safety, it may be necessary to insulate the heating elements and their feed electrodes from the outside. For this, the heating units comprise tubes inside which are located the heating elements and their electrodes, the inner surface of the tubes being provided with an electrically insulating layer to isolate the heating elements and their electrodes.

These heating devices comprise a distribution unit capable of controlling the current flowing in the heating units, in particular via an electronic card.

On this electronic board, switches are welded to control the current flowing in the electrodes. Each switch is electrically connected on the one hand to the electronic card, and on the other hand to an electrode.

This double connection is not easy to operate on the production lines. In particular, keeping the switch in position for its welding on the board electronic is not easy to set up, and the latter may not be exactly oriented as it should, and the connection of the electrodes in a second time is all the more difficult to perform.

Indeed, besides the electrical connection, there is also a mechanical connection to be operated between each switch and the electronic card, so that all the parts are correctly positioned relative to each other as well at the time of their assembly as for the duration of the heating device in general.

Summary of the invention

The present invention aims to overcome the various disadvantages mentioned above, by means of a heating device for electrical and mechanical connection between the heating body and the distribution unit which is simple to implement and which ensures proper positioning of all parts at the time of connection, as well as for the entire life of the heater and this with a limitation of relative movements between parts to avoid vibration problems and improve the reliability of the heating device.

This object is achieved by means of a heating device for an air conditioning box comprising, in a conventional manner, a heating body supplied with current via a distribution unit for heating an air flow passing through said heating body, the heating element comprising an alignment of tubes in which are:

heating elements traversed by said current;

electrodes located on either side of the heating elements for their power supply.

This device is mainly characterized in that the distribution unit comprises a docking station for the electrodes, said docking station having a plurality of housings accommodating the electrodes and in which there are means for mechanical and electrical connection of the electrodes. electrodes to the distribution unit.

The main idea of this invention is to provide a docking station, which is the intermediary between the parts belonging to the heating body and the parts belonging to the distribution unit, and which must be connected to each other. In this case, this docking station makes it possible to correctly position the electrodes, with a view to their connection. In addition, the docking station makes it possible to correctly position mechanical and electrical connection means, which will be described later. The docking station thus constitutes a stable base, which serves as a reference for positioning the various parts.

According to the different embodiments of the invention, which can be taken together or separately:

said means for mechanical and electrical connection of the electrodes to the distribution unit consist of switches positioned on the one hand in the housings and on the other hand fixed on an electronic power supply card belonging to the distribution unit : the docking station thus allows these switches to be held in position so that the mechanical and electrical connection can take place under the best conditions.

each housing comprises a central orifice through which the switch protrudes, said orifice being dimensioned so as to keep the switch in position when it is fixed on the electronic card.

each switch has a first electrical connection face to the electronic card, provided with at least one pin that can be soldered on the card, and a second electrical connection face to the electrode, with a female endpiece in which insert a male end of the electrode.

each electrode comprises a free end on which the male end is located, the male end pieces of the two electrodes relating to a heating element being arranged in staggered rows.

- For each heating element, the docking station has two staggered housing according to the arrangement of the male end of the two corresponding electrodes.

the male end of the electrode is inserted into the female end of the switch, said switch comprising at least one flexible blade able to exert pressure on the male end of the electrode so as to hold it in position and make the electrical connection. - The male end of the electrode consists of a tab, said switch having a plurality of flexible blades exerting a support on either side of said tab.

each housing comprises means for guiding the electrode.

- Said guide means consist of two pads located on either side of the housing and whose faces vis-à-vis are beveled towards the center of the housing so as to form guide rails of the electrode.

said docking station consists of a bar extending over the entire length of the heating body, according to the alignment of the electrodes.

the docking station comprises as many housings as electrodes present in the heating body, each housing accommodating an electrode.

- The docking station has two rows of housing, the housing of a row being offset from the housing of the other row.

said docking station is perforated between the adjacent dwellings.

- The docking station is made of electrically insulating material, plastic type.

- The docking station comprises a face vis-à-vis the electronic card, said face being provided with a longitudinal central rib resting on the electronic card.

- the docking station has, apart from the rib, one or spaces between the docking station and the electronic card, so as to allow other components to be soldered to the electronic card, under the station Home.

The invention also relates to an air conditioning unit comprising a heating device as described above. And finally, the invention relates to a method of mechanical and electrical connection of an electrode of a heating device as described above. In this case, this process comprises the following steps:

position the docking station on an electronic card;

insert switches in successive orifices provided for this purpose in the docking station and then in the electronic card until they are held in position;

solder the switches to the electronic card;

simultaneously plug all the electrodes of the heating body into the corresponding switches in a single translational movement of the heating body relative to the dispensing unit.

Presentation of figures

The invention will be better understood, and other objects, details, features and advantages thereof will become more clearly apparent in the following detailed explanatory description of at least one embodiment of the invention given to As a purely illustrative and non-limiting example, with reference to the accompanying schematic drawings.

On these drawings:

FIG. 1 illustrates in perspective a heating device according to the invention, with a heating body and a distribution unit,

FIG. 2 is an enlarged view of FIG. 1 showing more particularly the junction between the heating body and the distribution unit,

FIG. 3 shows FIG. 2, but without an electronic card,

FIG. 4 is an enlarged view of FIG. 3, showing the lower face of the docking station according to the invention,

FIG. 5 shows in perspective the upper face of the docking station according to the invention, with the connection of the electrodes,

FIG. 6 is a top view, in perspective, of part of the docking station,

FIG. 7 is a top view of the entire docking station,

FIGS. 8 to 11 illustrate in detail a switch,

FIGS. 12 and 13 show, in perspective, the connection between an electrode and a switch,

Figure 14 illustrates, in perspective, a free end of an electrode in a possible configuration. detailed description

With reference to FIG. 1, the invention relates to an electric heater 1. This is, for example, a heating device 1, said high voltage, that is to say intended to be supplied by a direct current (DC) or AC (AC) having a voltage greater than 60 V, especially between 60 and 1000 V, more particularly between 180 and 600 V, and / or for releasing a heating power on the air or an electric power consumption greater than 2 kW, in particular between 2 kW and 10 kW.

Said heating device 1 comprises a heating body 2 supplied with electric power to heat a flow of air passing through said heating body 2.

Said heating body 2 here has a substantially parallelepipedal configuration, extending on the surface. It is intended to be positioned transversely to the flow of air to be heated. More specifically, said air flow is intended to be oriented perpendicular to said heating body 2, that is to say perpendicularly to the plane of FIG. 1.

The heating body 2 is formed by a succession of aligned metal tubes 4. Inside each tube 4, there are heating elements 8 traversed by said current. The heating elements 8 are, for example, PTC resistors (for positive temperature coefficient). These heating elements 8 are particularly visible in FIG. 13.

Electrodes 9 are located on either side of the heating elements 8 for their power supply. More particularly, each heating element 8 is surrounded by a positive electrode 9 and a negative electrode 9.

In order to electrically insulate the tube 4 from the electrodes 9 and the heating elements 8, layers 12 of electrically insulating and thermally conductive materials are located between each electrode 9 and is an inside wall of the tube 4.

Each set - tube 4 / heating elements 8 / electrodes 9 - forms what is called a heating unit.

Said heating units are selectively powered. By this is meant that each heating unit is supplied with current independently of the others and can therefore be traversed by a different current, especially by its current intensity. going through the other heating units. The value of the current in play here is in particular the value of the average current or the effective current.

To return to FIG. 1, the heating body 2 may comprise heat sinks 13, for example fins, in thermal contact relation with the tubes 4. The heat sinks 13 are positioned, in particular, between said tubes 4. For the sake of clarity, only certain dissipators 13 extending from the end tubes 4 have been shown, so as not to overload FIG. 1.

Said heating body 2 comprises a frame 5, in particular made of plastic, accommodating said heating units and serving to hold said tubes 4. The tubes 4 are also held in position by means of intermediate plates 22.

Preferably, the heating device 1 further comprises a distribution unit 3 able to control the current flowing in said heating body 2.

Said distribution unit 3 is advantageously configured to control the current supplying the heating body 2, in particular the different heating units, in particular by means of controlled switches 15, making it possible respectively to control a flow of current in each of the heating units. heated. These switches 15 (visible in FIG. 4) are mounted on an electronic card 1 1 in the form of a T.

In Figure 2, we see the underside of the electronic card January 1, with a plurality of pins 7 which are welded there. These pins 7 belong to said switches 15.

In order to be able to correctly hold the switches 15 in place when they are attached to the electronic card January 1, a docking station 6 is provided and located just above the upper face of the electronic card January 1. This docking station 6 is particularly visible in FIG. 3 where the electronic card 1 1 is not shown for clarity.

This docking station 6 is thus disposed at the junction between, on the one hand, the heating body 2 with its heating units, and on the other hand the distribution unit 3 with its electronic card 1 1. docking station 6 consists of an intermediate base facilitating the electrical and mechanical connection of the heating body 2 to the distribution unit 3. As can be seen in FIG. 4, this station 6 accommodates on one side the electrodes 9 protruding from the tubes 4, and on the other hand the switches 15 able to be soldered to the electronic card 11.

More specifically, the docking station 6 has a lower face vis-à-vis the electronic card 1 1, and an upper face vis-à-vis the tubes 4. The docking station 6 consists of a bar, or a strip, extending over the entire length of the heating body 2, according to the alignment of the electrodes 9 at the outlet of the tube 4.

This underside is provided with a central rib 23 and oriented longitudinally along the docking station 6. This rib 23 is adapted to rest on the upper surface of the electronic card 1 1, so as to have a plane contact between the docking station 6 and the electronic card 1 1. This plane contact firstly makes it possible to position the docking station 6 above the electronic card 1 1 in a stable manner. Moreover, the docking station 6 makes it possible to increase the mechanical strength of the electronic card 1 1 according to two principles:

by increasing the overall rigidity of the electronic card 1 1 thanks to the greater moment of inertia of the electronic card assembly 1 1 / docking station 6;

- By acting more like an abutment limiting the deformation, that is to say the arrow, the electronic card 1 1 in case of vibration too strong.

On either side of the rib 23, there is therefore a space between the docking station 6 and the electronic card 1 1. Ideally and if necessary, this space is dimensioned so as to allow other components of to be welded to the electronic card 1 1, under the docking station 6.

The upper face, as for it, illustrated in FIGS. 5 to 7, comprises a plurality of housings 17 accommodating the electrodes 9 and in which there are means of mechanical and electrical connection of the electrodes 9 to the distribution unit 3, corresponding to the switches 15. In fact, inside each housing 17 is a central orifice in which a switch 15 is inserted.

This switch 15 is more particularly shown in FIGS. 8 to 1 1. It is a conventional switch 15, with a first face 19 of electrical connection to the electronic card 1 1, provided with two pins 7 capable of being welded to the card 1 1, and with a second face 18 of electrical connection to the electrode 9, with a female end acting as quick coupling. Indeed, this socket has a plurality of flexible blades 20 able to exert a pressure on the electrode 9 which enters. In this case, there are four flexible blades 20 on either side of the electrode 9 which comes to rely on she. The positioning of the flexible blades 20 of water and of the electrode 9 makes it possible to center the electrode 9 and maintain it in the centered position, unlike a configuration of a female end where there would be only blades 20 In addition, as is particularly visible in FIG. 11, each flexible blade has a zigzag shape, making it possible to have several points of support on the electrode 9. In particular, each zigzag tip 21 bears on the electrode 9.

Returning to FIG. 6, it is clearly visible that, for each housing 17, guide pads 14 extend on either side of the central orifice in the direction of the tubes 4. These studs 14 are intended to guide the electrode 9 to its insertion in the switch 15.

According to one possible configuration, for each housing 17, the faces 14a of the studs situated opposite each other are bevelled in the direction of the central orifice so as to form guide ramps of the electrode 9 towards the central orifice where is located the switch 15. These pads 14 and draw a V inside which inserts the electrode 9. This guidance of the electrodes 9 improves the assembly between the heating body 2 and the distribution unit 3.

The faces 14b of the studs 14 facing each other between two successive housings 17 are oriented perpendicularly to the docking station 6.

In general, the docking station 6 comprises as many housings 17 as 9 electrodes present in the heating body 2, each housing 17 accommodating an electrode 9.

More specifically, the electrodes 9 each comprise a free end protruding from the tubes 4. Each free end comprises a male endpiece 10 adapted to fit into the female end of the switch 15. This male endpiece 10 can be formed in one piece with the 9, or may consist of a separate piece mounted on the electrode 9, as is the case in the example shown in Figures 13 and 14. In this case, the male end 10 corresponds to a leg having a first end 10a is mounted and riveted on the electrode 9 for example and whose second end 10b enters the socket of the switch 15.

For each heating unit, the male tips 10 of the two electrodes 9 extend in the axial direction of the tube 4 but with a transverse offset. The male tips 10 are thus located in staggered rows.

Therefore, for each tube 4, the docking station 6 has two housings 17 staggered according to the arrangement of the male tips 10 of the two electrodes 9 corresponding, one positive and the other negative. In this way, the switches 15 inserted in these housings 17 are spaced apart from each other since it is important to maintain an isolation distance between the switches belonging to the positive current line and the switches 15. belonging to the negative current line.

Thus, as shown in Figure 7, the docking station 6 has two rows 6a, 6b of housing 17, the housing 17 of a row 6a being offset from the housing 17 of the other row 6b. One of the rows of housings 17 is on a positive current line to which the positive electrodes 9 are connected and the other row is on a negative current line to which the negative electrodes 9 are connected.

The docking station 6 is perforated between the adjacent housing 17, via windows 16. This allows the use of a minimum of material and obtaining a light bar.

The docking station 6 is designed in an electrically insulating material of the plastic type. Such a material also allows good resistance to temperature, non-flammability and moisture.

The docking station 6 is obtained by molding or by plastic injection.

Concretely the connection between the heating body 2 and the distribution unit 3 is carried out as follows.

The docking station 6 is positioned on the electronic card 1 1, so that its rib 23 bears on the upper surface of the card 1 1. When the docking station 6 and the card 1 1 are correctly positioned relative to each other, the switches 15 are inserted in the housings 17 provided for this purpose, and more precisely in the holes of the housings 17. The pins 7 of the switches 15 are then introduced into small holes provided For this purpose in the electronic card 1 1. The switches 15 are then in a stable position in the housing 17 of the docking station 6, and it is possible to weld the pins 7 to the electronic card January 1.

The last step then consists in inserting the male tips 10 of the electrodes 9 in the switches 15 of the docking station 6. This last step can be performed in a single gesture, via a rectilinear translation of the heating body 2 relative to the docking station 6, since a switch 15 is provided opposite each male endpiece 10.

This single movement is allowed in particular thanks to the guidance of the male end pieces 10 via the guide pads 14 and thanks to the quick coupling provided on the first connection face 18 of the switch 15. Indeed, it suffices to slide the male end piece 10 into the first face 18 connecting the switch 15 and the flexible blades 20 come make the electrical connection and the mechanical connection of the male end 10 because they exert a pressure on him so as to keep it in position.

With such a connection, the movements of the electronic card January 1 are very limited, which avoids vibration problems, and improve the reliability of the electronic card January 1, and the heater 1 in general.

The invention also relates to an air conditioning unit comprising a heating device 1 as described above. Said air conditioning unit comprises a circulation body of the air flow inside which said heating device 1 is located.

With respect to the above description, the optimal dimensional relationships for the parts of the invention, including variations in size, materials, shapes, function and modes of operation, assembly and use are considered apparent and obvious to those skilled in the art, and all relationships equivalent to what is illustrated in the drawings and what is described in the specification are intended to be included in the present invention.

Claims

claims

1. Heating device 1 for an air conditioning unit, said heating device 1 comprising a heating body 2 supplied with current via a distribution unit 3 for heating a flow of air passing through said heating body 2, the heating element 2 comprising an alignment of tubes 4 in which are:

heating elements 8 traversed by said current;

electrodes 9 located on either side of the heating elements 8 for their power supply;

said distribution unit 3 comprising a docking station 6 of the electrodes 9, said docking station 6 having a plurality of housings 17 accommodating the electrodes 9 and in which there are means for mechanical and electrical connection of the electrodes 9 to the distribution unit 3, said heating device 1 being characterized in that said means for mechanical and electrical connection of the electrodes 9 to the distribution unit 3 consist of switches 15 positioned on the one hand in the housings 17 and fixed on the other hand on an electronic card 1 1 of power supply belonging to the distribution unit 3.

2. Heating device 1 according to claim 1, characterized in that each housing 17 comprises a central orifice through which the switch, the said orifice being dimensioned so as to maintain in position the switch 15 when attached to the electronic card 1 1.

3. Heating device 1 according to the preceding claim, characterized in that each switch 15 has a first face 19 of electrical connection to the electronic card January 1, with at least one pin 7 adapted to be welded to the card 1 1 , and a second face 18 of electrical connection to the electrode 9, provided with a socket in which a male tip 10 of the electrode 9 is inserted.

4. Heating device 1 according to the preceding claim, characterized in that each electrode 9 has a free end on which is the male end 10, the male ends 10 of the two electrodes 9 relative to a heating element 8 being arranged in staggered.

5. Heating device 1 according to the preceding claim, characterized in that, for each heating element 8, the docking station 6 has two housings 17 staggered according to the arrangement of the male tips 10 of the two corresponding electrodes 9.

6. Heating device 1 according to one of claims 3 to 5, characterized in that the male end 10 of the electrode 9 is inserted into the socket of the switch 15, said switch 15 having at least one blade 20 flexible able to exert pressure on the male end 10 of the electrode 9 so as to maintain in position and make the electrical connection.

7. Heating device 1 according to one of the preceding claims, characterized in that each housing 17 comprises means for guiding the electrode 9.

8. Heating device 1 according to the preceding claim, characterized in that said guide means consist of two pads 14 located on either side of the housing 17 and whose faces 14a vis-à-vis are beveled in the direction of the center of the housing 17 so as to form guide ramps of the electrode 9.

9. Heating device 1 according to one of the preceding claims, characterized in that said docking station 6 consists of a bar extending over the entire length of the heater body 2, according to the alignment of the electrodes 9.

10. Heating device 1 according to one of the preceding claims, characterized in that the docking station 6 comprises as many housings 17 as 9 electrodes present in the heating body 2, each housing 17 accommodating an electrode 9.

1 1. Heating device 1 according to one of the preceding claims, characterized in that said docking station 6 has two rows 6a, 6b of housing 17, the housing 17 of a row 6a being offset from the housing 17 from the other row 6b.

12. Heating device 1 according to one of the preceding claims, characterized in that the docking station 6 comprises a face vis-à-vis the electronic card 1 1, said face being provided with a rib 23 central longitudinal bearing on the electronic card 1 1.

13. Heating device 1 according to one of the preceding claims, characterized in that the docking station 6 comprises, apart from the rib 23, one or spaces between the docking station 6 and the electronic card 1 1 , so as to allow other components to be soldered to the electronic card 1 1, under the docking station 6.

14. An air conditioning unit comprising a heater 1 according to any one of the preceding claims.

15. A method of mechanical and electrical connection of electrodes 9 of a heating device 1 as described in any one of claims 1 to 13, characterized in that it comprises the following steps:

positioning the docking station 6 on an electronic card 1 1;

- Insert switches 15 into successive holes provided for this purpose in the docking station 6 and in the electronic card 1 1 until they are held in position;

soldering the switches 15 to the electronic card 1 1;

simultaneously plug all the electrodes 9 of the heating body 2 into the corresponding switches in a single translational movement of the heating body 2 with respect to the distribution unit 3.