WO2024089239A1 - Heating assembly and heating device for a vehicle - Google Patents

Abstract

The invention relates to a heating assembly (100) for a vehicle, in particular for an electric or hybrid vehicle, comprising a heat exchanger (1) which has a support body (10) for an electric heating element (2a, 2b, 2c), wherein the support body (10) has a heating side (12) and a heat transfer side (11) opposite thereto, at least one electric heating element (2a, 2b, 2c) which is mounted on the heating side (12) of the support body (10), a control unit (3) for the at least one heating element (2a, 2b, 2c), and at least one electric contacting line (4a, 4b, 4c), which is connected to the control unit (3), for supplying power to the heating element (2a, 2b, 2c). The support body (10) has at least one through-opening (13a, 13b, 13c) from the heat transfer side (11) to the heating side (12), said contacting line (4a, 4b, 4c) extending through the through-opening. In this manner, a spatial separation of the control unit and the heating element is achieved, thus providing a high degree of flexibility for the control unit housing design.

Description

HEATING ARRANGEMENT AND HEATER FOR A VEHICLE

Technical area:

The invention relates to a heating arrangement and a heater, preferably a high-voltage heater, for a vehicle, in particular an electric or hybrid vehicle.

Technical background:

Heaters are used in vehicles to heat the interior or components. Special requirements are placed on electric heaters for use in electric or hybrid vehicles, which generate less waste heat than a conventional vehicle with a combustion engine. Air or water are mainly used as heat transfer media.

DE 102 16 010 A1 shows an electric heating device with a control device for controlling heating elements of a heating block. An electrical contact between contact points on the control device and contact points on the heating block is established via a fixed connection, in particular by means of screws or rivets, in order to prevent the contact from coming loose due to vibrations.

WO 2013/171079 A1 describes an electric vehicle heater, in particular for vehicles with hybrid drive or with electric drive, with a carrier body that has a ceramic substrate and is thermally coupled to a heat exchanger. The carrier body is divided into two adjacent heating zones with at least one heating element. A control unit is provided for controlling the heating elements independently of one another and is arranged in an area of the carrier body positioned outside the heating zones. The two heating zones and a control zone follow one another in the longitudinal extension of the ceramic substrate.

DE 10 2019 214 566 A1 relates to an electrical heating arrangement with heating elements arranged on at least two opposite sides of a coolant housing and a curved three-part circuit board. The coolant housing is arranged between opposite edge part circuit boards and the power supply terminals of the heating elements and the terminals of the edge sub-circuit boards are in electrical contact. A logic circuit is arranged on the middle sub-circuit board.

WO 2019/169501 A1 relates to a heat exchanger with an electrical heating element comprising an electrically insulating dielectric base layer and an electrical heating resistance layer on the base layer. A conductive layer is positioned in direct contact with the heating resistance layer and under the longitudinal edges of the heating resistance layer between the heating resistance layer and the dielectric base layer. The conductive layer represents a connection to an electrical power source.

For vehicles with a high-voltage electrical system, high-voltage heaters are known for electrically heating a water circuit via a heat exchanger. Heating elements based on layer heating technology convert direct or alternating electrical current into heat with high efficiency. In existing heaters, the heating elements and their electrical contact points are arranged on the same side of the heat exchanger. These heaters often have control units whose housings enclose both sides of the heat exchanger on the outside. One disadvantage is a lack of flexibility in the housing design.

Based on this prior art, the present invention has the task of providing a heating device for a vehicle, in particular an electric or hybrid vehicle, which enables a structurally simple contacting of a heating element and the greatest possible flexibility in the housing design. In addition, the production should be as cost-effective as possible.

This object is achieved by a heating arrangement according to claim 1 and by a heating device according to claim 14.

In particular, the above object is achieved by a heating arrangement for a vehicle, in particular an electric or hybrid vehicle, comprising a heat exchanger which has a carrier body for a, in particular flat, electric heating element, wherein the, in particular plate-shaped, carrier body has a heating side and opposite a heat transfer side, at least one electrical heating element, preferably a layer heating element, which is mounted on the heating side of the carrier body, a control unit for the at least one heating element, and at least one electrical contact line connected to the control unit for supplying power to the heating element, wherein the carrier body has at least one through-opening from the heat transfer side to the heating side, through which the contact line extends.

The heating arrangement according to the invention allows the electrical contacting of a heating element by the control unit to be arranged on the heat transfer side, i.e. on the (other) side opposite the heating side with the heating element. In comparison to the prior art, the electrical contacting of the heating element by the control unit is moved to the side facing away from the heating element. This spatially separates the control unit from the heating element. This results in a high degree of flexibility for the design of the control unit housing. The contacting points are thus more easily accessible for the control unit, in particular for the connection areas of the control unit housing (control housing) and the connection to a control board. A control housing and a housing of the heat exchanger (heat exchanger housing) can thus be designed more freely and preferably more cost-effectively depending on the given spatial requirements, for example due to the installation space of other vehicle components. In particular, the control housing and/or the heat exchanger housing can be designed as self-contained unit(s) in the sense of a modular design. The interface between the control unit and the heat exchanger is significantly simplified in design. In the following, the control housing is also referred to as the first module housing and the heat exchanger housing together with a housing cover for covering the heating elements and the associated power switching parts is also referred to as the second module housing.

The carrier body is in particular part of a heat exchanger housing. The through-opening can (only) penetrate the carrier body or (also) other parts of the heat exchanger, in particular the (entire) heat exchanger housing from one side to the other. The through-opening is preferably completely closed (bordered) on the side, but can be partially open on the side. In this respect, the through-opening can be understood as a recess in an edge region of the carrier body. The During operation, a heat transfer medium, preferably a liquid (coolant) such as water, flows through the heat exchanger.

The (plate-shaped) carrier body extends in particular (flat) along a main extension plane, is preferably designed as a (flat) carrier plate, and preferably has a rectangular basic shape. The carrier body has in particular a flat heating surface on the heating side, in particular in a heat transfer section, but preferably also in a connection section. On the heat transfer side, in particular in the heat transfer section, the carrier body is not necessarily flat, but can, for example, form one or more flow channels, or sections thereof. The carrier body (carrier plate) is preferably made of aluminum.

One heating element or several heating elements can be provided, which are arranged in particular next to one another in order to form a flat heating core (heating surface) together. A heating element preferably has at least one heating conductor. The heating element is in particular firmly connected to the carrier body. The (thin) heating element is preferably designed as a layer heating element, for example with a layer thickness of less than 1 mm, and is preferably connected (directly) to the heating surface of the carrier body, in particular glued on. A layer of adhesive, in particular electrically insulating, can be applied to the carrier body in some areas in order to connect the heating element (directly) to the carrier body. The heating element can preferably comprise a carrier layer, in particular electrically insulating, more preferably made of ceramic material, to which the heating conductor is applied.

The carrier layer can be a ceramic substrate plate, for example made of Al2O3. The heating conductor can be applied to the carrier layer (ceramic substrate plate) using a screen printing process. The heating conductor can be designed, for example, as a metallization made of a resistance alloy, which represents the corresponding heating resistance. An iron-nickel alloy or a nickel-chromium alloy can be considered, among others. An insulation interruption ensures the structuring of long conductor tracks from the layer that is otherwise applied flatly and later fired and can, for example, be created during application using a screen printing process. This embodiment of a heating element is preferred according to aspects of the invention. The carrier layer is preferably connected to the carrier body, more preferably glued. The carrier body in particular has a connection area for (direct or indirect) fastening of the heating element, in which an adhesive layer and/or a carrier layer of the heating element, preferably made of ceramic material, is preferably arranged. The connection area preferably corresponds (approximately) to the heat transfer section of the carrier body. A flat heating element has a large contact area for heat transfer and can efficiently convert electrical current into heat.

The heating element or the heating conductor layer can be implemented in various ways and the invention is not limited to specific embodiments thereof. The heating element can also consist of thermally sprayed layers, for example. During production, atmospheric plasma spraying can be used, for example, as a coating process. The layer structure, starting from the flat plate (carrier body), initially consists of an optional primer, then an insulating ceramic, the actual heating conductor layer and, if necessary, a cover layer or seal. The heating conductor layer can be structured by laser or by masking. The material of the heating conductor can be one with linear or PTC resistance behavior.

Polymer-based heating elements with PTC behavior are also an option. These can be heating elements made of plastic films. The heating elements usually consist of an extruded or laminated polymer matrix in which a heating conductor and a plus and minus electrode are embedded.

Furthermore, the heating elements can also be ceramic heating elements with PTC behavior (PTC thermistor).

The heat exchanger itself can be made of steel or aluminum, for example, preferably as an aluminum sheet heat exchanger.

Power supply can be understood as current feed-in, i.e. the feed-in of electrical current due to an applied electrical voltage (voltage potential), in particular through a connectable electrical power source. In one embodiment of the invention, the control unit, which is preferably designed to control several heating elements, comprises a control housing, in particular for accommodating a control board forming a control device, which is arranged on the heat transfer side of the carrier body. The control housing can be arranged, completely or at least substantially, on the heat transfer side of the carrier body. A connection section of the control housing with contact lines (conductor tracks) accommodated therein, which is designed in particular as a plastic insert, can extend into the through-opening or through the through-opening to the heating side. Several contact lines can be assigned to each heating element. The control unit can be designed to control, in particular power supply, several (all) heating elements and can therefore be understood as a higher-level control of the heating arrangement or the heating device. The control housing can be designed independently of the arrangement of the heating elements and any power switching parts present on the heating side due to the arrangement on the heat transfer side. The electrical contact points for the heating elements are easily accessible on the heat transfer side. The length of a seal between the control housing and the heat exchanger housing can be reduced.

In a further embodiment, the control unit and an inflow connection and/or an outflow connection for a heat transfer medium are arranged on the same side of the carrier body, preferably on the heat transfer side. By designing the heat exchanger so that inflow and/or outflow connections are arranged on the heat transfer side facing away from the heating elements, the largest possible area of the carrier body can be used for heat transfer, in particular without spatial restrictions for the arrangement of the heating elements. This reduces the installation space for the heating arrangement with the same heating output.

In a further embodiment, the carrier body has a heat transfer section in the region of the at least one heating element and a connection section outside the heat transfer section, wherein the at least one through-opening is formed in the connection section. The connection section is preferably provided on the edge of the carrier body, preferably along the shorter side edge(s) of the at least one (rectangular) heating element. In the connection section, the control housing is connected to the carrier body or is attached to it. The heat transfer section preferably extends in a central (rectangular) region of the carrier body.

In a further embodiment, the heat exchanger has at least one flow channel on the heat transfer side of the carrier body for the flow of a heat transfer medium. Flow channels can be formed by the inner surfaces of the heat exchanger housing or by separate channel structures that are arranged in a cavity (coolant space) of the heat exchanger housing.

In a further embodiment, the heat exchanger has a cover body which, together with the carrier body, forms a cavity through which a heat transfer medium can flow, in particular at least one flow channel. One or more flow channels can be formed by an (upper) surface of the carrier body and an (adapted) opposite (lower) surface of a cover body of the heat exchanger. In the heat transfer area of the carrier body, the cover body forms in particular a bowl-shaped depression and in particular an inflow connection and/or an outflow connection for a heat transfer medium. In particular, the cover body and the carrier body each form plate-shaped end sections which at least overlap in the area of the through-opening, in particular lie (congruently) on top of one another and preferably (directly) adjoin one another. A seal can be provided between the carrier body and the cover body.

In a further embodiment, the through-opening penetrates the cover body and the carrier body in the region of the connecting section of the carrier body. In this respect, the carrier body and the cover body each have a matching through-opening.

In a further embodiment, at least one power switching part for regulating the (electrical and/or thermal) power of the heating element is mounted on the heating side of the carrier body, wherein the power switching part is preferably arranged between the through-opening and the heating element and is in particular electrically contacted by the contact line. The power switching part is preferably arranged on a power board and is in particular designed to regulate the current flow through the heating element and/or to reduce or interrupt it above a certain threshold. A power switching part preferably comprises a temperature sensor, which is designed to monitor the heating temperature of a heating element or the carrier body heated by it or the heat transfer medium itself. A power switching part can also comprise a signal processing unit, which is in particular connected to the temperature sensor. This makes it unnecessary to forward signals to the (higher-level) control unit.

In a further embodiment, the power switching part is connected to a temperature sensor which is arranged on the heating side of the carrier body, preferably on a circuit board of the power switching part. The temperature sensor is designed in particular to monitor the temperature of a heating element or the carrier body heated by it or the heat transfer medium itself. This allows the thermal power output of the heating elements to be controlled and overheating to be avoided.

In a further embodiment, several heating elements are attached to the heating side of the carrier body and/or the carrier body has several through-openings, with each heating element preferably being assigned a through-opening. This allows the control device to electrically contact each heating element separately. The heating elements are arranged in particular next to one another and (essentially) directly adjacent to one another on the carrier body. The heating elements can be supplied with power or controlled differently by the control unit, with the power emitted by the heating elements in particular being adjustable to different levels.

In a further embodiment, each through-opening is assigned a power switching part, which is connected to a contact line, wherein in particular each heating element is assigned a power switching part. Preferably, each heating element is assigned (exactly) one through-opening. Power switching parts can in turn be electrically connected to heating elements (by conductor tracks), preferably each power switching part to (exactly) one heating element.

In a further embodiment, the main extension plane of the control board of the control unit is arranged at an angle of at least 45°, preferably (approximately) 90°, to the main extension plane of the power switching part and/or the heating element. The main extension plane in the control board and/or the power switching part is defined in particular by the extension plane of the circuit board(s). Preferably The control board is perpendicular to the main extension plane of the heating element (ie parallel to the heating surface). This allows the installation area of the heating arrangement to be reduced.

In a further embodiment, the contact line is designed as a conductor track partially enclosed by a plastic insert, in particular as a curved punched grid, with the outer contour of the plastic insert being adapted to the inner contour of the through-opening. Contact lines are preferably cast or molded into a plastic insert of the control housing as conductor tracks. The plastic insert is preferably inserted into a suitably shaped connection area of the control housing and can extend into the through-opening when inserted.

In a further embodiment, the contact line is angled, preferably twice, with the line end sections of the contact line extending in particular parallel to the main extension plane of the, preferably plate-shaped, carrier body, and in particular a line middle section extending perpendicular to the main extension plane of the carrier body. The cross section of a contact line can therefore be described as Z-shaped. The line middle section preferably extends into or through the through-opening. A line end section of the contact line facing the control unit runs in particular (essentially) perpendicular to the control board and is preferably (directly) connected to it, namely e.g. soldered and/or pressed into a through-opening of the control board. A line end section of the contact line facing the power switching part or the heating element runs in particular (essentially) parallel to its main extension plane and is preferably (directly) connected to a board of the power switching part (e.g. soldered). Due to this shape of the contact line, the contact point for the heating elements can be moved to the heat transfer side by the control unit in a structurally simple manner.

Furthermore, an embodiment provides that in the control housing, hereinafter also referred to as the first module housing, in order to distinguish this from a second module housing, which is formed by the heat exchanger on a heat transfer side and a housing cover for the heating side taken together, at least one aperture for passing through an electrical connection between the control device or the control board in the first module housing of the control unit and a power switching part for switching the heating element is formed in the second module housing. In this case, a lead frame with the contact lines embedded in a common plastic insert can be arranged in the at least one aperture, wherein the contact lines contact corresponding connection points on a control board forming the control device.

The stamped grids enable a robust electrical connection with the power switching elements provided in the power switching parts and/or with the heating elements, and allow a space-saving change of the sides of the heat exchanger, because the attachment of the first module housing to the second module housing preferably takes place in a direction substantially perpendicular to a plane of the heat exchanger, so that the nozzles (fluid inlet, fluid outlet) as well as the connector sections (high voltage, low voltage) can be made from the same side when installed in the vehicle. However, this in turn requires that the heating element(s) are arranged on an opposite side of the flat heat exchanger. The through openings in the carrier body of the heat exchanger therefore enable direct access to the second module housing on the side of the heating element(s).

Advantageously, the lead frame can extend through a through-opening formed in the carrier body and an aperture formed in the first module housing and aligned with the through-opening into an interior of the first module housing, where it is fixed by at least one positioning means, in particular a positioning pin, to the control board forming the control device of the control unit.

Fastening means, in particular one or more screws, can be provided for the mutual fixing of the two module housings in order to fasten the carrier body of the heat exchanger or of a heat exchanger module, which is formed by the heat exchanger and the heating elements with associated power switching part or associated power switching parts with associated housing cover, to the first module housing, wherein the carrier body has the through-opening which is aligned with the at least one aperture in the first module housing, so that the lead frame extends through the through-opening of the carrier body and provides contact connections for its contacting lines on the opposite side thereof.

A seal can be arranged between the mutually facing surfaces of the first module housing and the carrier body of the second module housing (of the heat exchanger), which seal seals the at least one through-opening or which encloses at least one aperture (in the case of several through-openings and associated apertures, encloses these together) and thereby protects the interior of the first module housing as well as an interior of the second module housing comprising the power switching part and the heating element from the ingress of moisture.

The stated object is also achieved in particular by a heater, preferably a high-voltage heater, for a vehicle, in particular an electric or hybrid vehicle, which comprises at least one heating arrangement according to the invention as described above. The functioning and advantages of the heater arise analogously to the structural and functional features described in connection with the heating arrangement. Such a heater is intended in particular for use in heating a vehicle interior and/or a vehicle component.

The heating elements of the heater or heating arrangement preferably have (overall) a heating output in the range of 1 to 100 kW, preferably between 2 and 20 kW, and can have an area of several 100 cm ² , for example 200 cm ² . Heating elements are preferably operated with direct current in the high voltage range, i.e. in the range of approximately 100 to 1000 volts (V). Such high voltages can be present in particular in electric or hybrid vehicles, for example in passenger vehicles up to approximately 500 V or more, e.g. up to 800 V or more, or in commercial vehicles such as buses or trucks up to approximately 100 V or more. In this respect, a heater with a heating arrangement according to the invention can be referred to as a high-voltage heater.

It should be noted that the electric heating arrangement or the electric heater according to the aspects and embodiments described here can in particular be a liquid heater. Liquid heating means that the medium flowing through the heat exchanger of the heating arrangement is liquid. The medium can in particular be liquid coolant of a vehicle, which transports heat in the vehicle and can release it at various points. Additionally or alternatively, the liquid heater can also be part of a heat pump of a vehicle, for example, so that the heat transfer medium can be or include a coolant of a heat pump, for example. It can be the case that the coolant is only in completely liquid form under certain conditions and only temporarily or perhaps never, and is otherwise partially or completely gaseous. Nevertheless, this is also understood to mean a liquid heater. Further embodiments of the invention emerge from the subclaims.

Short description of the drawings:

Embodiments of the invention are explained in more detail below with reference to the drawings.

Figure 1 is a schematic representation of an embodiment of a heating arrangement according to the invention in a perspective view according to a first embodiment;

Figure 2 is a schematic representation of the embodiment according to Figure 1 in a plan view of the heating side of the heat exchanger;

Figure 3a is a schematic representation of an embodiment of a heat exchanger of a heating arrangement according to the invention in a perspective view of the heating side;

Figure 3b is a schematic representation of an embodiment of a heat exchanger of a heating arrangement according to the invention in a perspective view of the heat transfer side;

Figure 4 is a schematic representation of the embodiment according to Figure 1 in a perspective view without the control board of the control unit;

Figure 5 is a schematic representation of the embodiment according to Figure 1 in a perspective view with control board of the control unit;

Figure 6 is a schematic representation of the embodiment according to Figure 1 in a sectional view;

Figure 7 is a schematic enlarged view of the sectional view according to Figure 6

Figure 8 shows a perspective view of an electrical high-voltage heating device according to a second embodiment;

Figure 9 shows a plan view of an arrangement of heating elements on a carrier plate of a heat exchanger of the heating device from Figure 8;

Figure 10 is a perspective view of the control module of the heating device of Figure 8, looking towards the outer second layer of electrically insulating plastic material;

Figure 11 as Figure 10, but with hidden high-voltage connector section; Figure 12 as Figure 11 , but with a view of the inner first layer of electrically conductive plastic material with the second layer hidden;

Figure 13 like Figure 12, but with the first and second layers hidden (only the base component, the cover still visible);

Figure 14 shows in isolated representation the positioning of punched grids, fastening screws, sheet metal inserts and seals;

Figure 15 shows a perspective view of the interior of the first module housing according to the embodiment;

Figure 16 shows a perspective view of the first module housing from behind, with the second layer as the outer surface;

Figure 17 like Figure 16, but with the second layer hidden, i.e. with a view of the inner first layer;

Figure 18 as Figure 15, but with all electronic components including control device installed but with the cover hidden;

Figure 19 as Figure 18, but with control device hidden (printed circuit board and potting or filling material hidden);

Figure 20 is a perspective view of the first module housing from below, without leadframe;

Figure 21 is a perspective view of one of the lead frames;

Figure 22 is another perspective view of the punched grid from Fig. 21.

Detailed description of preferred embodiments:

In the following description of preferred embodiments, it is to be understood that the present disclosure of the various aspects is not limited to the details of the construction and arrangement of the components as shown in the following description and in the figures. The embodiment can be practiced or carried out in a variety of ways. It is further to be understood that the phraseology and terminology used herein is for the purpose of specific description only and should not be interpreted as limiting by one skilled in the art.

In the following description of the invention, the same reference numerals are used for identical and equivalent elements, so that in some cases reference is made to a repeated detailed descriptions are omitted in order to preserve the compactness and clarity of the presentation.

Figures 1, 2 and 4 to 7 show a first embodiment of a heating arrangement 100 according to the invention in different views. Figures 3a and 3b show the heat exchanger 1 of a further embodiment of the invention.

The heating arrangement 100 according to the invention or a corresponding heating device, preferably designed as a high-voltage heating device, are particularly suitable for heating the vehicle interior or vehicle components in electric or hybrid vehicles. The heating arrangement 100 has a heat exchanger 1, several electrical heating elements 2a, 2b, 2c, a control unit 3, and several electrical contact lines 4a, 4b, 4c, which are connected to the control unit 3 and which are used to electrically contact the heating elements 2a, 2b, 2c.

The heat exchanger 1 has a carrier body 10 for the heating elements 2a, 2b, 2c, which is made of aluminum and is designed in the shape of a plate. The carrier body 10 has a heating side 12 with the heating elements 2a, 2b, 2c and an opposite heat transfer side 11. The carrier body 10 has several through openings 13a, 13b, 13c from the heat transfer side to the heating side 12, through which the contact lines 4a, 4b, 4c extend (see Figures 6 and 7). In the present case, three heating elements 2a, 2b, 2c with a rectangular basic shape are applied, in particular glued, to the surface of the carrier body 10 in a heat transfer section 14, wherein each heating element 2a, 2b, 2c is designed as a layer heating element and has at least one electrical heating conductor 20 running spirally in a main extension plane of the heating elements 2a, 2b, 2c. The heating elements 2a, 2b, 2c can comprise a ceramic carrier layer that is glued to the surface of the carrier body 10. Each heating element 2a, 2b and 2c is assigned a through opening 13a, 13b or 13c and a corresponding group of contact lines 4a, 4b or 4c.

The through-openings 13a, 13b, 13c with the contact lines 4a, 4b, 4c are arranged in a connection section 15 of the carrier body 10. In the connection section 15, outside the heat transfer section 14, in the edge area of the carrier body 10 on the heat transfer side 11, a control housing 30 of the higher-level control unit 3 with a control board 31 is arranged, which can be connected to the control board 31 via the screw openings 50 (see Figures 3a and 3b) inserted screws 51 are connected to the carrier body 10 and thus to the heat exchanger 1.

Between the contact lines 4a, 4b, 4c and the heating elements 2a, 2b, 2c, a power switching part 5a, 5b, 5c is placed on the carrier body 10, which comprises a temperature sensor 6a, 6b, 6c for monitoring the heating temperature of the respective associated heating element 2a, 2b, 2c and serves to regulate the thermal and/or electrical power of the respective heating element 2a, 2b, 2c. The temperature sensors 6a, 6b, 6c are each arranged on a circuit board of the power switching part 5a, 5b, 5c.

In addition to the carrier body 10, the heat exchanger 1 has a cover body 17, which together form a heat exchanger housing with an intermediate cavity in which one or more flow channels 16 are formed for the flow of a heat transfer medium. The cover body 17 forms an inflow connection 18 and an outflow connection 19 for the heat transfer medium, which can also be interchanged in one embodiment. Because the inflow connection 18 and the outflow connection 19 as well as the control unit 3 with the control housing 30 are arranged on the same side of the carrier body 10 or the heat exchanger 1, namely on the heat transfer side 11, the control housing 30 can be designed with great flexibility, in particular independently of the spatial arrangement and extension of the heating elements 2a, 2b, 2c and if necessary taking into account the available installation space in the vehicle due to adjacent vehicle components. In addition, the control housing 30 and the housing of the heat exchanger 1 can be designed as self-contained units in the sense of a modular design with simplified interfaces. This makes it possible to save costs.

In the connection section 15 of the carrier body 10, here designed as a rectangular carrier plate, the cover body 17, which is designed to be congruent in sections, and the carrier body 10 are penetrated by the through openings 13a, 13b and 13c, which are each completely closed on the side, i.e. bordered (see Figures 3a and 3b). A connection area of the control housing 30 is designed with three plastic inserts 32, which are inserted into the through openings 13a, 13b, 13c from the heat transfer side 11 during assembly with the pre-assembled, for example cast-in or molded-in, contact lines 4a, 4b, 4c. In Figures 6 and 7, the contact between the control unit 3 and the heating elements 2a, 2b, 2c or the power switching parts 5a, 5b, 5c is shown in cross section. In Figures 6 and 7, the middle element 2b, 4b, 5b, 13b is shown in section. Between the surface of the cover body 17 and the connection area of the control housing 30, a circumferential seal 33 is inserted into a circumferential groove, which could be simplified and made comparatively short due to the inventive arrangement of the control unit 3 on the heat transfer side 11. The main extension plane of the control board 31 is perpendicular to the main extension plane of the carrier body 10, the power switching parts 5a, 5b, 5c and the heating elements 2a, 2b, 2c.

The contact lines 4a, 4b, 4c are each designed as conductor tracks, with several contact lines each being manufactured as a double-bent metal stamped grid, which in cross section appears as a double-angled Z-shape. The line end sections 41, 43 of the contact lines 4a, 4b, 4c each run parallel to the main extension plane of the carrier body 10, while the line middle section 42 extends perpendicular to the main extension plane of the carrier body 10, i.e. parallel to the main extension plane of the control housing 30, in the through-opening 13a, 13b, 13c. The line end section 41 facing the control unit 3 is pressed into the control board 31. The line end section 43 facing the power switching part 5a, 5b, 5c is designed here with a bond pad. The electrical connection between the line end section 43 and the power switching parts 5a, 5b, 5c can be made by various common methods, in particular soldered or bonded, e.g. by ultrasonic bonding or laser bonding of bonding wires. In addition, a press fit between the line end section 43 and the power switching parts 5a, 5b and 5c is also possible. The heating arrangement 100 according to the invention shown allows great design freedom for the control housing 30 and can be produced easily and inexpensively.

A heating device can comprise additional components compared to the heating arrangement described, for example a cover of the control housing 30 shown open in Figure 1, further housing parts such as a cover of the heating side 11 and the elements attached thereto such as the heating elements 2a, 2b, 2c, the power switching parts 5a, 5b, 5c with corresponding circuit boards and the through openings 13a, 13b, 13c and the contact lines 4a, 4b, 4c passing through them, as well as electrical connections or supply lines for the heat transfer medium. A second embodiment (see FIGS. 8 to 22) of a heating arrangement 100 according to the present invention is shown in perspective view in FIG. 8. As with the first embodiment, this is in particular a heating arrangement 100 for a high-voltage liquid heater for electrically or hybrid-powered vehicles. It should be emphasized that elements shown in the second embodiment according to FIGS. 8 to 22 that cannot be seen in FIGS. 1 to 7 of the first embodiment, such as housing covers or details of the control unit 3 of the heat exchanger 1, etc., can nevertheless also be implemented there in a corresponding manner. In particular, the second embodiment can be combined with the first embodiment.

In this embodiment, the heating arrangement 100 also essentially comprises three components, namely a heat exchanger 1, a heat conversion unit 200 with heating elements 2a, 2b, 2c, and a control module or a control unit 3. The heat exchanger 1 and the heat conversion unit 200 can be structurally combined to form a heat exchanger module 500, to which the control unit 3 is attached. The heat exchanger module 500 has an essentially flat structure with a rectangular outline in plan view.

The heat exchanger 1 is oriented upwards in Fig. 8 and has a deep-drawn cover body 17 which, together with a flat or level carrier body 10, forms a fluid chamber 126 which is also flat and has the flow channel or channels 16 therein (in Fig. 8, the cover body 17 is at the top, the carrier body 10 at the bottom). A flat peripheral edge of the cover body 17 is soldered or welded to the carrier body 10 in order to close off the fluid chamber 126 at the side. Since the cover body 17 in Fig. 8 rests on the carrier body 10 (only indicated by an arrow), the carrier body 10 is hardly visible there. A turbulator (not shown in the figures) is inserted in the fluid chamber 126, which mixes the fluid flowing through, supports the heat transfer to the fluid and helps form the flow channels 16 (see Figs. 6 and 7). The fluid can flow into the fluid chamber 126 through an inflow connection 18 and, after being heated, flow out again through the outflow connection 19.

The heat conversion unit 200 has three heating elements 2a, 2b, 2c and - unlike in the first embodiment - a single common power switching part 5, which is covered by a housing cover 131, which is attached to the flat carrier body 10 (or the edge of the cover body 17 soldered or welded thereto) by means of folded tabs 133. From the housing cover 131, in the direction defined by the Heat exchanger 1 has attachment elements 123 which are directed laterally outwards and are formed integrally with the housing cover 131 and which allow fastening in a vehicle.

The carrier body 10 is designed as a flat plate. The cover body 17 of the heat exchanger 1 and the housing cover 131 of the heat conversion unit 200 together form a second module housing 420 for the heat transfer module 500 in the specific embodiment.

Fig. 9 shows the heating elements 2a, 2b, 2c and the power switching part 5 in the state attached to the carrier body 10 of the heat exchanger 1 in a top view. The heating elements 2a, 2b, 2c are designed in the present embodiments as a ceramic substrate (as a carrier layer), for example made of Al2O3, with a screen-printed heating conductor layer. The heating conductor layer is designed as a metallization made of a resistance alloy and provides the corresponding heating resistance. An insulation interruption ensures the structuring of long tracks of heating conductors 20. The ceramic substrate can be attached to the flat carrier body 10 via a heat-conducting adhesive layer/glue (not shown).

The conductor tracks of the heating conductors 20 are designed with regard to their resistances (determined by thickness, length, width and specific sheet resistance of the material used) in such a way that they can generate the desired heating power at the provided operating voltage in the high-voltage range, in the present embodiment for example 800 V, preferably in the range of 5 - 13 kW taken together.

The power switching part 5 comprises a circuit board or printed circuit board and has a number of power switching elements not shown separately here, for example IGBTs or power MOSFETs, with which the heating elements 2a, 2b, 2c can be operated, e.g. PWM-controlled. For this purpose, corresponding connection pads of the conductor tracks of the heating conductors 20 are connected to the power switching elements on the power switching part 5 via bond connections 137.

The power switching part 5 also has temperature sensors 6, which can detect a temperature of the carrier body 10 in their environment for the purpose of regulating the heating operation. Their position on the power component 5 corresponds in the embodiment to the Inflow connection 18 and the outflow connection 19 on the back of the carrier body 10 or the heat exchanger 1.

The power switching part 5 is connected via further bond connections 139 to respective connections that are set up on three lead frames 8 that are assigned to the respective heating elements 2a, 2b, 2c. The bond connections 139 contain electrical lines for the power supply (high voltage), for the control of the power switching elements and for the communication with the temperature sensors. The lead frames 8 are arranged in through openings 13a, 13b, 13c of the carrier body 10, which are set up in a connection section 15 of the carrier body 10 for attaching and fixing the control unit 3. In Fig. 9, the screw openings 50 shown in Figs. 3a and 3b for the first embodiment have been omitted merely for the sake of clarity, but are actually present in a corresponding position adjacent to the through openings 13a, 13b, and 13c.

The control unit 3 comprises a control device 35, a first module housing 410 receiving the control device, and a high-voltage connector section 60 and a low-voltage connector section 70 arranged therein. The first module housing 410 has a roughly cuboidal structure. The sections 60 and 70 are designed here as built-in plugs into which couplings of a corresponding vehicle-side high-voltage and low-voltage connection can be plugged.

Fig. 10 to 13 show more precise details of the structure of the control unit 3, wherein in the perspective of Fig. 10 - 13, elements are successively hidden in order to allow a view into the interior of the control unit 3.

In Fig. 10, only the control unit 3 and the power switching part 5 connected to the control device 35 are shown. It can be seen that the first module housing 410 has a base component 411 with a complex geometry and an essentially flat cover 412 which closes its opening (facing rearward in Fig. 10) and is fixed to it by ultrasonic welding. The base component 411 and cover 412 define an interior space 413 (not shown in Fig. 10) in which the control device 35 is arranged. Also visible in Fig. 10 are the bond connections 137 from the heating elements 2a, 2b, 2c (hidden in Fig. 10) to the power switching part 5 and also the further bond connections 139 from the power switching part 5 to the lead frames 8, which in turn are connected to the control device 35. In Fig. 10, a pressure equalization opening 419 is also shown, which connects an external environment with the interior 413 of the first module housing 410. A Gore-Tex membrane 491 is attached to the inside at this point (eg by ultrasonic welding) to prevent moisture from entering, see also Fig. 15 (only housing with pressure equalization opening 419, without further elements) and Fig. 19 (with membrane 491).

Fig. 11 shows the same view as Fig. 10, but with the high-voltage connector section 60 hidden. This shows an opening 414 for the high-voltage connector section 60, which is designed as an independent component and is to be inserted therein and fixed with screws 415.

The first module housing 410 is formed largely from two-component plastic material. In particular, the first module housing 410 comprises an inner first layer 440 and a second outer layer 450. In Figs. 10 and 11, the view is directed to the outer surface of the first module housing, so that the second outer layer 450 can be seen. The second outer layer 450 is formed from electrically insulating plastic. This is in particular a thermoplastic reinforced with glass fibers, for example PPS. The proportion (mass) of glass fibers in the material is preferably 40%.

Fig. 12 shows the same perspective of the first module housing 410 as in Fig. 10 or 11, but with the second layer 450 hidden so that the inner first layer 440 made of electrically conductive plastic material is visible. The plastic material is a thermoplastic reinforced with carbon fibers. The proportion (mass) of carbon fibers is preferably 40%. The thermoplastic here is also PPS, for example, so that both layers have similar and therefore compatible thermal properties. PPS is considered to be flame-retardant and is therefore particularly suitable for use in heating devices.

To produce the first module housing 410, the two plastic material compositions are injection molded one after the other. First, the plastic material of the first layer 440 is injection molded, and then, as long as the temperature is still slightly above 100 degrees, this is removed with the turntable and injected with the plastic material to form the second layer. The temperature ensures that good adhesion is achieved, but no mutual melting and Mixing is caused. In order to further improve mutual adhesion and thus ensure permanent one-piece construction, as shown in Fig. 12, a corrugation 415 formed during injection molding can be seen in the first layer 440, which is also reflected in the second layer 450 molded onto it (not shown).

Furthermore, it can be seen in Fig. 12 that the first layer 440 does not extend into a section 442 in which the low-voltage connector section 70 is formed. This section is, however, filled by the second layer 450, so that the low-voltage connector section 70 is formed integrally in the first module housing 410 (and does not represent a component to be subsequently fixed). As can be seen in the perspective view of the interior 413 of the first module housing 410 in Fig. 12, the pins 71 of the low-voltage connector section 70 extend directly through the second layer 450 and are thereby insulated from one another.

It is also visible in Fig. 12 that where in Fig. 11 self-tapping screws 415 for fixing the high-voltage connector section 60 (see Fig. 10) each form a comparatively small hole 451 in the second layer 450, the first layer is also excluded, cf. the larger holes 441 in Fig. 12. This ensures that no high-voltage voltage reaches the surface via the screws 415, which cannot be dissipated quickly enough due to the material of the first layer 440.

Furthermore, in Fig. 12, a recess is formed in the first layer 440 around the opening 414 for the high-voltage connector section 60, in which metal ring 91 of a sheet metal insert 9 is embedded, which serves to shield the area of the opening 414 when the high-voltage connector section 60 is inserted there and the heating operation is running. With the sheet metal insert integrated into the two-component plastic material, the basic component 411 is at least a three-component material.

The sheet metal insert 9 also has a first metal line 92 and a second metal line 93, as can best be seen in Fig. 14, which are also at least partially embedded in the first layer 440. The first metal line 92 extends from the metal ring 91 to a connection on the carrier body 10, which is formed by one of four fastening screws 51 for fixing the control unit 3 to the carrier body 10. For this purpose, screw openings 50 are formed in the carrier body 10 at a corresponding position, for example analogously to Fig. 3 and 4 of the first embodiment. can be seen. The second metal line 93 extends from the metal ring 91 to a connection on the control board 31 of the control device 35. The metal ring 91 is therefore safely at ground potential. Fig. 15 shows surfaces of the sheet metal insert 9 that are partially exposed towards the interior 413 in the inner first layer 440.

Fig. 16 and 17 show the control module or the control unit 3 from the rear, i.e. in particular the cover 412 of the module housing 410. In Fig. 16 the view is directed to the outer second layer 450, which also forms the outer surface, and in Fig. 17 the view is clear of the inner first layer 440 (the second layer is hidden in Fig. 10). The cover 412 is irreversibly fixed to the base component 411 by ultrasonic welding, for which purpose a groove 418 can be provided in the cover 412 (see Fig. 13), into which a circumferential nose 417 (see Fig. 15) of the base component 411 is inserted and welded.

The control device 35 can be seen best in Fig. 18. It is formed by a control board 31 with electronic components arranged thereon, in particular one or more microcontrollers (not shown). A potting compound 402 stabilizes and protects the control device 35 (i.e., the control board 31) in the interior 413 of the first module housing 410. In Fig. 15, four positioning pins 407 are shown which extend from the first module housing 410 (as an integral part thereof) into the interior 413 and, in the installed state, extend through holes (not shown) in the control board 31 and are hot-stamped to it, so that the control board 31 is firmly positioned and mounted in the interior 413.

The three punched grids 8 mentioned above are shown in Figs. 13 and 14 and in greater detail in Figs. 21 and 22. These each have contact lines 4a, 4b, 4c punched from a sheet metal, which are each embedded in a plastic insert 32. The contact lines 4a, 4b, 4c contact corresponding connection points on the control board 31 forming the control device 35. The relative positioning is achieved by dome-like positioning pins 85 which snap into or are fitted (press fit) into corresponding holes formed in the control board 31 (not shown).

The punched grids 8 are spatially arranged in respective apertures 430, which are arranged in a lower region of the first module housing 410, as can be seen in Figs. 8 and 13. In the assembled state, the apertures 430 of the first module housing 410 and the through openings 13 in the carrier body 10 are aligned with one another. so that the punched grids 8 extend through both and are fixed in position.

As shown in Fig. 21 and 22, the lead frames 8 have contact lines 4a, 4b, 4c with connections at both ends. First connections or line end sections 41 serve to contact the bond connections 139, with which the electrical connection to the power switching part 5 is realized. The opposite second connections or line end sections 43 are designed like pins and, in the assembled state, are fixed (soldered) to contact points on the control board 31 using THT technology (through-hole mounting), i.e. connected to the control device 35. The line center sections 42 of the contact lines 4a, 4b, 4c are essentially covered by the plastic insert 32. As in the first embodiment, the preferably double bending of the contact lines 4a, 4b, 4c shown in Fig. 21 and 22 results in a Z-shaped structure in lateral cross section. In particular, the line end sections 41, 43 of the respective contacting line 4a, 4b, 4c extend parallel to a main extension plane of the preferably plate-shaped carrier body 10, while the line middle section 42 embedded in the plastic insert extends perpendicular to the main extension plane of the carrier body 10.

In Fig. 20 it is shown that on the underside of the first module housing 410, next to the apertures 430 for the lead frames 8, in the area of four wall reinforcements 493 (cf. Fig. 19) in the first module housing 410, holes 494 for self-tapping fastening screws 51 are made, which are shown in their position relative to the module housing in Figs. 13 and 14. Also visible in Figs. 13 and 14 and 20 is a seal 492 which encloses the through openings 13a, 13b, 13c or the aperture 430 and thereby protects the interior 413 of the first module housing 410 and an interior of the second module housing 420, which accommodates the power switching part 5 and the heating elements 2a, 2b, 2c, from the ingress of moisture.

For assembly, the fastening screws 51 are inserted through corresponding screw openings 50 (not shown in Figs. 8 to 22, but in Figs. 3 and 4 of the first embodiment with corresponding implementation in the present embodiment) in the carrier body 10 and screwed into the wall reinforcements 493 shown in Fig. 19. The seal 492 is placed between the mutually facing surfaces of the carrier body 10 and the first module housing 410 or is molded onto the first module housing 410 in a groove provided on the latter and is held in place by the Fixation is pressed. In particular, the seal 492 can advantageously be molded directly onto the base component 411 by injection molding. In this variant, the base component 411 is therefore at least a four-component material due to the two different plastics, the sheet metal insert and the seal.

At this point it should be noted that all features of the invention described above, considered individually and in any technically reasonable combination, in particular the details shown in the drawings, belong to the invention.

List of reference symbols

1 heat exchanger

2a, 2b, 2c Heating element

3 Control unit

4a, 4b, 4c Contact line (e.g. in the lead frame)

5, 5a, 5b, 5c Power switching part

6a, 6b, 6c Temperature sensor

8 Punch grid

9 Sheet metal insertlO Carrier body

11 Heat transfer side

12 Heating side

13a, 13b, 13c Passage opening

14 Heat transfer section

15 Connection section

16 Flow channel

17 Cover body

18 Inflow connection

19 Outlet connection

20 heating conductors

30 Control housing (= first module housing)

31 Control board

32 Plastic insert for punch grid

33 Seal

35 Control device

41, 43 Line end section

42 Line section

50 screw opening

51 Screw

60 High-voltage connector section

70 Low voltage connector section

81 Connections for control device

83 connections for bonding

85 dome-like positioning pins

91 Metal ring

92 first metal line 93 second metal line

100 Heating arrangement

123 Attachment element

126 Fluid chamber

131 Housing cover

133 tab

137 Bond connection

139 additional bond connections

200 Heat Conversion Unit

402 Casting compound

407 positioning pins

410 first module housing

411 Basic component

412 Lid

413 Interior

414 Opening for high-voltage connector section

415 Corrugation

417 Nose

418 Groove

419 Pressure equalization opening

420 second module housing

430 aperture (in first module housing)

440 first layer of electrically conductive plastic material

441 holes in first layer

442 exempted section in first layer

443 Recess for metal ring in first layer

450 second layer of electrically insulating plastic material

491 Gore-Tex membrane

492 Seal (between control module and carrier plate)

493 Reinforcement (module housing)

494 Screw hole (module housing)

500 Heat transfer module

Claims

Expectations 1. Heating arrangement (100) for a vehicle, in particular an electric or hybrid vehicle, comprising a heat exchanger (1) which has a carrier body (10) for a, in particular flat, electrical heating element (2a, 2b, 2c), wherein the, in particular plate-shaped, carrier body (10) has a heating side (12) and opposite a heat transfer side (11), at least one electrical heating element (2a, 2b, 2c), preferably a layer heating element, which is mounted on the heating side (12) of the carrier body (10), a control unit (3) for the at least one heating element (2a, 2b, 2c), and at least one electrical contact line (4a, 4b, 4c) connected to the control unit (3) for supplying power to the heating element (2a, 2b, 2c), characterized in that the carrier body (10) has at least one through-opening (13a, 13b, 13c) from the heat transfer side (11) to the heating side (12), through which the contacting line (4a, 4b, 4c) extends. 2. Heating arrangement (100) according to claim 1, characterized in that the control unit (3), which is preferably designed to control several heating elements (2a, 2b, 2c), comprises a control housing (30), in particular for receiving a control board (31), which is arranged on the heat transfer side (11) of the carrier body (10). 3. Heating arrangement (100) according to claim 1 or 2, characterized in that the control unit (3) and an inflow connection (18) and/or an outflow connection (19) for a heat transfer medium are arranged on the same side of the carrier body (10), preferably on the heat transfer side (11). 4. Heating arrangement (100) according to one of the preceding claims, characterized in that the carrier body (10) has a heat transfer section (14) in the region of the at least one heating element (2a, 2b, 2c) and a connection section (15) outside the heat transfer section (14), wherein the at least one through opening (13a, 13b, 13c) is formed in the connection section (15). 5. Heating arrangement (100) according to one of the preceding claims, characterized in that the heat exchanger (1) has at least one flow channel (16) for the flow of a heat transfer medium on the heat transfer side (11) of the carrier body (10). 6. Heating arrangement (100) according to one of the preceding claims, characterized in that the heat exchanger (1) has a cover body (17) which, together with the carrier body (10), forms a cavity for the flow of a heat transfer medium, in particular at least one flow channel (16). 7. Heating arrangement (100) according to one of the preceding claims, characterized in that the through opening (13a, 13b, 13c) penetrates the cover body (17) and the carrier body (10) in the region of the connection section (15) of the carrier body (10). 8. Heating arrangement (100) according to one of the preceding claims, characterized in that at least one power switching part (5a, 5b, 5c) for regulating the power of the heating element (2a, 2b, 2c) is mounted on the heating side (12) of the carrier body (10), wherein the power switching part (5a, 5b, 5c) is preferably arranged between the through opening (13a, 13b, 13c) and the heating element (2a, 2b, 2c) and is electrically contacted in particular by the contacting line (4a, 4b, 4c). 9. Heating arrangement (100) according to one of the preceding claims, characterized in that the power switching part (5a, 5b, 5c) is connected to a temperature sensor (6) which is arranged on the heating side (12) of the carrier body (10), preferably on a circuit board of the power switching part (5a, 5b, 5c). 10. Heating arrangement (100) according to one of the preceding claims, characterized in that a plurality of heating elements (2a, 2b, 2c) are mounted on the heating side (12) of the carrier body (10) and/or that the carrier body (10) has a plurality of through openings (13a, 13b, 13c), wherein preferably each heating element (2a, 2b, 2c) is assigned a through opening (13a, 13b, 13c). 11. Heating arrangement (100) according to one of the preceding claims, characterized in that each through-opening (13a, 13b, 13c) is assigned a power switching part (5a, 5b, 5c), which is each connected to a contacting line (4a, 4b, 4c), wherein in particular each heating element (2a, 2b, 2c) is assigned a power switching part (5a, 5b, 5c). 12. Heating arrangement (100) according to one of the preceding claims, characterized in that the main extension plane of the control board (31) of the control unit (3) is arranged at an angle of at least 45°, preferably of 90°, to the main extension plane of the power switching part (5a, 5b, 5c) and/or the heating element (2a, 2b, 2c). 13. Heating arrangement (100) according to one of the preceding claims, characterized in that the contacting line (4a, 4b, 4c) is designed as a conductor track partially enclosed by a plastic insert (32), in particular as a curved punched grid, wherein the outer contour of the plastic insert is adapted to the inner contour of the through opening (13a, 13b, 13c). 14. Heating arrangement (100) according to one of the preceding claims, characterized in that the contacting line (4a, 4b, 4c) is angled, preferably twice, wherein in particular the line end sections (41, 43) of the contacting line (4a, 4b, 4c) extend parallel to the main extension plane of the preferably plate-shaped carrier body (10), and in particular a line middle section (42) extends perpendicular to the main extension plane of the carrier body (10). 15. Heating arrangement (100) according to one of the preceding claims, wherein at least one aperture (430) is formed in the control housing (30, 410) for passing through an electrical connection between a control board (31) forming a control device (35) in the control housing (30, 410) and the power switching part (5) for switching the electrical heating element (2a, 2b, 2c), and wherein a stamped grid (8) with the contact lines (4a, 4b, 4c) embedded in a plastic insert (32) is arranged in each of the at least one aperture (430), wherein the contact lines (4a, 4b, 4c) contact corresponding connection points on the control board (31) forming the control device (35). 16. Heating arrangement (100) according to claim 15, wherein the lead frame (8) extends through the aperture (430) and the through-opening (13a, 13b, 13c) into an interior (413) of the control housing (41), where it is fixed to the control board (31) forming the control device (35) by at least one positioning means, in particular a positioning pin (85). 17. Heating device, preferably a high-voltage heating device, for a vehicle, in particular an electric or hybrid vehicle, characterized by at least one heating arrangement (100) according to one of claims 1 to 16.