Field of the Invention
[0001] The present invention relates to an ultraflat heating assembly having application
in air conditioning industry, and more specifically in the field of dry heat electric
radiators, being constituted as a heat source, mainly, in domestic heaters, subject
to other uses or applications. The object of the invention has a simple, low-cost
construction, not requiring an outer enclosure, being highly reliable and safe, in
addition to being able to be easily integrated in the already existing radiator apparatuses.
Background of the Invention
[0002] On the market there is a large variety of electric resistances and electric heating
elements producing heat by Joule effect. Some of these types are air, incandescent,
on panel print resistances, with all types of supports and enclosures, this means
that each type of resistance is designed to operate at determined temperatures.
[0003] Such resistances transmit heat that they produce by any method, i.e., either by radiation,
convection, or conduction. Resistors which transmit heat by conduction have always
had an electrically insulated enclosure which also served for transmitting heat, as
is described, for example, in the European Patent no.
EP-1574803-B1, the Spanish validation of which is published with the no.
ES-2338575-T3, in which a dry heat modular electric radiator comprising a heating plate having
a base plate, a resistance wire and an external enclosure to insert it tightly into
a housing of the radiator is described.
[0004] Currently it has to be considered that in the design and manufacturing of any electric
heating element, i.e. of any electric resistance, it is necessary to face two requirements.
On one hand, the electric portions under stress must be perfectly insulated, and on
the other hand, the heating element must have a sufficient capacity to transmit the
heat effectively. By taking these two requirements into account, the currently existing
solutions can be considered more or less successful.
Description of the Invention
[0005] The present invention relates to an ultraflat heating assembly allowing a simple,
low-cost construction, in which the common outer enclosure is eliminated, being at
the same time highly reliable and safe, in addition to being able to be easily integrated
in dry heat electric radiator apparatuses, such as for example the radiator described
in the European Patent no.
EP-1574803-B1.
[0006] The heating assembly proposes by the invention comprises an electroresistant conductor
wire also called electric resistance, preferably made of chromium-nickel alloy, wound
around a support body or core made of heat resistant and insulating material having
a flat and elongated configuration, preferably made of micanite, an insulating matter
formed by thin mica sheets attached to one another by means of a suitable adhesive.
[0007] The conductor wire transmits heat by conduction when electric current flows through
said conductor wire. In addition, at least one insulation plate made of heat resistant
and insulating material, preferably micanite, is attached to each face of the support
body. In turn, the assembly comprises connectors made of steel, coupleable to the
ends of the support body and connectable to each end of the conductor wire at a connection
point, the support body and a coupling area of the connectors being located between
at least one insulation plate, all of this forming a sandwich attached by means of
pins, a cap made of elastic and insulating material closing and insulating the heating
assembly from the outside is coupled to the sandwich thereof at both ends.
[0008] For an effective protection and insulation of the support plate, the insulation plates,
as well as the support plate, have an elongated configuration, meaning they are preferably
rectangular plates, it is understood that their smaller sides are their ends, such
that the width of the insulation plates, i.e. the dimensions of their smaller side,
is greater than the width of the support plate, for the purpose of providing the resistance
with an insulation equivalent to the ends not covered by the sheets.
[0009] As has been mentioned, the assembly comprises a cap or elastic cover element made
of insulating material, such as rubber, arranged at each end of the sandwich, wherein
said caps protect the connectors, since according to a preferred embodiment of the
invention they are housed in said caps.
[0010] The assembly thus formed is to replace the heating assembly described in the aforementioned
European Patent no.
EP-1574803-B1, in which the resistance and the plates were located inside a flexible outer enclosure
which was press-fitted into the radiator. The ultraflat heating assembly proposed
by the present invention is designed to transmit heat by conduction, and has as an
outstanding feature that the outer enclosure has been eliminated in its construction
simplifying and limiting its construction to a very few parts and processes. Obviously,
in place of a wound electroresistant conductor wire, the possibility of alternatively
using a printed circuit with conductive ink is contemplated.
[0011] The cap is entrusted with the following functions:
- Electrically insulating both the connector and the terminal of said connector for
connecting to the electric power system, which may be a terminal called faston.
- Being housed in the insulation plates, preventing the movement thereof.
Since there is a cap at each end, the separation between both caps determines the
length or dimension of the length of the heating body, thus preventing the axial movement
of the electric resistance.
- Allowing the passage of an electric cable to connect the conductor wire to the electric
power system through the faston terminal.
- Modifying the trajectory of possible accidental drips of water as to prevent it from
being able to penetrate into the support body and the conductor wire. The point where
this risk is prevalent is located in the conjunction of the support body and the insulation
plates with the cap.
[0012] The possibility that each face of the support body is attached to a fist insulation
plate made of heat resistant and insulating material, which is in turn attached by
an opposite face to a second insulation plate made of heat resistant and insulating
material is contemplated.
[0013] The arrangement of a first heat resistant insulation plate at each side, and additionally
a second insulation plate at each side allows providing the assembly with class II
electric insulation. The number of insulation plates incorporated by the assembly
will depend on the type of insulation desired, either class I or class II. If the
resistance is to be incorporated to a class II radiator, it is necessary that it comprises
two insulation plates per face.
[0014] Likewise, it is contemplated that each end of the support body has a hole, for example
made by die-cutting. This hole has a geometry equivalent to that of the coupling area
of the connectors, so that said connectors can be fitted in the mentioned holes of
the support body. The coupling area of the connectors comprises an opening to house
the joint rivet which permanently attaches the support body, the insulating plates
and the connector itself, to form a sandwich. The coupling area of the connectors
has a point to be welded to the electroresistant wire.
Description of the Drawings
[0015] To complement the description that is being made and for the purpose of aiding to
better understand the features of the invention according to a preferred practical
embodiment thereof, a set of drawings is attached as an integral part of said description
in which the following has been depicted with an illustrative and non-limiting character:
Figure 1 shows an exploded schematic view of the heating assembly object of the invention.
Figure 2 shows an elevational longitudinal section, according to A-A cut line of the
assembly of the invention, the components thereof being assembled, as well as a plan
view and a cross section view, according to B-B cut line.
Figure 3 shows a perspective view of a cap.
Figure 4 shows three views of the cap, according to an elevational view, a cross section
view and a longitudinal section view.
Preferred Embodiment of the Invention
[0016] In view of the described drawings how in one of the possible embodiments of the invention
the ultraflat heating assembly proposed by the invention comprises a conductor wire
(6) wound around a support body (1) made of micanite having a flat and elongated configuration
can be observed. The conductor wire (6) transmits heat by conduction when electric
current flows through said conductor wire (6).
[0017] The assembly comprises connectors (4) made of steel, coupleable to the ends of the
support body (1) and connectable to each end of the conductor wire (6) at a connection
point (9), preferably a welding point, the support body (1) and a coupling area (4a)
of the connectors (4) being located between at least one insulation plate (2,3), all
of this forming a sandwich attached by means of pins (7), a cap (5) made of elastic
and insulating material closing and insulating the heating assembly from the outside
is coupled to the sandwich thereof at both ends.
[0018] For an effective protection and insulation of the support plate (1), the insulation
plates (2, 3), as well as the support plate (1) have an elongated configuration, meaning
that they are preferably rectangular plates, it is understood that their smaller sides
are their ends, such that the width of the insulation plates (2, 3), i.e. the dimensions
of their smaller side, is greater than the width of the support plate (1) to achieve
a sufficient side insulation at the ends of the sandwich.
[0019] Each end of the support body (1) has a hole (1a) in which the connection area (4a)
of each connector (4) will be tightly fitted. The two connectors (4) are thus coupleable
to the support body (1) for which said connectors (4) have a connection area (4a)
with a geometry substantially equivalent to that of the holes (1 a) of the support
body (1), said connection area (4a) of the connector also having an opening to house
the joint rivet (7) made of brass or another material. With these components the only
thing left is to assemble all the mentioned parts except the caps (5). To this end,
rivets (7) are used at each end leaving the assembly permanently reinforced with all
its components locked without any possibility of moving. The caps (5) are inserted
into the heating assembly stretching them and keeping them tight on the insulating
plates.
[0020] The connector (4) is a multifunction part which complies with these four tasks:
- Being welded to the conductor wire (6). Having an area specifically designed in the
connection area (4a) to carry out this welding accurately and safely.
- Locating and fitting the connector (4) inside the hole (1 a) in this case, the hole
of the support body (1) of the assembly. This male (connector (4)) and female (support
body (1)) set fit both parts (1, 4), preventing the connector (4) from rotating or
moving, both when it is to be welded, and when it is connected to or disconnected
from an electric connection cable (8).
[0021] In addition, each connector (4) can be connected to the connection cable (8) at an
end opposite to the connection area (4a). Thus, the other end of the connector (4)
made up a male faston terminal/connector arranged to receive the connection cable
with its corresponding output connector or female faston.
[0022] As has been indicated, the caps (5) are made of elastic material, allowing their
fit insertion and immobilization at the ends of the support body (1), whereby the
height of each cap (5) is less than the width of the insulating insulation plates
(2, 3) in which said cap (5) is inserted. Rubber-silicone is considered suitable to
perfectly comply with these requirements, without excluding other possible materials.
To insert and immobilize it in its housing, making use of its elastic characteristics
has been contemplated by making the height of the cap (5) less than the height of
the insulation plates (2, 3) where it is to be fitted.
[0023] Likewise, each cap (5) comprises at least one protuberance (5a), located inside,
preferably one lower and another upper, corresponding with an upper release flange
(5b). Such that said protuberances (5a) are configured to fit the cap (5) by elastic
deformation in a notch (2a, 3a) of the insulation plates (2, 3) have, said cap (5)
thus being fitted in the insulation plates (2, 3).
[0024] As seen in the drawings, the insulation plates (2, 3) have notches (2a, 3a) above
and below each end. The cap (5) in turn has corresponding protuberances (5a) provided
to be fitted in the aforementioned notches (2a, 3a), although the previously mentioned
height difference, and taking into account the special form of a preferred embodiment
of the cap (5), it being wider in the center and being narrow towards the upper and
lower ends. In order to fit them, the cap (5) is first inserted at the lower portion,
the cap (5) is at the same time stretched upwards using to that end the tongue or
flange (5b) to insert the cap (5). Next what left to be done is to move it until the
notches (2a, 3a) and protuberances (5a) are coupled. The cap (5) is thus perfectly
immobilized and completely functional. The cap fits tightly to the insulating plates,
as shown in section B-B of Figure 2.
[0025] The invention contemplates the use of a deflector visor provided to place the resistance
in vertical position. To place it in a horizontal or inclined position, the deflector
visor must be placed along the dimension exposed to the eventual drips of water.
[0026] Finally, it must be mentioned that that each cap (5) has a lower opening (5c) for
connecting the output connector (8) with the connector (4) housed in the cap (5),
which allows the connectors (4) housed in the cap (5) to be connected to the electric
power system through an faston output connector (8), which facilitates and expedites
the installation thereof in a radiator protecting it from water and insulating the
current.
[0027] In view of this description and set of drawings, the person skilled in the art will
understand that the embodiments of the invention which have been described can be
combined in many ways within the object of the invention. The invention has been described
according to several preferred embodiments thereof, but for the person skilled in
the art it will be evident that multiple variations can be introduced in said preferred
embodiments without exceeding the object of the claimed invention.
1. Ultraflat heating assembly comprising a conductor wire (6) wound around a support
body (1) made of heat resistant and insulating material having a flat and elongated
configuration, wherein the conductor wire (6) transmits heat when electric current
flows through said conductor wire (6), at least one insulation plate (2, 3) made of
heat resistant and insulating material being attached to each face of the support
body (1), characterized in that the assembly comprises connecters (4) coupleable to the ends of the support body
(1) and connectable to the conductor wire (6) at a connection point (9), the support
body (1) and a coupling area of the connectors (4a) located between at least one insulation
plate (2,3), all of this forming a sandwich attached by means of pins (7), a cap (5)
made of elastic and insulating material closing and insulating the heating assembly
from the outside is coupled to the sandwich thereof at both ends.
2. Ultraflat heating assembly according to claim 1, wherein each face of the support
body (1) is attached to a first insulation plate (2) made of heat resistant and insulating
material, which is in turn attached by a face opposite to a second insulation plate
(3) made of heat resistant and insulating material.
3. Ultraflat heating assembly according to any of the preceding claims, wherein each
end of the support body (1) has a hole (1a) in which a connection area (4a) comprising
each connector (4) is tightly fit.
4. Ultraflat heating assembly according to claim 3, wherein each connector (4), at an
end opposite to the connection area (4a), can be connected to a connection cable for
connecting to the electric power system through an output connector (8) comprising
the electric connection means (8) of the assembly.
5. Ultraflat heating assembly according to any of the preceding claims, wherein the caps
(5) have a height less than the width of the insulating insulation plates (2, 3).
6. Ultraflat heating assembly according to claim 5, wherein each cap (5) comprises at
least one protuberance (5a), located inside, configured to fit by elastic deformation
of the cap (5) in a notch (2a, 3a) of the insulation plates (2, 3) have, said cap
(5) thus being fitted in the insulation plates (2, 3).
7. Ultraflat heating assembly according to any of claims 4 to 6, wherein each cap (5)
has a lower opening (5c) the connection of the output connector (8) with the connector
(4) housed in the cap (5).