Heat sink for a PTC heating element and a PTC heating member made thereof

Abstract

There is disclosed a heat sink for a PTC heating element, which heat sink including a first end, a second end, and a pair of webs extending from the second end towards the first end, in which each of the webs is connected to the cover face via a respective curved section, and the curved section is inward of the respective web.

What is claimed is:  
     
         1 . A heat sink for a PTC heating element, said heat sink including a first end, a second end, and a pair of webs extending from said second end towards said first end, wherein each of said webs is connected to the first end via a respective curved section, and wherein said curved section is inward of the respective web.  
     
     
         2 . A heat sink according to  claim 1  wherein said webs extend substantially perpendicularly from said second end before and after deformation of said heat sink.  
     
     
         3 . A heat sink according to  claim 1  wherein said heat sink is deformable to engage with a heating surface of an electrical appliance.  
     
     
         4 . A heat sink according to  claim 3  wherein said heat sink includes at least one channel member or one ridge member adapted to be engaged with a heating surface of an electrical appliance.  
     
     
         5 . A heat sink according to  claim 3  wherein said heat sink includes a pair of channel members or a pair of ridge members.  
     
     
         6 . A heat sink according to  claim 5  wherein said channel members or said ridge members are substantially parallel to each other.  
     
     
         7 . A heat sink according to  claim 1  wherein said first end includes a ridge member.  
     
     
         8 . A heat sink according to  claim 7  wherein said ridge member of said first end extends in the longitudinal direction.  
     
     
         9 . A heat sink according to  claim 1  wherein said second end includes an outer surface adapted to be exposed to the outside environment when said heat sink is assembled to an electrical appliance.  
     
     
         10 . A heat sink according to  claim 9  wherein said outer surface of said second end is substantially planar.  
     
     
         11 . A heat sink according to  claim 1  wherein said second end includes a curved outer surface.  
     
     
         12 . A heat sink according to  claim 10  wherein said outer surface of said second end is curved.  
     
     
         13 . A heat sink according to  claim 1  wherein said heat sink includes a cavity for receiving a PTC heating element, which cavity including two oppositely-facing surfaces adapted to contact said PTC heating element, and wherein at least one of said surfaces includes a portion protruding into said cavity.  
     
     
         14 . A heat sink according to  claim 13  wherein said protruding portion includes a substantially planar surface.  
     
     
         15 . A heat sink according to  claim 9  wherein said heat sink is generally cylindrical in shape.  
     
     
         16 . A PTC heating member including a heat sink fixedly secured with a PTC heating element, wherein said heat sink includes a first end, a second end, and a pair of webs extending from said second end towards said first end, wherein each of said webs is connected to the first end via a curved section, and wherein said curved section is inward of the respective web.  
     
     
         17 . A PTC heating member according to  claim 16  wherein the height of said webs is larger than the thickness of said PTC heating element.  
     
     
         18 . A method of forming a PTC heating member, including the steps of: 
 (a) providing a heat sink with a first end, a second end, and a pair of webs extending from said second end towards said first end, wherein each of said webs is connected to the first end via a respective curved section, and wherein said curved section is inward of the respective web;    (b) providing a PTC heating element in a cavity of said heat sink; and    (c) deforming said heat sink to secure said PTC heating element with said heat sink.    
     
     
         19 . A method according to  claim 18  wherein said cavity includes two oppositely-facing surfaces for contacting said PTC heating element, and wherein at least one of said surfaces includes a portion protruding into said cavity.  
     
     
         20 . A method according to  claim 19  including the step (d) of placing said PTC heating element within the width of said protruding portion.  
     
     
         21 . A method of assembling a PTC heating member to a heating surface of an electrical appliance, including the steps of: 
 (a) providing a PTC heating member including a heat sink fixedly secured with a PTC pellet;    (b) loosely engaging said PTC heating member with said heating surface; and    (c) deforming said heat sink or said heating surface to secure said PTC heating member with said heating surface.    
     
     
         22 . A method according to  claim 21  including a step (d) of inserting a male member of said heating surface into a female member of said PTC heating member.  
     
     
         23 . A method according to  claim 22  including a step (e) of deforming said female member of said PTC heating member to secure said PTC heating member with said heating surface.  
     
     
         24 . A method according to  claim 22  wherein said female member comprises a channel member.  
     
     
         25 . A method according to  claim 24  wherein said heat sink includes at least two channel members.  
     
     
         26 . A method according to  claim 25  wherein said at least two channel members are substantially parallel to each other.  
     
     
         27 . A method according to  claim 22  wherein said male member of said heating surfaces comprises a ridge member.  
     
     
         28 . A method according to  claim 27  wherein said heating surface includes at least two ridge members.  
     
     
         29 . A method according to  claim 28  wherein said at least two ridge members are substantially parallel to each other.  
     
     
         30 . A method according to  claim 21  including a step (f) of inserting a male member of said PTC heating member into a female member of said heating surface.  
     
     
         31 . A method according to  claim 30  including a step (g) of deforming said female member of said heating surface to secure said PTC heating member with said heating surface.  
     
     
         32 . A method according to  claim 30  wherein said female member comprises a channel member.  
     
     
         33 . A method according to  claim 32  wherein said heat sink includes at least two channel members.  
     
     
         34 . A method according to  claim 33  wherein said at least two channel members are substantially parallel to each other.  
     
     
         35 . A method according to  claim 30  wherein said male member of said PTC heating member comprises a ridge member.  
     
     
         36 . A method according to  claim 35  wherein said PTC heating member includes at least two ridge members.  
     
     
         37 . A method according to  claim 36  wherein said at least two ridge members are substantially parallel to each other.  
     
     
         38 . A method according to  claim 21  wherein said heating surface is substantially cylindrical and with a hollow interior.  
     
     
         39 . A method according to  claim 38  wherein said PTC heating member includes an end with a curved outer surface.  
     
     
         40 . A method according to  claim 39  including a step (h) of abutting said curved outer surface of said end of said PTC heating member with an interior surface of said heating surface.  
     
     
         41 . A method of assembling a heat sink and a PTC heating member to a heating surface of an electrical appliance, including the steps of: 
 (a) providing a heat sink;    (b) providing a PTC pellet in a cavity of said heat sink;    (c) loosely engaging said heat sink with said heating surface; and    (d) deforming said heat sink or said heating surface to secure said PTC pellet, said heat sink and said heating surface with one another.    
     
     
         42 . A method according to  claim 41  including a step (e) of inserting a male member of said heating surface into a female member of said heat sink.  
     
     
         43 . A method according to  claim 42  including a step (f) of deforming said female member of said heat sink to secure said heat sink with said heating surface.  
     
     
         44 . A method according to  claim 42  wherein said female member comprises a channel member.  
     
     
         45 . A method according to  claim 44  wherein said heat sink includes at least two channel members.  
     
     
         46 . A method according to  claim 45  wherein said at least two channel members are substantially parallel to each other.  
     
     
         47 . A method according to  claim 42  wherein said male member of said heating surfaces comprises a ridge member.  
     
     
         48 . A method according to  claim 47  wherein said heating surface includes at least two ridge members.  
     
     
         49 . A method according to  claim 48  wherein said at least two ridge members are substantially parallel to each other.  
     
     
         50 . A method according to  claim 41  including a step (g) of inserting a male member of said heat sink into a female member of said heating surface.  
     
     
         51 . A method according to  claim 50  including a step (h) of deforming said female member of said heating surface to secure said heat sink with said heating surface.  
     
     
         52 . A method according to  claim 50  wherein said female member comprises a channel member.  
     
     
         53 . A method according to  claim 52  wherein said heat sink includes at least two channel members.  
     
     
         54 . A method according to  claim 53  wherein said at least two channel members are substantially parallel to each other.  
     
     
         55 . A method according to  claim 50  wherein said male member of said heat sink comprises a ridge member.  
     
     
         56 . A method according to  claim 55  wherein said heat sink includes at least two ridge members.  
     
     
         57 . A method according to  claim 56  wherein said at least two ridge members are substantially parallel to each other.  
     
     
         58 . A method according to  claim 51  wherein said heating surface is substantially cylindrical and with a hollow interior.  
     
     
         59 . A method according to  claim 58  wherein said heat sink includes an end with a curved outer surface.  
     
     
         60 . A method according to  claim 59  including a step (i) of abutting said curved outer surface of said end of said heat sink with an interior surface of said heating surface.  
     
     
         61 . A method of assembling a PTC heating member to a heating surface of an electrical appliance, including the steps of: 
 (a) providing a PTC heating member including a heat sink fixedly secured with a PTC pellet;    (b) abutting said PTC heating member with a side of said heating surface; and    (c) biasing said PTC heating member towards said side of said heating surface.    
     
     
         62 . A method according to  claim 61  wherein said PTC heating member is biased towards said side of said heating surface by at least one spring member.  
     
     
         63 . A method according to  claim 62  wherein said PTC heating member is biased towards said side of said heating surface by at least two spring members.  
     
     
         64 . A method according to  claim 61  including the step (d) of providing a stopper for limiting the axial movement of said PTC heating member relative to said heating surface.  
     
     
         65 . A method according to  claim 64  including the step (e) of forming said stopper integrally with said at least one spring member.  
     
     
         66 . A method according to  claim 61  wherein said heating surface is substantially cylindrical and with a hollow interior.  
     
     
         67 . A method according to  claim 66  wherein said PTC heating member includes an end with a curved outer surface.  
     
     
         68 . A method according to  claim 67  including a step (f) of abutting said curved outer surface of said end of said PTC heating member with said side of said heating surface.