BATTERY HEATING DEVICE

Abstract

The utility model relates to the field of vehicle electrical equipment. The technical result consists of increasing the reliability of an electric heating circuit under current overloads and environmental influences. A battery heating device comprises a thermal insulating cover adapted to accommodate a battery, and flexible heating plates arranged relative to the walls of the thermal insulating cover. An outer pocket for a control unit is secured to the outer wear-resistant layer of the cover. The pocket contains a control unit comprising a control unit housing with a printed circuit board located inside, electrically connected to power and heating LED indicators located on the outer wear-resistant layer of the cover. The control unit housing is equipped with a sealed cable entry through which a heater wire harness, enclosed in a protective braid, and a power cable equipped with a fuse holder with a fusible link are routed. 6 z.p.F-ly, 2 years.

Description

[0001] Technical field

[0002] The utility model relates to the field of electrical equipment for vehicles, in particular to thermal control and heating systems for batteries to ensure their reliable starting and operation in low temperature conditions [H01M 10 / 615, H01M 10 / 625, H01M 10 / 6571, B60R 16 / 04].

[0003] A BATTERY FOR A CAR is known from the prior art [WO 2006126860 A1, published 30.11.2006], comprising a container, a detachable lid and rectangular heat-protective plates mounted on the sides, to which reflective plates with a mirror surface for shielding heat are attached using glue.

[0004] The disadvantage of this analogue is its passive operating principle, based only on thermal insulation and reflection, which does not allow it to effectively maintain the battery's operating temperature during long periods of parking in extreme cold without an active heat source, which reduces the reliability of the electric heating circuit.

[0005] Also known from the prior art is a BATTERY WITH OVERHEATING PROTECTION [RU 128038 U1, published 10.05.2013], which is a heat-insulated structure with a housing made of a supporting and heat-insulating layer, into which self-regulating heating elements are built in, connected directly to the battery.

[0006] The disadvantages of this solution include the complexity of the design due to the integration of heaters directly into the structure of the battery housing, which reduces the maintainability of the system, as well as the lack of specialized circuit solutions to protect the heating circuit from external electrical influences, which reduces the reliability of the electrical heating circuit.

[0007] Also known from the prior art is a PROTECTIVE CASING FOR ELECTRIC VEHICLE BATTERIES [CN 205429035 U, published 03.08.2016], comprising a housing with a lid, an internal insulating layer made of fire-resistant materials, a thermal layer in the form of an electric heating grid and an external protective layer with an anti-radiation coating, equipped with a temperature sensor.

[0008] The disadvantage of the device is that its design is focused primarily on mechanical protection and thermal insulation, while sufficient reliability of the electrical circuit of the heating element is not ensured when current overloads occur, which reduces the overall fault tolerance of the system.

[0009] The closest in technical essence is the DEVICE FOR PRESERVING THE HEAT OF A BATTERY [CN 115395162 A, published 11 / 25 / 2022], comprising a housing with a lid, a heater, multilayer insulation made of polyurethane aerogel and felt with a reflective film, as well as a controller with a temperature measurement circuit that controls the energy supply.

[0010] The main technical problem of the prototype is the insufficient operational reliability of the electrical heating control circuit, which does not provide effective protection against significant current overloads (up to 30% of the nominal value) and exposure to an aggressive external environment, which limits the applicability of the device in difficult climatic and road conditions.

[0011] The purpose of the utility model is to eliminate the shortcomings of the prototype.

[0012] The technical result of the utility model is to increase the reliability of the electric heating circuit during current overloads and exposure to the external environment.

[0013] Disclosure of the essence of the utility model

[0014] The specified technical result is achieved due to the fact that the battery heating device, containing a heat-insulating cover, adapted to accommodate the battery, and flexible heating plates located relative to the walls of the heat-insulating cover, characterized in that an outer pocket for a control unit is fixed on the outer wear-resistant layer of the cover, in which a control unit is installed, including a control unit housing with a printed control board located inside, electrically connected to LED indicators for power and heating, displayed on the outer wear-resistant layer of the cover, wherein the control unit housing is equipped with a sealed cable entry, through which a harness of heater wires, enclosed in a protective braid of the harness, and a power cable equipped with a fuse holder with a fusible fuse are output.

[0015] In particular, the thermal insulation cover is made in the form of a rectangular box with a multi-layer wall structure, including a sequentially located outer wear-resistant cover layer, an intermediate heat-insulating layer and an inner heat-reflective layer.

[0016] In particular, the thermal insulation case is equipped with a hinged lid with a textile lid fastener and technological cutouts for the battery terminals in the areas where they meet the walls of the case.

[0017] Specifically, each flexible heating plate contains a resistive heating filament enclosed in a silicone heater insulation, and is provided with an adhesive layer for fixing the heater on the surface of the cover walls.

[0018] In particular, the temperature sensor connection cable is additionally routed through a sealed cable entry, and the temperature sensor connection sensor itself is protected by a heat-shrinkable sensor tube and is located in the internal space of a heat-insulating cover.

[0019] In particular, the fuse is made with a rating that exceeds the operating current of the device by 20-30%.

[0020] In particular, the printed circuit board of the control board is made with a protective coating applied to it in the form of a compound or varnish.

[0021] Brief description of drawings

[0022] Fig. 1 shows a general view of the battery heating device in assembly. It shows the shape of the thermal insulation cover 1, consisting of the front, rear, left side and right side walls 6, 7, 8 and 9 and the bottom of the cover 5, a closed hinged lid 10 with a textile cover fastener 11, mounting belts of the cover 39, an outer pocket for the control unit 13 with the control unit 15 and the outgoing positive and negative power cables 26 and 27. It demonstrates the general spatial arrangement of all external components. Repeating elements, such as the mounting belts of the cover 39, can be shown in detail only from one side.

[0023] Fig. 2 shows a multilayer structure of the walls and bottom, consisting of an outer wear-resistant cover layer 2, an intermediate heat-insulating layer 3 and an inner heat-reflecting layer 4. It allows you to see the method of fixing the left and right flexible heating plates 34 and 35 on the inner surface.

[0024] The following is indicated on the figures: 1 - heat-insulating cover, 2 - outer wear-resistant layer of the cover, 3 - intermediate heat-insulating layer, 4 - inner heat-reflecting layer, 5 - bottom of the cover, 6 - front wall, 7 - back wall, 8 - left side wall, 9 - right side wall, 10 - hinged lid, 11 - textile fastener of the lid, 12 - technological cutouts for battery terminals, 13 - outer pocket for the control unit, 14 - edging tape of the seams, 15 - control unit, 16 - control unit housing, 17 - control unit housing cover, 18 - control printed circuit board, 19 - microcontroller, 20 - green power LED, 21 - red heating LED, 22 - sealed cable entry, 23 - sensor connection cable temperature, 24 - temperature sensor, 25 - sensor heat shrink tube, 26 - positive power cable, 27 - negative power cable, 28 - fuse holder, 29 - fuse,30 - positive ring terminal, 31 - negative ring terminal, 32 - heater wire harness, 33 - harness protective braid, 34 - left flexible heating plate, 35 - right flexible heating plate, 36 - heater resistive threads, 37 - heater silicone insulation, 38 - heater fixing adhesive layer, 39 - boot mounting straps.

[0025] Implementation of a utility model

[0026] The device for preventing freezing of a car battery is prepared for operation by placing the thermal insulation cover 1 on the standard platform of the car. The battery is installed in the internal space of the thermal insulation cover 1, formed by the bottom of the cover 5, the front wall 6, the rear wall 7, the left and right side walls 8 and 9, wherein the multilayer structure of the walls 6, 7, 8, 9 and the bottom of the front 5 consists of an outer wear-resistant layer of the cover 2, an intermediate heat-insulating layer 3 and an internal heat-reflective layer 4. During installation, a tight fit of the left and right flexible heating plates 34 and 35, located on the inner surface of the walls, to the battery case is ensured. The battery terminals are brought out through technological cutouts for the terminals of the battery 12, at the exit points of which technological cutouts for the terminals of the battery 12 are made in the hinged cover 10, edged with seam tape 14.The hinged lid 10 is moved to the closed position and secured with the lid's textile fastener 11, providing thermal insulation for the interior. The thermal insulation cover 1 itself is securely fastened in the engine compartment using cover mounting straps 39. The control unit 15 is pre-positioned in the outer control unit pocket 13, which is secured to the outer surface of the thermal insulation cover 1.

[0027] To use the device as intended, connect the system electrically to the on-board network. The positive ring terminal 30 of the positive power cable 26 and the negative ring terminal 31 of the negative power cable 27 are connected to the corresponding battery terminals. When voltage is applied, the green power LED 20 on the control unit housing 16, which has a control unit housing cover 17, lights up. Microcontroller 19, installed on the control printed circuit board 18, reads the data from temperature sensor 24, located inside the heat-insulating cover 1, while the soldering point of the wires to temperature sensor 24 is protected by heat-shrinkable tube 25 of the sensor. If the temperature is recorded below a predetermined threshold, microcontroller 19 sends a command to turn on the heating. Current flows through the heater wire harness 32 to the resistive heater filaments 36 in the left and right flexible heating plates 34 and 35.At the same time, the red LED heating indicator 21 lights up on the housing. During operation, the protective braid of the harness 33 prevents mechanical damage to the wires, and the sealed cable entry 22 prevents moisture from entering the housing of the control unit 16.

[0028] The technical achievement is demonstrated using the device's operation under unstable on-board electrical conditions and in an aggressive external environment. When current overloads in the heating circuit occur, reaching values ​​20-30% higher than the rated operating current, fuse 29, installed in fuse holder 28, maintains circuit integrity, preventing false tripping, but reliably breaks the circuit in the event of a short circuit, thereby increasing system reliability. Simultaneously, when operating in conditions of high humidity and exposure to road chemicals, the reliability of the electronic component is ensured by the use of printed circuit board 18 with a protective coating (compound or varnish) and sealing of the communication input via sealed cable entry 22, through which the connection cable for temperature sensor 23 passes.The combination of these features allows the device to continuously perform its heating function, maintaining the functionality of the control elements and power supply circuit under external influences, which confirms the claimed increase in reliability.

[0029] Terms and Definitions

[0030] Thermal insulation cover 1 is a device in the form of a rectangular box formed by a bottom and walls connected to each other, made with a multilayer structure.

[0031] Outer wear-resistant layer of cover 2 - the outer element of the multilayer structure of the bottom and walls of the cover.

[0032] Intermediate heat-insulating layer 3 - an element of the multilayer structure of the bottom and walls, located sequentially between the outer wear-resistant and inner heat-reflecting layers.

[0033] Inner heat-reflecting layer 4 - an internal element of the multilayer structure of the bottom and walls of the cover.

[0034] Textile lid fastener 11 - a fixing element designed to hold the hinged lid in the closed position.

[0035] Technological cutouts for battery terminals 12 - holes made in the areas where the hinged cover meets the walls of the case.

[0036] Edging tape for seams 14 - material used to connect and process the edges of the walls and lid.

[0037] Sealed cable entry 22 is an element of the control unit housing equipment through which electrical communications are routed.

[0038] Temperature sensor 24 - a measuring element located at the end of the connection cable, protected by heat-shrinkable tube and placed in the interior of the case.

[0039] Positive and negative ring terminal lugs 30 and 31 are contact elements that terminate the positive and negative power cables, respectively.

[0040] Left and right flexible heating plates 34, 35 - heating elements located on the inner surface of the side walls or inside their structure, containing a resistive thread and provided with an adhesive fixing layer.

[0041] Resistive heating filament 36 - the functional element of the heating plate, enclosed in silicone insulation.

[0042] Silicon insulation of heater 37 - a protective shell in which the resistive thread of the heater is enclosed.

[0043] Cover mounting straps 39 - fastening elements fixed to the outside of the cover.

[0044] Disclosure of technical result

[0045] Increased reliability of the heating circuit under environmental influences is achieved by placing control unit 15 in an external pocket for control unit 13, secured to the outer surface of thermal insulation cover 1. This creates a physical barrier protecting control unit 16 from direct exposure to dirt, snow, and chemicals from the engine compartment. Equipping control unit 16 with a sealed cable entry 22 ensures the sealed entry point for communications, preventing moisture penetration and oxidation of control printed circuit board 18, thereby maintaining the unit's operability in a humid environment. Enclosing heater wiring harness 32 in protective braided harness 33 prevents mechanical damage and abrasive wear of the wire insulation during vehicle vibration loads, thereby eliminating short circuits in the circuit.Equipping the positive power cable 26 with a fuse holder 28 with a fuse ensures the circuit is interrupted in the event of an emergency current, preventing thermal damage to the wiring. Green and red LED indicators 20, 21 located on the housing surface allow visual monitoring of the power circuit integrity and heating process, ensuring prompt fault detection.

[0046] Examples of achieving technical results.

[0047] An example of implementation according to paragraph 1. The device is mounted in the engine compartment. Control unit 15 is placed in an external control unit pocket 13 made of dense fabric, which prevents oil mist from settling on the control unit housing 16. Heater wiring harness 32 is routed near metal body parts, but thanks to the nylon protective braid of harness 33, the wire insulation remains intact after 1,000 km of driving under vibration conditions. Sealed cable entry 22 with a PG7 gland tightly compresses the cables, preventing water from entering the housing during engine washing. A fuse is installed in fuse holder 28, which opens the circuit in the event of a critical failure.

[0048] Example implementation according to paragraph 2. The thermal insulation cover is designed as a rectangular box. The walls are 10 mm thick and consist of an outer wear-resistant cover layer 2 made of 600D Oxford fabric, an intermediate heat-insulating layer 3 made of foamed polyethylene, and an inner heat-reflective layer 4 made of metallized lavsan film. This structure retains the battery's heat at an external temperature of -30°C.

[0049] Example of implementation according to paragraph 3. Folding cover 10 fits tightly to the walls of thermal insulation cover 1 using a 20 mm wide textile fastener 11 (Velcro). U-shaped cutouts are provided in the cover for the battery terminals 12, edged with seam edging tape 14, which prevents the terminals from shorting to the cover material and ensures ease of installation without dismantling the vehicle's wiring.

[0050] Example of implementation according to paragraph 4. The left and right flexible heating plates 34, 35 are fixed to the inner walls of the cover using an acrylic adhesive layer for fixing the heater 38. The heating element is made of a carbon resistive heater thread 36, completely filled into the silicone insulation of the heater 37. The silicone maintains elasticity in frost and protects the thread from condensation formed when heating a cold battery.

[0051] Example implementation according to paragraph 5. Digital temperature sensor 24 DS18B20 is located between the battery wall and the case. The soldered wire connection to the sensor is protected by adhesive heat-shrinkable tubing 25, ensuring IP67 sealing. The sensor connection cable 23 passes through a common sealed cable entry 22, allowing microcontroller 19 to correctly shut off the heating when the target temperature is reached.

[0052] An example of implementation according to paragraph 6. The operating current of the heating system is 4.0 A. Fuse 29 is used. Lower limit (20%): the fuse rating is selected as 4.8 A. When the current jumps to 4.5 A (12.5% ​​higher than the nominal value) due to a change in the resistance of the cold filament, the circuit is not broken, and there is no false triggering. Upper limit (30%): the fuse rating is 5.2 A. In the event of a partial short circuit causing a current of 6.0 A, the fuse blows, protecting the wiring from melting. A negative example of going beyond the lower limit: installing a 4.2 A fuse (<5% of the reserve) leads to it blowing during a normal start-up of the system in severe frost. A negative example of exceeding the upper limit: installing a 7.0 A fuse (>70% reserve) leads to the fact that at an overload current of 6.5 A, the printed tracks on the control printed circuit board 18 overheat and are destroyed before the protection is triggered.

[0053] Example implementation according to paragraph 7. Control printed circuit board 18 is coated with three layers of polyurethane varnish (alternative 1) or filled with epoxy compound (alternative 2). When a dew point forms inside the housing of control unit 16 due to temperature differences, moisture settles on the surface of the coating without touching the current-carrying parts, which prevents electrochemical corrosion and short circuits between the tracks of microcontroller 19.

Claims

1. A battery heating device comprising a heat-insulating cover adapted to accommodate a battery and flexible heating plates located relative to the walls of the heat-insulating cover, characterized in that an outer pocket for a control unit is secured to the outer wear-resistant layer of the cover, in which a control unit is installed, including a control unit housing with a printed control board located inside, electrically connected to power and heating LED indicators displayed on the outer wear-resistant layer of the cover, wherein the control unit housing is equipped with a sealed cable entry, through which a harness of heater wires, enclosed in a protective braid of the harness, and a power cable equipped with a fuse holder with a fusible fuse are led out.

2. The device according to paragraph 1, characterized in that the heat-insulating cover is made in the form of a box of rectangular cross-section with a multi-layer wall structure, including a successively arranged outer wear-resistant layer of the cover, an intermediate heat-insulating layer, and an inner heat-reflecting layer.

3. The device according to paragraph 1, characterized in that the heat-insulating cover is provided with a hinged lid with a textile lid fastener and technological cutouts for the battery terminals in the areas of mating with the walls of the cover.

4. The device according to paragraph 1, characterized in that each flexible heating plate contains a resistive heating thread enclosed in silicone insulation of the heater, and is provided with an adhesive layer for fixing the heater to the surface of the walls of the cover.

5. The device according to paragraph 1, characterized in that a cable for connecting a temperature sensor is additionally brought out through a sealed cable entry, and the temperature sensor connection sensor itself is protected by a heat-shrinkable sensor tube and is placed in the internal space of a heat-insulating cover.

6. The device according to paragraph 1, characterized in that the fuse is made with a rating that exceeds the operating current of the device by 20-30%.

7. The device according to paragraph 1, characterized in that the printed circuit board of the control is made with a protective coating applied to it in the form of a compound or varnish.

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