Coolant heater for vehicles

Abstract

This invention relates to a coolant heater for a vehicle, comprising: a housing unit having an inlet for coolant inflow and an outlet for coolant discharge; a flow guiding assembly disposed within the interior space of the housing unit, having a first flow path for coolant flow in a first direction and a second flow path for coolant to flow through the first flow path in a second direction different from the first direction; a first heater section disposed in the first flow path; and a second heater section disposed in the second flow path. This coolant heater can achieve the beneficial effects of improved rapid heating performance and heating efficiency.

Description

[0001] Cross-references to related applications

[0002] This application claims priority and benefit to Korean Patent Application No. 10-2019-0110980, filed with the Korean Intellectual Property Office on September 6, 2019, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to a coolant heater for a vehicle, and more specifically, to a coolant heater for a vehicle capable of improving the fast-acting heating performance and heating efficiency of the vehicle. Background Technology

[0004] Currently, the most common type of vehicle is one powered by an engine that uses gasoline, diesel, or other similar fuels. However, due to various reasons such as environmental pollution caused by these energy sources and the depletion of oil reserves, the demand for new energy sources is growing.

[0005] Currently, one of the technologies closest to practical application is related to vehicles powered by fuel cells.

[0006] However, unlike vehicles that use engines, vehicles using fuel cells cannot use heating systems that utilize coolant. In other words, in the case of vehicles powered by petroleum-based engines, a significant amount of heat is generated within the engine. A coolant circulation system is provided to cool the engine, and the heat absorbed by the coolant from the engine is used for heating the vehicle's interior.

[0007] However, because vehicles using fuel cells generate less heat than those using engines, there is a problem that heating methods used in engine-powered vehicles cannot be applied to fuel cell vehicles.

[0008] Therefore, in the prior art, there is research into technologies for heating fuel cell vehicles by adding a heat pump to the air conditioning system to use the heat pump as a heat source or by setting up a separate heat source such as an electric heater.

[0009] Electric heaters are widely used because they have the advantage of easily heating the coolant without significantly affecting the air conditioning system.

[0010] Based on the heating method, electric heaters can be divided into air heaters for vehicles that directly heat the air blown into the vehicle's interior and coolant heaters that heat the coolant.

[0011] However, in the case of coolant heaters in the prior art, the box heater with heating element is installed inside the housing, and the coolant flowing into the housing is heated by the box heater. Therefore, it is difficult to form a sufficient flow path for heating the coolant flowing into the housing (i.e., the path for the coolant to be heated by the box heater), and it is difficult to improve the rapid heating performance (the time taken to reach the maximum temperature) and heating efficiency to a certain level.

[0012] Furthermore, in the prior art, since the cassette heater needs to be simply turned on / off in order to heat the coolant to the target temperature, it is difficult to accurately control the output of the cassette heater according to the heating load.

[0013] Therefore, various studies have been conducted recently to improve the rapid heating performance and efficiency of coolant heaters, but research remains insufficient. Thus, there is a need to develop a coolant heater with improved rapid heating performance and efficiency. Summary of the Invention

[0014] This disclosure aims to provide a coolant heater for vehicles with improved rapid heating performance and heating efficiency.

[0015] In particular, this disclosure also aims to fully ensure the coolant flow path, improve coolant heating efficiency, and reduce the time spent heating the coolant.

[0016] This disclosure also aims to precisely control the output of the coolant heater according to the heating load.

[0017] This disclosure also aims to prevent the coolant heater from being overheated and to improve stability and reliability.

[0018] To achieve the above objectives, embodiments of this disclosure provide a coolant heater for a vehicle. The coolant heater includes: a housing unit having an inlet for coolant inflow and an outlet for coolant discharge; a baffle assembly disposed within the interior space of the housing unit, having a first flow path for coolant flow in a first direction and a second flow path for coolant to flow through the first flow path in a second direction different from the first direction; a first heater section disposed in the first flow path; and a second heater section disposed in the second flow path.

[0019] This configuration is provided to improve the rapid heating performance and heating efficiency of vehicles (e.g., fuel cell vehicles).

[0020] In other words, in the prior art, the box heater with heating element is installed inside the shell, and the coolant flowing into the shell is heated by the box heater. Therefore, it is difficult to form a sufficient flow path for heating the coolant flowing into the shell (i.e., the path for the coolant to be heated by the box heater), and it is difficult to improve the rapid heating performance (the time taken to reach the maximum temperature) and heating efficiency to a certain level.

[0021] However, according to this disclosure, a first flow path and a second flow path are formed inside the housing unit, facing opposite directions, and the coolant is heated sequentially through the first and second flow paths, thereby ensuring a sufficient flow path for the heating coolant. Therefore, beneficial effects such as improved rapid heating performance and heating efficiency can be achieved.

[0022] Furthermore, according to this disclosure, since the coolant is initially heated by the first sheath heater and the second sheath heater while flowing spirally around the flow guide assembly through the first flow path and the second flow path, and then heated a second time by the third sheath heater, the beneficial effects of improving the heat transfer efficiency to the coolant and reducing the heating time can be obtained.

[0023] The housing unit can have various structures and shapes depending on the required conditions and design specifications, and this disclosure is not limited or restricted by the structure and shape of the housing unit.

[0024] As an example, the housing unit may include: a first housing, in which the flow guiding assembly is housed; a first cover, coupled to one end of the first housing; a second housing, configured to surround the first housing; a second cover, coupled to one end of the second housing to cover the first cover; a header plate, coupled to the other end of the first housing and the other end of the second housing; and a controller cover, coupled to the header plate.

[0025] The flow guiding assembly can divide the internal space of the first housing into a first space communicating with the inlet and a second space communicating with the outlet. The flow guiding assembly can further divide the first space into a first flow path disposed in a first direction and a second flow path disposed in a second direction different from the first direction.

[0026] As described above, the coolant flowing into the first housing through the inlet flows sequentially through the first and second flow paths in the first space, thereby ensuring a sufficient coolant flow path. Therefore, the beneficial effects of improving coolant heating efficiency and reducing the time spent heating the coolant can be achieved.

[0027] The flow guiding component may have various structures capable of dividing the internal space of the first housing into a first space and a second space, and further dividing the first space into a first flow path and a second flow path.

[0028] As an example, the flow guiding component may include: a baffle plate that divides the internal space of the housing unit into a first space communicating with the inlet and a second space communicating with the outlet; and a baffle shell that is connected to the baffle plate and divides the first space into a first flow path and a second flow path.

[0029] More specifically, the guide plate shell can be formed with a hollow cross-sectional shape and disposed in the length direction of the shell unit. One end of the guide plate shell can penetrate the guide plate, and the other end of the guide plate shell can be formed with an inflow hole. A first flow path can be formed between the guide plate shell and the shell unit, and a second flow path can be formed along the interior of the guide plate shell.

[0030] Preferably, the guide plate shell can be disposed within the internal space of the first shell and coaxially disposed with the first shell. The first flow path can be formed around the guide plate shell.

[0031] As described above, since the guide plate shell is disposed inside the first housing and coaxially disposed with the first housing, the first flow path formed around the guide plate shell can have a uniform cross-sectional area. Therefore, the beneficial effects of minimizing the heating deviation between coolants passing through the first flow path and improving heating performance can be obtained.

[0032] More preferably, the inlet can be formed adjacent to one end of the guide plate shell. The coolant flowing into the inlet can flow along the first flow path and then flow into the second flow path through the inlet hole formed at the other end of the guide plate shell.

[0033] As described above, a sufficient arrangement interval or distance is provided between the inlet and the inlet hole, allowing the coolant flowing into the inlet to flow sufficiently along the first flow path, and then through the inlet hole into the second flow path. Therefore, the beneficial effect of further improving the heat transfer efficiency to the coolant can be achieved.

[0034] Various heating devices capable of heating the coolant can be used as the first heater section.

[0035] As an example, the first heater section may include a first sheath heater formed in the shape of a coil and disposed in the first flow path. The first heater section may also include a second sheath heater formed in the shape of a coil and disposed in the first flow path.

[0036] Preferably, the first sheath heater and the second sheath heater can be coaxially arranged in the length direction of the first flow path (in the length direction of the first housing). The coolant can pass through the first sheath heater and the second sheath heater in sequence.

[0037] As described above, since multiple sheathed heaters constitute the first heating section, only some or all of the multiple sheathed heaters can be operated according to the required conditions (e.g., heating load). Therefore, the beneficial effect of accurately and quickly controlling the output of the coolant heaters according to the heating load can be obtained.

[0038] In addition, the coolant heater may include a first support portion that supports a first sheath heater and a second sheath heater.

[0039] As an example, the first support portion can be formed from the outer surface of the guide plate shell and can be in close contact with the inner surface of the first sheath heater and the inner surface of the second sheath heater.

[0040] As described above, since the inner surfaces of the first sheath heater and the second sheath heater are supported by the first support portion, the beneficial effect of further stabilizing the installation state of the first sheath heater and the second sheath heater can be obtained.

[0041] Various heating devices capable of heating the coolant can be used as a second heater section.

[0042] As an example, the second heater section may include a third sheath heater formed in the shape of a coil and disposed in the second flow path.

[0043] Additionally, the flow guiding assembly may include a second support portion that supports a third sheath heater.

[0044] As an example, the second support can be formed from the inner surface of the guide plate shell and can be in close contact with the outer surface of the third sheath heater.

[0045] As described above, since the outer surface of the third sheath heater is supported by the second support, the beneficial effect of further stabilizing the installation state of the third sheath heater can be obtained.

[0046] According to embodiments of this disclosure, a coolant heater for a vehicle may include a controller that individually controls a first sheath heater, a second sheath heater, and a third sheath heater.

[0047] As an example, the controller can be integrally attached to one end of the housing unit.

[0048] Preferably, the controller is configured to individually control the first sheath heater, the second sheath heater, and the third sheath heater via pulse width modulation (PWM) control.

[0049] As described above, since the first sheath heater, the second sheath heater, and the third sheath heater are individually controlled by PWM control, the beneficial effect of precisely controlling the output of the first sheath heater, the second sheath heater, and the third sheath heater can be obtained.

[0050] In other words, in the prior art, since the cassette heater needs to be simply turned on / off using a relay in order to heat the coolant to the target temperature, it is difficult to accurately control the output of the cassette heater according to the heating load.

[0051] However, according to this disclosure, since the first sheath heater, the second sheath heater, and the third sheath heater are individually controlled by PWM control, it is possible to precisely control the output of the first sheath heater, the second sheath heater, and the third sheath heater according to the heating load, thereby minimizing the power consumption of the first sheath heater, the second sheath heater, and the third sheath heater and increasing the driving range of the fuel cell vehicle.

[0052] Furthermore, according to this disclosure, each of the first, second, and third sheathed heaters constitutes an independent circuit. For example, even if any one of the first, second, and third sheathed heaters fails (e.g., short circuits), the remaining two sheathed heaters can still operate. Therefore, the beneficial effect of minimizing heating performance problems caused by failure can be achieved.

[0053] According to embodiments of this disclosure, when the first sheath heater, the second sheath heater, and the third sheath heater overheat, the operation of the first sheath heater, the second sheath heater, and the third sheath heater can be stopped.

[0054] As an example, a coolant heater for a vehicle may include a coolant temperature sensor that measures the outlet temperature of the coolant discharged from the outlet. When the coolant outlet temperature is higher than a predetermined temperature, the controller stops the operation of the first sheath heater, the second sheath heater, and the third sheath heater.

[0055] As another example, a coolant heater for a vehicle may include a surface temperature sensor that measures the temperature of the outer surface of the housing unit. When the coolant is heated and the temperature of the outer surface of the housing unit exceeds a predetermined temperature, the controller stops the operation of the first, second, and third housing heaters.

[0056] In addition, when the temperature of the outer surface of the housing unit is higher than the outlet temperature of the coolant, the controller determines that overheating has occurred, and therefore the controller stops the operation of the first sheath heater, the second sheath heater and the third sheath heater.

[0057] As another example, a coolant heater for a vehicle may include a water pump that supplies coolant to the inlet. When an abnormal signal related to the water pump is detected, the controller stops the operation of the first sheath heater, the second sheath heater, and the third sheath heater.

[0058] Optionally, a thermal fuse can be connected to the housing unit. When the coolant is heated and the temperature of the outer surface of the housing unit is higher than the short-circuit temperature of the thermal fuse, the thermal fuse can physically cut off the power supply to the first sheath heater, the second sheath heater, and the third sheath heater.

[0059] According to embodiments of this disclosure, a heat insulation layer may be formed between the outer surface of the first housing and the inner surface of the second housing.

[0060] Preferably, the insulation layer can be formed as an air layer or a vacuum layer.

[0061] As described above, since a heat insulation layer is formed between the outer surface of the first housing and the inner surface of the second housing, heat loss to the outside of the second housing can be minimized. Therefore, the beneficial effects of improving coolant heating efficiency and reducing the time spent heating the coolant can be achieved.

[0062] According to embodiments of this disclosure, the first sheath heater, the second sheath heater, and the third sheath heater can be fixed to the flow guide assembly and the first housing by welding or brazing.

[0063] According to embodiments of this disclosure, the first sheath heater, the second sheath heater, and the third sheath heater can be fixed to the head plate by welding or brazing.

[0064] According to embodiments of this disclosure, a sealing member may be inserted between the head plate and the other end of the first housing and the other end of the second housing. Attached Figure Description

[0065] Figure 1 This is a perspective view illustrating a coolant heater for a vehicle according to the present disclosure.

[0066] Figure 2 This is an exploded perspective view illustrating a coolant heater for a vehicle according to this disclosure.

[0067] Figure 3 This is a cross-sectional view used to illustrate a coolant heater for a vehicle according to this disclosure.

[0068] Figure 4 This is a view used to illustrate the flow path of coolant in a coolant heater for a vehicle according to this disclosure.

[0069] Figure 5 This is a diagram illustrating a coolant temperature sensor and a surface temperature sensor for a coolant heater for a vehicle according to this disclosure.

[0070] Figure 6 This is a diagram illustrating a water pump for a coolant heater for a vehicle according to this disclosure.

[0071] Figure 7 and Figure 8 This is a graph used to illustrate the efficiency of a coolant heater for a vehicle according to the present disclosure, based on the inlet temperature of the coolant.

[0072] Figure 9 This is a view used to illustrate the heat insulation layer of a coolant heater for a vehicle according to this disclosure.

[0073] Figure 10 It is a graph used to illustrate the temperature of the outer wall of the housing unit of the coolant heater for a vehicle according to this disclosure, depending on whether it has a heat insulation layer.

[0074] Figure 11 This is a view used to illustrate a coolant heater for a vehicle according to another embodiment of the present disclosure.

[0075] Explanation of reference numerals in the attached figures

[0076] 10: Coolant heater for vehicles; 100: Housing unit.

[0077] 102: First Space 102a: First Flow Path

[0078] 102b: Second Flow Path 104: Second Space

[0079] 110: First shell 120: First cover

[0080] 130: Second shell 132: Inlet section

[0081] 134: Export Department 140: Second Cover

[0082] 150: Headplate 160: Controller Cover

[0083] 170: Thermal insulation layer; 200: Airflow guiding component

[0084] 210: Deflector plate 220: Deflector plate housing

[0085] 222: Inlet hole; 230: First support section

[0086] 240: Second support section; 300: First heater section

[0087] 310: First sheath heater; 320: Second sheath heater

[0088] 400: Second heater section; 410: Third sheath heater section

[0089] 500: Controller; 610: Coolant temperature sensor

[0090] 620: Surface temperature sensor; 630: Water pump

[0091] 640: Thermal fuse Detailed Implementation

[0092] In the following, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings; however, the present disclosure is not limited to or restricted by the embodiments. For reference, in this specification, the same reference numerals denote substantially the same elements. Description may be carried out under this rule by taking into account the content shown in other accompanying drawings, and repetitions or content that is understood by one of ordinary skill in the art may be omitted.

[0093] When an element or component in the written specification and / or claims is identified and described as having a purpose or performing or implementing the said function, step, instruction set, etc., that element or component may also be considered as "configured" to have a purpose or perform or implement the said function, step, instruction set, etc.

[0094] Figure 1 This is a perspective view illustrating a coolant heater for a vehicle according to the present disclosure. Figure 2 This is an exploded perspective view illustrating a coolant heater for a vehicle according to this disclosure. Figure 3 This is a cross-sectional view used to illustrate the coolant heater for a vehicle according to this disclosure. Additionally, Figure 4 This is a view used to illustrate the flow path of coolant in a coolant heater for a vehicle according to this disclosure. Figure 5 This is a diagram illustrating the coolant temperature sensor and surface temperature sensor for a vehicle coolant heater according to this disclosure. Figure 6 This is a diagram illustrating a water pump for a vehicle's coolant heater according to this disclosure. Furthermore, Figure 7 and Figure 8 This is a graph used to illustrate the efficiency of a coolant heater for a vehicle according to the present disclosure, based on the inlet temperature of the coolant. Figure 9 This is a view illustrating the heat insulation layer of a coolant heater for a vehicle according to this disclosure. Figure 10 It is a graph used to illustrate the temperature of the outer wall of the housing unit of the coolant heater for a vehicle according to this disclosure, depending on whether it has a heat insulation layer.

[0095] Reference Figures 1 to 9According to the present disclosure, a coolant heater 10 for a vehicle includes: a housing unit 100 having an inlet 132 for coolant inflow and an outlet 134 for coolant discharge; a flow guide assembly 200 disposed in the interior space of the housing unit 100 and having a first flow path 102a for coolant flow in a first direction and a second flow path 102b for coolant flow through the first flow path 102a in a second direction different from the first direction; a first heater section 300 disposed in the first flow path 102a; and a second heater section 400 disposed in the second flow path 102b.

[0096] For reference, the coolant heater 10 for a vehicle according to this disclosure is used to heat the coolant in a fuel cell vehicle and to use the heated coolant for heating. As an example, the coolant heater 10 for a vehicle is configured to heat the air conditioning unit (HVAC) flowing into the fuel cell vehicle. Figure 6 The coolant in the heater core (not shown) of 20).

[0097] The housing unit 100 has a predetermined accommodating space (internal space) formed inside. The inlet 132 for coolant inflow is provided on one side of the housing unit 100. The outlet 134 for coolant discharge is provided on the other side of the housing unit 100.

[0098] The housing unit 100 may have various structures and shapes depending on the required conditions and design specifications, and this disclosure is not limited or restricted by the structure and shape of the housing unit 100.

[0099] As an example, housing unit 100 includes: a first housing 110, in which the flow guide assembly 200 is housed; a first cover 120, attached to one end of the first housing 110; a second housing 130, configured to surround the first housing 110; a second cover 140, attached to one end of the second housing 130 to cover the first cover 120; a header plate 150, attached to the other end of the first housing 110 and the other end of the second housing 130; and a controller cover 160, attached to the header plate 150 to protect the controller 500.

[0100] The first housing 110 is formed as a hollow cylinder with openings at both ends. An inlet hole (not shown) communicating with the inlet portion 132 is formed on one side of the first housing 110. An outlet hole (not shown) communicating with the outlet portion 134 is formed on the other side of the first housing 110.

[0101] The flow guiding assembly 200 is disposed inside the first housing 110. The flow guiding assembly 200 can divide the internal space of the first housing 110 into a first space 102 communicating with the inlet 132 and a second space 104 communicating with the outlet 134. The first space 102 is further divided into a first flow path 102a and a second flow path 102b.

[0102] The first cover 120 is formed in a generally circular plate shape and is attached to the first housing 110 to block one end of the first housing 110 (based on...). Figure 2 The opening at the left end.

[0103] Preferably, because coolant flows into and out of the first housing 110, the first housing 110 and the first cover 120 are connected to each other to form a sealed structure that can prevent coolant leakage.

[0104] As an example, the first housing 110 and the first cover 120 are fixed by welding or brazing.

[0105] The diameter of the second housing 130 is larger than the diameter of the first housing 110. The second housing 130 is formed as a hollow cylinder with openings at both ends. The second housing 130 is positioned to surround the first housing 110. An inlet (e.g., an inlet pipe) 132 for coolant inflow is provided on one side of the second housing 130. An outlet (e.g., an outlet pipe) 134 for coolant discharge is provided on the other side of the second housing 130.

[0106] The second cover 140 is formed in a generally circular plate shape and is attached to the second housing 130 to block one end formed in the second housing 130 (based on...). Figure 2 The opening at the left end.

[0107] The head plate 150 is formed in a generally circular plate shape and is connected to the first housing 110 and the second housing 130 to block the opening formed at the other end of the first housing 110 and the opening formed at the other end of the second housing 130.

[0108] Preferably, because coolant flows into and out of the first housing 110, the first housing 110 and the head plate 150 are connected to each other to form a sealed structure that prevents coolant leakage.

[0109] As an example, the first housing 110 and the headplate 150 are fixed by welding or brazing.

[0110] In addition, the controller cover 160 is connected to the headplate 150 to cover the controller 500, thereby protecting the controller 500.

[0111] The flow guiding assembly 200 is configured to divide the internal space of the first housing 110 into a first space 102 communicating with the inlet 132 and a second space 104 communicating with the outlet 134. The flow guiding assembly 200 further divides the first space 102 into a first flow path 102a disposed in a first direction and a second flow path 102b disposed in a second direction different from the first direction.

[0112] As described above, the coolant flowing into the first housing 110 through the inlet 132 flows sequentially through the first flow path 102a and the second flow path 102b in the first space 102, thereby ensuring a sufficient flow path for the coolant. Therefore, the beneficial effects of improving coolant heating efficiency and reducing the time spent heating the coolant can be achieved.

[0113] The flow guiding assembly 200 may have various structures that can divide the internal space of the first housing 110 into a first space 102 and a second space 104, and further divide the first space 102 into a first flow path 102a and a second flow path 102b.

[0114] As an example, the flow guiding assembly 200 includes: a flow guiding plate 210 that divides the internal space of the housing unit 100 into a first space 102 communicating with the inlet 132 and a second space 104 communicating with the outlet 134; and a flow guiding plate shell 220 that is connected to the flow guiding plate 210 and divides the first space 102 into a first flow path 102a and a second flow path 102b.

[0115] The guide plate 210 is formed into a circular plate shape with a diameter corresponding to the inner diameter of the first housing 110. The guide plate 210 is vertically installed in the internal space of the first housing 110 and is disposed between the inlet 132 and the outlet 134.

[0116] The deflector 210 can divide the internal space of the first housing 110 into a first space 102 that communicates with the inlet 132 (based on...). Figure 3 The space to the right of the deflector) and the second space 104 connected to the outlet 134 (based on Figure 3 (In the space to the left of the deflector).

[0117] Preferably, in order to ensure as much as possible the first space 102 for heating and cooling the first housing 110, the inlet 132 and the outlet 134 can be adjacent to one end of the first housing 110 (based on...). Figure 3 (Formed at the left end).

[0118] The guide plate housing 220 is connected to the guide plate 210 and may have various structures that can divide the first space 102 into a first flow path 102a and a second flow path 102b.

[0119] As an example, the guide plate shell 220 is formed with a hollow cross-sectional shape (e.g., a hollow cylindrical shape) and is disposed along the length of the housing unit 100. One end of the guide plate shell 220 can penetrate the guide plate 210. The other end of the guide plate shell 220 can have an inlet hole 222 formed therein. A first flow path 102a can be formed between the guide plate shell 220 and the housing unit 100. A second flow path 102b can be formed along the interior of the guide plate shell 220.

[0120] Preferably, the guide plate shell 220 is disposed in the internal space of the first shell 110 and is coaxially disposed with the first shell 110. The first flow path 102a is formed around the guide plate shell 220.

[0121] As described above, since the guide plate shell 220 is disposed inside the first housing 110 and coaxially disposed with the first housing 110, the first flow path 102a formed around the guide plate shell 220 can have a uniform cross-sectional area. Therefore, the beneficial effects of minimizing the heating deviation among the coolants passing through the first flow path 102a and improving heating performance can be obtained.

[0122] More preferably, the inlet portion 132 is formed adjacent to one end (e.g., the left end) of the guide plate housing 220. The coolant flowing into the inlet portion 132 flows along the first flow path 102a and then flows into the second flow path 102b through the inlet hole 222 formed at the other end (e.g., the right end) of the guide plate housing 220.

[0123] As described above, a sufficient arrangement interval or distance is provided between the inlet 132 and the inlet hole 222, allowing the coolant flowing into the inlet 132 to flow sufficiently along the first flow path 102a, and then through the inlet hole 222 into the second flow path 102b. Therefore, the beneficial effect of further improving the heat transfer efficiency to the coolant can be obtained.

[0124] Furthermore, the guide plate shell 220 is formed to have a uniform cross-sectional area throughout its length. As described above, since the guide plate shell 220 has a uniform cross-sectional area throughout, the second flow path 102b formed along the interior of the guide plate shell 220 can also have a uniform cross-sectional area. Therefore, beneficial effects such as minimizing heating deviations among coolants passing through the second flow path 102b, minimizing local flow rate reductions, and improving heating performance can be obtained.

[0125] The first heater section 300 is disposed in the first flow path 102a and heats the coolant flowing along the first flow path 102a.

[0126] Various heating devices capable of heating the coolant can be used as the first heater section 300, and this disclosure is not limited or restricted by the type and structure of the first heater section 300.

[0127] Preferably, the first heater section 300 can be constructed by using a sheath heater.

[0128] For reference, in this disclosure, the term "sheathed heater" refers to a tubular heater configured such that a heating wire is embedded in a coil shape inside a metal protective tube. To insulate the heating wire from the protective tube, the protective tube is filled with insulating powder made of magnesium oxide. The advantages of sheathed heaters are that they can resist external physical impacts, improve the efficiency of electrical and thermal energy, and can be freely shaped into various forms according to desired conditions.

[0129] As an example, the first heater section 300 includes a first sheath heater 310 formed in the shape of a coil and disposed in the first flow path 102a. The first heater section 300 also includes a second sheath heater 320 formed in the shape of a coil and disposed in the first flow path 102a.

[0130] More specifically, the first sheath heater 310 is formed in the shape of a coil surrounding the guide plate housing 220 and is disposed between the guide plate housing 220 and the first housing 110.

[0131] The second sheath heater 320 is formed in the shape of a coil surrounding the guide plate shell 220 and is disposed between the guide plate shell 220 and the first shell 110.

[0132] Preferably, the first sheath heater 310 and the second sheath heater 320 are coaxially arranged in the longitudinal direction of the first flow path 102a (the longitudinal direction of the first housing 110). Coolant can pass through the first sheath heater 310 and the second sheath heater 320 in sequence.

[0133] As described above, since the first heater section 300 consists of multiple sheathed heaters, only some or all of the multiple sheathed heaters can be operated according to the required conditions (e.g., heating load). Therefore, the beneficial effect of accurately and quickly controlling the output of the coolant heaters according to the heating load can be obtained.

[0134] More preferably, the first sheath heater 310 and the second sheath heater 320 are fixed to the first housing 110 by welding or brazing. As described above, since the first sheath heater 310 and the second sheath heater 320 are fixed to the first housing 110 by welding or brazing, it is beneficial to stably maintain the installation state of the first sheath heater 310 and the second sheath heater 320.

[0135] Additionally, the flow guiding assembly 200 may include a first support portion 230, which supports the first sheath heater 310 and the second sheath heater 320.

[0136] As an example, the first support portion 230 can be formed from the outer surface of the guide plate housing 220 and can be in close contact with the inner surface of the first sheath heater 310 and the inner surface of the second sheath heater 320.

[0137] As described above, since the inner surfaces of the first sheath heater 310 and the second sheath heater 320 are supported by the first support portion 230, the beneficial effect of further stabilizing the setting state of the first sheath heater 310 and the second sheath heater 320 can be obtained.

[0138] More preferably, the first sheath heater 310 and the second sheath heater 320 are fixed to the first support portion 230 by welding or brazing.

[0139] The second heater section 400 is disposed in the second flow path 102b and is configured to heat the coolant flowing along the second flow path 102b.

[0140] Various heating devices capable of heating the coolant can be used as the second heater section 400, and this disclosure is not limited or restricted by the type and structure of the second heater section 400.

[0141] As an example, the second heater section 400 includes a third sheath heater 410 formed in the shape of a coil and disposed in the second flow path 102b.

[0142] For reference, an example is described in the embodiments of this disclosure where only one third sheath heater 410 is provided in the second flow path 102b. However, according to another embodiment of this disclosure, multiple third sheath heaters may be provided in the second flow path, and this disclosure is not limited or restricted by the number of third sheath heaters or the arrangement intervals or distances between the third sheath heaters.

[0143] Additionally, the flow guiding assembly 200 may include a second support portion 240, which supports the third sheath heater 410.

[0144] As an example, the second support 240 can be formed from the inner surface of the guide plate housing 220 and can be in close contact with the outer surface of the third sheath heater 410.

[0145] As described above, since the outer surface of the third sheath heater 410 is supported by the second support portion 240, the beneficial effect of further stabilizing the installation state of the third sheath heater 410 can be obtained.

[0146] More preferably, the third sheath heater 410 is fixed to the second support 240 by welding or brazing.

[0147] With this structure, the coolant flowing into the inlet 132 is initially heated by the first sheath heater 310 and the second sheath heater 320 while flowing along the first flow path 102a (H1). The coolant is then reheated by the third sheath heater 410 while flowing along the second flow path 102b (H2). The coolant then flows through the second space 104 inside the first housing 110 and through the outlet 134 into the heater core of the air conditioning unit (HVAC) 20 of the fuel cell vehicle (see [link]). Figure 4 ).

[0148] As described above, according to this disclosure, since the coolant is initially heated by the first sheath heater 310 and the second sheath heater 320 while flowing spirally around the flow guide assembly 200 through the first flow path 102a and the second flow path 102b, and then heated a second time by the third sheath heater 310, the beneficial effects of improving the heat transfer efficiency to the coolant and reducing the heating time can be obtained.

[0149] In other words, such as Figure 7 and Figure 8 As shown, compared to existing technologies, the heat transfer efficiency to the coolant is improved because the coolant is heated while flowing in a zigzag pattern through the first flow path 102a and the second flow path 102b. Therefore, it is possible to achieve the beneficial effect of reducing the time spent heating the coolant and thus improving rapid heating performance and heating efficiency.

[0150] Additionally, the coolant heater 10 for a vehicle according to this disclosure includes a controller 500, which individually controls the first sheath heater 310, the second sheath heater 320, and the third sheath heater 410.

[0151] The controller 500 can be installed in various locations according to required conditions and design specifications. As an example, the controller 500 can be integrally connected to one end of the housing unit 100. More specifically, the controller 500 can be mounted on the headplate 150.

[0152] In embodiments of this disclosure, an example is described where the controller 500 is integrally coupled to one end of the housing unit 100. However, according to another embodiment of this disclosure, the controller 500 may be disposed separately from the housing unit 100.

[0153] More preferably, the controller 500 is configured to individually control the first sheath heater 310, the second sheath heater 320, and the third sheath heater 410 via pulse width modulation (PWM) control.

[0154] As described above, since the first sheath heater 310, the second sheath heater 320 and the third sheath heater 410 are individually controlled by PWM control, the beneficial effect of precisely controlling the output of the first sheath heater 310, the second sheath heater 320 and the third sheath heater 410 can be obtained.

[0155] In other words, in the prior art, since the cassette heater needs to be simply turned on / off using a relay in order to heat the coolant to the target temperature, it is difficult to accurately control the output of the cassette heater according to the heating load.

[0156] However, according to this disclosure, since the first sheath heater 310, the second sheath heater 320, and the third sheath heater 410 are individually controlled by PWM control, it is possible to obtain the beneficial effect of precisely controlling the output of the first sheath heater 310, the second sheath heater 320, and the third sheath heater 410 according to the heating load, minimizing the power consumption of the first sheath heater 310, the second sheath heater 320, and the third sheath heater 410, and increasing the driving range of the fuel cell vehicle.

[0157] Furthermore, according to this disclosure, each of the first sheath heater 310, the second sheath heater 320, and the third sheath heater 410 constitutes an independent circuit. For example, even if any one of the first sheath heater 310, the second sheath heater 320, and the third sheath heater 410 fails (e.g., short circuit), the remaining two sheath heaters can still operate. Therefore, the beneficial effect of minimizing heating performance problems caused by failure can be obtained.

[0158] Preferably, refer to Figure 5 and Figure 6 According to this disclosure, the coolant heater 10 for a vehicle is configured to stop the operation of the first sheath heater 310, the second sheath heater 320, and the third sheath heater 410 when they overheat.

[0159] The process of stopping the operation of the first sheath heater 310, the second sheath heater 320 and the third sheath heater 410 in case of overheating can be implemented in various ways according to the required conditions and design specifications.

[0160] As an example, the coolant heater 10 for a vehicle may include a coolant temperature sensor 610, which measures the outlet temperature of the coolant discharged from the outlet 134. When the coolant outlet temperature is higher than a predetermined temperature, the controller 500 stops the operation of the first sheath heater 310, the second sheath heater 320, and the third sheath heater 410.

[0161] As described above, since the operation of the first jacket heater 310, the second jacket heater 320, and the third jacket heater 410 is stopped when the outlet temperature of the coolant is higher than the predetermined temperature, the beneficial effects of preventing overheating due to insufficient coolant, minimizing damage to the first jacket heater 310, the second jacket heater 320, and the third jacket heater 410, and improving stability can be obtained.

[0162] As another example, the coolant heater 10 for a vehicle may include a surface temperature sensor 620 that measures the temperature of the outer surface of the housing unit 100. When the coolant is heated and the temperature of the outer surface of the housing unit 100 is higher than a predetermined temperature, the controller 500 stops the operation of the first sheath heater 310, the second sheath heater 320, and the third sheath heater 410.

[0163] As described above, since the operation of the first sheath heater 310, the second sheath heater 320, and the third sheath heater 410 is stopped when the temperature of the outer surface of the housing unit 100 is higher than a predetermined temperature, the beneficial effects of preventing overheating, minimizing damage to the first sheath heater 310, the second sheath heater 320, and the third sheath heater 410, and improving stability can be obtained.

[0164] In addition, when the temperature of the outer surface of the housing unit 100 is higher than the outlet temperature of the coolant, the controller 500 determines that overheating has occurred, and therefore the controller 500 stops the operation of the first sheath heater 310, the second sheath heater 320 and the third sheath heater 410.

[0165] As another example, the coolant heater 10 for a vehicle may include a water pump 630 that supplies coolant to the inlet 132. When an abnormal signal related to the water pump 630 is detected, the controller 500 stops the operation of the first sheath heater 310, the second sheath heater 320, and the third sheath heater 410.

[0166] In this case, the abnormal signal associated with the water pump 630 can represent a signal that deviates from the reference signal range that occurs when the water pump 630 is operating normally.

[0167] Optionally, the thermal fuse 640 can be connected to the housing unit 100. When the coolant is heated and the temperature of the outer surface of the housing unit 100 is higher than the short-circuit temperature of the thermal fuse, the thermal fuse 640 can physically cut off the power supply to the first sheath heater 310, the second sheath heater 320, and the third sheath heater 410.

[0168] Reference Figure 3 and Figure 9A heat insulation layer 170 may be formed between the outer surface of the first housing 110 and the inner surface of the second housing 130.

[0169] Various types of insulation layers 170 can be formed according to the required conditions and design specifications, and this disclosure is not limited or restricted by the type and structure of the insulation layer 170.

[0170] Preferably, the insulation layer 170 can be formed as an air layer or a vacuum layer. In some cases, instead of an air layer (vacuum layer), an insulation body made of insulation material can be provided between the outer surface of the first housing 110 and the inner surface of the second housing 130.

[0171] As an example, the first housing 110, the second housing 130, the first cover 120, the second cover 140, and the headplate 150 may cooperate with each other to form an insulation layer 170 (e.g., an air layer).

[0172] As described above, since a heat insulation layer 170 is formed between the outer surface of the first housing 110 and the inner surface of the second housing 130, heat loss to the outside of the second housing 130 can be minimized. Therefore, the beneficial effects of improving coolant heating efficiency and reducing the time spent heating the coolant can be obtained.

[0173] Reference Figure 10 It can be seen that if no heat insulation layer is provided between the outer surface of the first housing 110 and the inner surface of the second housing 130 (as in the prior art), the temperature of the outer wall of the second housing 130 rises rapidly, leading to increased heat loss to the outside of the second housing 130. Conversely, if... Figure 10 As shown, according to this disclosure, since a heat insulation layer 170 is provided between the outer surface of the first housing 110 and the inner surface of the second housing 130, the rate of temperature rise of the outer wall of the second housing 130 can be reduced, thereby reducing heat loss to the outside of the second housing 130.

[0174] Figure 11 This is a view illustrating a coolant heater for a vehicle according to another embodiment of the present disclosure. Furthermore, components identical and corresponding to those in the above configuration are indicated by the same or corresponding reference numerals, and their detailed descriptions are omitted.

[0175] In the embodiments of this disclosure described and illustrated above, an example is depicted where a first cover 120 and a second cover 140, made of a metallic material (e.g., stainless steel or aluminum), are fixed to a first housing 110 and a second housing 130, also made of a metallic material, by welding or brazing; and where a first sheath heater 310, a second sheath heater 320, and a third sheath heater 410, also made of a metallic material, are fixed to the first housing 110 and the second housing 130 by welding or brazing. However, according to another embodiment of this disclosure, the first cover 120, the second cover 140, the first housing 110, and the second housing 130 may be made of a material different from that of the first sheath heater 310, the second sheath heater 320, and the third sheath heater 410.

[0176] As an example, refer to Figure 11 The first cover 120 and the second cover 140, made of non-metallic materials (e.g., plastic), and the first housing 110 and the second housing 130, made of non-metallic materials (e.g., plastic), can be integrally formed by injection molding.

[0177] Additionally, a sealing member 101' (e.g., made of rubber or silicone) for forming a sealing structure can be inserted between the head plate 150 and the other end of the first housing (not shown) and the other end of the second housing 130'.

[0178] According to another embodiment of this disclosure, in order to reduce the size of the coolant heater for a vehicle, the coolant heater for a vehicle may be composed only of a housing unit and a first heater section (or both the first heater section and the second heater section) without a separate flow guiding assembly. Optionally, the housing unit may be composed only of a second housing without a separate first housing (including a heat insulation layer).

[0179] According to the present disclosure as described above, beneficial effects such as improved rapid heating performance and heating efficiency can be obtained.

[0180] Preferably, according to this disclosure, the beneficial effects of ensuring sufficient coolant flow path, improving coolant heating efficiency, and reducing the time spent heating the coolant can be obtained.

[0181] Furthermore, according to this disclosure, the beneficial effect of precisely controlling the output of the coolant heater according to the heating load can be obtained.

[0182] In addition, according to this disclosure, the beneficial effects of preventing the coolant heater from being overheated and improving stability and reliability can be obtained.

[0183] Although the present disclosure has been described above with reference to embodiments, it will be understood by those skilled in the art that various modifications and changes may be made to the present disclosure without departing from the spirit and scope of the disclosure as disclosed in the claims.

Claims

1. A coolant heater for a vehicle, comprising: The housing unit has an inlet for coolant to flow in and an outlet for coolant to flow out; A flow guiding assembly is disposed in the internal space of the housing unit and has a first flow path through which the coolant flows in a first direction and a second flow path through which the coolant flows in a second direction different from the first direction; A first heater section is disposed in the first flow path; as well as The second heater section is disposed in the second flow path. The flow guiding component includes: A baffle plate divides the internal space of the housing unit into a first space communicating with the inlet and a second space communicating with the outlet; and A flow guide shell is connected to the flow guide plate and divides the first space into the first flow path and the second flow path. The housing unit includes: A first housing, wherein the flow guiding assembly is housed within the first housing; The first cover is connected to one end of the first housing. The second housing is configured to surround the first housing; The second cover is attached to one end of the second housing to cover the first cover; Head plate, connected to the other end of the first housing and the other end of the second housing; and The controller cover is attached to the headplate.

2. The coolant heater according to claim 1, wherein, The guide plate shell is formed with a hollow cross-section and is disposed along the length of the housing unit. One end of the guide plate shell penetrates the guide plate, and the other end of the guide plate shell has an inflow hole. The first flow path is formed between the guide plate shell and the housing unit, and the second flow path is formed along the interior of the guide plate shell.

3. The coolant heater according to claim 2, wherein, The flow guide plate shell is disposed in the internal space of the housing unit and is coaxially disposed with the housing unit, and the first flow path is formed around the flow guide plate shell.

4. The coolant heater according to claim 2, wherein, The inlet is formed near one end of the guide plate shell, and the coolant flowing into the inlet flows along the first flow path and then flows into the second flow path through the inlet hole formed at the other end of the guide plate shell.

5. The coolant heater according to claim 2, wherein, The first heater section includes: A first sheath heater, formed in a coil shape and disposed in the first flow path; and The second sheath heater is formed in the shape of a coil and is disposed in the first flow path.

6. The coolant heater according to claim 5, wherein, The first sheath heater and the second sheath heater are coaxially arranged along the length of the first flow path.

7. The coolant heater according to claim 5, further comprising: A first support portion is formed on the outer surface of the guide plate shell and supports the first sheath heater and the second sheath heater.

8. The coolant heater according to claim 5, wherein, The second heater section includes: The third sheath heater is formed in the shape of a coil and is disposed in the second flow path.

9. The coolant heater according to claim 8, further comprising: The second support is formed on the inner surface of the guide plate shell and supports the third sheath heater.

10. The coolant heater according to claim 8, further comprising: The controller independently controls the first sheath heater, the second sheath heater, and the third sheath heater.

11. The coolant heater according to claim 10, wherein, The controller uses pulse width modulation (PWM) control to individually control the first sheath heater, the second sheath heater, and the third sheath heater.

12. The coolant heater according to claim 10, further comprising: A coolant temperature sensor measures the outlet temperature of the coolant discharged from the outlet. When the outlet temperature of the coolant is higher than a predetermined temperature, the controller stops the operation of the first sheath heater, the second sheath heater, and the third sheath heater.

13. The coolant heater according to claim 12, further comprising: A surface temperature sensor measures the temperature of the outer surface of the housing unit. When the temperature of the outer surface of the housing unit is higher than a predetermined temperature, the controller stops the operation of the first sheath heater, the second sheath heater, and the third sheath heater.

14. The coolant heater according to claim 13, wherein, When the temperature of the outer surface of the housing unit is higher than the outlet temperature of the coolant, the controller stops the operation of the first sheath heater, the second sheath heater, and the third sheath heater.

15. The coolant heater according to claim 13, further comprising: A thermal fuse is connected to the housing unit. When the temperature of the outer surface of the housing unit is higher than the short-circuit temperature of the thermal fuse, the thermal fuse cuts off the power supply to the first sheath heater, the second sheath heater, and the third sheath heater.

16. The coolant heater of claim 10, further comprising: A water pump supplies the coolant to the inlet. When an abnormal signal related to the water pump is detected, the controller stops the operation of the first sheath heater, the second sheath heater, and the third sheath heater.

17. The coolant heater according to claim 1, wherein, A heat insulation layer is formed between the outer surface of the first housing and the inner surface of the second housing.

18. The coolant heater according to claim 1, further comprising: A sealing member is inserted between the head plate and the other end of the first housing and the other end of the second housing.

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