A multi-zone PTC air heater assembly

Abstract

The present invention provides a multi-zone PTC wind heater assembly, comprising a first shell, a second shell, a left side plate, a right side plate and a heating core, wherein the heating core comprises a radiator and a plurality of heating rods, and the heating core is fixed in a frame surrounded by the first shell, the second shell, the left side plate and the right side plate, and the multi-zone PTC wind heater assembly also comprises a control box, a first bus bar, a second bus bar, a third bus bar and a fourth bus bar located above the heating body, wherein a controller, a bus bar and an adapter are arranged in the control box, and the adapter is welded on the bus bar, and the electrode sheet at the bottom of the heating rod is electrically connected to the electrode on the adapter after being partitioned by the first bus bar, the second bus bar and the third bus bar, and the electrode sheet at the top of the heating rod is electrically connected to the electrode on the adapter after being partitioned, and the electrode on the adapter is welded to the IGBT power tube on the controller.

Description

Technical Field

[0001] The invention relates to the field of PTC heaters, and in particular to a multi-zone PTC air heater assembly. Background Art

[0002] New energy vehicles are the future direction of global automobile development, and are also the direction that my country's policy focuses on supporting. Since new energy vehicles do not have engines, heating the entire vehicle becomes a problem, and additional heating equipment is required. The electric heating function of PTC ceramics just meets this demand.

[0003] PTC is a positive temperature coefficient ceramic material that can generate heat when powered on. It has the advantages of constant temperature, no open flame, safety, and environmental protection. When using the heating, defrosting and defogging functions of new energy vehicle air conditioners, it is necessary to provide a variety of heating methods according to the different needs of the vehicle. Therefore, it is necessary to design a new multi-zone PTC air heater assembly to solve the above problems. Summary of the invention

[0004] The purpose of the present invention is to overcome the defects of the prior art and provide a multi-zone PTC air heater assembly that can provide a variety of heating methods for different needs of the whole vehicle, at least solving some of the problems in the prior art.

[0005] The present invention is achieved in that:

[0006] The present invention provides a multi-zone PTC wind heater assembly, comprising a first shell, a second shell, a left side plate, a right side plate and a heating core, wherein the heating core comprises a radiator and a plurality of heating rods, and the heating core is fixed in a frame surrounded by the first shell, the second shell, the left side plate and the right side plate, and the multi-zone PTC wind heater assembly also comprises a control box, a first bus bar, a second bus bar, a third bus bar and a fourth bus bar located above the heating body, wherein a controller, a bus bar and an adapter are arranged in the control box, and the adapter is welded on the bus bar, and the electrode sheet at the bottom of the heating rod is electrically connected to the electrode on the adapter after being partitioned by the first bus bar, the second bus bar and the third bus bar, and the electrode sheet at the top of the heating rod is electrically connected to the electrode on the adapter after being partitioned, and the electrode on the adapter is welded to the IGBT power tube on the controller.

[0007] Preferably, the first electrode and the second electrode are injection molded inside the left plate, the third electrode and the fourth electrode are injection molded inside the right plate, the electrode sheet at the bottom of the heating rod includes three zones, namely, zone A, zone B and zone C, which are divided according to the arrangement order of the electrode sheets. The electrode sheet in zone A is electrically connected to the second electrode through the first bus bar, the electrode sheet in zone B is electrically connected to the third electrode through the second bus bar, the electrode sheet in zone C is electrically connected to the fourth electrode through the third bus bar, the common pole in zones A, B and C is electrically connected to the first electrode through the fourth bus bar, the first electrode, the second electrode, the third electrode and the fourth electrode are extended into the control box and welded on the bus bar, and the heating The electrode sheet at the top of the rod extends into the control box and is welded on the busbar. The electrode sheet at the top of the heating rod includes three areas, namely, area D, area E, and area F, which are divided according to the arrangement order of the electrode sheets. The adapter is provided with an area A electrode electrically connected to the second electrode, an area B electrode electrically connected to the third electrode, an area C electrode electrically connected to the fourth electrode, an area D electrode electrically connected to the electrode sheet in area D, an area E electrode electrically connected to the electrode sheet in area E, an area F electrode electrically connected to the electrode sheet in area F, and a common electrode electrically connected to the first electrode. The area A electrode, area B electrode, area C electrode, area D electrode, area E electrode, and area F electrode on the adapter are welded one by one to the IGBT power tube on the controller.

[0008] Preferably, the heating core comprises nine heating rods.

[0009] Preferably, the controller is fixed in the control box by screws.

[0010] Preferably, the first shell, the second shell and the control box are connected by screws.

[0011] Preferably, the busbar collecting area is sealed with liquid silicone.

[0012] Preferably, the electrode sheet confluence area at the bottom of the heating rod is sealed with liquid silicone.

[0013] Preferably, the multi-zone PTC wind heater assembly also includes a low-voltage connector, a high-voltage connector and a grounding harness, and the low-voltage connector, the high-voltage connector and the grounding harness are fixed to the control box by screws, and the low-voltage connector, the high-voltage connector and the grounding harness are all electrically connected to the controller.

[0014] Preferably, a cover plate is provided on the top of the control box, and the cover plate is interference fit with the control box.

[0015] Preferably, the first shell and the second shell are connected by screw buckles.

[0016] The present invention has the following beneficial effects:

[0017] 1. This patent involves a multi-zone controlled PTC heater assembly, which is mainly used for the heating, defrosting and defogging functions of new energy vehicle air conditioners. At the same time, the multi-zone design scheme can provide a variety of heating methods for the different needs of the whole vehicle.

[0018] 2. The present invention provides a multi-zone controlled PTC heater assembly. At the same time, the multi-zone design scheme can provide a variety of heating methods for different needs of the whole vehicle: when zones A+B are controlled simultaneously, zones D+E are controlled simultaneously, and zones F+C are controlled simultaneously, a three-zone heater is formed; when zones A+B+C are controlled simultaneously, zones D+E+F are controlled simultaneously, a two-zone heater is formed, and so on; according to product requirements, the present invention can form different zone heaters through any combination. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0020] Figure 1 An exploded view of a multi-zone PTC air heater assembly provided by an embodiment of the present invention;

[0021] Figure 2 A schematic diagram of the partitioning of a heating core provided by an embodiment of the present invention;

[0022] Figure 3 A schematic diagram of a heating core provided by an embodiment of the present invention;

[0023] Figure 4 A schematic diagram of a left side panel provided by an embodiment of the present invention;

[0024] Figure 5 A schematic diagram of a right side panel provided by an embodiment of the present invention;

[0025] Figure 6 A schematic diagram of a busbar provided in an embodiment of the present invention;

[0026] Figure 7 A schematic diagram of an adapter provided in an embodiment of the present invention;

[0027] Figure 8 An assembly diagram of a multi-zone PTC air heater assembly provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0028] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0029] In the description of the present invention, it should be understood that the terms "center", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship are based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0030] The terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features.

[0031] like Figure 1-Figure 8The embodiment of the present invention provides a multi-zone PTC air heater assembly, including a first shell 8, a second shell 15, a left side plate 5, a right side plate 13 and a heating core, the heating core includes a radiator and a plurality of heating rods, the heating core is fixed in a frame surrounded by the first shell 8, the second shell 15, the left side plate 5 and the right side plate 13, the multi-zone PTC air heater assembly also includes a control box 17 located above the heating body, a first busbar 9, a second busbar 11, a third busbar 12, and a fourth busbar 7, the control box 17 is provided with The controller 6, the busbar 18 and the adapter 19 are provided. The first electrode 14 and the second electrode 22 are injection molded inside the left plate 5, and the third electrode 23 and the fourth electrode 24 are injection molded inside the right plate 13. The electrode sheet at the bottom of the heating rod includes three areas, namely, area A, area B and area C, which are divided according to the arrangement order of the electrode sheets. The electrode sheet in area A is electrically connected to the second electrode 22 through the first busbar 9, the electrode sheet in area B is electrically connected to the third electrode 23 through the second busbar 11, and the electrode sheet in area C is electrically connected to the fourth electrode 24 through the third busbar 12. The common poles in the partitions A, B and C are electrically connected to the first electrode 14 through the fourth busbar 7. The first electrode 14, the second electrode 22, the third electrode 23 and the fourth electrode 24 extend into the control box and are welded on the busbar 18. The electrode sheet on the top of the heating rod extends into the control box and is welded on the busbar 18. The electrode sheet on the top of the heating rod includes three zones, namely, the partition D, the partition E and the partition F, which are divided according to the arrangement order of the electrode sheets. The adapter 19 is welded on the busbar 18. The adapter 19 is provided with a zone A electrically connected to the second electrode 22. Electrode 47, B zone electrode 48 electrically connected to the third electrode 23, C zone electrode 49 electrically connected to the fourth electrode 24, D zone electrode 51 electrically connected to the electrode sheet in partition D, E zone electrode 52 electrically connected to the electrode sheet in partition E, F zone electrode 53 electrically connected to the electrode sheet in partition F, and a common electrode 54 electrically connected to the first electrode 14, the A zone electrode 47, B zone electrode 48, C zone electrode 49, D zone electrode 51, E zone electrode 52, and F zone electrode 53 on the adapter 19 are welded one by one to the IGBT power tube on the controller 6.

[0032] The confluence area of ​​the confluence plate 18 is sealed with liquid silicone 2. The confluence area of ​​the electrode sheet at the bottom of the heating rod is sealed with liquid silicone 2.

[0033] The present invention provides a multi-zone controlled PTC heater assembly, which is mainly used for the heating, defrosting and defogging functions of new energy vehicle air conditioners. At the same time, the multi-zone design scheme can provide a variety of heating methods for different needs of the whole vehicle.

[0034] The first shell 8 and the second shell 15 are connected by screw buckles. In this embodiment, a first heating rod 10, a second heating rod 20, a third heating rod 30, a fourth heating rod 40, a fifth heating rod 50, a sixth heating rod 60, a seventh heating rod 70, an eighth heating rod 80, and a ninth heating rod 90 are provided. Figure 2 , the first heating rod 10 to the ninth heating rod 90 and a plurality of radiators 55 form a heating core, the left side plate 5 and the right side plate 13 are fixed on both sides of the heating core, the upper electrode sheet of the heating core passes through the control box 17, the heating core is fixed between the first shell 8 and the second shell 15, the first busbar 9 is welded with the electrode sheets 101, 201, 301 of the first heating rod 10, the second heating rod 20, and the third heating rod 30. The second busbar 11 is welded with the electrode sheets 401, 501, 601 of the fourth heating rod 40, the fifth heating rod 50, and the sixth heating rod 60. The third busbar 12 is welded with the electrode sheets 701, 801, 901 of the seventh heating rod 70, the eighth heating rod 80, and the ninth heating rod 90. The fourth busbar 7 is welded to the electrode sheets 102, 202, 302, 402, 502, 602, 702, 802, 902 of the first heating rod 10, the second heating rod 20, the third heating rod 30, the fourth heating rod 40, the fifth heating rod 50, the sixth heating rod 60, the seventh heating rod 70, the eighth heating rod 80, and the ninth heating rod 90. The fourth busbar 7 is welded to the first electrode 14 on the left side plate 5 to form a common electrode; Figure 2 , the first busbar 9 is welded to the second electrode 22 on the left plate 5 to form a partition A electrode; the second busbar 11 is welded to the third electrode 23 on the right plate 13 to form a partition B electrode; the third busbar 12 is welded to the fourth electrode 24 on the right plate 13 to form a partition C electrode. The welding area is filled and sealed with liquid silicone 2. Holes 25 to 34 on the busbar 18 are welded to the electrode sheets 103, 203, 303, 403, 503, 603, 703, 803, 903 of the first heating rod 10, the second heating rod 20, the third heating rod 30, the fourth heating rod 40, the fifth heating rod 50, the sixth heating rod 60, the seventh heating rod 70, the eighth heating rod 80, and the ninth heating rod 90. As Figure 2, 103, 203, 303 electrodes form partition D, 403, 503, 603 form partition E, 703, 803, 903 form partition F. The first electrode 14 and the second electrode 22 on the left plate 5 are welded to the holes 43 and 44 on the busbar 18. The fourth electrode 24 and the third electrode 23 on the right plate 13 are welded to the holes 45 and 46 on the busbar. The adapter 19 is provided with a fifth electrode 47 electrically connected to partition A, a sixth electrode 48 electrically connected to partition B, a seventh electrode 49 electrically connected to partition C, a D-zone electrode 51 electrically connected to partition D, an E-zone electrode 52 electrically connected to partition E, and an F-zone electrode 53 electrically connected to partition F. The six electrodes on the adapter 19 are welded to the holes 35 to 41 on the busbar 18, and the common electrode 54 of the remaining adapter is welded to the hole 42. The welding area is sealed with liquid silicone 2. The controller 6 is fixed in the control box 17 with screws. The six electrodes on the adapter 19 are welded to the six IGBT power tubes on the controller 6. The high voltage connector 3, the low voltage connector 16, and the grounding harness 4 are fixed to the control box 17 by screws. The cover plate 1 and the control box 17 are interference fit.

[0035] The present invention provides a multi-zone PTC wind heating assembly, including a heating rod, a radiator 55, a left side plate 5, a right side plate 13, a first shell 8, a second shell 15, an adapter, a first busbar 9, a second busbar 11, a third busbar 12, a fourth busbar 7, a busbar 18, a control box 17, a cover plate 1, a controller 6, a high-voltage connector 3, a low-voltage connector 16, and a grounding harness 4. The heating rod is divided into upper and lower zones by electrode sheets. The heating rod and the radiator are assembled together to form a heating core, and the left side plate 5 and the right side plate 13 are fixed on both sides of the heating core. The first busbar 9, the second busbar 11, the third busbar 12, and the fourth busbar 7 are welded on the lead-out electrodes below the heating core. The left and right side plates are connected to the busbars by welding. The heating rod and the left and right side plates above the heating core penetrate into the control box 17. The busbar 18 is welded on the lead-out electrodes. The adapter 19 is welded on the busbar 18 to realize the six-zone division of the entire heating core (zone A, zone B, zone C, zone D, zone E, zone F). The entire heating core is fixed in the first shell 8 and the second shell 15. The first shell 8, the second shell 15 and the control box 17 are connected by screws. The area where the busbar 18 is welded inside the control box 17 is sealed with liquid silicone 2. The electrodes exposed on the adapter 19 are connected to the controller 6. Each electrode corresponds to a group of IGBT power tubes on the controller 6. The area where the busbar is welded below the heating core is sealed with liquid silicone 2. The high-voltage connector 3 and the low-voltage connector 16 are respectively fixed to the control box 17 with screws.

[0036] In this embodiment, the first electrode 14 and the second electrode 22 are injection-molded inside the left plate 5 , and the fourth electrode 24 and the third electrode 23 are injection-molded inside the right plate 13 .

[0037] The busbar 18 has an internal circuit and 20 small holes are provided on the board for welding the heating rod electrodes and the side plate electrodes to realize the six-zone composition of the heating core.

[0038] Seven electrodes are injection-molded on the adapter 19, corresponding to the six partition electrodes and one common electrode of the heating core.

[0039] The 7 electrodes on the adapter are welded to the holes on the controller respectively, among which 6 partition electrodes correspond to 6 IGBT power tubes to realize separate control of each zone, and 1 hole is welded to the common circuit.

[0040] The present invention provides a multi-zone controlled PTC heater assembly. At the same time, the multi-zone design scheme can provide a variety of heating methods for different needs of the whole vehicle: when zones A+B are controlled simultaneously, zones D+E are controlled simultaneously, and zones F+C are controlled simultaneously, a three-zone heater is formed; when zones A+B+C are controlled simultaneously, zones D+E+F are controlled simultaneously, a two-zone heater is formed, etc.; according to product requirements, the present invention can form different zone heaters through any combination.

[0041] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A multi-zone PTC air heater assembly, characterized in that: It includes a first shell, a second shell, a left side plate, a right side plate and a heating core, the heating core includes a radiator and a plurality of heating rods, the heating core is fixed in a frame surrounded by the first shell, the second shell, the left side plate and the right side plate, the multi-zone PTC air heater assembly also includes a control box, a first busbar, a second busbar, a third busbar and a fourth busbar located above the heating body, the control box is provided with a controller, a busbar and an adapter, the adapter is welded on the busbar, the electrode sheet at the bottom of the heating rod is electrically connected to the electrode on the adapter after being partitioned by the first busbar, the second busbar and the third busbar, the electrode sheet at the top of the heating rod is electrically connected to the electrode on the adapter after being partitioned, and the electrode on the adapter is welded to the IGBT power tube on the controller; The first electrode and the second electrode are injection molded inside the left plate, and the third electrode and the fourth electrode are injection molded inside the right plate. The electrode sheet at the bottom of the heating rod includes three areas, namely, partition A, partition B, and partition C, which are divided according to the arrangement order of the electrode sheets. The electrode sheet in partition A is electrically connected to the second electrode through the first bus bar, the electrode sheet in partition B is electrically connected to the third electrode through the second bus bar, the electrode sheet in partition C is electrically connected to the fourth electrode through the third bus bar, and the common pole in partition A, partition B, and partition C is electrically connected to the first electrode through the fourth bus bar. The first electrode, the second electrode, the third electrode, and the fourth electrode extend into the control box and are welded on the bus bar. The top of the heating rod The electrode sheet is extended into the control box and welded on the busbar. The electrode sheet on the top of the heating rod includes three areas, namely, area D, area E, and area F, which are divided according to the arrangement order of the electrode sheets. The adapter is provided with an area A electrode electrically connected to the second electrode, an area B electrode electrically connected to the third electrode, an area C electrode electrically connected to the fourth electrode, an area D electrode electrically connected to the electrode sheet in area D, an area E electrode electrically connected to the electrode sheet in area E, an area F electrode electrically connected to the electrode sheet in area F, and a common electrode electrically connected to the first electrode. The area A electrode, area B electrode, area C electrode, area D electrode, area E electrode, and area F electrode on the adapter are welded to the IGBT power tube on the controller in a one-to-one correspondence. The fourth busbar is welded to the first electrode on the left side plate to form a common electrode; the first busbar is welded to the second electrode on the left side plate to form a partition A electrode; the second busbar is welded to the third electrode on the right side plate to form a partition B electrode; the third busbar is welded to the fourth electrode on the right side plate to form a partition C electrode; the holes on the busbar are welded to the 9 electrode sheets of the first heating rod, the second heating rod, the third heating rod, the fourth heating rod, the fifth heating rod, the sixth heating rod, the seventh heating rod, the eighth heating rod, and the ninth heating rod; the first electrode and the second electrode on the left side plate are welded to the holes on the busbar; the fourth electrode and the third electrode on the right side plate are welded to the holes on the busbar; the adapter is provided with a fifth electrode electrically connected to partition A, a sixth electrode electrically connected to partition B, a seventh electrode electrically connected to partition C, a D zone electrode electrically connected to partition D, an E zone electrode electrically connected to partition E, and an F zone electrode electrically connected to partition F; When zones A+B are controlled simultaneously, zones D+E are controlled simultaneously, and zones F+C are controlled simultaneously, a three-zone heater is formed; when zones A+B+C are controlled simultaneously, and zones D+E+F are controlled simultaneously, a two-zone heater is formed.

2. The multi-zone PTC air heater assembly according to claim 1, characterized in that: The heating core includes nine heating rods.

3. The multi-zone PTC air heater assembly according to claim 1, characterized in that: The controller is fixed in the control box by screws.

4. The multi-zone PTC air heater assembly according to claim 1, characterized in that: The first shell, the second shell and the control box are connected by screws.

5. The multi-zone PTC air heater assembly according to claim 2, characterized in that: The manifold area is sealed with liquid silicone.

6. The multi-zone PTC air heater assembly according to claim 2, characterized in that: The electrode sheet confluence area at the bottom of the heating rod is sealed with liquid silicone.

7. The multi-zone PTC air heater assembly according to claim 1, characterized in that: It also includes a low-voltage connector, a high-voltage connector and a grounding harness, which are fixed to the control box by screws, and are all electrically connected to the controller.

8. The multi-zone PTC air heater assembly according to claim 1, characterized in that: A cover plate is arranged on the top of the control box, and the cover plate is interference fit with the control box.

9. The multi-zone PTC air heater assembly according to claim 1, characterized in that: The first shell and the second shell are connected by screw buckles.

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