Air heater for new energy vehicles

Abstract

The present invention discloses an air heater for new energy vehicles, comprising a control box, a support base and a heating unit, wherein the support base is fixed on the outer bottom of the control box, the upper end of the heating unit is fixed to the support base, a circuit board is fixed inside the control box, the heating unit is electrically connected to the circuit board, the control box comprises an upper box body and a lower box body, the lower end of the upper box body is connected to the upper end of the lower box body, the upper box body and the lower box body are both made of plastic material, and the inner walls of the upper box body and the lower box body are both electroplated with a metal shielding layer; the present invention can reduce the weight and production cost of the air heater, and can meet the lightweight requirements of the automobile; in addition, the reason why the inner walls of the upper box body and the lower box body are electroplated with a metal shielding layer in the present invention is to prevent the circuit board inside the control box from being interfered by an external electromagnetic field, and also to prevent the electromagnetic field generated by the circuit board inside the control box when working from interfering with the work of other components in the whole vehicle.

Description

Technical Field

[0001] The present invention relates to the technical field of air heating devices for new energy vehicles, and in particular to an air heater for new energy vehicles. Background Art

[0002] In order to achieve the purpose of environmental protection, the current cars on the market are gradually developing towards the direction of using electric energy as a new energy source. At present, the cars on the market that use electric energy as a new energy source are all equipped with air heaters, which are used to heat the air. The heated air is used to be transported into the car to increase the temperature inside the car. The current air heaters on the market mainly include a control box, a support seat and a heating unit. The support seat is fixed on the outer bottom of the control box, and the upper end of the heating unit is fixed to the support seat. However, the control box in the air heaters on the market is made of aluminum material. As a result, not only does the air heater have the disadvantages of being heavy and having a high production cost, but it also fails to meet the lightweight requirements of the car. Summary of the invention

[0003] In view of the deficiencies in the prior art, the present invention provides an air heater for new energy vehicles. The control box inside the air heater is made of plastic material, which can reduce the weight and production cost of the air heater and meet the lightweight requirements of the vehicle.

[0004] The air heater for new energy vehicles of the present invention comprises a control box, a support base and a heating unit, the support base is fixed on the outer bottom of the control box, the upper end of the heating unit is fixed to the support base, a circuit board is fixed inside the control box, the heating unit is electrically connected to the circuit board, the control box comprises an upper box body and a lower box body, the lower end of the upper box body is connected to the upper end of the lower box body, the upper box body and the lower box body are both made of plastic material, and the inner walls of the upper box body and the lower box body are electroplated with metal shielding layers.

[0005] The air heater for new energy vehicles of the present invention comprises an IGBT unit electrically connected to the circuit board mounted on the circuit board, an insulating layer is arranged between the IGBT unit and the inner bottom of the lower box body, a heat conducting layer is arranged between the lower surface of the insulating layer and the inner bottom of the lower box body and between the upper surface of the insulating layer and the lower surface of the IGBT unit, a pressing frame for pressing the IGBT unit, the insulating layer and the two heat conducting layers onto the inner bottom of the lower box body is arranged between the IGBT unit and the circuit board, and the circuit board and the pressing frame are fixed together in the lower box body.

[0006] The air heater for new energy vehicles of the present invention has two first convex ribs on the lower surface of the clamping frame, and the two first convex ribs are used to abut against the upper surface of the IGBT unit, and a heat dissipation channel for dissipating heat from the IGBT unit is formed between the lower surface of the clamping frame between the two first convex ribs and the upper surface of the IGBT unit.

[0007] The air heater for new energy vehicles of the present invention comprises an IGBT unit including a plurality of IGBT modules, the pins of each IGBT module are welded to the circuit board, the lower surface of the clamping frame is provided with the same number of first limiting columns as the IGBT modules, each first limiting column is used to cooperate and plug with the first limiting hole in one of the IGBT modules; the upper surface of the clamping frame is provided with a plurality of grooves; the circuit board and the clamping frame are fixed in the lower box body by a plurality of first screws; and the first heat dissipation fin is provided on the outer bottom of the lower box body below the IGBT unit.

[0008] The air heater for new energy vehicles of the present invention comprises a conductive socket installed on the circuit board, which is electrically connected to the circuit board; a conductive connector is fixed on the upper box body, a conductive plug group is provided at the lower end of the conductive connector, the conductive plug group is used to cooperate with the conductive socket to enable the conductive socket and the conductive connector to be electrically connected, and a conductive joint part for electrically connecting to a power line is provided at the upper end of the conductive connector.

[0009] The air heater for new energy vehicles of the present invention is characterized in that a positioning block is arranged at the bottom of the conductive socket, and a positioning hole is arranged on the circuit board for the positioning block to pass through and for cooperating with the positioning block for positioning; a pair of first hooks are arranged at the bottom of the conductive socket, and a clamping hole is arranged on the circuit board for each first hook to pass through one by one, and each first hook is engaged with the circuit board located at the edge of the clamping hole after passing through the clamping hole at the corresponding position; a limiting block is arranged on the outer top of the upper box body, and the limiting block is used to be engaged with the limiting groove on the outer wall of the conductive connector; a plurality of second screws distributed circumferentially are movably penetrated at the edge of the conductive connector, and each second screw is threadedly connected to the upper box body, and the conductive connector is fixed to the upper box body by the plurality of second screws.

[0010] The air heater for new energy vehicles of the present invention has a sensor bracket installed on the front side of the heating unit, and a plurality of temperature sensors distributed in an array are installed on the sensor bracket. The lead wire of each temperature sensor passes through the lower box body and is electrically connected to the circuit board located in the lower box body.

[0011] The air heater for new energy vehicles of the present invention is provided with a pair of second hooks for engaging with connecting holes on the temperature sensor on the sensor bracket located at the position of each temperature sensor; and a pair of plug blocks for engaging with connecting holes on the temperature sensor to realize positioning of the temperature sensor are provided on the sensor bracket located at the position of each temperature sensor.

[0012] The air heater for new energy vehicles of the present invention is characterized in that the outside of the lead wire of each temperature sensor is covered with a wire protection tube, and the rear side surface of the sensor bracket is provided with an embedding groove for each wire protection tube to be embedded one by one, and the inner walls on the left and right sides of each embedding groove are provided with a plurality of blocks distributed along the length direction of the wire protection tube and used to cooperate with the wire protection tube to prevent the wire protection tube from escaping from the embedding groove; at least one third hook is provided on the left and right sides of the lower end of the sensor bracket, and the third hook is used to cooperate with the heating unit; at least one lug is provided on the upper end of the sensor bracket, and the sensor bracket is fixed to the support seat by a first bolt that is penetrated in the lug and threadedly connected to the support seat; a lead terminal is fixed to the bottom of the lower box body, and a first sealing ring is embedded between the lead terminal and the lower box body, and the lead wire of each temperature sensor passes through the lead terminal and then extends into the control box, and after the lead wire of the temperature sensor passes through the lead terminal, the lead terminal is filled with sealant; a protective frame is covered on the outside of the heating unit and the sensor bracket, and the upper end of the protective frame is fixed to the support seat by a plurality of second bolts.

[0013] The air heater for new energy vehicles of the present invention, wherein the heating unit includes a plurality of heat-conducting tubes distributed from left to right, a support seat is provided with through holes for the upper ends of the plurality of heat-conducting tubes to pass through one by one, each heat-conducting tube is tightly matched with the support seat after passing through the through holes at the corresponding positions, an electric heating tube assembly is inserted in each heat-conducting tube, the electric heating tube assembly is electrically connected to the circuit board, a plurality of second heat-dissipating fins distributed along the length direction of the heat-conducting tube are arranged on the outer walls on the left and right sides of each heat-conducting tube, an insulation pad is embedded between the support seat and the lower box body, the insulation pad is provided with the same number of clearance holes as the heat-conducting tube, each clearance hole is used for the heat-conducting tube at the corresponding position to pass through; the bottom of the lower box body is provided with the same number of jacks as the heat-conducting tube, each jack is used for the upper ends of the heat-conducting tube at the corresponding position to pass through. The ends are inserted, and a second sealing ring is embedded between the upper end of each heat-conducting tube and the socket at the corresponding position; two blocks are arranged above each socket and are distributed in the front-to-back direction and are used to abut against the upper end of the heat-conducting tube, and each block is connected to the lower box body as a whole; a plurality of second convex ribs are arranged on the inner walls on the left and right sides of each through hole, and after the heat-conducting tube passes through the through hole, the heat-conducting tube and the second convex ribs are interference fit; a plurality of second limiting holes are arranged in the support seat, and a second limiting column for one-to-one matching and plugging with the plurality of second limiting holes is arranged on the outer bottom of the lower box body; a plurality of third bolts are movably penetrated in the support seat, and a threaded blind hole for one-to-one threaded connection with the plurality of third bolts is arranged on the outer bottom of the lower box body, and the support seat is fixed to the outer bottom of the lower box body by the plurality of third bolts.

[0014] The control box inside the present invention is made of plastic material, which can reduce the weight and production cost of the air heater and meet the lightweight requirements of the automobile; in addition, the reason why the inner walls of the upper box body and the lower box body are electroplated with metal shielding layers is to prevent the circuit board inside the control box from being interfered with by the external electromagnetic field, and also to prevent the electromagnetic field generated by the circuit board inside the control box during operation from interfering with the operation of other components in the entire vehicle, that is, the metal shielding layer can achieve the effect of shielding the electromagnetic field. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The drawings described herein are used to provide a further understanding of the present application and constitute a part of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application and do not constitute an improper limitation on the present application. In the drawings:

[0016] Figure 1 It is a schematic diagram of the three-dimensional structure of the present invention;

[0017] Figure 2 It is a schematic diagram of the three-dimensional structure after the circuit board and the lower box body are assembled;

[0018] Figure 3 Schematic diagram of the three-dimensional structure of the lower box body;

[0019] Figure 4 It is a schematic diagram of the three-dimensional structure after the circuit board and the lower box body are separated;

[0020] Figure 5 It is a schematic diagram of the cross-sectional structure after the circuit board, the pressing frame, the IGBT unit, the insulating layer and the lower box body are assembled;

[0021] Figure 6 for Figure 5 The schematic diagram of the structure after the enlargement of A in the middle;

[0022] Figure 7 It is a schematic diagram of the three-dimensional structure after the IGBT unit, the clamping frame and the circuit board are assembled;

[0023] Figure 8 for Figure 7 A schematic diagram of a partially exploded three-dimensional structure;

[0024] Fig. 9 It is a schematic diagram of the three-dimensional structure after the pressing frame, IGBT unit, insulation layer and lower box body are assembled;

[0025] Fig.10 This is a schematic diagram of the three-dimensional structure of the present invention after removing the support base, the heating unit and the protective frame;

[0026] Fig.11 for Fig.10 A schematic diagram of a partially exploded three-dimensional structure;

[0027] Fig.12 for Fig.10 Another partially exploded three-dimensional structural diagram;

[0028] Fig.13 It is a schematic diagram of a partial three-dimensional structure after the conductive socket and the circuit board are assembled;

[0029] Fig.14 This is a schematic diagram of the main structure of the present invention after removing the upper box body, the protective frame and the sensor bracket;

[0030] Fig.15 This is a schematic diagram of the three-dimensional structure of the present invention after removing the heating unit and the protective frame;

[0031] Fig.16 for Fig.15 A schematic diagram of a partially exploded three-dimensional structure;

[0032] Fig.17 This is a schematic diagram of the three-dimensional structure of the present invention after removing the upper box body, circuit board, clamping frame, IGBT unit, protection frame and sensor bracket;

[0033] Fig.18 for Fig.17 The schematic diagram of the structure after enlargement at B in the middle;

[0034] Fig.19 This is a schematic diagram of the three-dimensional structure of the present invention after removing the upper box body and the protective frame;

[0035] Fig. 20 for Fig.19 The schematic diagram of the structure after enlargement at C in the middle;

[0036] Fig.21 for Fig.19 The schematic diagram of the structure after the enlargement of D in the middle;

[0037] Fig. 22 It is a schematic diagram of the three-dimensional structure after the temperature sensor, wire protection tube and sensor bracket are assembled;

[0038] Fig.23 for Fig. 22 The schematic diagram of the structure after enlargement at E in the middle;

[0039] Fig.24 This is a schematic diagram of the three-dimensional structure when the present invention adopts another control box form. DETAILED DESCRIPTION

[0040] The following will disclose multiple embodiments of the present invention with drawings. For the purpose of clear description, many practical details will be described together in the following description. However, it should be understood that these practical details should not be used to limit the present invention. That is, in some embodiments of the present invention, these practical details are not necessary. In addition, for the purpose of simplifying the drawings, some conventional structures and components will be depicted in a simple schematic manner in the drawings.

[0041] In addition, in the present invention, the descriptions of "first", "second", etc. are only used for descriptive purposes, and do not specifically refer to the order or sequence, nor are they used to limit the present invention. They are only used to distinguish components or operations described with the same technical terms, and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In addition, the technical solutions between the various embodiments can be combined with each other, but they must be based on the ability of ordinary technicians in the field to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0042] like Figure 1-Figure 23 As shown, the air heater for new energy vehicles of the present invention comprises a control box 1, a support base 2 and a heating unit 3, the support base 2 is fixed on the outer bottom of the control box 1, the upper end of the heating unit 3 is fixed to the support base 2, a circuit board 4 is fixed inside the control box 1, the heating unit 3 is electrically connected to the circuit board 4, the control box 1 comprises an upper box body 11 and a lower box body 12, the lower end of the upper box body 11 is connected to the upper end of the lower box body 12, the upper box body 11 and the lower box body 12 are both made of plastic material, and the inner walls of the upper box body 11 and the lower box body 12 are electroplated with a metal shielding layer; the metal shielding layer on the inner wall of the upper box body and the lower box body is realized in the following manner: first, a 1.5um thick aluminum material layer is electroplated on the inner wall of the upper box body and the lower box body, and then a 1.3um thick nickel material layer is electroplated on the basis of the aluminum material layer, and then a 1.1um thick chromium material layer is electroplated on the basis of the nickel material layer, and the aluminum material layer, the nickel material layer and the chromium material layer are combined to form a metal shielding layer.

[0043] An IGBT unit 41 electrically connected to the circuit board 4 is mounted on the circuit board 4, an insulating layer 13 is arranged between the IGBT unit 41 and the inner bottom of the lower box body 12, a heat-conducting layer 14 is arranged between the lower surface of the insulating layer 13 and the inner bottom of the lower box body 12, and between the upper surface of the insulating layer 13 and the lower surface of the IGBT unit 41, a pressing frame 5 for pressing the IGBT unit 41, the insulating layer 13 and the two heat-conducting layers 14 on the inner bottom of the lower box body 12 is arranged between the IGBT unit 41 and the circuit board 4, and the circuit board 4 and the pressing frame 5 are fixed together in the lower box body 12; the above-mentioned heat-conducting layer adopts a heat-conducting silicone layer; the IGBT unit inside the present invention is pressed by the pressing frame, that is, the circuit board does not need to apply pressure to the IGBT unit, so that the stress of the circuit board and electronic components around the IGBT can be eliminated, thereby effectively avoiding damage to the circuit board and electronic components, and further improving the reliability and service life of the air heater.

[0044] Two first convex ribs 51 are provided on the lower surface of the clamping frame 5, and the two first convex ribs 51 are used to abut against the upper surface of the IGBT unit 41. A heat dissipation channel 52 for dissipating heat from the IGBT unit 41 is formed between the lower surface of the clamping frame 5 located between the two first convex ribs 51 and the upper surface of the IGBT unit 41; after the two first convex ribs are provided on the lower surface of the clamping frame, the two first convex ribs can abut against the upper surface of the IGBT unit, so that a heat dissipation channel can be formed between the lower surface of the clamping frame and the upper surface of the IGBT unit, thereby enabling the IGBT unit to be better cooled.

[0045] The IGBT unit 41 includes a plurality of IGBT modules 411, the pins of each IGBT module 411 are welded to the circuit board 4, the lower surface of the clamping frame 5 is provided with the same number of first limiting posts 53 as the IGBT modules 411, each first limiting post 53 is used to cooperate with the first limiting hole 412 in one of the IGBT modules 411; a plurality of grooves 54 are provided on the upper surface of the clamping frame 5; the circuit board 4 and the clamping frame 5 are fixed in the lower box body 12 by a plurality of first screws 42; a first heat dissipation fin 121 is provided on the outer bottom of the lower box body 12 located below the IGBT unit 41; through the first limiting posts and the first The setting of the limiting hole can realize the positioning of the IGBT module and the clamping frame when the IGBT module is assembled with the clamping frame and the pins of the IGBT module are welded to the circuit board; the setting of the groove can improve the structural strength of the clamping frame and reduce the material cost when manufacturing the clamping frame. In addition, the weight of the clamping frame can be reduced to meet the lightweight requirements of the automobile; the first screw is used to fix the circuit board and the clamping frame, so that the circuit board and the clamping frame can be reliably fixed in the lower box body; the setting of the first heat dissipation fin, when the heat of the IGBT unit is transferred to the lower box body, the lower box body can better dissipate heat through the first heat dissipation fin.

[0046] A conductive socket 43 is installed on the circuit board 4, and the conductive socket 43 is electrically connected to the circuit board 4; a conductive connector 6 is fixed on the upper box body 11, and a conductive plug group 61 is provided at the lower end of the conductive connector 6, and the conductive plug group 61 is used to cooperate with the conductive socket 43 to make the conductive socket 43 and the conductive connector 6 electrically connected, and a conductive joint part 62 for electrically connecting to the power line is provided at the upper end of the conductive connector 6; after the conductive socket inside the present invention is cooperated with the conductive plug group located at the lower end of the conductive connector, the conductive socket and the conductive connector can be electrically connected, so that there is no need to use a wiring harness to connect the circuit board and the conductive connector, so that the connection between the circuit board and the conductive connector can be convenient. In addition, the following disadvantages of using a wiring harness to connect the circuit board and the conductive connector can be overcome: for example, if the circuit board and the conductive connector in the air heater are electrically connected by a wiring harness, during the assembly of the control box, if the position of the wiring harness is offset, the wiring harness is easily crushed or damaged, or when the car vibrates, the wiring harness is easy to touch the electronic components on the circuit board, which can easily cause damage to the electronic components. In addition, when a large current passes through the wiring harness, the parasitic capacitance generated in the wiring harness is easy to interfere with the electronic components on the circuit board; in addition, after the upper box body and the lower box body are assembled, the conductive plug group located at the bottom of the conductive connector can naturally cooperate with the conductive socket for plugging.

[0047] A positioning block 431 is provided at the bottom of the conductive socket 43, and a positioning hole 44 is provided on the circuit board 4 for the positioning block 431 to pass through and for cooperating with the positioning block 431 for positioning; a pair of first hooks 432 are provided at the bottom of the conductive socket 43, and a clamping hole 45 is provided on the circuit board 4 for each first hook 432 to pass through one by one, and each first hook 432 is clamped with the circuit board 4 located at the edge of the clamping hole 45 after passing through the clamping hole 45 at the corresponding position; a limiting block 111 is provided on the outer top of the upper box body 11, and the limiting block 111 is used to be engaged with the limiting groove 63 located on the outer wall of the conductive connector 6; a plurality of second screws 64 distributed circumferentially are movably penetrated at the edge of the conductive connector 6, and each second screw 64 is threadedly connected to the upper box body 11, and the conductive connector 6 is fixed to the upper box body 11 by the plurality of second screws 64; through the provision of the positioning block and the positioning hole, when the conductive socket and the circuit board are assembled, the positioning block 111 located on the conductive socket The positioning block can be plugged into the positioning hole on the circuit board, so that the conductive socket and the circuit board can achieve the positioning function, which can facilitate the assembly of the conductive socket and the circuit board and improve the reliability of the conductive socket and the circuit board after assembly; through the provision of the first hook and the hole, when the conductive socket and the circuit board are assembled, each first hook can pass through the hole at the corresponding position and be engaged with the circuit board at the edge of the hole. After the first hook and the circuit board at the edge of the hole are engaged, the conductive socket can be conveniently installed together with the circuit board; through the provision of the limit block, when the conductive connector and the upper box body are assembled, the limit block can be engaged with the limit groove on the outer wall of the conductive connector, so that the conductive connector and the upper box body can achieve the positioning function, which can facilitate the assembly of the conductive connector and the upper box body; through the provision of a plurality of second screws, the conductive connector can be reliably fixed to the upper box body.

[0048] A sensor bracket 71 is installed on the front side of the heating unit 3, and a plurality of temperature sensors 72 distributed in an array are installed on the sensor bracket 71. The lead wires of each temperature sensor 72 pass through the lower box body 12 and are electrically connected to the circuit board 4 located in the lower box body 12. Through the setting of the temperature sensor, the temperature sensor can accurately obtain the current temperature of the heating unit, thereby helping the temperature control system to accurately control the temperature of the heating unit. In addition, the plurality of temperature sensors in the present invention are distributed in an array, so that the zoned temperature measurement of the heating unit can be realized, thereby helping the temperature control system to control the zoned temperature of the heating unit. The above-mentioned temperature control system is an existing system in automobiles currently on the market, so it will not be described here.

[0049] A pair of second hooks 711 for engaging with the connecting holes 721 on the temperature sensor 72 are provided on the sensor bracket 71 located at the position of each temperature sensor 72; a pair of plug blocks 712 for engaging with the connecting holes 721 on the temperature sensor 72 to achieve positioning of the temperature sensor 72 are provided on the sensor bracket 71 located at the position of each temperature sensor 72; through the provision of the second hooks, each temperature sensor can be conveniently mounted on the sensor bracket; through the provision of the plug blocks, the temperature sensor can be positioned when being assembled with the sensor bracket.

[0050] The lead wires of each temperature sensor 72 are all covered with a wire protection tube 73 on the outside, and a groove 713 for each wire protection tube 73 to be embedded is provided on the rear side of the sensor bracket 71, and a plurality of blocks 714 distributed along the length direction of the wire protection tube 73 and used to cooperate with the wire protection tube 73 to prevent the wire protection tube 73 from falling out of the groove 713 are provided on the inner walls on the left and right sides of each groove 713; at least one third hook 715 is provided on the left and right sides of the lower end of the sensor bracket 71, and the third hook 715 is used to cooperate with the heating unit 3; at least one lug 716 is provided on the upper end of the sensor bracket 71, and the sensor bracket 71 is fixed to the support seat 2 by a first bolt 717 that is penetrated through the lug 716 and threadedly connected to the support seat 2; a lead terminal 74 is fixed to the bottom of the lower box body 12, and the lead terminal A first sealing ring is embedded between the sub-box 74 and the lower box body 12, and the lead wires of each temperature sensor 72 pass through the lead terminal 74 and then extend into the control box 1. After the lead wires of the temperature sensor 72 pass through the lead terminal 74, the lead terminal 74 is filled with sealant; the outside of the heating unit 3 and the sensor bracket 71 is sheathed with a protective frame 75, and the upper end of the protective frame 75 is fixed to the support seat 2 by a plurality of second bolts 718; through the setting of the wire protection tube, the wire protection tube can protect the lead wires of the temperature sensor; in addition, through the setting of the embedding groove and the clamping block, the wire protection tube can be conveniently clamped together with the sensor bracket; through the setting of the third hook, the sensor bracket can be conveniently clamped together with the heating unit, and through the setting of the lug, the sensor bracket can be reliably fixed to the support seat by the first bolt.

[0051] The heating unit 3 includes a plurality of heat-conducting tubes 31 distributed from left to right, and the support seat 2 is provided with through holes 21 for the upper ends of the plurality of heat-conducting tubes 31 to pass through one by one. After each heat-conducting tube 31 passes through the through hole 21 at the corresponding position, it is tightly matched with the support seat 2, and an electric heating tube assembly 32 is inserted in each heat-conducting tube 31, and the electric heating tube assembly 32 is electrically connected to the circuit board 4. A plurality of second heat dissipation fins 311 distributed along the length direction of the heat-conducting tube 31 are provided on the outer walls on the left and right sides of each heat-conducting tube 31, and a heat insulation pad 8 is embedded between the support seat 2 and the lower box body 12. The heat insulation pad 8 is provided with the same number of clearance holes 81 as the heat-conducting tube 31, and each clearance hole 81 is used for the heat-conducting tube 31 at the corresponding position to pass through; The bottom is provided with the same number of sockets 122 as the heat-conducting tubes 31, each socket 122 is used for inserting the upper end of the heat-conducting tube 31 at the corresponding position, and a second sealing ring 123 is embedded between the upper end of each heat-conducting tube 31 and the socket 122 at the corresponding position; two blocks 124 distributed in the front-to-back direction and used to abut against the upper end of the heat-conducting tube 31 are provided above each socket 122, and each block 124 is connected to the lower box body 12 as a whole; a plurality of second convex ribs 24 are provided on the inner walls on the left and right sides of each through hole 21, and after the heat-conducting tube 31 passes through the through hole 21, the heat-conducting tube 31 and the second convex rib 24 are interference fit; a plurality of second limiting holes 22 are provided in the support seat 2, and a second sealing ring 123 is provided on the outer bottom of the lower box body 12 for A second limiting column 125 is plugged in and matched with the plurality of second limiting holes 22 one by one; a plurality of third bolts 23 are movably inserted in the support seat 2, and a threaded blind hole 126 for threaded connection with the plurality of third bolts 23 is provided on the outer bottom of the lower box body 12, and the support seat 2 is fixed to the outer bottom of the lower box body 12 by the plurality of third bolts 23; after a thermal insulation pad is embedded between the support seat and the lower box body, the thermal insulation pad can effectively isolate the heat transfer between the support seat and the lower box body, so that the heat loss of the heat pipe can be effectively avoided, and the temperature increase of the lower box body can be avoided, so as to avoid affecting the operation of the electronic components in the control box and avoiding damage to the electronic components located in the control box; The support seat is made of aluminum material, and the tight fit between the heat-conducting pipe and the through hole refers to an interference fit. The heat-insulating pad can be a heat-insulating pad made of mica material; the second sealing ring is provided to prevent water vapor from entering the control box through the gap between the heat-conducting pipe and the plug hole. In addition, the sealing ring can also effectively isolate the heat transfer between the heat-conducting pipe and the control box. The sealing ring can be made of high-temperature resistant silicone material; through the setting of the stopper, after the upper end of the heat-conducting pipe is inserted into the plug hole, the upper end of the heat-conducting pipe can eventually abut against the stopper, so that the heat-conducting pipe can be limited; through the setting of the second rib, after the heat-conducting pipe is inserted into the through hole, the firmness of the heat-conducting pipe and the support seat after the tight fit can be further improved, and the tight fit is an interference fit;By setting the second limiting hole and the second limiting column, when the support base and the lower box body are assembled, the support base and the lower box body can achieve positioning, thereby facilitating the assembly of the support base and the lower box body; by setting the third bolt and the threaded blind hole, the support base can be reliably fixed to the lower box body. ;

[0052] The assembly process of the above-mentioned heating unit, support seat and lower box body is: first, fix the support seat to the outer bottom of the lower box body, and when the support seat and the lower box body are fixed, embed a thermal insulation pad between the support seat and the lower box body, then install an electric heating tube assembly in each heat-conducting tube, and then insert the upper end of each heat-conducting tube through the through hole located on the support seat and into the socket located at the bottom of the lower box body (when assembling the heat-conducting tube, the support seat and the lower box body, a clamp or extrusion tooling can be used to press the heat-conducting tube into the through hole so that the heat-conducting tube and the through hole have an interference fit), and finally embed the first sealing ring between the heat-conducting tube and the socket.

[0053] like Fig.24 As shown, the present invention can also be used Fig.24 In the form of a control box 1, Fig.24 The upper box body 11 and the lower box body 12 are connected together by a plurality of circumferentially distributed snap-fit ​​structures, which include a plurality of circumferentially distributed clamping platforms 112 on the outer wall of the upper box body 11, and the outer wall of the lower box body 12 is provided with spring buckles 127 corresponding to each clamping platform 112. After the upper box body 11 and the lower box body 12 are assembled, each spring buckle 127 is engaged with the clamping platform 112 at the corresponding position one by one. By adopting this method to connect the upper box body 11 and the lower box body 12, the upper box body 11 and the lower box body 12 are easily assembled.

[0054] The above description is only an embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent substitution, improvement, etc. made within the spirit and principle of the present invention should be included in the scope of the claims of the present invention.

Claims

1. An air heater for a new energy vehicle, comprising a control box (1), a support base (2) and a heating unit (3), wherein the support base (2) is fixed to the outer bottom of the control box (1), the upper end of the heating unit (3) is fixed to the support base (2), a circuit board (4) is fixed inside the control box (1), the heating unit (3) is electrically connected to the circuit board (4), the control box (1) comprises an upper box body (11) and a lower box body (12), the lower end of the upper box body (11) is connected to the upper end of the lower box body (12), and is characterized in that: The upper box body (11) and the lower box body (12) are both made of plastic material, and the inner walls of the upper box body (11) and the lower box body (12) are both electroplated with a metal shielding layer; an IGBT unit (41) electrically connected to the circuit board (4) is mounted on the circuit board (4), an insulating layer (13) is provided between the IGBT unit (41) and the inner bottom of the lower box body (12), and a lower surface of the insulating layer (13) and the inner bottom of the lower box body (12) are in contact with each other, and an upper surface of the insulating layer (13) and the IGBT unit (41) are in contact with each other. A heat-conducting layer (14) is disposed between the lower surfaces of the IGBT unit (41), a pressing frame (5) for pressing the IGBT unit (41), the insulating layer (13) and the two heat-conducting layers (14) onto the inner bottom of the lower box body (12) is disposed between the IGBT unit (41) and the circuit board (4), and the circuit board (4) and the pressing frame (5) are fixed together in the lower box body (12); two first convex ribs (51) are disposed on the lower surface of the pressing frame (5), and the two first convex ribs (51) are used to contact the IGBT unit (41) and the circuit board (4). The upper surface of the IGBT unit (41) abuts against the lower surface of the clamping frame (5) located between the two first ribs (51), and a heat dissipation channel (52) for dissipating heat from the IGBT unit (41) is formed between the lower surface of the clamping frame (5) and the upper surface of the IGBT unit (41); the IGBT unit (41) comprises a plurality of IGBT modules (411), the pins of each of the IGBT modules (411) are welded to the circuit board (4), and the lower surface of the clamping frame (5) is provided with a pin that is welded to the IGBT module (411). ) the same number of first limiting columns (53) each of which is used to cooperate and plug with a first limiting hole (412) in one of the IGBT modules (411); a plurality of grooves (54) are provided on the upper surface of the clamping frame (5); the circuit board (4) and the clamping frame (5) are fixed in the lower box body (12) by means of a plurality of first screws (42); and a first heat dissipation fin (121) is provided on the outer bottom of the lower box body (12) located below the IGBT unit (41).

2. The air heater for new energy vehicles according to claim 1, characterized in that: A conductive socket (43) is mounted on the circuit board (4), and the conductive socket (43) is electrically connected to the circuit board (4); a conductive connector (6) is fixed on the upper box body (11), and a conductive plug group (61) is provided at the lower end of the conductive connector (6), and the conductive plug group (61) is used to cooperate with the conductive socket (43) to plug and match the conductive socket (43) so that the conductive socket (43) and the conductive connector (6) are electrically connected, and a conductive joint portion (62) is provided at the upper end of the conductive connector (6) for electrically connecting to a power line.

3. The air heater for new energy vehicles according to claim 2, characterized in that: A positioning block (431) is provided at the bottom of the conductive socket (43), and a positioning hole (44) is provided on the circuit board (4) for the positioning block (431) to pass through and for cooperating with the positioning block (431) for positioning; a pair of first hooks (432) are provided at the bottom of the conductive socket (43), and a clamping hole (45) is provided on the circuit board (4) for each first hook (432) to pass through one by one, and each first hook (432) is aligned with a clamping hole (45) located on the side of the clamping hole (45) after passing through the clamping hole (45) at the corresponding position. The circuit board (4) at the edge of the upper box body (11) is engaged with the circuit board (4) in a cooperating manner; a limiting block (111) is provided on the outer top of the upper box body (11), and the limiting block (111) is used to engage with a limiting groove (63) located on the outer wall of the conductive connector (6); a plurality of second screws (64) distributed in a circumferential direction are movably penetrated at the edge of the conductive connector (6), each of the second screws (64) is threadedly connected to the upper box body (11), and the conductive connector (6) is fixed to the upper box body (11) by the plurality of second screws (64).

4. The air heater for new energy vehicles according to claim 1, characterized in that: A sensor bracket (71) is installed on the front side of the heating unit (3), and a plurality of temperature sensors (72) distributed in an array are installed on the sensor bracket (71), and a lead wire of each temperature sensor (72) passes through the lower box body (12) and is electrically connected to a circuit board (4) located in the lower box body (12).

5. The air heater for new energy vehicles according to claim 4, characterized in that: A pair of second hooks (711) for engaging with connection holes (721) on the temperature sensor (72) are provided on the sensor bracket (71) at the location where each temperature sensor (72) is located; and a pair of plug blocks (712) for engaging with connection holes (721) on the temperature sensor (72) to achieve positioning of the temperature sensor (72) are provided on the sensor bracket (71) at the location where each temperature sensor (72) is located.

6. The air heater for new energy vehicles according to claim 4, characterized in that: The lead wire of each temperature sensor (72) is sheathed with a wire protection tube (73) on the outside, and the rear side surface of the sensor bracket (71) is provided with an embedding groove (713) for each wire protection tube (73) to be embedded one by one. The inner walls on the left and right sides of each embedding groove (713) are provided with a plurality of blocks (714) distributed along the length direction of the wire protection tube (73) and used to cooperate with the wire protection tube (73) to prevent the wire protection tube (73) from falling out of the embedding groove (713); at least one third hook (715) is provided on the left and right sides of the lower end of the sensor bracket (71), and the third hook (715) is used to cooperate with the heating unit (3); the upper end of the sensor bracket (71) is provided with at least one lug (716), and the sensor The sensor bracket (71) is fixed to the support base (2) by a first bolt (717) which is inserted into the lug (716) and threadedly connected to the support base (2); a lead terminal (74) is fixed to the bottom of the lower box body (12); a first sealing ring is embedded between the lead terminal (74) and the lower box body (12); the lead wire of each temperature sensor (72) passes through the lead terminal (74) and then extends into the control box (1); after the lead wire of the temperature sensor (72) passes through the lead terminal (74), the lead terminal (74) is filled with sealing glue; a protective frame (75) is sheathed on the outside of the heating unit (3) and the sensor bracket (71); the upper end of the protective frame (75) is fixed to the support base (2) by a plurality of second bolts (718).

7. The air heater for new energy vehicles according to claim 1, characterized in that: The heating unit (3) comprises a plurality of heat-conducting tubes (31) distributed from left to right. The support seat (2) is provided with through holes (21) for the upper ends of the plurality of heat-conducting tubes (31) to pass through one by one. After passing through the through holes (21) at corresponding positions, each of the heat-conducting tubes (31) is tightly matched with the support seat (2). An electric heating tube assembly (32) is inserted into each of the heat-conducting tubes (31). The electric heating tube assembly (32) is electrically connected to the circuit board (4). The left and right outer walls of each of the heat-conducting tubes (31) are provided with a plurality of through holes (21) for passing through the upper ends of the plurality of heat-conducting tubes (31). A plurality of second heat dissipation fins (311) are distributed in a certain direction, a heat insulation pad (8) is embedded between the support seat (2) and the lower box body (12), the heat insulation pad (8) is provided with the same number of clearance holes (81) as the number of heat conduction pipes (31), each of the clearance holes (81) is used for allowing the heat conduction pipe (31) at a corresponding position to pass through; the bottom of the lower box body (12) is provided with the same number of insertion holes (122) as the number of heat conduction pipes (31), each of the insertion holes (122) is used for allowing the upper end of the heat conduction pipe (31) at a corresponding position to be inserted, and each of the heat conduction pipes (31) is provided with a plurality of second heat dissipation fins (311) distributed in a certain direction, a heat insulation pad (8) is embedded between the support seat (2) and the lower box body (12), the same number of clearance holes (81) as the number of heat conduction pipes (31) being provided in the heat insulation pad (8), each of the clearance holes (81) is used for allowing the upper end of the heat conduction pipe (31) at a corresponding position to pass through. A second sealing ring (123) is embedded between the upper end of each through hole (31) and the insertion hole (122) at the corresponding position; two stoppers (124) are arranged above each of the insertion holes (122) and are distributed in the front-to-back direction and are used to abut against the upper end of the heat-conducting pipe (31); each of the stoppers (124) is integrally connected to the lower box body (12); a plurality of second convex ribs (24) are arranged on the inner walls on the left and right sides of each through hole (21); after the heat-conducting pipe (31) passes through the through hole (21), the heat-conducting pipe (31) and the second convex ribs (24) are in contact with each other. interference fit; a plurality of second limiting holes (22) are provided in the support seat (2); a second limiting column (125) for one-to-one matching and plugging with the plurality of second limiting holes (22) is provided on the outer bottom of the lower box body (12); a plurality of third bolts (23) are movably inserted through the support seat (2); a threaded blind hole (126) for one-to-one threaded connection with the plurality of third bolts (23) is provided on the outer bottom of the lower box body (12); the support seat (2) is fixed to the outer bottom of the lower box body (12) by the plurality of third bolts (23).

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