An electric heating tube casting heater for vehicle

Abstract

The application provides a vehicle electric heating tube casting heater, which comprises a heater main body, a heater base, an upper cover plate and a lower cover plate, the outer part of the upper cover plate and the lower cover plate are provided with outer cover plates; the heater main body is provided with a first inlet and outlet and a second inlet and outlet, and the heater main body is internally provided with a heating assembly; the heating assembly is composed of a heating element and fins, the fins are arranged on the upper and lower end faces of the heating element, the gap between adjacent fins forms a heat exchange flow channel, the two sides of the fins are respectively provided with an inlet water flow channel and an outlet water flow channel, the inlet water flow channel and the outlet water flow channel are connected through the heat exchange flow channel, and the inlet water flow channel and the outlet water flow channel are both provided with a gradually narrowed channel structure. The application has the beneficial effects that: the application adopts an immersed double-sided heating design, fully utilizes the heat dissipation area, and has high heating efficiency; meanwhile, the flow channel structure combining the inlet water flow channel, the outlet water flow channel and the heat exchange flow channel, and the intermittent and winding fin structure can increase the heat exchange area and the disturbed water flow, and increase the heat exchange effect.

Description

Technical Field

[0001] This invention relates to the field of heaters, and mainly to a cast heater for automotive electric heating tubes. Background Technology

[0002] Currently, most automotive heaters use PTC heaters. While PTC heaters offer good safety performance, they suffer from drawbacks such as susceptibility to oxidation at high temperatures, power degradation, and short lifespan. Automotive electric heating tube cast heaters, while exhibiting better performance in these aspects, may experience higher temperatures and lack self-regulation. The thermal power and heating rate of automotive electric heating tube heaters are significantly affected by the flow channel, whose structure influences coolant flow resistance and heat transfer efficiency. When heat transfer capacity is low, the heat dissipated by the heating tube cannot be effectively carried away by the coolant, increasing the resistance of the heating wire and reducing the heating power under constant voltage conditions. Lower thermal efficiency leads to increased battery consumption.

[0003] A search revealed Chinese patent CN107710867B, which discloses a fluid heating device comprising: a heating element that generates heat when energized; electrical components for controlling the energization of the heater; a housing with an opening that houses the heating element; a top plate that seals the opening of the housing to form a fluid chamber for fluid flow; and a first and a second flow port for allowing fluid to flow through the fluid chamber. The electrical components are disposed along the top plate on the outside of the fluid chamber. According to this technical solution, heat generated in the electrical components is transferred to the fluid flowing in the fluid chamber via the top plate. Its drawback is that the heater is located inside the cylindrical heating element, and the water flow must pass through the interior of the heating element; therefore, the heater has a relatively large volume or weight. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a casting heater for automotive electric heating tubes.

[0005] The objective of this invention is achieved through the following technical solution. A casting heater for automotive electric heating tubes includes a heater body, a heater base, an upper cover plate, and a lower cover plate. Both the upper and lower cover plates are externally covered. The heater body has openings at both ends, which are welded and sealed to the upper and lower cover plates respectively. The heater body has a first inlet and a second inlet / outlet. A heating assembly is installed in the middle of the heater body. The heating assembly consists of heating elements and fins. The fins are disposed on the upper and lower end faces of the heating elements. The gaps between adjacent fins form heat exchange channels. Inlet and outlet channels are respectively provided on both sides of the fins. The inlet and outlet channels are connected to the first and second inlets / outlets, respectively. The inlet and outlet channels are connected through the heat exchange channels. Both the inlet and outlet channels have a gradually narrowing channel structure.

[0006] Furthermore, an NTC bracket is provided between the upper cover plate and the outer cover plate. The NTC bracket is equipped with electrical components for detecting temperature and is located near the first inlet or the second inlet or outlet.

[0007] Furthermore, the heater base contains a PCB board for controlling the heater, and there is a plastic bracket between the PCB board and the heater base. The heater base is sealed to the bottom cover plate.

[0008] Furthermore, the first inlet and the second inlet are located on the same side of the heater body, and both the inlet and outlet channels are provided with protrusions. The protrusions are set at a certain angle and form a streamlined structure, so that the channels away from the first inlet or the second inlet gradually narrow.

[0009] Furthermore, the protrusion has a hollow structure and may contain electrical components for temperature detection.

[0010] Furthermore, the heating element includes, but is not limited to, heating tubes, heating plates, and heating films, wherein the heating tubes adopt a flat structure or PTC characteristic heating wire material to reduce the heating rate of the heater in case of dry burning abnormalities.

[0011] Furthermore, the heating element is equipped with a fixing plate, which is used to fix the heater in place during the casting process by contacting the mold on one side, thereby improving the positional accuracy of the heater.

[0012] Furthermore, the upper and lower surfaces of the fins are designed to be partially connected to the upper and lower cover plates, respectively, with gaps formed at the points of non-connection; the gaps between the fins and the upper cover plate and between the fins and the lower cover plate form heat exchange channels.

[0013] Furthermore, the heater body, upper cover plate, and lower cover plate are all integral die-cast aluminum alloy structures.

[0014] Furthermore, the fins are wavy, serrated, straight, or platform-shaped, and the fins are continuous or discontinuous, with a height of 2–5 mm.

[0015] Furthermore, the heater body and the heater base are integrally cast.

[0016] Furthermore, the upper and lower cover plates are provided with grooves to facilitate welding.

[0017] Furthermore, the upper cover plate is equipped with a location near the inlet and outlet for installing inlet and outlet water temperature monitoring equipment.

[0018] The beneficial effects of this invention are as follows:

[0019] 1. Conventional aluminum castings have a single-sided heating structure, with one side in contact with the liquid and the other side in contact with the air, resulting in low thermal efficiency. This invention adopts an immersion-type double-sided heating design, making full use of the heat dissipation area and achieving high heating efficiency. Simultaneously, it employs a flow channel structure combining inlet, outlet, and heat exchange channels, and the intermittent and curved fin structure increases the heat exchange area and disturbs the water flow, thereby enhancing the heat exchange effect.

[0020] 2. The inlet and outlet channels are designed with gradually narrowing channels, which narrows the channels away from the inlet and outlet, increases the flow velocity, and enhances heat exchange.

[0021] 3. The upper and lower surfaces of the fins are partially connected to the upper and lower cover plates, respectively, which reduces the heat transfer area between the heating components and the upper and lower cover plates, thus reducing unnecessary heat transfer; at the same time, the gap at the non-connection point forms a heat exchange channel, which increases the flow area of ​​the heat exchange channel.

[0022] 4. Heating tubes with PTC resistance wires offer stable heating power and a longer lifespan, while also improving overall safety; the flat heating tube structure increases the planar heat exchange area, thereby increasing heat exchange capacity.

[0023] 5. Design a fixing plate as a fixing method for the electric heating tube during the die casting process to ensure that the electric heating tube is horizontal and not exposed during the die casting process, that the heating effect on both sides is consistent, and that the water temperature is uniform, thereby improving the positional accuracy of the heater. Attached Figure Description

[0024] Figure 1 This is an exploded three-dimensional schematic diagram of the present invention.

[0025] Figure 2 This is a three-dimensional view of the assembly of the present invention with the heater base removed.

[0026] Figure 3 This is a schematic diagram of the main structure of the present invention with the top cover removed.

[0027] Figure 4 for Figure 2 A schematic diagram of the main structure.

[0028] Figure 5 for Figure 4 A schematic diagram of the CC cross-section structure.

[0029] Figure 6 for Figure 2 A partial cross-sectional three-dimensional schematic diagram.

[0030] Figure 7 This is a schematic diagram of the fin structure of the present invention. Figure 1 .

[0031] Figure 8 This is a schematic diagram of the fin structure of the present invention. Figure 2 .

[0032] Figure 9 This is a schematic diagram of the three-layer flow channel structure of the present invention.

[0033] Figure 10 This is a schematic diagram of the main structure of the electric heating element.

[0034] Figure 11 This is a schematic diagram of the heating element from below.

[0035] Figure 12 This is a schematic diagram of the positioning structure during the casting of the electric heating tube.

[0036] Explanation of reference numerals in the attached drawings: 1. Upper cover plate; 2. Heater body; 2. First inlet / outlet 2-1; 2. Second inlet / outlet 2-2; 3. Lower cover plate; 4. Heating element; 5. Water inlet channel; 6. Heat exchange channel; 7. Fin; 8. Protrusion; 9. Heater base; 10. Outer cover plate; 11. NTC bracket; 12. Bottom cover plate; 13. PCB board; 14. Plastic bracket; 15. Fixing piece; 16. Upper mold; 17. Lower mold; 18. Water outlet channel. Detailed Implementation

[0037] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0038] like Figures 1-6As shown, a vehicle-mounted electric heating tube casting heater includes a heater body 2, a heater base 9, an upper cover plate 1, and a lower cover plate 3. Both the upper cover plate 1 and the lower cover plate 3 are externally covered by an outer cover plate 10. The heater body 2, upper cover plate 1, and lower cover plate 3 are all integral die-cast aluminum alloy structures. Using aluminum alloy material reduces the overall weight while ensuring heat transfer effect and strength. An NTC bracket 11 is provided between the upper cover plate 1 and the outer cover plate 10. The NTC bracket 11 is equipped with electrical components for temperature detection and is positioned near the first inlet / outlet 2-1 or the second inlet / outlet 2-2. The heater base 9 contains a PCB board 13 for controlling the heater. A plastic bracket 14 is provided between the PCB board 13 and the heater base 9. The heater base 9 is sealed to the bottom cover plate 12.

[0039] The heater body 2 is open at both ends and welded and sealed to the upper cover plate 1 and the lower cover plate 3 respectively. The heater body 2 is provided with a first inlet and outlet 2-1 and a second inlet and outlet 2-2. A heating assembly is installed in the middle of the heater body 2. The heating assembly consists of a heating element 4 and fins 7. The fins 7 are arranged on the upper and lower end faces of the heating element 4. The gap between adjacent fins 7 forms a heat exchange channel 6. The upper and lower heat exchange channels form an immersion double-sided heating structure. The two sides of the fins 7 are respectively provided with an inlet channel 5 and an outlet channel 18. The inlet channel 5 and the outlet channel 18 are connected to the first inlet and outlet 2-1 and the second inlet and outlet 2-2 respectively. The inlet channel 5 and the outlet channel 18 are connected by the heat exchange channel 6. Both the inlet channel 5 and the outlet channel 18 are provided with a gradually narrowing channel structure. After the fluid passes through this structure, the channel narrows, the fluid stratifies, the flow resistance gradually decreases, the flow velocity increases, and the heat exchange effect is increased.

[0040] As a preferred technical solution, the first inlet / outlet 2-1 and the second inlet / outlet 2-2 are located on the same side of the heater body 2. The inlet channel 5 and the outlet channel 18 are both provided with protrusions 8. The protrusions 8 are streamlined hollow structures with a certain slope and can be provided with electrical components for detecting temperature inside, so that the channels away from the first inlet / outlet 2-1 or the second inlet / outlet 2-2 gradually narrow.

[0041] As a preferred technical solution, the heating element 4 includes, but is not limited to, an electric heating tube, a heating plate, and a heating film. In this embodiment, the electric heating tube is a flat structure or a heating wire material with PTC characteristics, which reduces the heating rate of the heater in case of dry burning abnormalities. Flattening the electric heating tube provides a higher level of safety. The flat electric heating tube structure increases the planar heat exchange area, reduces the amount of cast aluminum material, lightens the overall weight, and increases the heat exchange capacity.

[0042] As a preferred technical solution, the immersion-type double-sided heating design adopted in this invention fully utilizes the heat dissipation area and has high heating efficiency. However, this design places high demands on the quality control of the casting process. To ensure that the heating element is not exposed horizontally during the die-casting process, that the heating effect on both sides is consistent, and that the water temperature is uniform, a fixing plate is designed as a method of fixing the heating element during the die-casting process, such as... Figure 10-11 As shown, a fixing plate 15 is provided on the heating element. During the casting process, the fixing plate 15 contacts and fixes the heater to one side of the mold to improve the positional accuracy of the heater. Figure 12 The positioning method of the heating element shown is as follows: 15 is a fixing plate, 16 and 17 are the upper and lower molds respectively, and 4 is the heating element. During the mold closing process, the fixing plate 15 is clamped between the upper mold 16 and the lower mold 17, so that the heating element is stable and firm during the casting process and does not shift or misalign. The end of the fixing plate can be milled off during the post-processing of the casting without affecting the product performance.

[0043] As a preferred technical solution, the upper and lower surfaces of the fins 7 are partially connected to the upper cover plate 1 and the lower cover plate 3, respectively, with gaps formed at the unconnected points. The gaps between the upper layer of fins 7 of the heating element and the upper cover plate 1, and the gaps between the lower layer of fins 7 of the heating element and the lower cover plate 3, form heat exchange channels 6. That is, only necessary connections are left between the heating assembly and the upper and lower cover plates, reducing unnecessary heat transfer.

[0044] As a preferred technical solution, the fins 7 are wavy, serrated, straight, or truncated structures, and the fins 7 are continuous or discontinuous, with a height of 2-5 mm, a thickness of 1-4 mm, and a spacing of 2-7 mm. Figure 7 As shown, the discontinuous, wave-shaped fin structure forms a wave-shaped heat exchange channel 6. This channel is relatively unobstructed, increasing the heat dissipation area while enhancing the turbulent flow of water. (The last sentence appears to be incomplete and unrelated to the preceding text.) Figure 8 It has a continuous linear fin structure, thus forming a linear heat exchange channel 6.

[0045] As a preferred technical solution, such as Figure 9 As shown, a flow channel structure formed by adding the gap between the middle fins is added to the upper and lower heat exchange channels to form a three-layer heat exchange channel. Similarly, more than three layers of heat exchange channels can also be made.

[0046] As a preferred technical solution, the upper cover plate 1 and the lower cover plate 3 are provided with grooves that facilitate welding, the thickness of the upper and lower cover plates is 1mm to 5mm, and the thickness of the grooves is 0.5mm to 4mm.

[0047] As a preferred technical solution, the upper cover plate 1 is provided with a position for installing monitoring equipment for inlet and outlet water temperature near the inlet and outlet.

[0048] As a preferred technical solution, the heating element can be a single structure, or it can be as follows: Figure 10-11 The two-strand structure shown can be used in the same way as a multi-strand structure with two or more strands.

[0049] Working process: Water enters from the first inlet / outlet 2-1 into the inlet channel 5. One flow enters into the gap between adjacent fins 7 on the upper layer of the heating element to form a heat exchange channel, and the gap between the fins 7 on the upper layer of the heating element and the upper cover plate 1 to form a heat exchange channel. The other flow enters into the gap between adjacent fins 7 on the lower layer of the heating element to form a heat exchange channel, and the gap between the fins 7 on the lower layer of the heating element and the upper cover plate 1 to form a heat exchange channel. After sufficient heat exchange in the heat exchange channels, the water flows out through the outlet channel 18 and the second inlet / outlet 2-2.

[0050] It is understood that, for those skilled in the art, any equivalent substitutions or modifications to the technical solutions and inventive concepts of this invention should fall within the scope of protection of the appended claims.

Claims

1. A casting heater for automotive electric heating tubes, characterized in that: It includes a heater body (2), a heater base (9), an upper cover plate (1) and a lower cover plate (3), and an outer cover plate (10) is provided on the outside of the upper cover plate (1) and the lower cover plate (3); The heater body (2) has two openings and is welded and sealed to the upper cover plate (1) and the lower cover plate (3) respectively. The heater body (2) is provided with a first inlet and outlet (2-1) and a second inlet and outlet (2-2). A heating component is installed in the middle of the heater body (2). The heating assembly consists of a heating element (4) and fins (7). The fins (7) are arranged on the upper and lower end faces of the heating element (4), and the gap between adjacent fins (7) forms a heat exchange channel (6). The fins (7) are provided with an inlet channel (5) and an outlet channel (18) on both sides respectively. The inlet channel (5) and the outlet channel (18) are connected to the first inlet / outlet (2-1) and the second inlet / outlet (2-2) respectively. The inlet channel (5) and the outlet channel (18) are connected by a heat exchange channel (6). The first inlet / outlet (2-1) and the second inlet / outlet (2-2) are located on the same side of the heater body (2). The inlet channel (5) and the outlet channel (18) are both provided with protrusions (8). The protrusions (8) are set at a certain angle and form a streamlined structure, so that the channels away from the first inlet / outlet (2-1) or the second inlet / outlet (2-2) gradually narrow. The protrusion (8) is a hollow structure, and an electrical component for detecting temperature is installed inside; The upper and lower surfaces of the fins (7) are respectively connected to the upper cover plate (1) and the lower cover plate (3) in a structure that is not completely connected, and a gap is formed at the unconnected part; the gap between the fins (7) and the upper cover plate (1) and the gap between the fins (7) and the lower cover plate (3) form a heat exchange channel (6).

2. The automotive electric heating tube casting heater according to claim 1, characterized in that: An NTC bracket (11) is provided between the upper cover plate (1) and the outer cover plate (10). The NTC bracket (11) is equipped with an electrical component for detecting temperature and is located near the first inlet / outlet (2-1) or the second inlet / outlet (2-2).

3. The automotive electric heating tube casting heater according to claim 1, characterized in that: The heater base (9) contains a PCB board (13) for controlling the heater. There is a plastic bracket (14) between the PCB board (13) and the heater base (9). The heater base (9) is sealed to the bottom cover plate (12).

4. The automotive electric heating tube casting heater according to claim 1, characterized in that: The heating element (4) includes a heating tube, a heating plate or a heating film, wherein the heating tube adopts a flat structure or a heating wire material with PTC characteristics to reduce the heating rate of the heater when dry burning is abnormal.

5. The automotive electric heating tube casting heater according to claim 4, characterized in that: The heating element is provided with a fixing plate (15), which is fixed by contacting the mold on one side during the casting process to improve the positional accuracy of the heater.

6. The automotive electric heating tube casting heater according to claim 1, characterized in that: The heater body (2), upper cover plate (1) and lower cover plate (3) are all integral die-cast aluminum alloy structures.

7. The automotive electric heating tube casting heater according to claim 1, characterized in that: The fins (7) are wavy, sawtooth, straight or platform-shaped structures, and the fins (7) are continuous or discontinuous structures with a height of 2~5mm.

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