Vehicle liquid heater capable of increasing power in leap-over mode

Abstract

The vehicle liquid heater is characterized in that water chambers are arranged on the two sides in a main shell of a shell assembly, the lower ends of the water chambers are open, and a water inlet and outlet pipe is arranged at the position, corresponding to the water chambers on the two sides, of the front portion of the main shell; the efficient heat exchange unit comprises a flat pipe body, a first thick film heating resistance layer and a second thick film heating resistance layer, two ends of the flat pipe body are matched and welded with lower end openings of the water chambers on two sides to form closed water chambers; the control unit is installed in the main shell and located above the efficient heat exchange unit and comprises a control panel, a plurality of IGBTs and a water temperature sensor. The plurality of IGBTs are welded with the control panel through pins, the water temperature sensor is integrated on the control panel, and the temperature measuring end of the water temperature sensor is inserted into a water temperature sensor positioning hole in the main shell; the two groups of terminal strips are respectively connected with the thick film heating resistance layers on the two surfaces and are connected with the control panel; the high-voltage plug connector and the low-voltage plug connector are respectively fixed at corresponding mounting ports at the front end of the main shell. The device is small in size, light in weight and capable of achieving power crossing.

Description

Technical Field

[0001] The invention belongs to the technical field of automobile air conditioners, and in particular relates to a vehicle liquid heater structure capable of leapfrogging to increase power. Background Art

[0002] A car fluid heater is an important automotive component that plays a key role in cold weather conditions by heating the vehicle's coolant and delivering warm air into the vehicle interior to provide a comfortable driving environment.

[0003] New energy vehicles are developing rapidly towards platformization. In order to save development and manufacturing costs, the requirement for the same parts to match different models and different performances has been widely proposed. However, the existing automotive liquid heaters are limited by structure and material limitations and can only adjust the power within a small range within their limited power. It is impossible to achieve the requirement of leapfrogging the power under the existing size, which seriously restricts the development of the industry. Summary of the invention

[0004] In view of the deficiencies in the prior art, the present invention proposes a vehicle liquid heater which is simple, compact, light in weight and can meet the heating requirements of vehicles of different models and performances without changing the external dimensions and can increase the power in a leapfrog manner.

[0005] The above-mentioned object of the present invention is achieved by the following technical solutions:

[0006] A vehicle liquid heater capable of leapfrogging to increase power, characterized in that it mainly comprises a high-efficiency heat exchange unit, a housing assembly, a high-voltage connector, a low-voltage connector, a control unit, an IGBT fixing plate, and a terminal block;

[0007] The housing assembly is composed of a main housing, an upper cover and a lower cover; the upper cover and the lower cover are respectively sealed and fixedly connected to the upper end and the lower end of the main housing; water chambers are arranged on both sides of the main housing, and the lower ends of the water chambers on both sides are open; an outwardly extending inlet and outlet water pipes are respectively arranged at the front of the main housing at positions corresponding to the water chambers on both sides, and the inlet and outlet water pipes on both sides are respectively connected to the water chambers on the corresponding sides;

[0008] The high-efficiency heat exchange unit comprises a flat tube body, a first thick film heating resistor layer printed on one side of the flat tube body, and a second thick film heating resistor layer printed on the other side of the flat tube body; the two ends of the flat tube body of the high-efficiency heat exchange unit are matched with the lower end open positions of the two side water chambers on the main shell and connected by circumferential welding to form a closed water chamber;

[0009] The control unit is installed in the main housing above the high-efficiency heat exchange unit. The control unit consists of a control board, multiple IGBTs, and a water temperature sensor. The multiple IGBTs are welded to the control board through a pin structure and are pressed and fixed by an IGBT fixing plate fixedly connected to the main housing. The water temperature sensor is integrated on the control board, and the temperature measuring end of the water temperature sensor is inserted into the water temperature sensor positioning hole on the main housing.

[0010] The terminals at one end of the two sets of terminal blocks are respectively connected to the two sides of the high-efficiency heat exchange unit and the reserved pads of the corresponding thick film heating resistor layer by welding, and the other ends of the two sets of terminal blocks are connected to the control board;

[0011] The high-voltage connector and the low-voltage plug connector are respectively fixed at the high-voltage connector installation interface and the low-voltage plug connector installation interface positions at the front end of the main housing, and are both connected to the control board.

[0012] Moreover, both ends of the flat tube body are located below the flat tube hole and are welded with outwardly extending flow channel plates; the flow channel plates at both ends cover the lower end opening of the corresponding water chamber and are welded to the inner wall of the main shell to form a closed water chamber; guide protrusions are arranged on the flow channel plates at both ends, and the guide protrusions are evenly distributed and inclined along the water flow direction in the water chamber, and the inclination directions of the guide protrusions on the flow channel plates at both ends are set in opposite directions.

[0013] Moreover, the two ends of the flat tube body adopt a structural form in which the upper wall is removed to expose the flat tube hole. The two ends of the flat tube body cover the lower end opening of the corresponding water chamber and are welded to the inner wall of the main shell to form a closed water chamber; terminal row connection holes and openings are formed between the two groups of flow channels on both sides of the flat tube.

[0014] Moreover, one of the two groups of terminal blocks consists of a plastic insulating protective shell and wiring terminals fixed thereon, and the other group of terminal blocks consists of a plastic insulating protective shell and wiring terminals fixed thereon and a board temperature sensor; both groups of terminal blocks are installed at the terminal block connection holes on the flat tube, and the temperature sensing probe of the board temperature sensor is inserted into the opening on the flat tube to monitor the temperature of the thick film heating resistor layers on both sides.

[0015] Moreover, the first thick film heating resistor layer and the second thick film heating resistor layer on the two side surfaces of the flat tube adopt the same power density, wherein the thick film heating resistor layer on the side away from the control board is the main heating unit, and the thick film heating resistor layer on the other side is the auxiliary heating unit; the ratio of the heating power of the auxiliary heating unit to the heating power of the main heating unit is 0.8 to 1.0.

[0016] Moreover, the main shell adopts a hollow structure, and a circle of annular grooves are provided at the upper and lower ends of the main shell. The edges of the upper cover and the lower cover are provided with annular edges, and the annular edges of the upper cover and the lower cover are respectively inserted into the annular grooves at the upper end of the main shell and the annular grooves at the lower end of the main shell, and the main shell forms a plug-in sealing connection with the upper cover and the lower cover by filling the sealant in the gap between the annular grooves and the corresponding annular edges.

[0017] Furthermore, it also includes a heat insulation board, which is arranged between the upper part of the high-efficiency heat exchange unit and the lower part of the control board; the heat insulation board and the control board share a common mounting point and are fixed to the main shell together.

[0018] The advantages and positive effects of the present invention are:

[0019] 1. The present invention directly welds the two ends of the flat tube of the high-efficiency heat exchange unit to the water chambers on both sides of the main shell. Compared with the existing structure in which the high-efficiency heat exchange unit and the main shell are assembled separately, it has the advantages of compact structure, small volume and light weight. Compared with products of the same specifications, it can reduce weight by about 30%.

[0020] 2. The present invention realizes the use of 0 sealing rings between the high-efficiency heat exchange unit and the main shell, and between the main shell and the upper and lower covers, with good sealing and high reliability.

[0021] 3. By controlling the power of the single and double-sided thick film heating resistor layer, the present invention can achieve a leapfrog increase in power compared to heaters of the same size and specification, and can increase the heating power by up to 1 times. The structure and its multi-level control can meet the use requirements of different models without changing the external dimensions and interfaces, promote the platformization of the heater, and reduce repeated design and development costs; in addition, through the multi-level control principle, the high-efficiency heat exchange unit can start the thick film heating resistor layer on the other side after one thick film heating resistor layer fails, without affecting the power output, thereby improving the reliability of the thick film heater.

[0022] 4. The combination of the flat tube and the guide plate of the present invention is an innovative structure. The guide plate can balance the water channel inside the flat tube, making the flow field of the flat tube more uniform. At the same time, the raised structure of the guide plate can play a reinforcing role and increase the structural strength of the entire water channel.

[0023] 5. In the second embodiment of the present invention, the terminal block and the temperature sensor are integrated together, and the two temperature sensors are optimized into one sensor through an innovative structure, which does not affect the temperature monitoring of the thick film, saves costs, and can effectively improve the space utilization of the thick film layout.

[0024] 6. The present invention has a wide applicable voltage range and can be applied to voltage requirements of DC800V and above, and can match the power according to the customer's heating power requirements, up to 10kW and above. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is the overall appearance of the first embodiment of the present invention. Figure 1 ;

[0026] Figure 2 This is the overall appearance of the first embodiment of the present invention. Figure 2 ;

[0027] Figure 3 is a three-dimensional exploded view of the first embodiment of the present invention;

[0028] Figure 4 is an appearance diagram of a high-efficiency heat exchange unit in Embodiment 1 of the present invention;

[0029] Figure 5 is a three-dimensional exploded view of a high-efficiency heat exchange unit in Embodiment 1 of the present invention;

[0030] Figure 6 6a is a schematic diagram of the installation of a high-efficiency heat exchange unit and a terminal block in the first embodiment of the present invention, 6a is a front schematic diagram, and 6b is a rear schematic diagram;

[0031] Figure 7 This is a schematic diagram of the installation of PCBA and other connectors in the first embodiment of the present invention;

[0032] Figure 8 is an overall half-section view of the first embodiment of the present invention;

[0033] Fig. 9 This is the overall appearance of the second embodiment of the present invention. Figure 1 ;

[0034] Fig.10 This is the overall appearance of the second embodiment of the present invention. Figure 2 ;

[0035] Fig.11 is a three-dimensional exploded view of the second embodiment of the present invention;

[0036] Fig.12 is an appearance diagram of a high-efficiency heat exchange unit in Embodiment 2 of the present invention;

[0037] Fig.13 is a three-dimensional exploded view of a high-efficiency heat exchange unit in Embodiment 2 of the present invention;

[0038] Fig.14 14a is a schematic diagram of the installation of the high-efficiency heat exchange unit and the terminal block on the main housing in the second embodiment of the present invention, 14b is a schematic diagram of the reverse side;

[0039] Fig.15 Schematic diagram of the installation of PCBA and other connectors on the main housing in the second embodiment of the present invention;

[0040] Fig.16 is an assembly diagram of the wiring terminal and the board temperature sensor in the second embodiment of the present invention;

[0041] Fig.17 It is a schematic diagram of the installation of the wiring terminal and the board temperature sensor in the second embodiment of the present invention;

[0042] Fig.18 is an overall half-section view of the second embodiment of the present invention;

[0043] Fig.19 is a schematic diagram of a heat device control unit of the present invention;

[0044] Fig. 20 It is a diagram of the installation structure of the water temperature sensor of the heater of the present invention.

[0045] Fig.21 Schematic diagram of the water circuit of the heater of the present invention (taking the second embodiment as an example);

[0046] Fig. 22 It is a schematic diagram of the multi-stage control principle of the present invention. DETAILED DESCRIPTION

[0047] The structure of the present invention is further described below with reference to the accompanying drawings and by way of examples. It should be noted that the present examples are descriptive rather than restrictive.

[0048] A car fluid heater that can greatly increase power, see Figure 1-Figure 22 The invention point is: it mainly includes a high-efficiency heat exchange unit, a shell assembly, a high-voltage connector 11, a low-voltage connector 10, a grounding bolt 9, a control unit 2, an IGBT fixing plate 1, and a terminal block.

[0049] The housing assembly is composed of a main housing 3, an upper cover 4 and a lower cover 6 connected together.

[0050] The main invention points of the vehicle liquid heater with leap-forward power increase are as follows: 1. The main shell adopts a hollow structure, and a ring groove is provided at the upper and lower ends of the main shell. The edges of the upper cover and the lower cover are provided with ring edges. The ring edge of the upper cover is inserted into the ring groove at the upper end of the main shell, and is bonded and connected by filling sealant to achieve sealing. Similarly, the ring edge of the lower cover is inserted into the ring groove at the lower end of the main shell, and is bonded and connected by filling sealant to achieve sealing, so that the upper and lower ends of the main shell can achieve a good sealing effect. In addition, water chambers 13 are provided on both sides of the hollow in the main shell, and the lower ends of the water chambers on both sides are open. An outwardly extending inlet and outlet water pipes are respectively provided at the front of the main shell corresponding to the positions of the water chambers on both sides. The inlet and outlet water pipes on both sides are respectively connected to the water chambers on the corresponding sides, and the inlet and outlet water pipes on one side are used as the inlet pipe, and the inlet and outlet water pipes on the other side are used as the outlet pipe. A high-voltage connector installation interface and a low-voltage plug-in installation structure are provided at the position between the two inlet and outlet water pipes on the front wall of the main shell.

[0051] 2. The two ends of the flat tubes of the high-efficiency heat exchange unit are matched with the lower open positions of the water chambers on both sides of the main shell and are directly welded and connected through the circumference to form a closed water chamber.

[0052] 3. Thick film heating resistor layers are printed on both sides of the flat tubes of the high-efficiency heat exchange unit, and the thick film heating on both sides is individually heated and controlled by a control unit.

[0053] The two achievable structural forms of the vehicle liquid heater that can leapfrog to increase power are as follows:

[0054] Embodiment 1:

[0055] In this embodiment, the high-efficiency heat exchange unit 8 is composed of a flat tube body 8.1, a first thick film heating resistor layer 8.2 printed on one side of the flat tube body, a second thick film heating resistor layer 8.3 printed on the other side of the flat tube body, a first flow channel plate 8.4 and a second flow channel plate 8.5.

[0056] The main structure of the flat tube is drawn from aluminum profiles and does not require secondary processing. Its main function is to be used as a substrate for printing thick film heating resistor layers. The second function is to provide a water flow channel and play a role in heat exchange. The first thick film heating resistor layer and the second thick film heating resistor layer are both composed of an insulating layer, a resistor conductor layer, and a protective layer. They are formed after multiple sintering and printing in the furnace. Its main function is to provide a heat source. The first flow channel plate and the second flow channel plate are aluminum plate stamping structures, on which guide protrusions are arranged. The guide protrusions are evenly distributed along the long side of the flow channel plate. One is to balance the water flow and strengthen the structure. The other is to connect the flat tube and the shell to form a complete water flow channel. The guide protrusions arranged on the two flow channel plates can have various forms, not limited to Figure 4 , Figure 5 Examples in .

[0057] The assembly sequence of the high-efficiency heat exchange unit in this embodiment is as follows: After the flat tube is drawn, it is first necessary to clean and dry it, and then print the first thick film heating resistor layer and the second thick film heating resistor layer on both sides of the flat tube. After completion, the first flow channel plate and the second flow channel plate are welded to both ends of the flat tube by laser welding to form a high-efficiency heat exchange unit, such as Figure 4 Specifically, the two flow channel plates are flush with the lower end surfaces of both ends of the flat tube, and the thickness of the flow channel plate should be smaller than the distance between the lower edge of the flat tube hole and the lower end surface of the flat tube to avoid the flow channel plate blocking the flat tube hole.

[0058] The advantages of this high-efficiency heat exchange unit are: the flat tube does not require secondary processing, the surface of the flat tube will not be damaged for the second time, the flat tube has a high pass rate, plays a positive role in printing thick films, and at the same time saves a lot of machining processes to reduce processing costs.

[0059] Embodiment 2:

[0060] In this embodiment, the high-efficiency heat exchange unit 14 is mainly composed of a flat tube body 14.1, a first thick film heating resistor layer 14.2 and a second thick film heating resistor layer 14.3. The flat tube is also drawn from an aluminum profile, and certain machining is required to print the thick film heating resistor layer, such as Fig.12 and Fig.13 As shown, its function is the same as that of the flat tube in Example 1. The first thick film heating resistor layer and the second thick film heating resistor layer have the same structure and function as those in Example 1.

[0061] The assembly sequence of the high-efficiency heat exchange unit in this embodiment is as follows: after the flat tube is drawn, the upper wall part is firstly processed and removed from the upper part of both ends of the flat tube, and the terminal row connection holes are processed between the two groups of flow channels on both sides of the flat tube. After completion, the two sides of the flat tube need to be polished, then cleaned and dried, and then the thick film heating resistor layer is printed on the surface of both sides of the flat tube to form a high-efficiency heat exchange unit. Fig.12 and Fig.13 shown.

[0062] In this embodiment, the flat tube is matched with the shell by machining, and no guide plate needs to be welded. The advantages are as follows:

[0063] ①The flat tube is integrated, which will not increase the number of welds and reduce the defects caused by welding;

[0064] ② By machine-adding holes on the flat tube to achieve the installation and fixation of the terminal block, the board temperature sensor and the terminal block can be integrated together, which can save space for the printed thick film heating resistor layer, thereby arranging more heating resistors and increasing the power of the entire heater. At the same time, the integrated structure can reduce the number of terminals in the terminal block, facilitating the subsequent connection of the electronic control board.

[0065] The inner flow channel of the flat tube of the present invention is arranged with an inner wing structure to enhance the heat exchange effect.

[0066] The first thick film heating resistor layer and the second thick film heating resistor layer on both sides of the flat tube must have the same power density, that is, the ratio of the heat dissipation area to the heating area on both sides of the flat tube must be the same, so as to avoid uneven heat exchange and cause abnormal high temperature in the thick film heating resistor layer. The heating power of the thick film heating resistor layer on the side away from the control board is greater than that of the thick film heating resistor layer on the other side, so the thick film heating resistor layer on the side away from the control board can be used as the main heating unit, and the thick film heating resistor layer on the other side can be used as the auxiliary heating unit.

[0067] The ratio of the heating power of the auxiliary heating unit to the heating power of the main heating unit is preferably controlled between 0.8 and 1. The ratio depends on the structural selection. In Example 1, the ratio is 1; in Example 2, the ratio is 0.85. When the heating power of the auxiliary heating unit is the same as that of the main heating unit, the heating power of the heater can be increased by 1 times. Under different usage requirements, the auxiliary heating unit can be selectively used or printed, which can reduce costs.

[0068] After the high-efficiency heat exchange unit is completed, it needs to be welded to the main shell. Both sides of the connection between the high-efficiency heat exchange unit and the shell need to be welded in a full circle to form a complete water flow channel.

[0069] The main function of the terminal row is to electrically connect the high-efficiency heat exchange unit with the control unit. The two sets of terminal rows are reflow-welded to weld the terminals at one end to the reserved pads on both sides of the high-efficiency heat exchange unit. In the first embodiment, the two terminal rows 7 and 12 need to be reflow-welded after the high-efficiency heat exchange unit is welded to the main shell. In the second embodiment, the two terminal rows 15 and 16 can be welded before or after the high-efficiency heat exchange unit is welded to the main shell. In order to save welding costs, it is recommended that the terminal rows be welded before welding the shell.

[0070] In the first embodiment, board temperature sensors are provided on both sides of the flat tube body to measure the temperature of the thick film surface on the corresponding side. In the second embodiment, one group of terminal rows 15 is composed of wiring terminals and a plastic insulating protective shell, while the other group of terminal rows 16 is composed of wiring terminals 16.1, a plastic insulating protective shell 16.3 and a board temperature sensor 16.2. The terminal row arrangement of the second embodiment simplifies the two board temperature sensors on both sides of the first embodiment into one board temperature sensor. In the second embodiment, a hole is opened in the middle of the flat tube, and the temperature probe of the board temperature sensor is inserted into the inside of the flat tube. To ensure the accuracy of temperature measurement, high-efficiency thermal conductive silicone grease is arranged between the temperature probe and the reserved opening of the flat tube. Fig.16 As shown, one board temperature sensor can monitor the temperature of two thick film heating surfaces.

[0071] The control unit is installed in the main housing above the high-efficiency heat exchange unit. The control unit can adjust the heating power of the high-efficiency heat exchange unit and realize various functions and protection of the heater. It is mainly composed of a control board 2.1, an IGBT 2.2, and a water temperature sensor 2.3. Fig.19 As shown. Among them, there are multiple capacitors, resistors, inductors and control circuits arranged on the PCB board, which mainly realize the connection and control functions. The IGBT is fixed on the control board through the pin structure welding, and its function is to control the heating power of the heater through the duty cycle; the water temperature sensor is integrated on the control board, and its function is to monitor the coolant temperature inside the inlet and outlet water pipes and feed back to the control board. Compared with the existing temperature sensor structure, it has a high degree of integration, does not need to be arranged and installed separately, and can save most of the space and the number of fasteners.

[0072] In order to achieve heat insulation between the efficient heat exchange unit and the control unit and avoid the adverse effects of high temperature on electronic components, in the present invention, a heat insulation board 5 is installed between the top of the efficient heat exchange unit and the bottom of the control board. The heat insulation board is made of PA66+30% glass fiber injection molding, and honeycomb-shaped reinforcement ribs are evenly distributed on the heat insulation board to increase the strength. For implementation 2, avoidance holes for terminal row installation need to be set at corresponding positions on the heat insulation board. The heat insulation board and the control board (PCBA) share a common installation point and are fixed to the main housing together.

[0073] The present invention adopts a multi-level control principle, such as Fig. 22 As shown, the principle is as follows:

[0074] ① For low-power models, the control board controls the power output of the main heating unit through IGBT1 and IGBT3, and the auxiliary heating unit does not work.

[0075] In low-power models, the function of the auxiliary heating unit is: after the main heating unit fails, the control board can start the auxiliary heating unit through IGBT2 and IGBT4 control, and cut off the main heating unit at the same time, which can improve the overall reliability of the heater and extend its service life.

[0076] ② For high-power models, auxiliary heating units and related components need to be arranged. The control board can simultaneously control the power of the main heating unit and auxiliary heating unit through all IGBTs.

[0077] The assembly sequence of the whole machine of the present invention is:

[0078] ①The two ends of the flat tubes of the high-efficiency heat exchange unit are welded to the circumference of the 6 main shell to ensure the sealing of the water channel.

[0079] ② The two sets of terminal rows connecting the thick film heating components on both sides are fixed to the main shell (Example 1) or the mounting holes reserved for the high-efficiency heat exchange unit (Example 2) by fastening screws. After fixing, the two sets of terminal rows and the reserved pads of the high-efficiency heat exchange unit are soldered together by reflow soldering to ensure the electrical connection between the thick film heating element and the terminal row.

[0080] ③After the terminal block is welded, gel is poured on both sides of the high-efficiency heat exchange unit, which can isolate condensed water and provide heat insulation.

[0081] ④ After the gel is cured, press the lower cover onto the main shell, and seal the lower cover and the main shell with sealant.

[0082] ⑤ Fix the low-voltage connector to the low-voltage connector installation interface position on the main housing by tightening the screws.

[0083] ⑥ The water temperature sensor positioning hole reserved on the main shell and the plate temperature sensor positioning hole reserved in the high-efficiency heat exchange unit are filled with thermal grease; an insulating film is arranged at the contact position between the IGBT and the shell. Among them, there are two water temperature sensor positioning holes reserved on the main shell, which are respectively set above the water chambers on both sides and close to the inlet and outlet pipes, but are not connected to the inner cavity of the water chamber.

[0084] ⑦ Arrange the heat insulation board and control unit in the shell according to the reserved positions and fix them with fastening screws.

[0085] ⑧After the control unit is fixed, fix the IGBT with the IGBT fixing plate.

[0086] ⑨ Weld the low-voltage connector pins, the two sets of terminal block pins and the control unit control board by welding.

[0087] ⑩ The high-voltage connector is fixed to the high-voltage connector installation interface position on the main housing by means of fastening screws, and the wiring on the high-voltage connector is connected to the control unit by means of fastening screws.

[0088] The upper cover is pressed onto the main shell, and the circumference of the upper cover and the main shell is sealed with sealant.

[0089] Finally, install the grounding bolt to complete the assembly of the entire heater.

[0090] The water channel of the vehicle liquid heater capable of leapfrogging to increase power of the present invention is shown in FIG. Fig.21 The water channel structure of the invention is completed by laser welding, which has high reliability. The main shell and the upper and lower covers adopt a buckled sealant structure to achieve the application of 0 sealing rings, which is safer and more reliable than the existing sealing ring structure. At the same time, it adopts an efficient heat exchange flow channel structure, with a high degree of component integration, more compact, lighter weight, fewer types of parts, and simple and quick assembly.

[0091] It should be particularly emphasized that compared with existing heaters of the same specifications and sizes, the heating power of the main heating unit alone is equivalent to that of existing heaters. When the main and auxiliary heating units are arranged at the same time, the heating power is up to 2 times larger. Therefore, the structure of the present invention and its multi-level control can meet the use requirements of different models without changing the external dimensions and interfaces, promote the platformization of heaters, and reduce design and development costs.

[0092] Although the embodiments and drawings of the present invention are disclosed for illustrative purposes, those skilled in the art will appreciate that various substitutions, changes and modifications are possible without departing from the spirit and scope of the present invention and the appended claims. Therefore, the scope of the present invention is not limited to the contents disclosed in the embodiments and drawings.

Claims

1. A vehicle liquid heater capable of increasing power in leaps and bounds, characterized in that: Including high-efficiency heat exchange unit, housing assembly, high-voltage connector, low-voltage connector, control unit, IGBT fixing plate, terminal block; The housing assembly is composed of a main housing, an upper cover and a lower cover; the upper cover and the lower cover are respectively sealed and fixedly connected to the upper end and the lower end of the main housing; water chambers are arranged on both sides of the main housing, and the lower ends of the water chambers on both sides are open; an outwardly extending inlet and outlet water pipes are respectively arranged at the front of the main housing at positions corresponding to the water chambers on both sides, and the inlet and outlet water pipes on both sides are respectively connected to the water chambers on the corresponding sides; The high-efficiency heat exchange unit comprises a flat tube body, a first thick film heating resistor layer printed on one side of the flat tube body, and a second thick film heating resistor layer printed on the other side of the flat tube body; the two ends of the flat tube body of the high-efficiency heat exchange unit are matched with the lower end open positions of the two side water chambers on the main shell and connected by circumferential welding to form a closed water chamber; The control unit is installed in the main housing above the high-efficiency heat exchange unit. The control unit consists of a control board, multiple IGBTs, and a water temperature sensor. The multiple IGBTs are welded to the control board through a pin structure and are pressed and fixed by an IGBT fixing plate fixedly connected to the main housing. The water temperature sensor is integrated on the control board, and the temperature measuring end of the water temperature sensor is inserted into the water temperature sensor positioning hole on the main housing. The terminals at one end of the two sets of terminal blocks are respectively connected to the two sides of the high-efficiency heat exchange unit and the reserved pads of the corresponding thick film heating resistor layer by welding, and the other ends of the two sets of terminal blocks are connected to the control board; The high-voltage connector and the low-voltage plug connector are respectively fixed at the high-voltage connector installation interface and the low-voltage plug connector installation interface positions at the front end of the main housing, and are both connected to the control board.

2. The vehicle liquid heater capable of leapfrogging power increase according to claim 1, characterized in that: The two ends of the flat tube body are located below the flat tube holes and are welded with outwardly extending flow channel plates; the flow channel plates at both ends cover the lower end opening of the corresponding water chamber and are welded to the inner wall of the main shell to form a closed water chamber; guide protrusions are arranged on the flow channel plates at both ends, and the guide protrusions are evenly distributed and inclined along the water flow direction in the water chamber, and the inclination directions of the guide protrusions on the flow channel plates at both ends are set in opposite directions.

3. The vehicle liquid heater capable of leapfrogging power increase according to claim 1, characterized in that: The two ends of the flat tube body adopt a structural form in which the upper wall is removed to expose the flat tube hole; the two ends of the flat tube body cover the lower end opening of the corresponding water chamber and are welded to the inner wall of the main shell to form a closed water chamber; terminal row connection holes and openings are formed between the two groups of flow channels on both sides of the flat tube.

4. The vehicle liquid heater capable of leapfrogging power increase according to claim 3, characterized in that: One of the two groups of terminal blocks consists of a plastic insulating protective shell and wiring terminals fixed thereon; the other group of terminal blocks consists of a plastic insulating protective shell and wiring terminals fixed thereon and a board temperature sensor; the two groups of terminal blocks are respectively installed at corresponding terminal block connection holes on the flat tube, and the temperature sensing probe of the board temperature sensor is inserted into the opening on the flat tube to monitor the temperature of the thick film heating resistor layers on both sides.

5. The vehicle liquid heater capable of leapfrogging power increase according to claim 1, characterized in that: The first thick film heating resistor layer and the second thick film heating resistor layer on the two side surfaces of the flat tube adopt the same power density, wherein the thick film heating resistor layer on the side away from the control board is the main heating unit, and the thick film heating resistor layer on the other side is the auxiliary heating unit; the ratio of the heating power of the auxiliary heating unit to the heating power of the main heating unit is 0.8 to 1.

0.

6. The vehicle liquid heater capable of leapfrogging power increase according to claim 1, characterized in that: The main shell adopts a hollow structure, and a circle of annular grooves are provided at the upper end and the lower end of the main shell. The edges of the upper cover and the lower cover are provided with annular edges. The annular edges of the upper cover and the lower cover are respectively inserted into the annular grooves at the upper end and the lower end of the main shell, and the main shell forms a plug-in sealing connection with the upper cover and the lower cover by filling the sealant in the gap between the annular grooves and the corresponding annular edges.

7. The vehicle liquid heater capable of leapfrogging power increase according to claim 1, characterized in that: It also includes a heat insulation board, which is arranged between the upper part of the high-efficiency heat exchange unit and the lower part of the control board; the heat insulation board and the control board share a common mounting point and are fixed to the main shell together.

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