Immersed thick film heating element based on new energy automobile

Abstract

The invention relates to the technical field of new energy heating, in particular to an immersed thick film heating element based on a new energy automobile, which comprises a substrate, a conductor layer and a resistive layer, a first insulating layer is arranged between the substrate and the conductor layer, and one end of the resistive layer is connected with a second insulating layer. A heating element is formed among the substrate, the first insulating layer, the conductor layer, the resistance layer and the second insulating layer, and the heating element is of an immersed structure with two sides in contact with cooling liquid; according to the structure, a double-face contact cooling liquid mode is adopted, the defect that a traditional single-face contact cooling liquid mode can only heat the cooling liquid from one direction is overcome, the heating element can heat the cooling liquid from two directions at the same time due to the double-face contact cooling liquid design, and the heating efficiency is improved; the high-voltage power supply can be used on a high-voltage version and can reach 800VDC, and the withstand voltage can reach 4000VDC; the heat efficiency is improved, and the heat loss is less; and meanwhile, the assembling space is small.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy heating, and in particular to an immersion thick film heating element based on new energy vehicles. Background Art

[0002] A thick film heating element is a heating device manufactured using thick film technology and is widely used in various application scenarios that require local or rapid heating. This technology prints a resistive material on a substrate through methods such as screen printing and then forms a strong and efficient heating layer through high-temperature sintering. Immersion means soaking the entire heating element in a coolant to reduce the impact of overheating on the heating element.

[0003] However, the disadvantages of existing products are as follows: Firstly: The existing products use the PTC heating method on high-voltage platforms, with poor insulation. They usually adopt a one-piece coating structure. When the coating structure is damaged, it is easy to form a short circuit, local overheating, or directly cause the product to be scrapped. Secondly: The existing heating efficiency is low. Most of the existing products use the single-sided heating method. When the coolant contacts the heating element, one end of the heating element can contact the coolant, while the other end is in a vacant state, resulting in ineffective heating and the occurrence of useless work behavior. Thirdly: The assembly space is large. Multiple mounting surfaces are required to enable the heating element to contact the coolant on both sides, increasing the manufacturing cost while reducing the working efficiency. Moreover, the area of the PTC heating method has a brick structure, which occupies a large area and is prone to breakage after heating. Therefore, the inventor has proposed an immersion thick film heating element based on new energy vehicles to solve the above-mentioned technical problems. Summary of the Invention

[0004] The invention aims to provide a technical solution to overcome the above deficiencies.

[0005] An immersion thick film heating element based on new energy vehicles includes a substrate, a conductor layer, and a resistive layer. The resistive layer is installed on the surface of the conductor layer. A first insulating layer is provided between the substrate and the conductor layer. One end of the resistive layer is connected to a second insulating layer. The substrate, the first insulating layer, the conductor layer, the resistive layer, and the second insulating layer form a heating element. The heating element has a thick film structure and is an immersion structure with double-sided contact with the coolant. This structure uses the method of double-sided contact with the coolant to improve the pain point of the traditional single-sided contact with the coolant, which can only heat the coolant from one direction. The design of double-sided contact with the coolant enables the heating element to heat the coolant from two directions simultaneously, improving the heating efficiency and making the heating of the coolant by the heating element more effective. The traditional design of single-sided contact with coolant has limitations in heating efficiency and heat dissipation performance, which easily leads to problems such as uneven heating and poor heat dissipation. By adopting the design method of double-sided contact with coolant, heat can be more evenly distributed, reducing the phenomenon of thermal stress concentration caused by local overheating, and lowering the risk of material fatigue and damage. First: The double-sided contact design can transfer heat to the coolant more evenly, avoiding problems such as local overheating or uneven heating, enhancing the overall heating effect, thus improving the heat exchange efficiency, enabling heat to be carried away by the coolant more quickly, preventing the heating element from overheating. Moreover, due to more efficient heat dissipation, it avoids the overheating phenomenon at one end after heating while the other end does not contact the coolant or does not dissipate heat in time, reducing the risk of aging and damage of the heating element caused by overheating, and extending its service life. Second: The design of double-sided contact with coolant can provide a higher heating power within the same volume, optimizing the space utilization rate. This design is specifically tailored to fit the limited space environment in new energy vehicles. And this design can flexibly adjust the size and shape of the heating element according to actual needs, adapt to different installation positions and requirements, facilitate disassembly and installation, and improve the assembly efficiency. Third: This design can transfer heat to the coolant faster, achieving the effect of rapid temperature rise, enhancing the user experience. Due to higher heating efficiency, the system can reach the set temperature in a shorter time, reducing energy consumption, meeting the requirements of energy conservation and environmental protection. By the way of immersion double-sided contact with coolant, the heating element effectively solves problems such as uneven heating and poor heat dissipation that may be encountered in traditional heating methods, further reducing energy consumption and achieving the effect of rapid temperature rise. On the other hand, the first insulating layer and the second insulating layer provide double insulation protection to ensure that current does not leak into the coolant or into the components adjacent to the heating element, improving the safety of the system. Adopting the double-insurance method of the first insulating layer and the second insulating layer as insulation, this structure effectively prevents the risk of electrical short circuit or leakage, ensuring the reliability and safety of the system operation. The heating element in this structure is a thick-film heating element structure, which is 500 nanometers to 5 micrometers thicker than traditional thin films. The thick-film technology can achieve a higher power density in a smaller area, enabling the heating element to provide more heat output in a limited space, which is suitable for the application scenario of internal heating of new energy vehicles with limited space. In addition, due to the close connection of the thick-film heating element, it can quickly respond to temperature changes, provide efficient heating performance, and has good thermal conductivity. This allows the heating element to quickly convert electrical energy into heat energy and quickly transfer it to the coolant or other media, achieving rapid temperature rise and avoiding problems such as local overheating or uneven cooling. Moreover, the thick-film structure has a low resistivity, which can achieve high-power output at a lower voltage, improving the energy utilization efficiency. After the thick-film heating element in this structure undergoes high-temperature sintering treatment, its internal structure is dense, with corresponding mechanical strength and anti-fatigue performance, and can maintain stable performance during use.

[0006] Further, the substrate, the first insulating layer, the conductor layer, the resistance layer, and the second insulating layer are arranged in sequence; adopting the above structural arrangement method plays a role in improving electrical safety and preventing short circuits and leakage. The first insulating layer is located between the substrate and the conductor layer, and the second insulating layer is located at one end of the resistance layer, ensuring that the current does not directly contact the substrate or the components adjacent to the substrate, thus effectively preventing the occurrence of short circuits and leakage; and by setting two insulating layers, namely the first insulating layer and the second insulating layer, this structure provides double electrical isolation protection, achieving a double protection effect and further enhancing the safety and reliability of the system; This structure adopts the method of arranging each layer of materials in a specific order to form the overall structure of the heating element, which not only enhances the mechanical strength and stability of the entire heating element, but also reduces the risk of delamination caused by temperature changes or external stresses, improving the reliability of long-term use. The production process is simplified through a simple hierarchical structure, reducing the overall assembly difficulty and time, and improving the production efficiency; The orderly arranged layers of materials can select suitable high-temperature resistant materials according to actual needs to ensure that the heating element can still operate stably in a high-temperature environment; in this structure, the substrate is one of a ceramic matrix, a stainless steel matrix, or an aluminum matrix.

[0007] Further, the first insulating layer, the conductor layer, the resistance layer, and the second insulating layer are all printed on the surface of the substrate by screen printing, and the resistance layer is arranged in a linear stepped shape on the surface of the substrate; This structure uses screen printing technology to achieve patterned deposition, ensuring that each of the first insulating layer, the conductor layer, the resistance layer, and the second insulating layer can be printed on the substrate according to the design requirements. Using screen printing can ensure the consistency of products between batches, reduce the differences between batches, and improve the stability of product quality; The resistive layer is arranged in a linear stepped pattern, enabling the current to be evenly distributed across the entire heating element, avoiding problems such as local overheating or uneven electric fields, enhancing the overall electrical performance. The operator can adjust the resistance value as needed to achieve the desired heating power and temperature control effect, thereby realizing local temperature gradient control to meet the requirements of specific application scenarios. In addition, the resistive layer with a linear stepped arrangement can more effectively disperse heat, making the heat more evenly distributed on the surface of the substrate, thus improving the heat conduction efficiency.

[0008] Furthermore, the first insulating layer includes a first dielectric layer, a second dielectric layer, a third dielectric layer, and a fourth dielectric layer. The individual layer thickness of the first dielectric layer, the second dielectric layer, the third dielectric layer, and the fourth dielectric layer is approximately 35 micrometers, and the total film thickness of the first insulating layer is greater than or equal to 110 micrometers. In addition, when the total thickness is 110 micrometers, it not only ensures sufficient insulation performance but also does not overly increase the thermal resistance, ensuring that heat can be efficiently conducted out to prevent overheating. By adjusting the thickness and material combination of each dielectric layer, fine adjustment of the insulation performance and heat conduction performance can be achieved to meet the requirements of different application scenarios.

[0009] Furthermore, screen printing is used for coating and forming connections between the first dielectric layer, the second dielectric layer, the third dielectric layer, and the fourth dielectric layer, and it is a composite coating connection structure with one coating and one sintering each time. By using the method of coating only one dielectric layer material at a time and sintering it thereon, it can ensure that each layer reaches the best uniformity and consistency. This structure helps to avoid problems such as uneven thickness or bubbles caused by coating too much material at one time. Through the method of layer-by-layer coating and sintering, the thickness and performance parameters of each layer can be more precisely controlled, thus ensuring the high quality of the final product. After each layer of material is independently sintered, a strong bonding interface is formed, enhancing the mechanical strength and stability of the overall structure. This layered structure helps to disperse stress, reducing deformation or damage caused by excessive local stress. Moreover, the composite structure formed by layer-by-layer coating and sintering has better fatigue resistance and can remain stable during long-term use, extending the service life of the product.

[0010] Furthermore, the second insulating layer includes a first protective layer, a second protective layer, a third protective layer, and a fourth protective layer. The individual layer thickness of the first protective layer, the second protective layer, the third protective layer, and the fourth protective layer is approximately 35 micrometers, and the total film thickness of the second insulating layer is greater than or equal to 110 micrometers. The material, process, and function of the second insulating layer are the same as those of the first insulating layer described above.

[0011] Furthermore, the first protective layer, the second protective layer, the third protective layer and the fourth protective layer are all coated and connected by screen printing, and it is a composite coating connection structure that is coated and sintered once.

[0012] Furthermore, the surfaces of the first insulating layer and the second insulating layer are respectively provided with a first reserved hole, a second reserved hole and a third reserved hole, and the resistance layer and the conductor layer are both arranged with clearance grooves paired with the first reserved hole, the second reserved hole and the third reserved hole.

[0013] Furthermore, the surface of the substrate is provided with an installation reserved hole for placing an external temperature probe. The installation reserved hole sequentially penetrates through the first insulating layer, the conductor layer, the resistance layer and the second insulating layer, and an avoidance area corresponding to the installation reserved hole is provided in the middle of the conductor layer and the resistance layer.

[0014] Furthermore, one end of each of the first insulating layer and the second insulating layer is provided with a convex structure. A pad reserved hole is provided on the surface of the convex structure of the second insulating layer, and a pad structure is filled on the surface of the pad reserved hole; One end of the conductor layer and the resistance layer are respectively provided with a resistance pin and an extension pin. One end of the resistance pin and the extension pin both extend to the surface of the pad structure. An insulating sealing ring placed externally is connected to the edge of the pad structure, and the insulating sealing ring is attached to the surface of the pad structure by an externally placed method; The design of the pad reserved hole and the pad structure enables the resistance pin and the extension pin to be accurately welded and connected to the external circuit, ensuring that current can smoothly pass through each layer and reducing problems such as poor contact or open circuit, providing electrical connection points, ensuring that current can be smoothly transmitted to the external circuit, and enabling more reliable electrical interconnection between different layers through the pad structure, simplifying the welding steps and reducing the complexity of manual operations.

[0015] Compared with the prior art, the beneficial effects of the present invention are: 1. This structure adopts the method of double-sided contact with the coolant, improving the pain point drawback that the traditional method of single-sided contact with the coolant can only heat the coolant from one direction. The design of double-sided contact with the coolant enables the heating element to heat the coolant from two directions simultaneously, improving the heating efficiency and making the heating element more effective in heating the coolant; 2. The present invention improves the limitations of the traditional design of single-sided contact with the coolant in terms of heating efficiency and heat dissipation performance, which is prone to problems such as uneven heating and poor heat dissipation. By adopting the design method of double-sided contact with the coolant, the heat can be more evenly distributed, reducing the phenomenon of thermal stress concentration caused by local overheating and reducing the risk of material fatigue and damage; 3. The double-sided contact design can transfer heat to the coolant more evenly, avoiding problems such as local overheating or uneven heating, improving the overall heating effect, thus enhancing the heat exchange efficiency, enabling the heat to be carried away by the coolant faster, preventing the heating element from overheating, and due to more efficient heat dissipation, avoiding the overheating phenomenon at one end after heating while the other end does not contact the coolant or does not dissipate heat in time, reducing the risk of aging and damage of the heating element caused by overheating, and extending its service life; 4. The design of double-sided contact with the coolant can provide a higher heating power within the same volume, optimizing the space utilization rate. This design is specifically tailored to fit the limited space environment in new energy vehicles, and this design can flexibly adjust the size and shape of the heating element according to actual needs, adapt to different installation positions and requirements, facilitate disassembly and installation, and improve the assembly efficiency; 5. This design can transfer heat to the coolant faster, achieving the effect of rapid temperature rise and enhancing the user experience. Since the heating efficiency is higher, the system can reach the set temperature in a shorter time, reducing energy consumption, meeting the requirements of energy conservation and environmental protection. By the way of immersing the heating element in the coolant with double-sided contact, the heating element effectively solves the problems such as uneven heating and poor heat dissipation that may be encountered in traditional heating methods, further reducing energy consumption and achieving the effect of rapid temperature rise; 6. The first insulating layer and the second insulating layer provide double insulation protection to ensure that current does not leak into the coolant or into the components adjacent to the heating element, improving the safety of the system. Using the first insulating layer and the second insulating layer as a double-insurance insulation method, this structure effectively prevents the risk of electrical short circuit or leakage, ensuring the reliability and safety of the system operation; 7. The heating element in this structure is a thick-film heating element structure, which is 500 nanometers to 5 micrometers thicker than traditional thin films. Using thick-film technology can achieve a higher power density in a smaller area, enabling the heating element to provide more heat output in a limited space, suitable for the application scenario of internal heating in new energy vehicles with limited space; 8. Due to the tight connection of the thick-film heating element, it can quickly respond to temperature changes, provide efficient heating performance, and has good thermal conductivity. This enables the heating element to quickly convert electrical energy into heat energy and quickly transfer it to the coolant or other media, achieving rapid temperature rise, avoiding problems such as local overheating or uneven cooling, and the thick-film structure has a lower resistivity, which can achieve high-power output at a lower voltage, improving the energy utilization efficiency; 9. After the thick-film heating element in this structure undergoes 4-layer screen printing and 4 times of high-temperature sintering cross-treatment, its internal structure is dense, with corresponding mechanical strength and anti-fatigue performance, and can maintain stable performance during use; 10. This product can be used in high-voltage versions up to 800 VDC, with a withstand voltage of up to 4000 VDC; moreover, the thermal efficiency is improved and the heat loss is less; at the same time, it has the advantage of a small assembly space. On the premise that the electrical connection needs to be sealed, this structure can be immersed in the coolant, so as to achieve the effect of insulating operation. Brief Description of the Drawings

[0016] Figure 1 is the front view of an immersion thick-film heating element based on a new energy vehicle; Figure 2 is the front view of the second insulating layer in this embodiment; Figure 3 is the front view of the resistance layer in this embodiment; Figure 4 is the front view of the conductor layer in this embodiment; Figure 5 is the front view of the first insulating layer in this embodiment; Figure 6 is the front view of the substrate in this embodiment; Figure 7 is a partial enlarged view of an immersion thick-film heating element based on a new energy vehicle; Figure 8 is an exploded view of an immersion thick-film heating element based on a new energy vehicle; Figure 9 is a layered structure of an immersion thick-film heating element based on a new energy vehicle; Figure 10 is a three-dimensional view of the housing in an immersion thick-film heating element based on a new energy vehicle; Figure 11 is a reference diagram for the modeling operation of an immersion thick-film heating element based on a new energy vehicle.

[0017] In the figure: Substrate - 1, Conductor layer - 2, Resistance layer - 3, First insulating layer - 4, Second insulating layer - 5, First dielectric layer - 6, Second dielectric layer - 7, Third dielectric layer - 8, Fourth dielectric layer - 9, First protective layer - 10, Second protective layer - 11, Third protective layer - 12, Fourth protective layer - 13, First reserved hole - 14, Second reserved hole - 15, Third reserved hole - 16, Clearance groove - 17, Mounting reserved hole - 18, Avoidance area - 19, Protrusion structure - 20, Pad reserved hole - 21, Pad structure - 22, Resistance pin - 23, Extension pin - 24, Insulating sealing ring - 25, Housing - 26, Power contact area - 27, Mounting groove - 28, Partition - 29, Flow channel - 30, Water inlet - 31, Water outlet - 32, Mounting area - 33, Temperature measurement area - 34. Detailed Embodiment

[0018] The present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0019] For this embodiment, please refer to Figures 1-11 , a specific implementation of an immersion thick-film heating element based on a new energy vehicle, which includes a substrate 1, a conductor layer 2, and a resistance layer 3. The resistance layer 3 is installed on the surface of the conductor layer 2. A first insulating layer 4 is provided between the substrate 1 and the conductor layer 2. One end of the resistance layer 3 is connected to a second insulating layer 5. The substrate 1, the first insulating layer 4, the conductor layer 2, the resistance layer 3, and the second insulating layer 5 form a heating element. The heating element is a thick-film structure and is an immersion structure that is in double-sided contact with the coolant. This structure adopts the method of double-sided contact with the coolant, improving the pain and disadvantages of the traditional single-sided contact with the coolant, which can only heat the coolant from one direction. The design of double-sided contact with the coolant enables the heating element to heat the coolant from two directions simultaneously, improving the heating efficiency and making the heating element more effective in heating the coolant. The traditional design of single-sided contact with the coolant has limitations in heating efficiency and heat dissipation performance, easily leading to problems such as uneven heating and poor heat dissipation. By adopting the design method of double-sided contact with the coolant, the heat can be more evenly distributed, reducing the phenomenon of thermal stress concentration caused by local overheating, and lowering the risk of material fatigue and damage. First: The double-sided contact design can transfer heat to the coolant more evenly, avoiding problems such as local overheating or uneven heating, enhancing the overall heating effect, thus improving the heat exchange efficiency, enabling the heat to be taken away by the coolant faster, preventing the heating element from overheating. And due to more efficient heat dissipation, it avoids the overheating phenomenon caused by the other end not contacting the coolant or not dissipating heat in time after one end is heated, reducing the risk of aging and damage of the heating element caused by overheating, and extending its service life. Second: The design of double-sided contact with the coolant can provide a higher heating power within the same volume, optimizing the space utilization rate. This design is specifically tailored to fit the limited space environment in new energy vehicles, and the design can flexibly adjust the size and shape of the heating element according to actual needs, adapt to different installation positions and requirements, facilitate disassembly and installation, and improve the assembly efficiency. Third: This design can transfer heat to the coolant faster, achieving the effect of rapid temperature rise, enhancing the user experience. Due to higher heating efficiency, the system can reach the set temperature in a shorter time, reducing energy consumption, meeting the requirements of energy conservation and environmental protection. By means of immersion double-sided contact with the coolant, the heating element effectively solves problems such as uneven heating and poor heat dissipation that may be encountered in traditional heating methods, further reducing energy consumption and achieving the effect of rapid temperature rise. On the other hand, double insulation protection is provided by the first insulating layer 4 and the second insulating layer 5, ensuring that current leakage occurs into the coolant or components adjacent to the heating element, improving the safety of the system. By using the double insurance of the first insulating layer 4 and the second insulating layer 5 as the insulation method, this structure effectively prevents the risks of electrical short - circuit or electric leakage, ensuring the reliability and safety of the system operation; The heating element in this structure is a thick - film heating element structure, which is 500 nanometers to 5 micrometers thicker than traditional thin films. The thick - film technology can achieve a higher power density in a smaller area, enabling the heating element to provide more heat output in a limited space, which is suitable for the application scenario of internal heating in new - energy vehicles with limited space. In addition, due to the tight connection of the thick - film heating element, it can quickly respond to temperature changes, providing efficient heating performance and good thermal conductivity. This allows the heating element to quickly convert electrical energy into heat energy and rapidly transfer it to the coolant or other media, achieving rapid temperature rise, avoiding problems such as local overheating or uneven cooling. Moreover, the thick - film structure has a lower resistivity, enabling high - power output at a lower voltage, improving the energy utilization efficiency. After the thick - film heating element in this structure undergoes high - temperature sintering treatment, its internal structure is dense, having corresponding mechanical strength and fatigue resistance, and can maintain stable performance during use.

[0020] The substrate 1, the first insulating layer 4, the conductor layer 2, the resistance layer 3 and the second insulating layer 5 are arranged in sequence; Adopting the above - mentioned structural arrangement method plays a role in improving electrical safety and preventing short - circuit and electric leakage. The first insulating layer 4 is located between the substrate 1 and the conductor layer 2, and the second insulating layer 5 is located at one end of the resistance layer 3, ensuring that the current does not directly contact the substrate 1 or components adjacent to the substrate 1, thus effectively preventing the occurrence of short - circuit and electric - leakage phenomena. By setting two insulating layers, namely the first insulating layer 4 and the second insulating layer 5, this structure provides double electrical isolation protection, achieving a double - protection effect and further enhancing the safety and reliability of the system; In addition, through the close contact between the conductor layer 2 and the resistance layer 3, this contact helps to achieve more precise temperature control, ensuring that the heating element can operate stably within the set temperature range. At the same time, the heat generated by the resistance layer 3 can be quickly conducted to the conductor layer 2 and transferred to the coolant through the conductor layer 2, optimizing the heat - conduction path. This structural design reduces the thermal resistance, improves the heat - conduction efficiency, and further achieves the effect of efficient heat conduction. Moreover, as an intermediate layer, the conductor layer 2 can not only quickly conduct heat but also evenly distribute the heat over the entire surface, avoiding local overheating and extending the service life of the heating element; This structure forms the overall structure of the heating element by arranging the materials of each layer in a specific order. It not only enhances the mechanical strength and stability of the entire heating element, but also reduces the risk of delamination caused by temperature changes or external stresses, improving the reliability for long-term use. The production process is simplified through a simple hierarchical structure, reducing the overall assembly difficulty and time, and improving production efficiency; The materials of each layer arranged in an orderly manner can select appropriate high-temperature resistant materials according to actual needs to ensure that the heating element can still operate stably in a high-temperature environment. In this structure, the substrate 1 is one of a ceramic matrix, a stainless steel matrix, or an aluminum matrix: The ceramic matrix includes alumina ceramics, aluminum nitride ceramics, and zirconia ceramics, which have good thermal conductivity and mature processes; The stainless steel matrix has good thermal conductivity, high mechanical strength, and good toughness, and there is no mechanical damage during rapid cooling and heating; The aluminum matrix has the advantages of good thermal conductivity, high mechanical strength, and good toughness, and there is no mechanical damage during rapid cooling and heating; The conductor layer 2 is coated by screen printing of conductor paste. The functional phases of the conductor paste include gold, silver, palladium, platinum in the noble metal system and copper, nickel in the base metal system. The conductor layer 2 can select one of them as the conductor; The resistance layer 3 is coated by screen printing of resistance paste. The functional phases of the resistance paste include silver, palladium, ruthenium dioxide in the noble metal system and nickel, tungsten in the noble metal system or graphene in the graphene carbon system. The resistance layer 3 can select one of them as the resistance.

[0021] The first insulating layer 4, the conductor layer 2, the resistance layer 3, and the second insulating layer 5 are all printed and coated on the surface of the substrate 1 by screen printing. The resistance layer 3 is arranged in a linear stepped shape on the surface of the substrate 1; This structure realizes patterned deposition by screen printing technology, ensuring that each of the first insulating layer 4, the conductor layer 2, the resistance layer 3, and the second insulating layer 5 can be printed and coated on the substrate 1 according to the design requirements. Using screen printing can ensure the consistency of products between batches, reduce the differences between batches, and improve the stability of product quality; The linear stepped arrangement of the resistance layer 3 enables the current to be evenly distributed across the entire heating element, avoiding problems such as local overheating or uneven electric fields, enhancing the overall electrical performance. Operators can adjust the resistance value as needed to achieve the ideal heating power and temperature control effects, thereby realizing local temperature gradient control to meet the requirements in specific application scenarios. In addition, the resistance layer 3 arranged in a linear stepped shape can more effectively disperse heat, making the heat more evenly distributed on the surface of the substrate 1, thus improving the heat conduction efficiency; The design of this structure is not only applicable to the heating system of new energy vehicles, but also to fields such as household appliances, medical equipment, and office equipment. The medical equipment field includes but is not limited to far-infrared physiotherapy devices, ventilators, and moxibustion devices; the office equipment field includes but is not limited to laser printers.

[0022] The first insulating layer 4 includes a first dielectric layer 6, a second dielectric layer 7, a third dielectric layer 8, and a fourth dielectric layer 9. The individual layer thicknesses of the first dielectric layer 6, the second dielectric layer 7, the third dielectric layer 8, and the fourth dielectric layer 9 are approximately 35 microns, and the total film thickness of the first insulating layer 4 is greater than or equal to 110 microns; The first insulating layer 4 is coated by screen printing of dielectric paste. The dielectric paste includes barium titanate, borosilicate, and alumina ceramics. Each of the four dielectric layers can be coated with one of barium titanate, borosilicate, and alumina ceramics. The design of multiple dielectric layers increases the thickness of the overall insulating layer, thereby improving the electrical insulation performance, ensuring that current does not leak to other components or the coolant, and enhancing the safety of the system; In this structure, each dielectric layer provides a certain degree of insulation protection. A multiple protection barrier is formed through the combined action of the four dielectric layers, further reducing the risk of electric leakage. Moreover, the multi-layer structure can effectively disperse external stress, reduce deformation or damage caused by excessive local stress, enhance the mechanical strength and stability of the entire insulating layer. Since each dielectric layer can share a part of the stress, it helps to evenly distribute heat, avoid local overheating, improve the overall thermal management ability, and at the same time make the overall structure have better durability and fatigue resistance, extending the service life; In addition, when the total thickness is 110 microns, it not only ensures sufficient insulation performance but also does not overly increase the thermal resistance, ensuring that heat can be efficiently conducted out to prevent overheating. By adjusting the thickness and material combination of each dielectric layer, fine adjustment of the insulation performance and heat conduction performance can be achieved to meet the requirements of different application scenarios; The conductor paste, resistor paste, and dielectric paste are bonded through a bonding phase. The bonding phase includes glass powder, oxides, and mixtures of glass powder and oxides. The glass powder is high borosilicate or aluminum silicate. The organic carriers between the conductor paste, resistor paste, and dielectric paste are organic solvents, thickening agents, ethyl cellulose, and lecithin. The organic solvents include one of terpineol, butyl carbitol acetate, and terpineol in alcohols.

[0023] The first dielectric layer 6, the second dielectric layer 7, the third dielectric layer 8, and the fourth dielectric layer 9 are all coated by screen printing to form connections, and it is a composite coating connection structure with one coating and one sintering; By applying the medium layer material one layer at a time and sintering it thereon, the best uniformity and consistency can be ensured for each layer. This structure helps to avoid problems such as uneven thickness or bubbles caused by applying too much material at one time. Through the method of layer-by-layer coating and sintering, the thickness and performance parameters of each layer can be more precisely controlled, thus ensuring the high quality of the final product; After each layer of material is sintered independently, a strong bonding interface is formed, enhancing the mechanical strength and stability of the overall structure. This layered structure helps to disperse stress, reduce deformation or damage caused by excessive local stress, and the composite structure formed by layer-by-layer coating and sintering has better fatigue resistance, can remain stable during long-term use, and extends the service life of the product; In addition, after each layer of material is sintered independently, heat conduction and diffusion can be better achieved, avoiding the problem of increased thermal resistance caused by applying too much material at one time, helping to improve the overall thermal management efficiency, preventing overheating. On the other hand, by using the method of layer-by-layer coating and sintering, the operator can adjust the thermal conductivity of each layer of material, thus achieving more precise temperature gradient control to meet the requirements of specific application scenarios. When a defect appears or adjustment is needed in a certain layer, it can be treated separately without affecting other layers, simplifying the production process and improving production efficiency; Each layer of material in this structure can adopt a single-layer structure layer composed of one of barium titanate, borosilicate, and alumina ceramics. This single-layer structure has good anti-vibration performance and is suitable for applications in environments with frequent vibrations such as new energy vehicles to maintain long-term stable operation; On this basis, each dielectric layer provides a certain degree of electrical isolation protection. The four dielectric layers work together to form a multi-layer protection barrier, further reducing the risk of leakage and enhancing the safety of the system. At the same time, it has good sealing performance, can effectively prevent moisture and other impurities from entering, and improves the reliability and durability of the equipment.

[0024] The second insulating layer 5 includes a first protective layer 10, a second protective layer 11, a third protective layer 12, and a fourth protective layer 13. The individual layer thicknesses of the first protective layer 10, the second protective layer 11, the third protective layer 12, and the fourth protective layer 13 are approximately 35 microns. The total thickness of the second insulating layer 5 is greater than or equal to 110 microns. The material, process, and function of the second insulating layer 5 are the same as those of the first insulating layer 4 described above. The functions, materials, processes, and functions of the first protective layer 10, the second protective layer 11, the third protective layer 12, and the fourth protective layer 13 are equivalent to the functions, materials, processes, and functions of the first dielectric layer 6, the second dielectric layer 7, the third dielectric layer 8, and the fourth dielectric layer 9.

[0025] The first protective layer 10, the second protective layer 11, the third protective layer 12, and the fourth protective layer 13 are all coated and connected by screen printing, and are a composite coating connection structure formed by coating and sintering once. The functions, materials, processes, and functions of the first protective layer 10, the second protective layer 11, the third protective layer 12, and the fourth protective layer 13 are the same as those of the first dielectric layer 6, the second dielectric layer 7, the third dielectric layer 8, and the fourth dielectric layer 9.

[0026] On the surfaces of the first insulating layer 4 and the second insulating layer 5, first reserved holes 14, second reserved holes 15, and third reserved holes 16 are respectively provided. The resistor layer 3 and the conductor layer 2 are both arranged with clearance grooves 17 used in pair with the first reserved holes 14, the second reserved holes 15, and the third reserved holes 16. On the surface of the substrate 1, an installation reserved hole 18 for placing an external temperature probe is provided. The installation reserved hole 18 sequentially penetrates through the first insulating layer 4, the conductor layer 2, the resistor layer 3, and the second insulating layer 5. Avoidance areas 19 corresponding to the installation reserved hole 18 are provided in the middle of the conductor layer 2 and the resistor layer 3. Among them, the first reserved hole 14, the clearance groove 17, the installation reserved hole 18, and the avoidance area 19 form an installation area 33. This installation area 33 is used to connect external screws or fasteners to facilitate the position limitation of the heating element and achieve the effect of installation and fixation, as Figure 1 shown; The second reserved hole 15, the third reserved hole 16, and the clearance groove 17 form a temperature measurement area 34. The temperature measurement area 34 is assisted in temperature measurement by an external temperature measurement component. The working mode of the temperature measurement area 34 is that the external temperature measurement component extends into the housing 26 and obtains temperature measurement data after contacting the surface of the temperature measurement area 34, as Figure 1 shown.

[0027] At one end of the first insulating layer 4 and the second insulating layer 5, a convex structure 20 is provided. On the surface of the convex structure 20 of the second insulating layer 5, a pad reserved hole 21 is provided, and a pad structure 22 is filled on the surface of the pad reserved hole 21. At one end of the conductor layer 2 and the resistor layer 3, a resistor pin 23 and an extension pin 24 are respectively provided. One ends of the resistor pin 23 and the extension pin 24 both extend to the surface of the pad structure 22. An insulating sealing ring 25 placed externally is connected to the edge of the pad structure 22. The insulating sealing ring 25 is attached to the surface of the pad structure 22 by an externally placed method. The design of the pad reserved hole 21 and the pad structure 22 enables the resistor pin 23 and the extension pin 24 to be accurately connected to the external circuit by welding, ensuring that the current can smoothly pass through each layer and reduce the problem of poor contact or open circuit, providing an electrical connection point to ensure that the current can be smoothly transmitted to the external circuit, and more reliable electrical interconnection can be achieved between different layers through the pad structure 22, simplifying the welding steps and reducing the complexity of manual operation; The raised structure 20 can disperse external stress and increase the heat dissipation area to a certain extent while protecting the product. During the installation process, if the product falls to the ground due to a mistake or incorrect operation, the raised structure 20 will preferentially contact the ground and collide with the ground under the influence of gravity due to the change in the center of gravity, thereby reducing the probability of forming multiple impact points and causing further damage to the product, thereby protecting the product. The design of the resistor pin 23 and the extension pin 24 can also avoid excessive heat accumulation at specific locations, thereby reducing the formation of hot spots, helping to evenly distribute heat and improve overall thermal management efficiency. The insulating sealing ring 25 plays a filling and blocking role, reducing the probability of leakage and coolant penetrating into the pad structure 22.

[0028] The key points of the design of the present invention are: it can be used in a high voltage version up to 800VDC, and the withstand voltage can reach 4000VDC; the thermal efficiency is improved, and the heat loss is less; at the same time, it has the advantage of small assembly space. Under the premise that the electrical connection is sealed, the structure can be immersed in the coolant, so as to achieve the effect of insulation operation; This structure adopts a double-sided contact coolant method, which improves the disadvantage that the traditional single-sided contact coolant method can only heat the coolant from one direction. The double-sided contact coolant design allows the heating element to heat the coolant from two directions at the same time, improving the heating efficiency and making the heating element more effective in heating the coolant. The present invention improves the traditional single-sided coolant contact design, which has limitations in heating efficiency and heat dissipation performance and easily leads to uneven heating and poor heat dissipation. The double-sided coolant contact design can distribute heat more evenly, reduce the thermal stress concentration caused by local overheating, and reduce the risk of material fatigue and damage. The double-sided contact design can transfer heat to the coolant more evenly, avoiding local overheating or uneven heating, improving the overall heating effect, thereby enhancing the heat exchange efficiency, allowing heat to be taken away by the coolant faster, preventing the heating element from overheating. Moreover, since the heat dissipation is more efficient, it avoids overheating caused by one end being heated while the other end is not in contact with the coolant or not dissipating the heat in time, thereby reducing the risk of aging and damage of the heating element due to overheating and extending its service life.

[0029] The operation process of the present invention is as follows: By installing a heating element inside the housing 26, a power contact area 27 is provided inside the housing 26. The external power supply is electrically connected to the pad structure 22 through the power contact area 27, so that the heat generated by the resistance layer 3 can be quickly conducted to the conductor layer 2 and the substrate 1, and is transferred to the coolant through the conductor layer 2 and the substrate 1. The heat conduction path is optimized, and the design reduces the thermal resistance and improves the heat conduction efficiency. An installation groove 28 for placing the heating element is opened inside the housing 26. A partition 29 is connected inside the installation groove 28, and the area formed between adjacent partitions 29 is a flow channel 30. An inlet 31 and an outlet 32 are respectively provided inside the installation groove 28. Both the inlet 31 and the outlet 32 penetrate the inside of the installation groove 28 and extend beyond the outside of the housing 26, as Figure 11 shown; When the heating element is placed inside the installation groove 28, the coolant enters the inside of the installation groove 28 through the inlet 31. Since the housing 26 is an up-and-down closed installation structure to form a closed space, the coolant contacts the surface of the heating element through the flow channel 30. When the coolant inside the housing 26 completely immerses the heating element, the heating element has also completed heating the coolant. Affected by the water pressure, the coolant is discharged from the inside of the installation groove 28 through the outlet 32. At the same time, the heated coolant is transported to the corresponding operation module through a pipeline. The operation modules are in a mutual reflux structure to achieve a circulating effect. Finally, the coolant passes through the operation module and is transported to a water storage tank or a container for storing the coolant through a pipeline, and then the coolant is pressed in by pressurizing the container to complete the process of recycling, as Figure 11 shown.

[0030] In this embodiment: The base material 1 is austenitic stainless iron series 4; The first insulating layer 4 is a high borosilicate glass system and is used to form insulation with the base material 1; the conductor layer 2 is a silver palladium / silver platinum system and is used for conducting electricity and electrical connection; the resistance layer 3 is a silver palladium / silver platinum system and is used as a heating layer; the second insulating layer 5 is a high borosilicate glass system and is used to insulate with the external coolant. The low voltage platform of this heating element is 400 VDC, the high voltage platform is 800 VDC, and the working voltage is manually adjusted by the operator according to the working or environmental requirements; the rated power is: 3500 W - 7000 W; the insulation withstand voltage value is: 2300 Vac / 5 mA / 1 min, and the maximum temperature that can be tolerated is 250 °C - 300 °C.

[0031] In this embodiment, the test temperatures of the thick film heating element are 25 °C, 60 °C, 100 °C, and 125 °C, and the temperature coefficient reference table is as follows: Table 1: TCR Temperature Coefficient Reference Table The above content is a further detailed description of the present invention in combination with specific preferred embodiments. It cannot be determined that the specific implementation of the present invention is only limited to these descriptions. For those of ordinary skill in the technical field to which the present invention pertains, without departing from the concept of the present invention, several simple deductions or substitutions can still be made, which should all be regarded as the protection scope of the present invention.

Claims

1. An immersion thick film heating element based on a new energy vehicle, comprising a substrate, a conductor layer and a resistance layer, characterized in that: The resistance layer is installed on the surface of the conductor layer. A first insulating layer is provided between the substrate and the conductor layer. One end of the resistance layer is connected with a second insulating layer. A heating element is formed among the substrate, the first insulating layer, the conductor layer, the resistance layer and the second insulating layer. The heating element is an immersion structure that is in double-sided contact with the coolant.

2. The immersion thick film heating element based on a new energy vehicle according to claim 1, characterized in that: The substrate, the first insulating layer, the conductor layer, the resistance layer and the second insulating layer are arranged in sequence.

3. The immersion thick film heating element based on a new energy vehicle according to claim 1, wherein: The first insulating layer, the conductor layer, the resistance layer and the second insulating layer are all printed on the surface of the substrate by screen printing. The resistance layer is arranged in a linear stepped pattern on the surface of the substrate.

4. A submerged thick-film heating element based on a new energy vehicle according to any one of claims 1-3, characterized in that: The first insulating layer includes a first dielectric layer, a second dielectric layer, a third dielectric layer and a fourth dielectric layer.

5. The immersion thick film heating element based on a new energy vehicle according to claim 4, characterized in that: The connection between the first dielectric layer, the second dielectric layer, the third dielectric layer and the fourth dielectric layer is formed by screen printing coating, and it is a composite coating connection structure with one coating and one sintering.

6. A submersed thick film heating element based on a new energy vehicle according to any one of claims 1-3, characterized in that: The second insulating layer includes a first protective layer, a second protective layer, a third protective layer and a fourth protective layer.

7. The immersion thick film heating element based on a new energy vehicle according to claim 6, wherein: The connection between the first protective layer, the second protective layer, the third protective layer and the fourth protective layer is formed by screen printing coating, and it is a composite coating connection structure with one coating and one sintering.

8. A submerged thick film heating element based on a new energy vehicle according to any one of claims 1-3, characterized in that: First reserved holes, second reserved holes and third reserved holes are respectively formed on the surfaces of the first insulating layer and the second insulating layer. The resistance layer and the conductor layer are both arranged with clearance grooves that are paired with the first reserved holes, the second reserved holes and the third reserved holes.

9. A submerged thick film heating element based on a new energy vehicle according to any one of claims 1-3, characterized in that: Installation reserved holes for connecting external screws are formed on the surface of the substrate. The installation reserved holes sequentially penetrate through the first insulating layer, the conductor layer, the resistance layer and the second insulating layer. Avoidance areas corresponding to the installation reserved holes are formed in the middle of the conductor layer and the resistance layer.

10. A submerged thick-film heating element based on a new energy vehicle according to any one of claims 1-3, characterized in that: Convex structures are provided at one end of both the first insulating layer and the second insulating layer. Pad reserved holes are formed on the surface of the convex structure of the second insulating layer, and pad structures are filled on the surfaces of the pad reserved holes; Resistance pins and extension pins are respectively provided at one end of the conductor layer and the resistance layer. One ends of the resistance pins and the extension pins both extend to the surface of the pad structure, and an insulating sealing ring placed externally is connected to the edge of the pad structure.

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