Heating module for PTC (Positive Temperature Coefficient) air heater and PTC air heater

Abstract

The invention discloses a heating module for a PTC air heater and the PTC air heater, and relates to the technical field of heating equipment. The heating module comprises a first electrode plate, a second electrode plate and a plurality of PTC heating resistors, one end of the first electrode plate is provided with a first extending end, one end of the second electrode plate is provided with a second extending end, and the first extending end and the second extending end are located on the same side of the heating module. And the plurality of terminals are detachably connected with the convergence sheet. The PTC heating resistors are arranged between the first electrode plate and the second electrode plate and abut against the first electrode plate and the second electrode plate. Based on the technical scheme disclosed by the invention, local heating can be prevented from occurring between the confluence sheet and the heating module, the service life of the heating module is ensured, unnecessary wiring can be reduced, and the internal structure of the PTC air heater is effectively simplified.

Description

Technical Field

[0001] The present invention relates to the technical field of heating devices, and particularly relates to a heating module for a PTC air heater and a PTC air heater. Background Art

[0002] A PTC air heater is a heating device, and its core function is to achieve a fast and stable heating effect based on the self-limiting temperature characteristic of PTC ceramic materials and combined with forced convection of a fan.

[0003] A PTC air heater generally includes a PTC heating module, an electrical control system, and a mechanical protection structure. Inside it, multiple heating cores usually need to be connected in series with a bus bar, and a sensor is required to detect the temperature and feedback to the electrical control system to ensure that the outlet air temperature is stable at a set value.

[0004] In the related art, the existing PTC air heaters usually use laser electric welding to weld the bus bar to the heating core to achieve the series connection of multiple heating modules. This method has high requirements for the laser welding process, and poor welding will cause local overheating. Moreover, the sensors of the existing PTC air heaters are generally arranged inside the mechanical protection structure, and this arrangement method also requires additional wiring, which is rather cumbersome. Summary of the Invention

[0005] The purpose of the present invention is to overcome the above technical deficiencies, and propose a heating module for a PTC air heater and a PTC air heater, so as to solve the technical problems that poor welding between the bus bar and the heating core in the prior art easily causes local heating and the sensor wiring is cumbersome.

[0006] To achieve the above technical purpose, the present invention adopts the following technical solutions: In a first aspect, the present invention provides a heating module for a PTC air heater, including: A first electrode plate, one end of which is provided with a first extended end; A second electrode plate, arranged in parallel and spaced from the first electrode plate, and one end of the second electrode plate is provided with a second extended end; and Multiple PTC heating resistors, arranged between the first electrode plate and the second electrode plate, and opposite sides of the multiple PTC heating resistors respectively abut against the first electrode plate and the second electrode plate; Wherein, the first extended end and the second extended end are located on the same side of the heating module and are both detachably connected to a bus bar.

[0007] In some embodiments, the multiple PTC heating resistors are arranged in sequence in the same direction between the first electrode plate and the second electrode plate.

[0008] In some embodiments, dummy chips are provided on one side or both sides of the arrangement direction of the plurality of PTC heating resistors.

[0009] In some embodiments, a metal housing is sleeved outside the first electrode plate and the second electrode plate, and insulating layers are provided between the metal housing and the first electrode plate and the second electrode plate respectively.

[0010] In some embodiments, it further includes fins, and the fins are in contact with the outside of the metal housing.

[0011] In a second aspect, the present invention further provides a PTC air heater, including a housing, a bus bar, and the above-mentioned heating module, and the bus bar is detachably connected to the first protruding end and the second protruding end on the heating module.

[0012] In some embodiments, the PTC air heater further includes: a control box, which is detachably connected to the housing, and a grounding connection line is provided on the control box; and a metal elastic member, one side of which is in contact with the metal housing and the other side is in contact with the control box.

[0013] In some embodiments, a circuit board is fixedly arranged in the control box, and a temperature sensor for detecting the metal elastic member is integrally arranged on the circuit board.

[0014] In some embodiments, at least two heating modules are arranged side by side on the housing in the same direction, and the metal housings on each heating module are all in contact with the metal elastic member.

[0015] In some embodiments, a heat dissipation opening is provided on one side of the housing; each heating module is arranged side by side inside the heat dissipation opening in the same direction.

[0016] Compared with the prior art, the heating module and the PTC air heater for the PTC air heater provided by the present invention respectively set a first protruding end and a second protruding end on the first electrode plate and the second electrode plate, and are detachably connected to the bus bar through the first protruding end and the second protruding end, avoiding the traditional laser welding method, preventing local heating between the bus bar and the heating module, and ensuring the service life of the heating module; at the same time, by directly integrating the temperature sensor on the circuit board and cooperating with the metal elastic member to detect the temperature of the heating module, unnecessary wiring is reduced, and the internal structure of the PTC air heater is effectively simplified. Description of the Drawings

[0017] Figure 1 is a schematic diagram of the overall structure when the heating module in an embodiment of the present invention is applied to a PTC air heater; Figure 2 It is a schematic cross-sectional view of a PTC heating element in an embodiment of the present invention; Figure 3 It is an isometric view of a PTC heating element in an embodiment of the present invention; Figure 4 It is a schematic overall structure view of a PTC air heater in an embodiment of the present invention; Figure 5 It is a schematic cross-sectional view of a PTC air heater in an embodiment of the present invention; Figure 6 It is Figure 5 A partial enlarged schematic view of part A in [figure number], mainly used to show the bus bar and the grounding spring piece.

[0018] Explanation of reference numerals: 1, fin; 2, PTC heating element; 21, first electrode plate; 211, first extended end; 22, second electrode plate; 221, second extended end; 23, PTC heating resistor; 24, dummy piece; 25, metal shell; 26, insulating layer; 3, housing; 31, first housing; 32, second housing; 4, control box; 41, cover plate; 42, high-voltage plug-in connector; 43, low-voltage plug-in connector; 44, grounding connection wire; 5, heat dissipation opening; 6, circuit board; 7, bus bar; 71, metal sheet; 8, grounding spring piece; 9, temperature sensor. Detailed implementation manners

[0019] In order to make the objectives, technical solutions and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0020] To solve the above technical problems, the present invention provides a heating module for a PTC air heater and a PTC air heater, which can not only prevent local heating between the bus bar 7 and the heating module, ensure the service life of the heating module, but also reduce unnecessary wiring and effectively simplify the internal structure of the PTC air heater.

[0021] Please refer to Figure 1 , the present invention provides a heating module for a PTC air heater, which can be applied to the air-conditioning heating system of new energy vehicles. It includes a PTC heating element 2 and fins 1. The PTC heating element 2 uses the self-limiting temperature characteristic of PTC ceramic material to achieve heating, and the fins 1 can increase the heat dissipation area of the PTC heating element 2, thereby improving the heating effect.

[0022] Specifically, as Figure 2As shown, the above-mentioned PTC heating element 2 includes a first electrode sheet 21, a second electrode sheet 22, and a plurality of PTC heating resistors 23 disposed between the first electrode sheet 21 and the second electrode sheet 22.

[0023] Among them, the first electrode sheet 21 and the second electrode sheet 22 can be copper electrode sheets, or electrode sheets of other materials can be used according to needs, and no specific limitation is made thereto. The first electrode sheet 21 and the second electrode sheet 22 can be arranged in parallel at intervals, and a space for accommodating a plurality of PTC heating resistors 23 is formed therebetween.

[0024] A plurality of PTC heating resistors 23 are disposed between the first electrode sheet 21 and the second electrode sheet 22, and the specific number thereof can be set according to needs, and no specific limitation is made thereto. Taking any one of the PTC heating resistors 23 as an example, plating layers (not shown in the figure) are provided on both opposite sides of the PTC heating resistor 23. During actual assembly, a plurality of PTC heating resistors 23 can be arranged in sequence in the same direction between the first electrode sheet 21 and the second electrode sheet 22, and a plurality of PTC heating resistors 23 are respectively abutted against the first electrode sheet 21 and the second electrode sheet 22 through the plating layers on both sides thereof.

[0025] Combined Figure 3 , to facilitate the connection of the bus bar 7 on the PTC air heater, one end of the above-mentioned first electrode sheet 21 extends out a first extending end 211, and one end of the second electrode sheet 22 extends out a second extending end 221. The first extending end 211 and the second extending end 221 are located on the same side of the heating module. During actual assembly, the first extending end 211 and the second extending end 221 can be detachably connected to the bus bar 7 on the PTC air heater by a snap connection method.

[0026] Meanwhile, on both sides of the plurality of PTC heating resistors 23 in the arrangement direction of the plurality of PTC heating resistors 23, dummy sheets 24 are provided, and the dummy sheets 24 on both sides can block the opening between the first electrode sheet 21 and the second electrode sheet 22. In actual application, the dummy sheets 24 can play a protective role for the plurality of PTC heating resistors 23, reduce the risk of damage to the PTC heating resistors 23, and prevent impurities such as dust from entering the interior of the heating module, ensuring the cleanliness of the interior of the heating module.

[0027] It can be understood that two of the above-mentioned dummy sheets 24 can be provided according to needs, and on the premise of meeting the design requirements, only one of them can also be provided according to needs, and the specific one can be determined according to the design requirements of a specific occasion.

[0028] In this embodiment, a metal housing 25 is further sleeved outside the first electrode sheet 21 and the second electrode sheet 22. The material of the metal housing 25 can be an aluminum housing, or a housing of other materials can be used according to needs, and no specific limitation is made thereto.

[0029] Meanwhile, an insulating layer 26 is also provided between the metal housing 25 and the first electrode plate 21 and the second electrode plate 22. The insulating layer 26 is preferably an insulating film with insulating function. The insulating layer 26 can achieve an insulating effect between the metal housing 25 and the first electrode plate 21 / the second electrode plate 22, avoiding the metal housing 25 from being charged.

[0030] In this embodiment, the above-mentioned fin 1 can be arranged on the outer side of the metal housing 25 and abutted against the metal housing 25 to achieve the heat dissipation function. The material of the fin 1 can be a metal that is easy to conduct heat. Its structure can adopt a continuously bent metal sheet 71, or other structural forms that can increase the heat dissipation area of the metal housing 25, and specific limitations are not made thereto.

[0031] Please refer to Figure 4 , the present invention also provides a PTC air heater, which can be applied to the air conditioning heating system of new energy vehicles. It includes a housing 3, a control box 4 and the above-mentioned heating module. Among them, the control box 4 is arranged on one side of the housing 3, and the heating module is arranged inside the housing 3.

[0032] Specifically, the housing 3 includes a first housing 31 and a second housing 32. The first housing 31 and the second housing 32 are detachably connected, and the two can jointly enclose an internal space for accommodating the above-mentioned heating module. The connection method between the first housing 31 and the second housing 32 can be realized by snap connection for pre-fixing. On this basis, in order to further ensure the structural stability of the housing 3, the first housing 31 and the second housing 32 can also be fixed by screws.

[0033] After the first housing 31 and the second housing 32 are stably connected, the two can enclose an internal space for accommodating the above-mentioned heating module. For convenient heat dissipation, heat dissipation openings 5 can be opened on opposite sides of the housing 3, that is, heat dissipation openings 5 can be provided on both the first housing 31 and the second housing 32. Thus, the above-mentioned heating modules can be arranged in two rows between the first housing 31 and the second housing 32. Both rows of heating modules are composed of multiple heating modules, and the two rows of heating modules are respectively located inside the heat dissipation openings 5 on the corresponding sides.

[0034] Specifically, taking the heat dissipation opening 5 on the first housing 31 as an example, multiple heating modules can be arranged side by side in the same direction inside the heat dissipation opening 5. During assembly, since the heating module includes a PTC heating element 2 and a fin 1, inside the heat dissipation opening 5, the arrangement form of multiple heating modules can be arranged in the order of "PTC heating element 2 - fin 1 - PTC heating element 2", that is, any two adjacent PTC heating elements 2 are connected by a fin 1. Thus, the performance of multiple PTC heating elements 2 can be fully exerted to ensure the heating effect.

[0035] Meanwhile, since the heating module needs to be connected to the bus bar 7, and the bus bar 7 is located inside the control box 4, during actual assembly, the first protruding end 211 and the second protruding end 221 on the heating module should face the side where the control box 4 is located.

[0036] It can be understood that the assembly structure of the multiple heating modules inside the heat dissipation opening 5 on the second housing 32 can be referred to the relevant settings on the first housing 31, and will not be elaborated here.

[0037] In some other embodiments, the above-mentioned multiple heating modules can also be arranged in only one row. At this time, a heat dissipation opening 5 can be selected to be arranged on the first housing 31 or the second housing 32, and the multiple heating modules can be arranged inside the heat dissipation opening 5.

[0038] In this embodiment, the control box 4 is arranged on one side of the housing 3, and is detachably connected to the housing 3. Specifically, the connection method between the control box 4 and the housing 3 can also be referred to the connection method between the first housing 31 and the second housing 32, that is, the control box 4 and the housing 3 can be pre-fixed by a snap connection first, and then the control box 4 can be fixed to the housing 3 by screws.

[0039] For the convenience of installing components into the control box 4 and for later maintenance and repair, an opening can also be provided at the top of the control box 4, and a cover plate 41 can be detachably arranged at the opening. The cover plate 41 and the main body of the control box 4 can be fixed by screws.

[0040] It can be understood that since the heating module needs to be connected to the components inside the control box 4, after the control box 4 and the housing 3 are assembled, the control box 4 and the housing 3 should be interconnected.

[0041] Please refer to Figures 5-6 , a circuit board 6 is fixedly arranged inside the control box 4, and the circuit board 6 can be fixed inside the control box 4 by screws. For the convenience of connecting the heating module below, the circuit board 6 and the heating module below are preferably arranged vertically.

[0042] Correspondingly, a high-voltage plug-in connector 42, a low-voltage plug-in connector 43 and a grounding connection line 44 are respectively arranged on the control box 4. The high-voltage plug-in connector 42, the low-voltage plug-in connector 43 and the grounding connection line 44 can all be fixedly connected to the control box 4 by screws. Among them, the high-voltage plug-in connector 42 and the low-voltage plug-in connector 43 can be respectively arranged on opposite sides of the control box 4, and are both electrically connected to the circuit board 6.

[0043] During operation, the above-mentioned high-voltage connector 42 can be electrically connected to the vehicle's high-voltage power supply system to provide power. The low-voltage connector 43 can be electrically connected to the vehicle's low-voltage system, facilitating the connection to an externally supported control system to control the PTC air heater. The grounding connection line 44 is connected to the control box 4, enabling the grounding of the control box 4.

[0044] In this embodiment, a busbar 7 is further provided inside the control box 4. The above-mentioned multiple heating modules are connected to the circuit board 6 through the busbar 7, thereby realizing the power supply to the multiple heating modules.

[0045] Specifically, multiple card slots can be provided on the busbar 7, and the multiple card slots can be respectively used to connect the above-mentioned multiple heating modules. During actual assembly, when the multiple heating modules are arranged side by side inside the housing 3, taking any one of the heating modules as an example, the first protruding end 211 and the second protruding end 221 on the heating module can be inserted into the corresponding card slots on the busbar 7, so that the multiple heating modules and the busbar 7 can form a whole by means of snap connection.

[0046] For connecting to the circuit board 6, multiple metal sheets 71 can be provided on the busbar 7. The metal sheets 71 extend upward and form a snap-fit with the card slots on the circuit board 6. In this way, the busbar 7 can be electrically connected to the circuit board 6 through the multiple metal sheets 71 thereon, so the busbar 7 can be powered through the circuit board 6.

[0047] It can be understood that since there are multiple heating modules and the multiple heating modules are neatly arranged inside the housing 3, when the multiple heating modules are connected to the busbar 7 at the same time, the multiple heating modules actually also form a structure arranged as a whole on the busbar 7.

[0048] At the same time, since the busbar 7 can be powered through the circuit board 6, and the multiple heating modules are all connected to the busbar 7 through the first protruding end 211 and the second protruding end 221, the multiple heating modules can be powered through the busbar 7.

[0049] In this embodiment, to achieve the grounding of the multiple heating modules, a metal elastic member is further provided inside the control box 4. The metal elastic member can be a grounding spring piece 8, and the grounding spring piece 8 can be made of any elastic conductive metal material, and no specific limitation is made thereto.

[0050] Specifically, since the multiple heating modules can be arranged in two rows inside the housing 3, two corresponding grounding spring pieces 8 can be provided. The two grounding spring pieces 8 are respectively used to realize the grounding of the two rows of heating modules.

[0051] Taking multiple heating modules inside the first housing 31 as an example, the grounding spring piece 8 can be integrally embedded between the multiple heating modules and the inner wall of the control box 4. One side of the grounding spring piece 8 abuts against the metal shell 25 on the multiple heating modules, while the opposite side thereof abuts against the inner wall of the control box 4.

[0052] In this way, since the grounding spring piece 8 itself has elasticity, after abutting against the multiple heating modules and the inner wall of the control box 4 on both sides respectively, under the combined action of the elastic restoring force and the frictional force, the grounding spring piece 8 will be stably stuck between the multiple heating modules and the inner wall of the control box 4.

[0053] It can be understood that since the multiple heating modules are arranged side by side, in order to achieve the simultaneous grounding of the multiple heating modules, the grounding spring piece 8 and the heating module are preferably arranged vertically. In this way, the grounding spring piece 8 can abut against multiple heating modules on the same side at the same time. At this time, the multiple heating modules on the same side can also be regarded as arranged in sequence along the extending direction of the adjacent grounding spring pieces 8.

[0054] After the grounding spring piece 8 is arranged, since the control box 4 can be grounded through the grounding connection line 44, and the grounding spring piece 8 is also connected to the metal shell 25 of the control box 4 and the multiple heating modules, the multiple heating modules on the same side can be grounded through the grounding spring piece 8 to ensure safety and reliability.

[0055] In this embodiment, a temperature sensor 9 can also be arranged inside the control box 4 to detect the heating conditions of the multiple heating modules.

[0056] Specifically, the temperature sensor 9 can be integrally arranged on the circuit board 6 and close to the above-mentioned grounding spring piece 8. In this way, in cooperation with the supporting control system, the temperature sensor 9 can detect the temperature of the grounding spring piece 8 in real time, and since the grounding spring piece 8 is in direct contact with the multiple heating modules, it also equivalently realizes the real-time detection of the heating conditions of the multiple heating modules, which is convenient to adjust the power of the multiple heating modules through the supporting control system.

[0057] To better understand the present invention, the technical solutions of the present invention will be described in detail below with reference to the accompanying drawings: First, by respectively arranging a first extending end 211 and a second extending end 221 on the first electrode piece 21 and the second electrode piece 22 on the heating module, the first extending end 211 and the second extending end 221 can form a snap-fit with the card slots on the bus bar 7, avoiding the use of the traditional laser welding operation method, thereby preventing local overheating due to poor welding between the bus bar 7 and the heating module, and ensuring the service life of the heating module.

[0058] Secondly, apply the above-mentioned heating module to the PTC air heater, so that multiple heating modules are arranged side by side in sequence inside the heat dissipation opening 5 on the housing 3; multiple heating modules are connected to the circuit board 6 through a bus bar 7 to achieve power supply. At the same time, multiple heating modules can also be connected to the inner wall of the control box 4 through a grounding spring piece 8. Since the inner wall of the control box 4 is connected to a grounding connecting wire 44, the grounding of multiple heating modules can be achieved to ensure safety and reliability.

[0059] In addition, by directly integrating and setting a temperature sensor 9 on the circuit board 6, the temperature sensor 9 can detect the temperature of the grounding spring piece 8, thereby indirectly detecting the heating conditions of multiple heating modules, which is convenient for adjusting the power of multiple heating modules through a supporting control system.

[0060] It can be seen that through the above method, the present invention can not only prevent local heating between the bus bar 7 and the heating module, ensure the service life of the heating module, but also reduce unnecessary wiring, effectively simplify the internal structure of the PTC air heater, and facilitate the real-time monitoring and adjustment of the heating conditions of multiple heating modules.

[0061] In the description of the present application, it should be noted that the orientation or positional relationship indicated by terms such as "upper" and "lower" is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present application. Unless otherwise clearly specified and limited, the terms "mounted", "connected" and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected, or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present application can be understood according to specific circumstances.

[0062] It should be noted that in the present application, relational terms such as "first" and "second" are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprising", "including" or any other variation thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements, but also includes other elements not expressly listed, or elements inherent to such process, method, article or device. Without further limitation, an element defined by the statement "comprising one..." does not exclude the presence of additional identical elements in the process, method, article or device including the said element.

[0063] The specific embodiments of the present invention described above do not constitute a limitation on the protection scope of the present invention. Any other corresponding changes and deformations made according to the technical concept of the present invention shall be included in the protection scope of the claims of the present invention.

Claims

1. A heating module for a PTC air heater, characterized in that, Comprising: A first electrode plate, with a first protruding end provided at one end of the first electrode plate; A second electrode plate, arranged in parallel and spaced apart from the first electrode plate, and a second protruding end is provided at one end of the second electrode plate; and A plurality of PTC heating resistors, arranged between the first electrode plate and the second electrode plate, and opposite sides of the plurality of PTC heating resistors respectively abut against the first electrode plate and the second electrode plate; Wherein, the first protruding end and the second protruding end are located on the same side of the heating module and are both detachably connected to the bus bar.

2. The heating module according to claim 1, characterized in that, The plurality of PTC heating resistors are arranged in sequence in the same direction between the first electrode plate and the second electrode plate.

3. The heating module according to claim 2, wherein Dummy plates are arranged on one side or both sides of the arrangement direction of the plurality of PTC heating resistors.

4. The heating module according to claim 1, wherein The outer sides of the first electrode plate and the second electrode plate are sleeved with a metal shell, and insulating layers are provided between the metal shell and the first electrode plate and the second electrode plate respectively.

5. The heating module according to claim 4, characterized in that, It further includes fins, and the fins abut against the outer side of the metal shell.

6. A PTC air heater, characterized in that, Comprising a housing, a bus bar, and a heating module as described in any one of claims 1-5, and the bus bar is detachably connected to the first protruding end and the second protruding end on the heating module.

7. The PTC air heater according to claim 6, wherein It further includes: A control box, detachably connected to the housing, and a grounding connection wire is provided on the control box; and A metal elastic member, with one side abutting against the metal shell and the other side abutting against the control box.

8. The PTC air heater according to claim 7, wherein, A circuit board is fixedly arranged in the control box, and a temperature sensor for detecting the metal elastic member is integrally arranged on the circuit board.

9. The PTC air heater according to claim 7, wherein, At least two heating modules are arranged side by side in the same direction on the housing, and the metal shells of each heating module are all abutted against the metal elastic member.

10. The PTC air heater according to claim 9, characterized in that, A heat dissipation opening is provided on one side of the housing; each heating module is arranged side by side in the same direction inside the heat dissipation opening.

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