Anti-overburning thick film heater module and integrated module electric compressor

Abstract

The invention provides an anti-overburning thick film heater module and an integrated module electric compressor, and the anti-overburning thick film heater module comprises a first housing, one surface of the first housing is recessed inwards to form a caulking groove; the second shell is embedded into the caulking groove, and a heat exchange cavity is formed in the side, away from the caulking groove, of the second shell so that a heat-conducting medium can circulate; the heating plate is arranged on the surface, deviating from the caulking groove, of the first shell, and the heating plate is formed by laminating an aluminum oxide ceramic base layer, a conductor layer, a resistance layer and a protection layer which are sequentially close to the first shell. When the anti-overburning thick film heater module provided by the invention is applied to the integrated module electric compressor, the safety performance is higher, the service life is longer, and the stable operation of the integrated module electric compressor can be effectively ensured.

Description

Technical Field

[0001] The present invention belongs to the technical field of compressors, and in particular relates to an anti-overburning thick film heater module and an integrated module electric compressor. Background Art

[0002] At present, under the strong national policies, the popularization of electric vehicles has become an inevitable trend. However, in the process of developing electric vehicles, more and more problems are becoming increasingly prominent. For example, in conventional air-conditioning systems, the heater and compressor are separate structures, and two sets of high-voltage terminals are required for power supply, which is costly. In response to this problem, those skilled in the art are constantly trying to make improvements. For example, patent application number CN202410603030.5 discloses an integrated modular electric compressor with an integrated heating module, which integrates the heater and the compressor. In order to reduce costs, the heater integrated on the compressor generally adopts a thick film heater with stainless steel as the substrate, but this heater has the following defects: the expansion coefficients of stainless steel and die-cast aluminum are greatly different, and the degree of deformation during the heating process is very different, which makes it easy to cause irreversible deformation, shortening its service life. In order to prevent leakage, multiple layers of insulation need to be plated on the stainless steel substrate, which invisibly increases the cost investment. The insulation layer has the risk of burning through when heated for a long time or overheated. Summary of the Invention

[0003] In view of the problems existing in the above-mentioned prior art, the main purpose of the present invention is to provide an anti-overburning thick film heater module and an integrated module electric compressor. When the provided anti-overburning thick film heater module is applied to the integrated module electric compressor, it has higher safety performance and longer service life, and can effectively ensure the stable operation of the integrated module electric compressor.

[0004] The purpose of the present invention is achieved through the following technical solutions:

[0005] The present invention provides an anti-overburning thick film heater module, the anti-overburning thick film heater module comprising:

[0006] A first shell, one side of which is recessed inward to form a groove;

[0007] a second shell, the second shell being embedded in the embedding groove, and a heat exchange cavity being formed on a side of the second shell facing away from the embedding groove for circulating a heat-conducting medium;

[0008] The heating plate is arranged on the side of the first shell away from the embedding groove thereof, and the heating plate is formed by stacking an alumina ceramic base layer, a conductor layer, a resistor layer and a protective layer in sequence close to the first shell.

[0009] As a further description of the above technical solution, the heating plate includes a first plate body and a second plate body, and the first plate body and the second plate body are both arranged perpendicular to the thickness direction of the heating plate body;

[0010] A preset gap is formed between the first plate and the second plate.

[0011] As a further description of the above technical solution, a mounting portion is provided on the circumferential outer edge of the heating plate, and the mounting portion is used to be connected to the first shell.

[0012] As a further description of the above technical solution, the mounting portion is provided with multiple first mounting holes, the first shell is provided with multiple second mounting holes corresponding one-to-one to the first mounting holes, and the first mounting holes and the second mounting holes are connected by fasteners and / or adhesives.

[0013] As a further description of the above technical solution, the first shell is made of die-cast aluminum.

[0014] As a further description of the above technical solution, the heat exchange cavity includes a first cavity wall and a second cavity wall opposite to each other; wherein,

[0015] At least one first partition extends inwardly from the first cavity wall, and a surface of the first partition facing the second cavity wall is separated from the second cavity wall;

[0016] At least one second partition plate extends inwardly from the second cavity wall, and a plate surface of the second partition plate facing the first cavity wall is separated from the first cavity wall;

[0017] The total length of the first partition and the second partition in their extending direction is greater than the distance between the first cavity wall and the second cavity wall.

[0018] As a further description of the above technical solution, the first partition plate and the second partition plate are arranged at equal intervals.

[0019] As a further description of the above technical solution, the first baffle and the second baffle each have a plate surface facing toward and away from the bottom wall of the embedded groove and abutting against the wall of the heat exchange chamber, thereby forming a tortuous heat exchange channel in the heat exchange chamber;

[0020] The first shell is provided with a liquid inlet and a liquid outlet, and the liquid inlet and the liquid outlet are respectively communicated with two ends of the heat exchange channel.

[0021] As a further description of the above technical solution, a plurality of heat exchange columns are further provided in the heat exchange cavity.

[0022] The present invention also provides an integrated modular electric compressor, comprising the anti-overburning thick film heater module and a controller as described above, wherein the anti-overburning thick film heater module is electrically connected to the controller.

[0023] By means of the above technical solutions, the outstanding effects of the present invention are:

[0024] 1. In the anti-overburn thick-film heater module provided by the present invention, the conventional stainless steel base layer in the heating plate is replaced with an alumina ceramic base layer. Due to its inherent insulation properties, it is no longer necessary to plate an insulating layer on the base layer (usually four insulating layers are required). At the same time, even if the heater module overburns in extreme circumstances, it can still ensure its own insulation performance, significantly reducing the risk of leakage.

[0025] 2. In the anti-overburn thick-film heater module provided by the present invention, the heating plate includes a first plate body and a second plate body, and both plates are arranged perpendicular to the thickness of the heating plate body. Compared with a single piece of heating plate, processing is more convenient, and a preset gap is formed between the two plates, which allows for deformation during the heating process, thereby effectively reducing the damage rate of the heating plate caused by thermal deformation during the heating process.

[0026] 3. In the anti-overburn thick-film heater module provided by the present invention, the first housing is made of die-cast aluminum. The expansion coefficients of alumina and die-cast aluminum are similar, and the impact of thermal stress is low. This can effectively reduce the probability of magnetic deformation, cracking, and mechanical property degradation between the first housing and the alumina ceramic substrate, significantly improving the operating stability of the anti-overburn thick-film heater module.

[0027] 4. In the anti-overburning thick film heater module provided by the present invention, a winding heat exchange channel is formed by arranging the first partition and the second partition in the heat exchange cavity, and heat exchange columns are arranged at the same time, which effectively improves the heat exchange efficiency while also disturbing the heat exchange medium, making the heat exchange more uniform. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 An exploded view of an anti-overburning thick film heater module according to an embodiment of the present invention;

[0029] Figure 2 An exploded view of a heating plate according to an embodiment of the present invention;

[0030] Figure 3 Schematic diagram of the structure of the anti-overburning thick film heater module in an embodiment of the present invention;

[0031] Figure 4 Schematic diagram of the structure of the anti-overburning thick film heater module installed on the integrated module electric compressor in an embodiment of the present invention.

[0032] Description of Figure Numbers:

[0033] 1. First shell; 2. Second shell; 3. Heat exchange chamber; 4. Heating plate; 5. Alumina ceramic base layer; 6. Conductor layer; 7. Resistance layer; 8. Protective layer; 9. First plate body; 10. Second plate body; 11. Mounting portion; 12. First mounting hole; 13. Second mounting hole; 14. First partition; 15. Second partition; 16. Liquid inlet; 17. Liquid outlet; 18. Heat exchange column; 19. Integrated module electric compressor. DETAILED DESCRIPTION

[0034] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0035] In the description of the present invention, it should be noted that the terms "upper", "middle", "lower", "inside", "outside", "front", "back", "left", "right", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, they cannot be understood as limitations on the present invention. In addition, the terms "first", "second", and "third" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances. The following describes an implementation method of the present invention based on its overall structure.

[0036] See also Figures 1 to 4 The present invention discloses an anti-overburn thick film heater module, the anti-overburn thick film heater module comprising:

[0037] A first shell 1, one side of which is recessed inward to form a groove;

[0038] A second shell 2, the second shell 2 is embedded in the embedding groove, and a heat exchange cavity 3 is formed on the side of the second shell 2 facing away from the embedding groove to circulate a heat-conducting medium;

[0039] The heating plate 4 is arranged on the side of the first shell 1 away from the embedding groove thereof. The heating plate 4 is formed by stacking an alumina ceramic base layer 5, a conductor layer 6, a resistor layer 7 and a protective layer 8 in sequence close to the first shell 1.

[0040] With the above structure, in the overburn prevention thick-film heater module, one side of the first shell 1 is recessed inward to form a groove for embedding the second shell 2. The side of the second shell 2 facing away from the groove forms a heat exchange chamber 3 for circulating a heat-conducting medium. The heating plate 4 is disposed on the side of the first shell 1 facing away from the groove and is used to heat the heat-conducting medium. The heating plate 4 is composed of an alumina ceramic base layer 5, a conductor layer 6, a resistor layer 7, and a protective layer 8 stacked in sequence adjacent to the first shell 1. Compared to the stainless steel base layer used in the prior art, the alumina ceramic base layer 5 used in this embodiment has inherent insulation properties, eliminating the need for an insulating layer (generally four layers are required). Furthermore, even if the heater module overburns in extreme circumstances, it still maintains its insulation properties, significantly reducing the risk of leakage.

[0041] Please refer to the figure. Specifically, in this embodiment, the heating plate 4 includes a first plate body 9 and a second plate body 10. The first plate body 9 and the second plate body 10 are arranged perpendicular to the direction of the plate thickness of the heating plate 4. Compared with the whole heating plate 4, it is more convenient to process, and a preset gap is formed between the first plate body 9 and the second plate body 10, which allows the deformation of the first plate body 9 and the second plate body 10 to have a tendency to move during the heating process, thereby effectively reducing the damage rate of the heating plate 4 caused by thermal deformation during the heating process.

[0042] Specifically, in this embodiment, a mounting portion 11 is provided on the circumferential outer edge of the heating plate 4, and the mounting portion 11 is used to connect to the first shell 1. More specifically, the mounting portion 11 is made of an insulating material. The mounting portion 11 is provided with a plurality of first mounting holes 12, and the first shell 1 is provided with a plurality of second mounting holes 13 corresponding one to one with the first mounting holes 12. The first mounting holes 12 and the second mounting holes 13 are connected by fasteners (such as bolts) and adhesives (such as thermally conductive adhesives), so that the heating plate 4 is connected to the first shell 1 to achieve a better fixing effect and higher heat exchange efficiency. Of course, in other embodiments, the first mounting holes 12 and the second mounting holes 13 can also be connected separately by fasteners (such as bolts) or adhesives (such as thermally conductive adhesives).

[0043] Specifically, in this embodiment, the first shell 1 is made of die-cast aluminum. The reason is that the expansion coefficients of alumina and die-cast aluminum are similar, and the influence of thermal stress is low, which can effectively reduce the probability of magnetic deformation, cracking and mechanical property degradation between the first shell 1 and the alumina ceramic base layer 5, and significantly improve the stability of the operating state of the anti-overburning thick film heater module.

[0044] Specifically, in this embodiment, the heat exchange chamber 3 is generally rectangular and includes a first chamber wall and a second chamber wall relative to each other; wherein, the first chamber wall has two first partitions 14 extending inwardly, and the plate surface of the first partition 14 facing the second chamber wall is separated from the second chamber wall; the second chamber wall has a second partition 15 extending inwardly, and the plate surface of the second partition 15 facing the first chamber wall is separated from the first chamber wall; the total length of the first partition 14 and the second partition 15 in their extension direction is greater than the distance between the first chamber wall and the second chamber wall, so that the heat exchange medium flowing in the heat exchange chamber 3 can be turbulent, and the heat exchange is more sufficient. Among them, the first partition 14 and the second partition 15 are arranged at equal intervals. At the same time, the first partition 14 and the second partition 15 both have plate surfaces facing and away from the bottom wall of the embedded groove and abutting against the wall of the heat exchange chamber 3, thereby forming a tortuous heat exchange channel in the heat exchange chamber 3 for the heat exchange medium to flow in a tortuous manner in the heat exchange chamber 3 for uniform heat exchange; the first shell 1 is provided with a liquid inlet 16 and a liquid outlet 17, and the liquid inlet 16 and the liquid outlet 17 are respectively connected to the two ends of the heat exchange channel.

[0045] Specifically, in this embodiment, a plurality of heat exchange columns 18 are further provided in the heat exchange chamber 3. On the one hand, they can transfer the heat absorbed by the second shell 2 to the heat exchange chamber 3 more quickly, and on the other hand, they can also turbulently flow the heat exchange medium to effectively improve the uniformity of heating the heat exchange medium.

[0046] Specifically, this embodiment also discloses an integrated modular electric compressor 19, including the anti-overburning thick film heater module and a controller (not shown in the figure) as described above, wherein the anti-overburning thick film heater module is integrated on the compressor body of the integrated modular electric compressor 19 and is electrically connected to the controller.

[0047] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or make equivalent substitutions for some of the technical features therein. Any changes, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. An anti-overburn thick film heater module, characterized in that: include: A first shell, one side of which is recessed inward to form a groove; a second shell, the second shell being embedded in the embedding groove, and a heat exchange cavity being formed on a side of the second shell facing away from the embedding groove for circulating a heat-conducting medium; The heating plate is arranged on the side of the first shell away from the embedding groove thereof, and the heating plate is formed by stacking an alumina ceramic base layer, a conductor layer, a resistor layer and a protective layer in sequence close to the first shell.

2. The anti-overburn thick film heater module according to claim 1, characterized in that: The heating plate includes a first plate body and a second plate body, and the first plate body and the second plate body are both arranged perpendicular to the plate body thickness direction of the heating plate; A preset gap is formed between the first plate and the second plate.

3. The anti-overburn thick film heater module according to claim 1, characterized in that: A mounting portion is provided on the circumferential outer edge of the heating plate, and the mounting portion is used to be connected to the first shell.

4. The anti-overburn thick film heater module according to claim 3, characterized in that: The mounting portion is provided with a plurality of first mounting holes, the first shell is provided with a plurality of second mounting holes corresponding one-to-one to the first mounting holes, and the first mounting holes and the second mounting holes are connected by fasteners and / or adhesives.

5. The anti-overburn thick film heater module according to claim 1, characterized in that: The first housing is made of die-cast aluminum.

6. The anti-overburn thick film heater module according to claim 1, characterized in that: The heat exchange cavity comprises a first cavity wall and a second cavity wall opposite to each other; wherein, At least one first partition extends inwardly from the first cavity wall, and a surface of the first partition facing the second cavity wall is separated from the second cavity wall; At least one second partition plate extends inwardly from the second cavity wall, and a plate surface of the second partition plate facing the first cavity wall is separated from the first cavity wall; The total length of the first partition and the second partition in their extending direction is greater than the distance between the first cavity wall and the second cavity wall.

7. The anti-overburn thick film heater module according to claim 6, characterized in that: The first partition plate and the second partition plate are arranged at equal intervals.

8. The anti-overburn thick film heater module according to claim 7, characterized in that: The first baffle and the second baffle both have plate surfaces facing toward and away from the bottom wall of the embedded groove and abutting against the wall of the heat exchange cavity, thereby forming a tortuous heat exchange channel in the heat exchange cavity; The first shell is provided with a liquid inlet and a liquid outlet, and the liquid inlet and the liquid outlet are respectively communicated with two ends of the heat exchange channel.

9. The anti-overburn thick film heater module according to claim 8, characterized in that: A plurality of heat exchange columns are also provided in the heat exchange cavity.

10. An integrated modular electric compressor, characterized in that: The invention comprises the anti-overburning thick film heater module according to any one of claims 1 to 9 and a controller, wherein the anti-overburning thick film heater module is electrically connected to the controller.

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