Heating bag structure of high-compatibility electric heater and assembly method of heating bag structure

Abstract

The invention discloses a heating package structure of a high-compatibility electric heater and an assembling method of the heating package structure. The heating package structure comprises a first electrode plate, a ceramic heating plate, a second electrode plate, an insulating heat conduction material and an inverted-U-shaped wedge. The first electrode plate forms a positioning and limiting structure through insert injection molding and is matched with the second electrode plate to prevent relative displacement; the insulating heat conduction material is packaged on the outer surfaces of the first electrode plate and the second electrode plate to form a heating bag, the inverted U-shaped wedge is wrapped outside the heating bag, and the heating bag is clamped with the inverted U-shaped wedge through the first electrode plate buckle structure to limit the multi-directional displacement of the heating bag. The heating bag structure of the high-compatibility electric heater can adapt to ceramic heating pieces with different thicknesses, universalization of parts and equipment is achieved, production investment is saved, the heat conductivity coefficient and the insulating strength of the heating bag structure of the electric heater are greatly improved, product reliability and market competitiveness are improved, and the heating bag structure is suitable for popularization and application. The method has excellent innovativeness and application value.

Description

Technical Field

[0001] This invention belongs to the field of electric heater technology, and mainly relates to the heating pack structure and assembly method of a highly compatible electric heater. Background Technology

[0002] Electric heaters in new energy vehicles are used for auxiliary heating of the battery system or the passenger compartment. Since pure electric vehicles do not have engines, or new energy hybrid vehicles have engines but do not have enough heat to provide for heating the passenger compartment when starting up; and since the ideal operating temperature of new energy batteries is 25-35℃, the batteries need to be electrically heated to the ideal operating temperature before starting in low temperatures to ensure battery reliability, hence the need for electric heaters to provide heat.

[0003] However, existing electric heater heating packs suffer from the following technical bottlenecks: (1) Insulation and thermal conductivity contradiction: Traditional insulating materials (such as single silicone) have low thermal conductivity (<1.0W / mK), while high thermal conductivity materials (such as metal substrates) have insufficient insulation performance, making it difficult to meet the requirements of high voltage (≥1000V) scenarios.

[0004] (2) Poor assembly stability: Stacking multiple parts can easily cause interlayer displacement, resulting in poor electrode contact or local overheating.

[0005] (3) Weak production versatility: Products of different voltage levels require customized molds and manufacturing equipment, resulting in low equipment reuse rate. Summary of the Invention

[0006] The purpose of this invention is to provide a heating pack structure and assembly method for a highly compatible electric heater, in order to solve the technical problem in the prior art where the heating pack is not fixed and limited during the production and assembly process, which easily leads to relative displacement and deviations in the installed dimensions and performance.

[0007] To achieve the above objectives, the technical solution of the present invention is as follows: The present invention provides a heating element structure for a highly compatible electric heater, comprising: The second electrode sheet includes a frame and a groove. On one side of the frame, there are two symmetrical positioning bosses, two symmetrical snap-fit ​​structures, and electrode pins. The ceramic heating elements are arranged in the groove of the second electrode sheet according to the design sequence and are flush with the inner side of the frame. The first electrode plate covers the outer side of the ceramic heating plate, and the limiting holes of its main limiting platform and the secondary limiting platform correspond to the limiting holes of the two positioning bosses of the second electrode plate, respectively, and are fixed by limiting pins to clamp the ceramic heating plate between the first electrode plate and the second electrode plate. Insulating and thermally conductive material is encapsulated on the outer surfaces of the first and second electrode sheets to form a heating package: except for the two transverse end faces, the main limiting platform, the secondary limiting platform, the positioning boss, the snap-fit ​​structure and the electrode pins, the rest of the parts are all wrapped with insulating and thermally conductive material; The inverted U-shaped wedge is wrapped around the heating pack, and the heating pack is engaged with the inner or outer rib of the inverted U-shaped wedge by a snap-fit ​​structure on the second electrode plate.

[0008] The present invention provides a method for assembling a heating element structure of a highly compatible electric heater, comprising the following steps: S1, arrange the ceramic heating elements in the groove of the second electrode according to the actual required quantity and design order; S2, cover the outside of the ceramic heating plate with the first electrode plate, and fix the limiting holes of the main limiting platform and the secondary limiting platform of the first electrode plate with the limiting holes of the two positioning protrusions of the second electrode plate respectively by the limiting pin, and clamp the ceramic heating plate between the first electrode plate and the second electrode plate. S3, an insulating and thermally conductive material is encapsulated on the outer surfaces of the first and second electrode sheets to form a heating pack; S4, Wrap the inverted U-shaped wedge around the heating pack, and use the snap-fit ​​structure on the second electrode plate to snap into the inner or outer rib of the inverted U-shaped wedge to limit the heating pack and the inverted U-shaped wedge; S5. Press the inverted U-shaped wedge with the opening to make its inner surface fit with the outer insulation layer of the heating pack, thus completing the assembly of the heating pack structure of the electric heater.

[0009] Depending on the actual needs, the ceramic heating element and the second electrode sheet, and the ceramic heating element and the first electrode sheet, are respectively bonded and fixed with adhesive silicone, or they may not be fixed.

[0010] Preferably, the two positioning bosses of the second electrode sheet and the main limiting platform and the secondary limiting platform of the first electrode sheet are formed by insert injection molding. The shapes of the positioning bosses, the main limiting platform and the secondary limiting platform include cylindrical frustum, oval frustum, square frustum, etc., which ensure positioning and can be adjusted according to the different thickness specifications of the selected ceramic heating element to meet the actual use requirements.

[0011] The second electrode plate is assembled with the first electrode plate via the positioning boss and has no relative displacement (it can only move axially through the limiting structure). The snap-fit ​​structure on the second electrode plate engages with the inner or outer rib of the inverted U-shaped wedge, and the limiting structure inside the heating pack abuts against the inner wall of the inverted U-shaped wedge to restrict its multi-directional displacement.

[0012] Preferably, the snap-fit ​​structure is integrally formed with the second electrode sheet by insert injection molding.

[0013] Compared with the prior art, the beneficial effects of the present invention are as follows: To address the demands of different voltage levels, this invention solves the problem of material versatility for both the first and second electrode plates. It eliminates the need to develop new materials simply by changing the voltage platform required for a vehicle; only the specifications of the ceramic heating element need to be replaced. The highly compatible electric heater's heating element structure can accommodate ceramic heating elements of varying thicknesses, achieving parts and equipment standardization, saving production costs, and significantly improving the thermal conductivity and insulation strength of the heating element structure. This enhances product reliability and market competitiveness, demonstrating excellent innovation and application value. Attached Figure Description

[0014] Figure 1 Exploded views of the various components of this invention are shown.

[0015] Figure 2 This is a schematic diagram of the structure of the second electrode plate.

[0016] Figure 3 This is a schematic diagram of the structure of the first electrode sheet.

[0017] Figure 4 This is a schematic diagram of an inverted U-shaped wedge.

[0018] Figure 5 The inner rib position of the inverted U-shaped wedge and the inner buckle form of the heating pack buckle.

[0019] Figure 6 The front view shows the outer rib of the inverted U-shaped wedge and the outer buckle of the heating pack.

[0020] Figure 7 This is a top view showing the outer rib position of the inverted U-shaped wedge and the outer buckle form of the heating pack clip.

[0021] Figure 8 This is the effect of combining an inverted U-shaped wedge with heated packaging. Detailed Implementation

[0022] Those skilled in the art should recognize that this embodiment is only used to illustrate the present invention and is not intended to limit the present invention. Any changes or modifications to the embodiment within the scope of the present invention are within the scope of the claims of the present invention.

[0023] Example 1 A heating pack structure for a highly compatible electric heater includes: The second electrode sheet 3 includes a frame 31 and a groove 32. Two symmetrical positioning bosses 33, two symmetrical snap-fit ​​structures 34 and electrode pins 35 are provided on one side of the frame 31. The ceramic heating sheet 2 is arranged in the groove 32 of the second electrode sheet 3 according to the design order and is flush with the inner side of the frame 31 of the second electrode sheet 3. The first electrode plate 1 covers the outer side of the ceramic heating plate 2. The limiting holes of its main limiting platform 11 and the secondary limiting platform 12 correspond to the limiting holes of the two positioning protrusions 33 of the second electrode plate 3, and are fixed by limiting pins, thus clamping the ceramic heating plate 2 between the first electrode plate 1 and the second electrode plate 3. Insulating and thermally conductive material 4 is encapsulated on the outer surfaces of the first electrode sheet 1 and the second electrode sheet 3 to form a heating envelope: except for the two transverse end faces ( Figure 1 Except for the two end faces in directions B and C shown, the main limiting platform 11, the secondary limiting platform 12, the positioning boss 33, the snap-fit ​​structure 34 and the electrode pin 35, the rest of the parts are all wrapped with insulating and heat-conducting material 4. The inverted U-shaped wedge 5 is wrapped around the heating pack. The heating pack is connected to the inner rib 51 between the inverted U-shaped wedge 5 and the second electrode plate 3 by a snap-fit ​​structure 34 (the end face inclination angle α of the snap-fit ​​structure 34 is 30°). Figure 1 , Figure 4-5 (Snap-on type) snap-fit, or with the outer ribs at both ends of the inverted U-shaped wedge 52 (such as...) Figure 6-7 (Snap-on type) snap-on connection, the dimensional tolerance of the distance between the inner rib position 51 and the outer rib position 52 and the two snap-on structures 34 of the second electrode plate 3 is ±0.2mm.

[0024] The snap-fit ​​structure 34 is integrally formed with the second electrode sheet 3 by insert injection molding; the two positioning bosses 33 of the second electrode sheet 3 and the main limiting platform 11 and the secondary limiting platform 12 of the first electrode sheet 1 are square platforms formed by insert injection molding process.

[0025] The first electrode plate 1 and the second electrode plate 3 are made of one of the following materials: copper H62, aluminum AL3003, AL5052, or copper-aluminum composite material. The appropriate material can be selected based on the actual current-carrying performance requirements of the product. The thickness of the ceramic heating element 2 is selected according to the operating voltage level, including 2.1mm, 2.6mm, 3.2mm, and 4.0mm, corresponding to rated voltage scenarios of 350V, 600V, 800V, 1000V, and above, respectively.

[0026] The material of the buckle structure 34 is PA66-GF30 (30% glass fiber reinforced nylon 66, tensile strength 177.7MPa, flexural strength ≥225.2MPa, temperature resistance ≥250℃) or PPS-G40 (40% glass fiber reinforced polyphenylene sulfide, tensile strength still ≥170MPa at 200℃, chemical corrosion resistance close to PTFE, good thermoplasticity with copper / aluminum electrode materials), the buckle thickness is 1.5~2.2mm, the root radius is 0.2~1.5mm, and the tensile strength is ≥3kg.

[0027] The insulating and thermally conductive material 4 includes any one of the following: ① polyimide film (PI film); ② a combination of polyimide film (PI film) and graphene; ③ a combination of polyimide film (PI film) and silicone; ④ a ceramic substrate.

[0028] The polyimide film (PI film) has a thickness of 0.03–0.2 mm, a breakdown voltage ≥ 6 kV, and a temperature resistance ≥ 300 °C, making it suitable for low-voltage (≤ 500 V) applications and those with less stringent heat exchange efficiency requirements. The combination of the polyimide film (PI film) and graphene, achieved through a nano-pressing process, forms a sandwich structure with an in-plane thermal conductivity > 15 W / mK and an insulation strength > 3.5 kV, meeting medium-voltage (500–1000 V) requirements. The combination of the polyimide film (PI film) and silicone, with thermally conductive silicone filling the gaps in the PI film, results in an interfacial thermal resistance < 0.1 °C·cm. 2 / W (Test method: ASTM D5470), with an overall thermal conductivity of ≥5W / mK, suitable for high humidity environments; the ceramic substrate is a 95% alumina ceramic sheet with a dielectric strength of ≥15KV / mm and a thermal resistance as low as 0.14K / W (0.25mm thickness), making it suitable for scenarios with ≥1000V high voltage and high requirements for leakage current.

[0029] The inverted U-shaped wedge 5 is made of aluminum alloy, preferably 6063-T5 or 6061-T6 aluminum alloy (tensile strength 310~572MPa, thermal conductivity 167~180W / mK); it is formed into a sheet through hot extrusion and stamping; the dimensional tolerance of the distance between the inner or outer rib of the inverted U-shaped wedge and the two snap-fit ​​structures of the second electrode sheet is ±0.2mm, and the end face inclination angle α of the snap-fit ​​structure is 5~60° (preferably α is 25~35°); the rib of the inverted U-shaped wedge is locked by the deformation of the snap-fit ​​on the second electrode sheet under force, so as to achieve one-time fixation.

[0030] The assembly method for the heating element structure of a highly compatible electric heater includes the following steps: S1, according to the actual voltage design requirements, select the ceramic heating element of the corresponding specification and place it in the storage bin of the equipment. The equipment pushes the ceramic heating element to the equipment placement platform through the feeding mechanism. After the equipment resistance is detected, the equipment suction cup arranges the ceramic heating element 2 in the groove 32 of the second electrode plate 3 according to the actual required quantity and design order. S2, the robotic arm of the equipment picks up the first electrode plate 1 and covers it on the second electrode plate 3 where the ceramic heating plate 2 is placed. The limiting holes of the main limiting platform 11 and the secondary limiting platform 12 are respectively fixed to correspond to the limiting holes of the two positioning protrusions 33 of the second electrode plate 3 by limiting pins, thus clamping the ceramic heating plate 2 between the first electrode plate 1 and the second electrode plate 3; adhesive silicone is used to bond and fix the first electrode plate 1 and the ceramic heating plate 2. S3, the heating pack is conveyed by a conveyor belt to the insulating material attachment area, and then encapsulated on the outer surfaces of the first electrode sheet 1 and the second electrode sheet 3 by the equipment's robotic arm using insulating and thermally conductive material 4 (in this embodiment, a combination of polyimide film and silicone) to form a heating pack: except for the two transverse end faces ( Figure 1 Except for the two end faces (B and C directions shown), the main limiting platform 11, the secondary limiting platform 12, the positioning boss 33 and the buckle structure 34, the rest of the parts are all wrapped with insulating and heat-conducting material 4. S4, the robotic arm picks up the heating pack and places it into the inverted U-shaped wedge groove, wraps the inverted U-shaped wedge 5 around the heating pack, presses the heating pack tightly, and uses the snap-fit ​​structure 34 on the second electrode plate 3 to snap into the rib position 51 on the inverted U-shaped wedge 5 to form a limit on the heating pack and the inverted U-shaped wedge 5; S5, pushed by the conveyor belt to the pressing area, where the equipment pressing fixture presses the inverted U-shaped wedge of the opening to the inner surface to fit with the outer insulation layer of the heating pack; thus completing the assembly of the heating pack structure of the electric heater.

[0031] The heating element structure of the electric heater manufactured using the assembly method of the present invention, the assembly displacement error, the reuse rate of production equipment, and the product performance are shown in Table 1.

[0032] Table 1 This invention solves the technical problem that the lack of fixed positioning of the heating pack during the production and assembly process easily leads to relative displacement, resulting in deviations in installation dimensions and performance. As can be seen from Table 1, this invention significantly improves the thermal conductivity and insulation strength of the heating pack structure of the electric heater, demonstrating excellent innovation and application value.

Claims

1. A heating pack structure for a highly compatible electric heater, characterized in that, include: The second electrode sheet (3) includes a frame (31) and a groove (32). Two symmetrical positioning bosses (33), two symmetrical snap-fit ​​structures (34) and electrode pins (35) are provided on one side of the frame (31). The ceramic heating sheet (2) is arranged in the groove (32) in the design order and is flush with the inner side of the frame (31). The first electrode plate (1) covers the outside of the ceramic heating plate (2), and the limiting holes of its main limiting platform (11) and the secondary limiting platform (12) correspond to the limiting holes of the positioning boss (33) respectively, and are fixed by limiting pins, so that the ceramic heating plate (2) is sandwiched between the first electrode plate (1) and the second electrode plate (3). Insulating and thermally conductive material (4) is encapsulated on the outer surface of the first electrode sheet (1) and the second electrode sheet (3) to form a heating package: except for the two transverse end faces, the main limiting platform (11), the secondary limiting platform (12), the positioning boss (33), the snap-fit ​​structure (34) and the electrode pin (35), the rest are all wrapped by insulating and thermally conductive material (4); The inverted U-shaped wedge (5) is wrapped around the heating pack, and the heating pack is engaged with the inner rib (51) or outer rib (52) of the inverted U-shaped wedge (5) by the snap-fit ​​structure (34) on the second electrode sheet (3).

2. The heating pack structure according to claim 1, characterized in that, The snap-fit ​​structure (34) is integrally formed with the second electrode sheet (3) by insert injection molding.

3. The heating pack structure according to claim 1, characterized in that, The positioning boss (33), main limiting platform (11) and secondary limiting platform (12) are formed by insert injection molding process, and their shapes are one of cylindrical platform, oval platform and square platform.

4. The heating pack structure according to claim 1, characterized in that, The first electrode sheet (1) and the second electrode sheet (3) are made of one of the following materials: copper H62, aluminum AL3003, AL5052 or copper-aluminum composite material.

5. The heating pack structure according to claim 1, characterized in that, The thickness of the ceramic heating element (2) includes 2.1mm, 2.6mm, 3.2mm and 4.0mm, respectively, which are suitable for rated voltage scenarios of 350V, 600V, 800V, 1000V and above.

6. The heating pack structure according to claim 1, characterized in that, The material of the buckle structure (34) is PA66-GF30 or PPS-G40; the buckle thickness is 1.5-2.2mm, the root radius is 0.2-1.5mm, and the tensile strength is ≥3kg.

7. The heating pack structure according to claim 1, characterized in that, The insulating and thermally conductive material (4) includes any one of the following: ① polyimide film (PI film); ② a combination of polyimide film (PI film) and graphene; ③ a combination of polyimide film (PI film) and silicone; ④ a ceramic substrate.

8. The heating pack structure according to claim 7, characterized in that, The polyimide film has a thickness of 0.03–0.2 mm, a breakdown voltage ≥ 6 kV, and a temperature resistance ≥ 300 °C. The polyimide film and graphene are combined using a nano-pressing process to form a sandwich structure with an in-plane thermal conductivity > 15 W / mK and an insulation strength > 3.5 kV. The polyimide film and silicone are combined, with thermally conductive silicone filling the gaps in the PI film, resulting in an interfacial thermal resistance < 0.1 °C·cm. 2 / W, with an overall thermal conductivity of ≥5W / mK; the ceramic substrate is a 95% alumina ceramic sheet with a dielectric strength of ≥15KV / mm.

9. The assembly method of the heating pack structure of the highly compatible electric heater according to any one of claims 1 to 8, characterized in that, Includes the following steps: S1, arrange the ceramic heating elements in the groove of the second electrode according to the actual required quantity and design order; S2, cover the outside of the ceramic heating plate with the first electrode plate, and fix the limiting holes of the main limiting platform and the secondary limiting platform of the first electrode plate with the limiting holes of the two positioning protrusions of the second electrode plate respectively by the limiting pin, and clamp the ceramic heating plate between the first electrode plate and the second electrode plate. S3, an insulating and thermally conductive material is encapsulated on the outer surfaces of the first and second electrode sheets to form a heating pack; S4, Wrap the inverted U-shaped wedge around the heating pack, and use the snap-fit ​​structure on the second electrode plate to snap into the inner or outer rib of the inverted U-shaped wedge to limit the heating pack and the inverted U-shaped wedge; S5. Press the inverted U-shaped wedge with the opening to make its inner surface fit with the outer insulation layer of the heating pack, thus completing the assembly of the heating pack structure of the electric heater.

10. The assembly method of the heating pack structure according to claim 9, characterized in that, The inverted U-shaped wedge is made of aluminum alloy; it is formed into a sheet through hot extrusion and stamping; the dimensional tolerance of the distance between the inner or outer rib of the inverted U-shaped wedge and the two snap-fit ​​structures of the second electrode sheet is ±0.2mm.

11. The assembly method of the heating pack structure according to claim 9, characterized in that, The snap-fit ​​structure is integrally formed with the second electrode sheet by insert injection molding.

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