Profile double-sided film heater core body and manufacturing method

Abstract

The invention discloses a profile double-sided film heater core and a manufacturing method. The heat exchanger comprises a shell located in the middle, a plurality of longitudinally-extending ribs are arranged in an inner cavity of the shell and divide the inner cavity into a plurality of parallel flow channels, and a plurality of communicated transition cavities are formed in the front end and the rear end of the inner cavity respectively. A water inlet and a water outlet are formed in the end part of the shell, and a fluid circulation channel is formed through the transition cavity and the flow channel; the front end face and the rear end face of the shell are sealed through sealing plates, and an upper thick film heating layer composed of a first sintered glass layer, a silver electrode conductor layer, a resistance heating layer and a second sintered glass layer is sequentially arranged on the upper surface of the shell in a stacked mode. A lower thick film heating layer symmetrical to the upper thick film heating layer is arranged on the lower surface of the shell; the manufacturing method comprises the steps that a section of aluminum profile comprising the rectangular outer wall and the internal ribs is cut out, part of the ribs of the front section and the rear section of the aluminum profile are removed, so that the first cavity, the second cavity, the third cavity, the fourth cavity and the fifth cavity are formed, and the shell is formed.

Description

Technical Field

[0001] This invention belongs to the field of water heating heaters for new energy vehicles, and in particular relates to a profile double-film heater core and its manufacturing method. Background Technology

[0002] With the widespread adoption of new energy vehicles, their onboard thermal management systems place higher demands on the performance of heating devices. Traditional gasoline vehicles rely on the waste heat from the engine to heat the passenger compartment, while new energy vehicles, lacking an engine heat source, typically use electric heaters as the heat source for their water-based heating systems. This is achieved through coolant circulation to heat the passenger compartment, maintain battery temperature, and control the temperature of the powertrain.

[0003] Existing water heaters for new energy vehicles mostly use PTC heating elements or stainless steel thick film heaters. Although PTC heaters have a simple structure, they suffer from problems such as low thermal efficiency, slow temperature rise, and limited power density. While stainless steel thick film heaters have improved heat exchange efficiency, their overall structure is complex, their size is large, their processing cost is high, and their uneven temperature distribution due to single-sided heating remains a significant drawback.

[0004] Furthermore, existing thick-film heating cores are mostly single-sided heating structures, with fluid flowing in a single direction within the channel, leading to localized overheating and thermal stress concentration, which is detrimental to long-term stable operation. The relatively long heat conduction path between the metal substrate and the heating layer also limits efficient energy transfer. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a profile double-film heater core with a compact structure, large heat exchange area, capable of achieving uniform heating on both sides, and having good thermal conductivity, as well as a manufacturing method thereof.

[0006] To solve the above-mentioned technical problems, the profile double-film heater core of the present invention includes a shell located in the middle. The inner cavity of the shell is provided with several longitudinally extending ribs that divide the inner cavity into multiple parallel flow channels. Several interconnected transition cavities are provided at the front and rear ends of the inner cavity. The ends of the shell are provided with water inlet and water outlet, and a fluid circulation path is formed through the transition cavities and flow channels. The front and rear ends of the shell are both sealed by sealing plates. The upper surface of the shell is provided with an upper thick film heating layer consisting of a first sintered glass layer, a silver electrode conductor layer, a resistance heating layer, and a second sintered glass layer. The lower surface of the shell is provided with a lower thick film heating layer that is symmetrical to the upper thick film heating layer.

[0007] The transition cavities within the shell include a first cavity, a third cavity, and a fifth cavity located on the front side, and a second cavity and a fourth cavity located on the rear side; the first cavity, the second cavity, the third cavity, the fourth cavity, and the fifth cavity are connected sequentially by flow channels divided by ribs; the inlet is connected to the first cavity, and the outlet is connected to the fifth cavity.

[0008] The shell and internal ribs are made of integrally formed aluminum profiles.

[0009] The resistive heating layer is made of ruthenium-based precious metal material.

[0010] A temperature sensor is installed at the solder joint of the silver electrode conductor layer.

[0011] A method for manufacturing a profile double-film heater core: A section of aluminum profile containing a rectangular outer wall and internal ribs is cut, and some of the ribs at the front and rear ends of the aluminum profile are removed to form a first cavity, a second cavity, a third cavity, a fourth cavity, and a fifth cavity, forming a shell; the first cavity, the third cavity, and the fifth cavity are separated by two ribs that have not been removed, and the second cavity and the fourth cavity are separated by one rib that has not been removed; thus, the first cavity is connected to the second cavity through a left-side flow channel, the second cavity is connected to the third cavity through a middle left-side flow channel, the third cavity is connected to the fourth cavity through a middle other-side flow channel, and the fourth cavity is connected to the fifth cavity through a right-side flow channel, forming a circulating channel.

[0012] After the shell is processed, the upper and lower surfaces of the shell are sequentially printed and sintered to form the first sintered glass layer, the silver electrode conductor layer, the resistance heating layer and the second sintered glass layer, respectively, to obtain a symmetrical thick film heating layer structure; finally, the sealing plate is fixed to the front and rear ends of the aluminum profile to achieve a sealed connection.

[0013] Advantages of this invention: 1. By setting thick film heating layers on the upper and lower surfaces of the aluminum profile, simultaneous heating on both sides is achieved, so that the fluid is heated evenly on both sides of the channel, which significantly improves heat exchange efficiency and reduces local overheating. 2. The profile is integrally molded, so it has excellent thermal conductivity and high mechanical strength. The shell and internal ribs are integrally die-cast or extruded, which not only eliminates the splicing interface and improves the overall thermal conductivity and structural strength, but also facilitates manufacturing and mass production. 3. The multi-cavity interconnected flow channel design ensures smooth fluid circulation and a large heat exchange area. The internal multi-cavity and longitudinal flow channel form a continuous loop, which extends the fluid path and increases the contact area with the heating surface, resulting in more complete heat exchange and more uniform temperature distribution. Attached Figure Description

[0014] Figure 1 This is an exploded view of the profile double-film heater core of the present invention; Figure 2 This is a schematic diagram of the shell structure in the profile double-film heater core of the present invention; Figure 3 This is a side view of the housing in the profile double-film heater core of the present invention; Figure 4 This is an assembly structure diagram of the profile double-film heater core of the present invention; Figure 5 This is a top view of the assembly of the profile double-film heater core of the present invention. Detailed Implementation

[0015] The following detailed description of the profile double-film heater core and manufacturing method of the present invention, in conjunction with the accompanying drawings and specific embodiments, provides further insight. Example

[0016] The core of the profile double-film heater includes a shell 1 located in the middle. The inner cavity of the shell 1 is provided with several longitudinally extending ribs 4, which divide the inner cavity into multiple parallel flow channels. Several interconnected transition cavities are provided at the front and rear ends of the inner cavity. The left side of the end of the shell 1 is provided with a water inlet 2 and the right side is provided with a water outlet 3. A fluid circulation path is formed through the transition cavities and flow channels. The front and rear ends of the shell 1 are both sealed by sealing plates 9. The upper surface of the shell 1 is provided with an upper thick film heating layer consisting of a first sintered glass layer 5, a silver electrode conductor layer 6, a resistance heating layer 7, and a second sintered glass layer 8. The lower surface of the shell 1 is provided with a lower thick film heating layer that is symmetrical to the upper thick film heating layer. Low-temperature glass is screen-printed on the upper surface of the shell 1, and an insulating layer is formed by low-temperature sintering at 450°. After screen-printing the silver electrode conductor layer on the insulating layer, it is sintered. Then, a ruthenium-based noble metal resistance heating layer is screen-printed and sintered again. Low-temperature glass is screen-printed and sintered again. The lower surface of the shell 1 is screen-printed and sintered in the same way as the upper surface, so that the heating film is sintered on both the upper and lower surfaces at the same time.

[0017] The transition cavities within the housing 1 include a first cavity 9, a third cavity 11, and a fifth cavity 13 located on the front side, and a second cavity 10 and a fourth cavity 12 located on the rear side; the first cavity 9, the second cavity 10, the third cavity 11, the fourth cavity 12, and the fifth cavity 13 are sequentially connected by flow channels divided by ribs 4; the inlet 2 is connected to the first cavity 9, and the outlet 3 is connected to the fifth cavity 13; the housing 1 and the internal ribs 4 are made of integrally formed aluminum profiles (ADC12 aluminum alloy); the resistive heating layer 7 is made of ruthenium-based precious metal materials; a temperature sensor 14 (a membrane temperature NTC for real-time detection of heating temperature and temperature control) is provided at the solder joint of the silver electrode conductor layer 6.

[0018] Manufacturing method of the core of a double-sided film heater: A section of aluminum profile containing a rectangular outer wall and internal ribs 4 is cut. Part of the ribs 4 at the front and rear ends of the aluminum profile are removed to form a first cavity 9, a second cavity 10, a third cavity 11, a fourth cavity 12, and a fifth cavity 13, forming a shell 1. The first cavity 9, the third cavity 11, and the fifth cavity 13 are separated by two remaining ribs 4, and the second cavity 10 and the fourth cavity 12 are separated by one remaining rib 4. This allows the first cavity 9 to connect to the second cavity through a left-side flow channel. 10. The second cavity 10 is connected to the third cavity 11 through the middle left flow channel. The third cavity 11 is connected to the fourth cavity 12 through the middle other flow channel. The fourth cavity 12 is connected to the fifth cavity 13 through the right flow channel, forming a circulating channel. After the shell 1 is processed, the first sintered glass layer 5, the silver electrode conductor layer 6, the resistance heating layer 7 and the second sintered glass layer 8 are sequentially printed and sintered on the upper and lower surfaces of the shell 1 to obtain a symmetrical thick film heating layer structure. Finally, the sealing plate 9 is fixed to the front and rear end faces of the aluminum profile 1 to achieve a sealed connection.

Claims

1. A profile double-film heater core, characterized in that: The shell (1) is located in the middle. The inner cavity of the shell (1) is provided with several longitudinally extending ribs (4) that divide the inner cavity into multiple parallel flow channels. Several interconnected transition cavities are provided at the front and rear ends of the inner cavity. The end of the shell (1) is provided with an inlet (2) and an outlet (3), and a fluid circulation path is formed through the transition cavities and flow channels. The front and rear ends of the shell (1) are closed by sealing plates (9). The upper surface of the shell (1) is provided with an upper thick film heating layer consisting of a first sintered glass layer (5), a silver electrode conductor layer (6), a resistance heating layer (7), and a second sintered glass layer (8). The lower surface of the shell (1) is provided with a lower thick film heating layer that is symmetrical to the upper thick film heating layer.

2. The profile double-film heater core according to claim 1, characterized in that: The transition cavities within the housing (1) include a first cavity (9), a third cavity (11), and a fifth cavity (13) located on the front side, and a second cavity (10) and a fourth cavity (12) located on the rear side; the first cavity (9), the second cavity (10), the third cavity (11), the fourth cavity (12), and the fifth cavity (13) are connected sequentially by flow channels divided by ribs (4); the inlet (2) is connected to the first cavity (9), and the outlet (3) is connected to the fifth cavity (13).

3. The profile double-film heater core according to claim 1, characterized in that: The shell (1) and the internal ribs (4) are made of integrally formed aluminum profiles.

4. The profile double-film heater core according to claim 1, characterized in that: The resistive heating layer (7) is made of ruthenium-based precious metal material.

5. The profile double-film heater core according to claim 1, characterized in that: A temperature sensor (14) is provided at the solder joint of the silver electrode conductor layer (6).

6. A method for manufacturing a profile double-film heater core according to claim 3, characterized in that: A section of aluminum profile containing a rectangular outer wall and internal ribs (4) is cut off, and some of the ribs (4) in the front and rear sections of the aluminum profile are removed to form a first cavity (9), a second cavity (10), a third cavity (11), a fourth cavity (12) and a fifth cavity (13), forming a shell (1); the first cavity (9), the third cavity (11) and the fifth cavity (13) are separated by two ribs (4) that have not been removed, and the second cavity (10) and the fourth cavity (12) are separated by one rib (4) that has not been removed; thus, the first cavity (9) is connected to the second cavity (10) through the left flow channel, the second cavity (10) is connected to the third cavity (11) through the middle left flow channel, the third cavity (11) is connected to the fourth cavity (12) through the middle other flow channel, and the fourth cavity (12) is connected to the fifth cavity (13) through the right flow channel, forming a circulating channel.

7. A method for manufacturing a profile double-film heater core according to claim 7, characterized in that: After the shell (1) is processed, the upper and lower surfaces of the shell (1) are printed and sintered in sequence to form the first sintered glass layer (5), the silver electrode conductor layer (6), the resistance heating layer (7) and the second sintered glass layer (8), respectively, to obtain a thick film heating layer structure with symmetrical upper and lower surfaces; finally, the sealing plate (9) is fixed to the front and rear end faces of the aluminum profile (1) to achieve a sealed connection.

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