Air-cooled PTC (Positive Temperature Coefficient) core radiating fin mechanism

Abstract

The invention discloses an air-cooled PTC (Positive Temperature Coefficient) core radiating fin mechanism, which relates to the technical field of new energy automobile heating systems and comprises a core assembly and a control assembly, the core assembly comprises a radiating fin assembly, a heating pipe and a framework assembly; the heat dissipation fin assembly is manufactured through integrated punch forming, the shape of the heat dissipation fin assembly is a plurality of fins arranged in parallel, the heat dissipation fin assembly is used for increasing the heat dissipation area, and the fins comprise ventilation heat dissipation fins a and heating pipe heat conduction fins b which are arranged at intervals. The cooling fins, the frameworks on the two sides of the fins, the middle of the bottom and the framework on the top of the core body are produced in an integrated punch forming mode, the cooling fins and the heating pipes are installed in an inserted mode, the fins and the frameworks are installed in an inserted mode, the fins and the heating pipes make direct contact with the heating pipes through clamping rings, and the core body assembly production process is simple and suitable for large-scale automatic production; the heating pipe support is in metal connection, the contact resistance is small, and the core noise is small; the heating pipes and the fins do not need to be baked at high temperature, and the insulating film cannot be damaged due to high temperature.

Description

Technical Field

[0001] This invention relates to the field of heating system technology for new energy vehicles, specifically to an air-cooled PTC core heat dissipation fin mechanism. Background Technology

[0002] Current new energy vehicle air conditioning and battery thermal management systems consist of heating and cooling systems. The heating system comprises an air-cooled PTC heater and a water-cooled heater; the air conditioning and battery cooling systems are handled by a compressor-based refrigeration system. The heating of the air conditioning unit is regulated by an air-cooled PTC heater controller, while the battery thermal management system is regulated by a water-cooled heater.

[0003] The existing air-cooled PTC heat sink fin manufacturing process is complex, with many assembly steps for the heat sink fins and heating tubes. The heat sink fins and heating tubes are bonded together with adhesive and require high-temperature baking. The heating tubes have high resistance, and the core is noisy during operation. High-temperature baking can also damage the insulation film, resulting in an increase in defective products. Summary of the Invention

[0004] This invention addresses the problems of complex manufacturing processes for air-cooled PTC heat sink fins in new energy vehicles, numerous assembly steps for the heat sink fins and heating tubes, the need for adhesive bonding and high-temperature baking between the heat sinks and heating tubes, high resistance between the heating tubes, high core noise during operation, and damage to the insulation film caused by high-temperature baking, leading to an increase in defective products. To achieve the above objectives, this invention provides the following technical solution: A wind-cooled PTC core heat dissipation fin mechanism includes a core assembly and a control assembly; The core assembly includes a heat sink fin assembly, a heating tube, and a frame assembly; The heat dissipation fin assembly is manufactured by integral stamping and is shaped as multiple parallel fins to enhance the heat dissipation area. The heat dissipation fin assembly is provided with a clamping ring, which is a ring-shaped elastic structure and is sleeved on the outside of the heating tube to achieve heat conduction through direct contact. The frame assembly is integrally stamped and includes two side frames, a top frame and a bottom frame, which are used to support and fix the heat dissipation fin assembly and the heating tube. The heat dissipation fin assembly is connected to the heating tube by a plug-in method, eliminating the need for adhesive bonding or high-temperature baking. The control assembly includes a control box and a top cover, which are connected to the core assembly by screws.

[0005] Preferably, the fins of the heat dissipation fin assembly are rectangular sheet-like structures, and the two side skeletons, bottom skeleton and top skeleton of the fins are integrally formed by stamping to optimize airflow and heat dissipation efficiency.

[0006] Preferably, the clamping ring is made of metal material, and its inner diameter is smaller than the outer diameter of the bottom skeleton of the heating tube. It clamps the surface of the heating tube by elastic deformation, increasing the contact area and improving the heat conduction efficiency.

[0007] Preferably, the insertion method is a stacked insertion, and the heating tube is a multi-tube structure that is inserted in parallel into the fin gaps of the heat dissipation fin assembly, so that the heating tubes are connected through the metal fins, thereby reducing capacitive noise during PWM control.

[0008] Preferably, it also includes a waterproof assembly, which includes a sealing gasket and an adhesive filling tank; The sealing gasket is located between the control box and the core assembly, and between the control box and the top cover, and is physically sealed by screws. The glue-filling groove is located at the base of the core assembly, and a waterproof layer is formed by injecting epoxy resin glue.

[0009] Preferably, the high-pressure and low-pressure interfaces of the control assembly are waterproofed by screw-fastened connectors. The connectors are threaded and tightened after matching with the interfaces to prevent moisture intrusion.

[0010] Preferably, the side frame of the skeleton assembly is provided with a snap-fit ​​structure, which cooperates with the fin insertion of the heat dissipation fin assembly to ensure overall stability and is suitable for automated production lines.

[0011] Preferably, the integrated mechanism is applied to the air conditioning and battery thermal management system of new energy vehicles, and is formed by integral stamping and insertion assembly.

[0012] Preferably, it also includes a housing assembly, which includes an upper core base and a lower core base; The core assembly is located between the upper core base and the lower core base and is connected by fasteners. The upper core base and the lower core base are rectangular frames made of aluminum alloy and have slots on their inner walls. They are inserted into the side frame of the skeleton assembly to form a sealed protective shell for dust prevention, mechanical support and enhanced waterproofing.

[0013] Compared with the prior art, the beneficial effects of the present invention are: The heat dissipation fins of the core of this invention are integrally stamped and formed from the frame on both sides, the middle bottom, and the top. The heat dissipation fins are inserted into the heating tube, the fins are inserted into the frame, and the fins are in direct contact with the heating tube through clamping rings. The core assembly and production process of this invention is simple and suitable for mass automated production. The heating tube support is metal-connected, with low contact resistance and low core noise. The heating tube and fins do not require high-temperature baking of the insulating film and will not be damaged by high temperature. Attached Figure Description

[0014] Figure 1 This is an exploded view of a heat dissipation fin mechanism for an air-cooled PTC core according to the present invention; Figure 2 This is a three-view schematic diagram of the heat dissipation fin mechanism of the air-cooled PTC core of the present invention. Figure 3 This is a schematic diagram of the waterproof assembly in the air-cooled PTC core heat sink fin mechanism of the present invention; Figure 4 This is a three-view schematic diagram of the core assembly in the air-cooled PTC core heat dissipation fin mechanism of the present invention; Figure 5 This is an exploded view of the core assembly in the air-cooled PTC core heat dissipation fin mechanism of the present invention; Figure 6 This is a multi-view structural schematic diagram of the heat dissipation fin assembly in the air-cooled PTC core heat dissipation fin mechanism of the present invention; Figure 7 This is a multi-view structural diagram of the side frame in the air-cooled PTC core heat dissipation fin mechanism of the present invention; Figure 8 This is a schematic diagram of the skeleton assembly in the air-cooled PTC core heat dissipation fin mechanism of the present invention; Figure 9 This is a multi-view structural schematic diagram of the clamping ring in the air-cooled PTC core heat dissipation fin mechanism of the present invention.

[0015] In the diagram: 100, Core assembly; 101, Heat sink fin assembly; 102, Fins; 103, Clamping ring; 104, Heating tube; 105, Frame assembly; 102a, ventilation fins; 102b, heat-conducting fins for heating tubes; 105a, side frame; 105b, top frame; 105c, bottom frame; 105d, snap-fit ​​structure; 105e, heating tube fixing hole; 200. Control assembly; 201. Control box; 202. Top cover; 300, Waterproof assembly; 301, Sealing gasket; 302, Potting groove; 303, Screw fastening connector; 400, Housing assembly; 401, Upper core base; 402, Lower core base; 403, Fastener; 404, Slot. Detailed Implementation

[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] Please see Figures 1-9 This invention provides a technical solution: a heat dissipation fin mechanism for an air-cooled PTC core. The core of this invention lies in the collaborative design of the core assembly 100 and the control assembly 200. The core assembly 100 is integrally stamped to form a heat dissipation fin assembly 101, which is inserted and connected to the heating tube 104, and directly contacts the heat for heat conduction using a clamping ring 103. The frame assembly 105 provides support. The control assembly 200 integrates a waterproof assembly 300, which is waterproofed through a sealing gasket 301 and a potting groove 302. The entire mechanism does not require high-temperature baking and is suitable for automated production.

[0018] More specifically, the core assembly 100 includes a heat sink fin assembly 101, a heating tube 104, and a frame assembly 105.

[0019] The heat dissipation fin assembly 101 is integrally stamped and is shaped as multiple parallel fins 102 to enhance the heat dissipation area. The fins 102 include spaced-apart ventilation fins 102a and heating tube heat-conducting fins 102b.

[0020] The heat dissipation fin assembly 101 is provided with a clamping ring 103, which is a ring-shaped elastic structure and is sleeved on the outside of the heating tube 104 to achieve heat conduction through direct contact.

[0021] The frame assembly 105 is integrally stamped and includes two side frames 105a, a top frame 105b and a bottom frame 105c, which are used to support and fix the heat dissipation fin assembly 101 and the heating pipe 104.

[0022] The heat sink fin assembly 101 is connected to the heating tube 104 by inserting, without the need for adhesive or high-temperature baking.

[0023] The control assembly 200 includes a control box 201 and a top cover 202, which are connected to the core assembly 100 by screws.

[0024] like Figure 1 As shown, the core assembly 100 includes a heat dissipation fin assembly 101, a heating tube 104, and a frame assembly 105. The heat dissipation fin assembly 101 is integrally stamped and formed into multiple parallel fins 102 to increase the heat dissipation area. The mechanism is that the stamping process is completed in one step, avoiding multiple bending, reducing stress concentration, and improving structural consistency. The clamping ring 103 is made of spring steel, with an inner diameter smaller than the outer diameter of the heating tube 104. It directly clamps the surface of the heating tube 104 through elastic deformation. The principle is that direct metal-to-metal contact reduces thermal resistance, and the thermal conductivity is higher than that of adhesive bonding.

[0025] The frame assembly 105 is integrally stamped and includes two side frames 105a, a top frame 105b and a bottom frame 105c, which are used to support and fix the heat dissipation fin assembly 101 and the heating pipe 104. The integral molding of the frame assembly 105 ensures the stability of the support.

[0026] The heat sink fin assembly 101 is connected to the heating tube 104 via a plug-in method, eliminating the need for adhesive bonding or high-temperature baking. The plug-in connection uses mechanical fitting instead of adhesive bonding, avoiding damage to the insulation film caused by high-temperature baking. The control assembly 200 includes a control box 201 and a top cover 202, which are connected to the core assembly 100 by screw locking. Through the above process, the manufacturing process is reduced from 10 steps to 5 steps, and the contact resistance is reduced.

[0027] In another feasible option, such as Figure 6 As shown, the fins 102 of the heat dissipation fin assembly 101 are rectangular sheet structures. The two side skeletons 105a, the bottom skeleton 105c and the top skeleton 105b of the fins are integrally formed by stamping. The arrangement spacing is 0.5-2mm. This arrangement optimizes airflow. The principle is to increase the surface area to enhance convective heat dissipation, thereby improving heat dissipation efficiency.

[0028] In another feasible option, such as Figure 9 As shown, the clamping ring 103 is made of metal and has a closed ring structure. Its inner diameter is smaller than the outer diameter of the heating tube 104. It clamps the surface of the heating tube 104 through elastic deformation. Its elastic mechanism is based on Hooke's law. The clamping force maximizes the contact area, reduces the interfacial thermal resistance, improves the uniformity of heat conduction, avoids local overheating, and increases the contact area to improve the heat conduction efficiency.

[0029] In another feasible solution, the plug-in connection is as follows: Figure 5 As shown, the insertion method is a stacked insertion method. The heating tube 104 is a multi-tube structure that is inserted parallel to the fin gap of the heat sink fin assembly 101, so that the heating tubes 104 are connected through the metal fins. The contact resistance is less than 0.1Ω, which reduces capacitive noise during PWM control. The heating tube 104 is made of stainless steel tube. Specifically, the bottom frame 105c is provided with heating tube fixing holes 105e.

[0030] Metal fins, acting as conductors, can reduce resistance; during PWM control, low capacitance (below 1μF) reduces current fluctuations, thereby suppressing electromagnetic noise and reducing noise to 25 dB.

[0031] In another feasible option, such as Figure 3 As shown, the present invention also includes a waterproof assembly 300, which includes a sealing gasket 301 and an adhesive filling groove 302.

[0032] The sealing gasket 301 is located between the control box 201 and the core assembly 100, and between the control box 201 and the top cover 202, and is physically sealed by tightening with screws.

[0033] The glue-filling tank 302 is located at the base of the core assembly 100, and a waterproof layer is formed by injecting epoxy resin glue.

[0034] The sealing gasket 301 is made of silicone and is compressed and sealed by screws; epoxy resin is poured into the potting tank 302 and then cured. By physically blocking water penetration, the waterproof rating reaches IP67.

[0035] In another feasible solution, the high-pressure and low-pressure interfaces of the control assembly 200 are waterproofed by screw fastening connector 303. The connector 303 has a threaded structure and is tightened after mating with the interface to prevent water intrusion. The screw fastening connector 303 is preferably an M4 thread structure. After mating with the interface, it is tightened to seal the thread and prevent leakage, thereby enhancing reliability.

[0036] In another feasible solution, the side frame 105a of the skeleton assembly 105 is provided with a snap-fit ​​structure 105d, which is inserted into the fins 102 of the heat dissipation fin assembly 101 to ensure overall stability and is suitable for automated production lines. The snap-fit ​​structure 105d of the skeleton assembly 105 is a protruding design, which is inserted into the groove of the fins 102 to ensure positioning accuracy in automated production and reduce manual intervention.

[0037] See attached document Figure 7 As shown, the side frame 105a is also provided with fixing holes for the top frame 105b and the bottom frame 105c, and also with limiting holes for the heat dissipation fin assembly 101.

[0038] Another feasible option also includes a housing assembly 400. The housing assembly 400 is an important protective structure of this invention, and the housing assembly 400 includes an upper core base 401 and a lower core base 402. For example... Figure 1 and Figure 5 As shown, the upper substrate 401 and lower substrate 402 of the core are symmetrical rectangular frame structures, made of aluminum alloy through die casting, which are lightweight and high-strength. Their inner walls have slots 404 that engage with the side frame 105a of the skeleton assembly 105 via insertion, ensuring the core assembly 100 is securely fixed. The connection mechanism involves the upper substrate 401 and lower substrate 402 being locked together with fasteners 403 (such as M4 screws) to form a closed shell, enclosing the core assembly 100. This provides a physical barrier against external dust and mechanical impact, and in conjunction with the glue-filling groove 302 of the waterproof assembly 300, improves the overall waterproof rating to IP68. This simplifies assembly steps during production (rapid positioning via insertion), reduces component wear, and further lowers the defect rate.

[0039] The overall structure of this invention is applied to the air conditioning and battery thermal management system of new energy vehicles. Through integrated stamping and insertion assembly, mass production can be achieved through the above design.

[0040] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A heat dissipation fin mechanism for an air-cooled PTC core, characterized in that, Includes a core assembly (100) and a control assembly (200); The core assembly (100) includes a heat sink fin assembly (101), a heating tube (104), and a frame assembly (105). The heat dissipation fin assembly (101) is integrally stamped and formed, and its shape is multiple parallel fins (102) to enhance the heat dissipation area. The fins (102) include ventilated heat dissipation fins (102a) and heat-conducting fins (102b) of heating pipes. The heat dissipation fin assembly (101) is provided with a clamping ring (103), which is a ring-shaped elastic structure and is sleeved on the outside of the heating tube (104) to achieve heat conduction through direct contact; The skeleton assembly (105) is integrally stamped and includes two side skeletons (105a), a top skeleton (105b) and a bottom skeleton (105c), which are used to support and fix the heat dissipation fin assembly (101) and the heating tube (104). The heat dissipation fin assembly (101) and the heating tube (104) are connected by a plug-in method, without the need for adhesive or high-temperature baking; The control assembly (200) includes a control box (201) and a top cover (202), which are connected to the core assembly (100) by screw locking.

2. The air-cooled PTC core heat dissipation fin mechanism according to claim 1, characterized in that: The fins (102) of the heat dissipation fin assembly (101) are rectangular sheet structures. The two side skeletons (105a), the bottom skeleton (105c) and the top skeleton (105b) of the fins are integrally formed by stamping to optimize airflow and heat dissipation efficiency.

3. The air-cooled PTC core heat dissipation fin mechanism according to claim 1, characterized in that: The clamping ring (103) is made of metal material and its inner diameter is smaller than the outer diameter of the heating tube (104). It clamps the surface of the heating tube (104) by elastic deformation, increasing the contact area and improving the heat conduction efficiency.

4. The air-cooled PTC core heat dissipation fin mechanism according to claim 1, characterized in that: The insertion method is a stacked insertion, and the heating tube (104) is a multi-tube structure that is inserted in parallel into the fin gap of the heat dissipation fin assembly (101), so that the heating tubes (104) are connected through the metal fins, thereby reducing capacitive noise during PWM control.

5. The air-cooled PTC core heat dissipation fin mechanism according to claim 1, characterized in that: It also includes a waterproof assembly (300), which includes a sealing gasket (301) and an adhesive filling groove (302). The sealing gasket (301) is located between the control box (201) and the core assembly (100), and between the control box (201) and the top cover (202), and is physically sealed by screws. The glue-filling groove (302) is located at the base of the core assembly (100) and forms a waterproof layer by injecting epoxy resin glue.

6. The air-cooled PTC core heat dissipation fin mechanism according to claim 5, characterized in that: The high-pressure and low-pressure interfaces of the control assembly (200) are waterproofed by screw-fastened connectors (303). The connectors (303) have a threaded structure and are tightened after being matched with the interfaces to prevent moisture from entering.

7. The air-cooled PTC core heat dissipation fin mechanism according to claim 1, characterized in that: The side frame (105a) of the skeleton assembly (105) is provided with a snap-fit ​​structure (105d), which is inserted and matched with the fins (102) of the heat dissipation fin assembly (101) to ensure overall stability and is suitable for automated production lines.

8. The air-cooled PTC core heat dissipation fin mechanism according to claim 1, characterized in that: The integrated structure is used in the air conditioning and battery thermal management systems of new energy vehicles, and is formed by integral stamping and insertion assembly.

9. The air-cooled PTC core heat dissipation fin mechanism according to claim 1, characterized in that: It also includes a housing assembly (400), which includes an upper core substrate (401) and a lower core substrate (402). The core assembly (100) is located between the upper core base (401) and the lower core base (402) and is connected by fasteners (403). The upper core base (401) and the lower core base (402) are rectangular frames made of aluminum alloy. Their inner walls are provided with slots (404) that fit into the side frame (105a) of the skeleton assembly (105) to form a sealed protective shell for dust prevention, mechanical support and enhanced waterproofing.

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