High-voltage electric heater for hybrid vehicle

Abstract

This invention provides a high-voltage electric heater for hybrid vehicles, comprising: a housing in the shape of a ring; a heating tube wound into a disc shape and disposed within the housing; a metal assembly disposed on the side of the heating tube and attached to the heating tube; and a connecting assembly capable of connecting the end of the heating tube to the housing and used to electrically connect the end of the heating tube to a power cord connector. This invention provides a high-voltage electric heater for hybrid vehicles, which achieves insulation and heat conduction by configuring the heating tube as a three-layer composite structure of heating wire, insulating ceramic, and heating tube body; the disc-shaped heating tube and the first and second metal carriers on both sides provide structural stability, good heat conduction, facilitate heat transfer, increase the heating surface area, and improve heating efficiency; and the inclusion of a support plate, inner insulating tube, and outer insulating tube ensures insulation between the heating tube and the housing, achieving good insulation and eliminating safety hazards.

Description

Technical Field

[0001] This invention belongs to the field of exhaust aftertreatment technology for hybrid vehicles, and particularly relates to a high-voltage electric heater for hybrid vehicles. Background Technology

[0002] With the development of new energy vehicles, hybrid electric vehicles (HEVs) have become widely used. When HEVs use an internal combustion engine as their power system or when the battery is depleted and the internal combustion engine is used as a generator, they inevitably produce air pollutants such as HC, CO, and NOx. These pollutants must be effectively purified by an after-treatment system to meet the emission requirements of relevant national regulations. Furthermore, compared to traditional gasoline vehicles, HEVs experience more frequent engine starts during operation, leading to increased emissions due to frequent cold starts. With the promulgation of emission regulations, stricter emission requirements have been imposed on cold-start emissions. Existing hybrid vehicles are equipped with high-voltage battery packs, often exceeding 400V. Compared to conventional low-voltage electric heaters, high-voltage systems place higher demands on the insulation of the electric heaters. Therefore, it is necessary to design a high-voltage electric heater suitable for HEVs to meet these requirements. Summary of the Invention

[0003] To address the shortcomings of existing technologies, embodiments of the present invention provide a high-voltage electric heater for hybrid vehicles, suitable for high-voltage systems. To achieve the above technical objectives, the technical solution adopted in the embodiments of the present invention is as follows: This invention provides a high-voltage electric heater for hybrid vehicles, comprising: The housing is annular and extends axially, and has two through holes, one of which penetrates the housing radially. A heating element, which is wound into a disc shape and disposed within the housing, has one end passing through one of the aforementioned through holes and the other end passing through another of the aforementioned through holes. A metal component is disposed on the side of the heating tube and is attached to the heating tube; the metal component is fixedly connected to the housing. A connecting assembly capable of connecting the end of the heating tube to the housing and for electrically connecting the end of the heating tube to a power cord connector.

[0004] Furthermore, the heating tube includes a starting section and an ending section. The heating tube starts from the initial section, rotates inward along an arc to the center, and forms a first disc segment. It then extends axially to form a connecting section, and finally rotates outward along an arc from the center to form a second disc segment. The first disk segment and the second disk segment are arranged side by side.

[0005] Furthermore, the metal component includes: A first metal carrier is disposed on one side of the heating tube and is attached to the first disc segment; The second metal carrier is located on the other side of the heating tube and is attached to the second disc segment.

[0006] Further, the first metal carrier and the second metal carrier comprise: A plurality of concentric metal rings, wherein there is a gap between any two adjacent metal rings; Several metal foils are arranged in a corrugated pattern, with one of the metal foils located in any of the intervals.

[0007] Furthermore, the metal component also includes: A first retaining ring is fitted onto the first metal carrier, and the first retaining ring, the first metal carrier, and the shell are fixedly connected. The second retaining ring is fitted onto the second metal carrier, and the second retaining ring, the second metal carrier, and the shell are fixedly connected.

[0008] Furthermore, the heating element includes: Heating element body, A heating wire is disposed in the heating tube body, and the extension direction of the heating wire is consistent with the extension direction of the heating tube body; An insulating ceramic is disposed in the heating tube body and fills the gap between the heating tube body and the heating wire.

[0009] Furthermore, the heating wire is made of an iron-chromium-aluminum alloy.

[0010] Furthermore, the connection component includes: A fixing bolt and a fixing nut, wherein the fixing bolt includes a bolt head and a threaded portion, the threaded portion extends axially, the bolt head is fixedly connected to one end of the threaded portion, and the fixing nut is threadedly connected to the other end of the threaded portion; An inner insulating tube is sleeved over the screw portion and positioned between the bolt head and the fixing nut; Two support plates are fixedly connected to the housing. The two support plates are spaced apart along the axial direction. Each support plate is provided with a support hole, and the inner insulating tube is sleeved in each support hole. Two outer insulating tubes are arranged axially spaced apart, and each outer insulating tube is sleeved over the inner insulating tube and disposed between two support plates; The heating tube is provided with a heating tube connector at its end. The heating tube connector is fitted with the inner insulating tube and is located between the two outer insulating tubes. A power cord connector is provided between the end of the heating tube and the outer insulating tube.

[0011] Furthermore, the inner insulating tube is made of ceramic. And / or, the outer insulating tube is made of ceramic.

[0012] The beneficial effects of the technical solution provided by the embodiments of the present invention are as follows: (1) The present invention provides a high-voltage electric heater for hybrid vehicles. By setting the heating tube as a three-layer composite structure of heating wire, insulating ceramic and heating tube body, it plays a role in insulation and heat conduction. Through the disc-shaped heating tube and the first metal carrier and the second metal carrier on both sides, the structure is stable and has good heat conduction effect, which facilitates heat transfer, increases the heating surface area and improves heating efficiency. By setting the support plate, inner insulating tube and outer insulating tube, the heating tube is insulated from the shell, which plays a good insulation role and eliminates safety hazards.

[0013] (2) The present invention provides a high-voltage electric heater for hybrid vehicles. The whole adopts an insulated heating tube to solve the insulation problem of high-voltage electric heating. Under the same design power, the high-voltage system requires less current, the requirements for the line are reduced, the insulation performance is better, and the exhaust temperature can be quickly increased so that the after-treatment system can play its role as soon as possible. It can effectively solve the problem of excessive emissions of pollutants such as HC, CO and NOx caused by frequent cold starts of hybrid vehicles. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of a high-voltage electric heater for hybrid vehicles in an embodiment of the present invention.

[0015] Figure 2 This is an exploded view of a high-voltage electric heater for a hybrid vehicle in an embodiment of the present invention.

[0016] Figure 3 This is a cross-sectional view of a high-voltage electric heater for a hybrid vehicle in an embodiment of the present invention.

[0017] Figure 4 This is a partial schematic diagram of the first metal carrier and the second metal carrier in an embodiment of the present invention.

[0018] Figure 5 This is a schematic diagram of the heating tube in an embodiment of the present invention.

[0019] Figure 6 This is a cross-sectional view of the heating tube in an embodiment of the present invention. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the 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 merely illustrative and not intended to limit the invention.

[0021] This invention provides a high-voltage electric heater for hybrid vehicles, comprising: The housing 1 is annular and extends axially. The housing 1 has two through holes, and either of the through holes penetrates the housing 1 radially. Heating tube 2, which is wound into a disc shape and disposed in the housing 1, has one end passing through one of the through holes and the other end passing through another of the through holes. Metal component 3 is disposed on the side of the heating tube 2 and is attached to the heating tube 2. Metal component 3 is fixedly connected to the housing 1. The connecting component 4 is capable of connecting the end of the heating tube 2 to the housing 1 and is used to electrically connect the end of the heating tube 2 to the power cord connector.

[0022] In a specific embodiment, such as Figure 1 , Figure 2 As shown, the housing 1 extends from left to right, the heating tube 2 is disposed in the housing 1, and the metal component 3 is attached to the heating tube 2, that is, the metal component 3 is in direct contact with the heating tube 2. Thus, after the heating tube 2 is heated, it can transfer heat to the metal component 3 through the contact surface, thereby heating the metal component 3. As a result, the heating tube 2 and the metal component 3 form a heat capacity, increasing the heat exchange area with the gas. At the same time, the metal component 3 can also serve to fix the heating tube 2.

[0023] Furthermore, the heating tube 2 includes a starting section and an ending section. The heating tube 2 starts from the initial section, rotates inward along an arc to the center, and forms the first disc section 21. Then it extends axially to form the connecting section 22. Finally, it rotates outward along an arc from the center to form the second disc section 23. The first disk segment 21 and the second disk segment 23 are arranged side by side.

[0024] Furthermore, the metal component 3 includes: The first metal carrier 31 is disposed on one side of the heating tube 2 and is attached to the first disc segment 21; The second metal carrier 32 is located on the other side of the heating tube 2 and is attached to the second disc segment 23.

[0025] Further, the first metal carrier 31 and the second metal carrier 32 include: A plurality of concentric metal rings 3a, wherein there is a gap between any two adjacent metal rings 3a; A plurality of metal foils 3b are arranged in a corrugated manner, and one of the metal foils 3b is provided in any of the intervals.

[0026] like Figure 4 As shown, the metal foil is corrugated, which increases the structural strength of the first and second metal carriers and expands their heat transfer area, facilitating heating.

[0027] Furthermore, the metal component 3 also includes: The first retaining ring 33 is sleeved on the first metal carrier 31, and the first retaining ring 33, the first metal carrier 31, and the shell 1 are fixedly connected; The second retaining ring 34 is fitted with the second metal carrier 32, and the second retaining ring 34, the second metal carrier 32, and the housing 1 are fixedly connected.

[0028] The method of fixed connection is not limited; in one embodiment, such as... Figure 3 As shown, the first metal carrier 31, the first retaining ring 33, and the housing 1 are welded together, as are the second metal carrier 32, the second retaining ring 34, and the housing 1. During installation, the first metal carrier 31 is first attached to the first disc segment 21, the first retaining ring 33 is fitted onto the first metal carrier 31, and the first retaining ring 33 is welded to the outer ring of the first metal carrier 31 and the housing 1. Similarly, the second metal carrier 32 is attached to the second disc segment 23, the second retaining ring 34 is fitted onto the second metal carrier 32, and the second retaining ring 34 is welded to the outer ring of the second metal carrier 32 and the housing 1. Thus, the metal assembly 3 and the heating tube 2 can be formed as a whole.

[0029] Furthermore, the heating tube 2 includes: Heating element body 24, A heating wire 25 is disposed in the heating tube body 24, and the extending direction of the heating wire 25 is consistent with the extending direction of the heating tube body 24. An insulating ceramic 26 is disposed in the heating tube body 24 and fills the gap between the heating tube body 24 and the heating wire 25.

[0030] Understandable, such as Figure 5 , Figure 6 As shown, the heating wire 25 is the heating body, which generates heat after being energized. The insulating ceramic 26 serves to insulate and conduct heat. The heating tube body 24 is wrapped around the insulating ceramic 26 to form the heating tube 2. The heating tube body 24 can be made of metal with high thermal conductivity.

[0031] During manufacturing, the cylindrical heating wire 25 is installed in the heating tube body 24, and insulating ceramic powder is filled between the heating wire 25 and the heating tube body 24. After fixing and sintering, the structure of the heating tube is formed, and the heating tube can play the role of insulation and heat conduction.

[0032] Furthermore, the heating wire 25 is made of iron-chromium-aluminum alloy, which has high thermal conductivity and is conducive to rapid heat transfer.

[0033] Furthermore, the connection component 4 includes: The fixing bolt 41 and the fixing nut 42 are provided. The fixing bolt 41 includes a bolt head 41a and a threaded portion 41b. The threaded portion 41b extends axially. The bolt head 41a is fixedly connected to one end of the threaded portion 41b. The fixing nut 42 is threadedly connected to the other end of the threaded portion 41b. An inner insulating tube 43 is sleeved on the screw portion 41b and is located between the bolt head 41a and the fixing nut 42; Two support plates 44 are fixedly connected to the housing 1. The two support plates 44 are spaced apart along the axial direction. Each support plate 44 is provided with a support hole, and the inner insulating tube 43 is sleeved in each support hole. Two outer insulating tubes 45 are arranged axially spaced apart, and each outer insulating tube 45 is sleeved on the inner insulating tube 43 and disposed between two support plates 44; The heating tube 2 is provided with a heating tube connector 2a at its end. The heating tube connector 2a is sleeved on the inner insulating tube 43 and is located between the two outer insulating tubes 45. A power cord connector is provided between the end of the heating tube 2 and the outer insulating tube 45.

[0034] In a specific embodiment, such as Figure 2 , Figure 3As shown, the two support plates 44 are spaced apart vertically. The screw portion 41b of the fixing bolt 41 extends from bottom to top and is disposed in the support hole of the support plate 44. The lower side of the lower support plate 44 is the bolt head 41a, and the upper side of the upper support plate 44 is the fixing nut 42. The inner insulating tube 43 on the screw portion 41b is disposed between the screw head and the fixing nut 42. Two outer insulating tubes 45 are spaced apart vertically on the inner insulating tube 43. The heating tube connector 2a at the right end of the heating tube 2 is fitted with the inner insulating tube 43, and the space between the end of the heating tube 2 and the outer insulating tube 45 is used for setting... The power cord connector allows the two ends of the heating tube 2 to be connected to the positive and negative terminals of the power supply, enabling the heating tube 2 to be energized and heated. The inner insulating tube 43 and the outer insulating tube 45 provide insulation, thus insulating the heating tube 2, the power cord connector, and the housing 1. The inner insulating tube 43, the outer insulating tube 45, the heating tube connector 2a, and the power cord connector are fixed by the fixing bolts 41 and the fixing nuts 42, preventing the heating tube connector 2a and the power cord connector from loosening and falling off, ensuring the safety of the high-voltage electric heater for hybrid vehicles. This structural design provides good fixing and insulation of the power connector, making it very suitable for electric heaters in high-voltage systems.

[0035] Furthermore, the inner insulating tube is made of ceramic. And / or, the outer insulating tube is made of ceramic, which has high thermal conductivity and insulation properties, ensuring the safety of the high-voltage electric heater for hybrid vehicles.

[0036] Finally, it should be noted that the above specific embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A high-voltage electric heater for hybrid vehicles, characterized in that, include: The housing (1) is annular and extends axially. The housing (1) has two through holes, and either of the through holes penetrates the housing (1) radially. A heating tube (2) is wound into a disc shape and disposed in the housing (1). One end of the heating tube (2) passes through one of the through holes and the other end passes through another of the through holes. A metal component (3) is disposed on the side of the heating tube (2) and is attached to the heating tube (2). The metal component (3) is fixedly connected to the housing (1). Connection component (4), which is capable of connecting the end of the heating tube (2) to the housing (1) and is used to electrically connect the end of the heating tube (2) to the power cord connector.

2. The high-voltage electric heater for hybrid vehicles as described in claim 1, characterized in that, The heating tube (2) includes a starting section and an ending section. The heating tube (2) starts from the starting section, rotates inward along an arc to the center, and forms a first disc section (21), then extends along the axial direction to form a connecting section (22), and then rotates outward along an arc from the center to form a second disc section (23). The first disk segment (21) and the second disk segment (23) are arranged side by side.

3. The high-voltage electric heater for hybrid vehicles as described in claim 2, characterized in that, The metal component (3) includes: The first metal carrier (31) is disposed on one side of the heating tube (2) and is attached to the first disc segment (21); The second metal carrier (32) is located on the other side of the heating tube (2) and is attached to the second disc segment (23).

4. The high-voltage electric heater for hybrid vehicles as described in claim 3, characterized in that, The first metal carrier (31) and the second metal carrier (32) include: A plurality of concentric metal rings (3a), wherein there is a gap between any two adjacent metal rings (3a); A plurality of metal foils (3b) are arranged in a corrugated manner, and one of the metal foils (3b) is provided in any of the intervals.

5. The high-voltage electric heater for hybrid vehicles as described in claim 3, characterized in that, The metal component (3) also includes: The first retaining ring (33) is fitted onto the first metal carrier (31), and the first retaining ring (33), the first metal carrier (31), and the shell (1) are fixedly connected; The second retaining ring (34) is fitted with the second metal carrier (32), and the second retaining ring (34), the second metal carrier (32), and the shell (1) are fixedly connected.

6. The high-voltage electric heater for hybrid vehicles as described in claim 1, characterized in that, The heating element (2) includes: Heating tube body (24). A heating wire (25) is disposed in the heating tube body (24), and the extension direction of the heating wire (25) is consistent with the extension direction of the heating tube body (24); An insulating ceramic (26) is disposed in the heating tube body (24) and fills the gap between the heating tube body (24) and the heating wire (25).

7. The high-voltage electric heater for hybrid vehicles as described in claim 6, characterized in that, The heating wire (25) is made of iron-chromium-aluminum alloy.

8. The high-voltage electric heater for hybrid vehicles as described in claim 6, characterized in that, The connection component (4) includes: A fixing bolt (41) and a fixing nut (42) are provided. The fixing bolt (41) includes a bolt head (41a) and a threaded portion (41b). The threaded portion (41b) extends axially. The bolt head (41a) is fixedly connected to one end of the threaded portion (41b). The fixing nut (42) is threadedly connected to the other end of the threaded portion (41b). An inner insulating tube (43) is sleeved on the screw part (41b) and located between the bolt head (41a) and the fixing nut (42); Two support plates (44) are fixedly connected to the housing (1). The two support plates (44) are spaced apart along the axial direction. Each support plate (44) has a support hole, and the inner insulating tube (43) is sleeved in each support hole. Two outer insulating tubes (45) are arranged axially spaced apart, and each of the outer insulating tubes (45) is sleeved on the inner insulating tube (43) and is located between two support plates (44); The heating tube (2) has a heating tube connector (2a) at its end. The heating tube connector (2a) is fitted with the inner insulating tube (43) and is located between the two outer insulating tubes (45). A power cord connector is set between the end of the heating tube (2) and the outer insulating tube (45).

9. The high-voltage electric heater for hybrid vehicles as described in claim 8, characterized in that, The inner insulating tube is made of ceramic. And / or, the outer insulating tube is made of ceramic.

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