Ultrahigh power density PTC heater

Abstract

The utility model relates to the technical field of PTC (Positive Temperature Coefficient) heaters, and discloses an ultra-high power density PTC heater, which comprises a heater main body, a liquid inlet / outlet baffle plate and a water channel baffle plate, and is characterized in that the heater main body is an integrally formed structural member and is integrally formed by adopting an aluminum alloy material through a die casting process; a plurality of grooves are formed in the heater body, the grooves are symmetrically distributed on the two sides of the interior of the heater body, a PTC heating bag set is correspondingly assembled in each groove, the grooves are symmetrically distributed on the two sides of the interior of the heater body and connected into a whole, and a through channel is formed in the middle of the heater body. The PTC heating bag group is arranged in the heater main body and is matched with the U-shaped sheet, so that the volume of the heater main body can be smaller under the same power condition, the ultra-high density distribution of the PTC heating bag group is realized, the PTC heating bag group is tightly clamped in the heater main body, and heat energy generated by the PTC heating bags can be efficiently and quickly transferred into the heater main body.

Description

Technical Field

[0001] The utility model relates to the technical field of PTC heaters, in particular to an ultra-high power density PTC heater. Background Art

[0002] PTC heating elements are a type of semiconductor ceramics with barium titanate (BaTiO3), strontium titanate (SrTiO3), and lead titanate (PbTiO3) as basic components. This type of ceramic has low resistance at low temperatures; but when the temperature is above a certain temperature (called the Curie temperature Tc), its own resistance rises sharply by 3-8 orders of magnitude (103-108 times), and the resistor has a large positive temperature coefficient. The heater flow channel structure is a general term for a series of devices used to conduct and release heat. The PTC heating element converts electrical energy into thermal energy, and then carries the heat away through the coolant in the heater flow channel structure to achieve heating of the entire vehicle cockpit or battery pack.

[0003] In the prior art, the internal flow channel structure of the heater is composed of multiple parts assembled from the heater and other shells. The multiple parts are fastened by screws and the interior is sealed by a sealing ring. The assembly is complicated and the quality is difficult to control. The slots for assembling the PTC heating elements on the heater are distributed on the front and are single-sided closed countersunk holes. A larger assembly volume is required under the same power conditions. The assembly between the PTC heating element and the heater slot is usually fastened by a metal gasket plus a wedge-shaped piece or a potting glue. This method has complicated assembly and low heat transfer efficiency. The multiple protruding closed slots on the heater make the die-casting manufacturing process difficult. Utility Model Content

[0004] To solve the problems of the existing internal flow channel structure of the heater, which is composed of multiple parts of the heater and other shells, assembled by screws between multiple parts, sealed by sealing rings inside, with complex assembly, difficult quality control, low distribution density of PTC heating elements assembled on the heater, and larger assembly volume required under the same power condition, and complex assembly and low heat transfer efficiency of PTC heating elements, the present utility model is realized through the following technical solutions: A super-high power density PTC heater includes a heater body, an inlet and outlet liquid baffle, and a water channel baffle. The heater body is an integrally formed structural part, which is integrally formed by die-casting process using aluminum alloy material. A number of cavities are provided in the heater body, and a number of the cavities are symmetrically distributed on both sides inside the heater body. Each cavity is correspondingly assembled with a PTC heating pack group. On both sides corresponding to the cavities in the heater body, a multi-contact electrode plate is installed, and a number of PTC heating pack groups are connected in series by using the multi-contact electrode plate, and then communicated with the PCBA in the tail cavity of the heater body. The distribution design of the cavities inside the heater body can densely distribute the PTC heating pack groups in the heater body, and the volume of the heater body can be made smaller under the same power condition;

[0005] The inlet and outlet liquid baffle and the water channel baffle are an integral part with the heater body. The inlet and outlet liquid baffle, the water channel baffle and the heater body are welded into a whole. A flow channel is provided inside the heater body, and both ends of the flow channel correspond to the inlet and outlet liquid baffle and the water channel baffle respectively. The inlet and outlet liquid baffle, the water channel baffle and the heater body construct a flow channel inside. The distribution design of the flow channel can enable the heat energy generated by the PTC heating pack group to be efficiently and quickly transferred to the heater body.

[0006] Further, an inlet and an outlet are provided on the side of the inlet and outlet liquid baffle. The inlet and the outlet are both communicated with the flow channel, used for the PTC heating pack group to convert electrical energy into heat energy, and then the coolant in the flow channel takes away the heat, so as to realize heating the whole vehicle cockpit or battery pack.

[0007] Further, the flow channels are distributed in a "field" shape, and a number of the flow channels are communicated with each other. This design can reduce the die-casting manufacturing process difficulty of the heater body, and the aluminum liquid flows smoothly in the mold, solving common defects such as air holes and cold shuts caused by poor aluminum liquid flow during die-casting.

[0008] Further, a U-shaped sheet is provided outside the PTC heating pack group, and the U-shaped sheet is press-fitted inside the cavity;

[0009] Folding ears are turned outwards on both sides of the U-shaped sheet, and the folding ears are stuck on the heater body.

[0010] Furthermore, the outer side wall of the U-shaped sheet is configured as a first tapered portion, the inner groove wall of the groove hole is configured as a second tapered portion, and the first tapered portion is adapted to the second tapered portion.

[0011] Furthermore, the second conical portions in the two horizontally corresponding grooves on both sides of the heater body are symmetrically distributed, and the two second conical portions are connected as a whole. A through channel is set in the middle of the two grooves, so that the volume of the heater body can be made smaller under the same power conditions.

[0012] Furthermore, the first tapered portion and the second tapered portion are both inclined surfaces, and the angles between the first tapered portion and the second tapered portion and the horizontal plane are 1-5°, so that the U-shaped sheet can be tightly fixed by using the groove.

[0013] Furthermore, side covers are installed on both sides of the heater body corresponding to the reconnected electrode plate, a snap-fitting piece is provided at the connection between the side cover and the heater body, a slot is provided at the connection between the heater body and the side cover, the slot is adapted to the snap-fitting piece, the side cover is fixedly connected to the heater body via the snap-fitting piece, the connection between the side cover and the heater body is filled with a glue layer, and the connection between the side cover and the heater body is filled with glue, so that the side cover and the heater body are together constructed into a closed sealed chamber.

[0014] Furthermore, a PCBA is provided on one side of the water channel baffle away from the heater body, and the PCBA is electrically connected to the composite electrode plates on both sides of the heater body;

[0015] A back cover is provided on one side of the PCBA away from the water channel baffle, a snap-fit ​​piece is provided at the connection between the back cover and the heater body, a slot is provided at the connection between the heater body and the back cover, the slot is matched with the snap-fit ​​piece, the back cover is fixedly connected to the heater body through the snap-fit ​​piece, a glue layer is filled at the connection between the back cover and the heater body, and the connection between the back cover and the heater body is filled with glue, so that the back cover and the heater body are together constructed into a closed sealed chamber.

[0016] Compared with the prior art, the utility model has the following beneficial effects:

[0017] The utility model has grooves symmetrically distributed on both sides of the heater body and connected as a whole with a through channel in the middle. Together with the U-shaped sheet, the volume of the heater body can be made smaller under the same power conditions, thereby achieving ultra-high density distribution of the PTC heating pack group. The PTC heating pack group is tightly stuck in the heater body, which can efficiently and quickly transfer the heat energy generated by the PTC heating pack to the heater body.

[0018] In the present utility model, the internal flow channels of the heater body are distributed in a "field" shape, and several flow channels are arranged in a row and connected to each other, reducing the difficulty of die-casting manufacturing process. The molten aluminum flows smoothly in the mold, solving defects such as air holes and cold shuts commonly caused by poor flow of molten aluminum during die-casting. At the same time, the heat transfer can be accelerated. The heater body is an integrally die-cast part, and then it is welded together with the inlet and outlet baffle plates and the water channel baffle plates to form a whole. The structure is simple, can be fully automatically welded, and the quality is reliable and stable. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 is a schematic exploded view of the overall structure of the PTC heater of the present utility model;

[0020] Figure 2 is a schematic structural view of the internal structure of the heater body of the present utility model;

[0021] Figure 3 is a schematic structural view of the internal flow channels of the PTC heater of the present utility model;

[0022] Figure 4 is a schematic structural view of the internal structure of the PTC heater of the present utility model.

[0023] In the figure: 1. Heater body; 2. Inlet and outlet baffle plate; 3. Water channel baffle plate; 4. PTC heating pack group; 5. Reconnection electrode plate; 6. Side cover; 7. PCBA; 8. Rear cover; 9. Buckle part; 10. U-shaped piece; 11. First conical part; 12. Second conical part; 13. Flow channel; 14. Through-channel. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0024] The following will clearly and completely describe the technical solutions in the embodiments of the present utility model with reference to the accompanying drawings in the embodiments of the present utility model. Obviously, the described embodiments are only a part of the embodiments of the present utility model, rather than all the embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present utility model.

[0025] The embodiments of the ultra-high power density PTC heater are as follows:

[0026] Please refer to Figure 1-Figure 4 , an ultra-high power density PTC heater, including a heater body 1, an inlet and outlet baffle plate 2, a water channel baffle plate 3, a PTC heating pack group 4, a reconnection electrode plate 5, a side cover 6, a PCBA 7, and a rear cover 8. The heater body 1 is integrally formed by die-casting using an aluminum alloy material; several cavities are provided in the heater body 1, and several cavities are symmetrically distributed on both sides inside the heater body 1, and a PTC heating pack group 4 is correspondingly assembled in each cavity.

[0027] The inlet / outlet baffle 2, the water channel baffle 3 and the heater body 1 are welded into a whole, and a flow channel structure, namely the flow channel 13, is constructed inside the inlet / outlet baffle 2, the water channel baffle 3 and the heater body 1. The flow channel 13 is located at the outer side wall of the cavity. The shape of the flow channel structure 13 is a "field" - shaped structure. A number of flow channels 13 are connected in a row. The design of the flow channel 13 reduces the difficulty of die - casting manufacturing process. The molten aluminum flows smoothly in the mold, solving the common defects such as air holes and cold shuts caused by the不畅 flow of molten aluminum during die - casting, and at the same time, it can accelerate the transfer of heat energy.

[0028] The side of the inlet / outlet baffle 2 is provided with an inlet and an outlet. Both the inlet and the outlet are connected to the flow channel 13. The PTC heating pack group 4 is used to convert electrical energy into heat energy, and then the coolant in the flow channel 13 takes away the heat, realizing the heating of the whole vehicle cockpit or the battery pack.

[0029] A U - shaped piece 10 is arranged outside the PTC heating pack group 4. The U - shaped piece 10 is in close contact with the cavity and is press - fitted. The two sides of the U - shaped piece 10 are turned outwards to be provided with folded ears, and the folded ears are stuck on the heater body 1. The outer side wall of the U - shaped piece 10 is set as the first conical part 11, and the inner groove wall of the cavity is set as the second conical part 12. The first conical part 11 and the second conical part 12 are adapted to each other.

[0030] Both the first conical part 11 and the second conical part 12 are inclined surfaces, and the included angle between the first conical part 11, the second conical part 12 and the horizontal plane is 1 - 5°. It is convenient to fix the U - shaped piece 10 tightly by using the cavity. The second conical parts 12 in the two horizontally corresponding cavities on both sides inside the heater body 1 are symmetrically distributed, and the two second conical parts 12 are connected as a whole. A through - type channel 14 is arranged in the middle of the two cavities. Under the condition of the same power, the volume of the heater body 1 can be made smaller.

[0031] The multiple - connection electrode plates 5 are symmetrically distributed on both sides of the heater body 1, used to connect a number of PTC heating pack groups 4 in series, and then connect them to the PCBA7 in the tail cavity of the heater body 1. The PCBA7 is a printed circuit board.

[0032] The side covers 6 are symmetrically distributed on both sides of the heater body 1, fixedly connected to the heater body 1 through the buckle parts 9, and then sealed with glue, together with the heater body 1 to form a closed sealed cavity; the PCBA7 is distributed in the tail cavity of the heater body 1, connecting the multiple - connection electrode plates 5 on both sides and controlling the operation of the heater. The rear cover 8 is distributed at the tail of the heater body 1, fixedly connected to the heater body 1 through the buckle parts 9, and then sealed with glue, together with the heater body 1 to form a closed sealed cavity.

[0033] The structural composition and working principle of the PTC heater:

[0034] The heater body 1 is welded to the liquid inlet and outlet baffles 2 and the waterway baffle 3 as a whole. The U-shaped sheets 10 are first clamped on both sides of the PTC heating pack group 4, and then placed in the grooves of the heater body 1 respectively, and then a certain pressure is applied to make it slowly enter the grooves. After being pressed into a certain depth, the first conical portions 11 of the outer walls on both sides of the U-shaped sheet 10 are completely fitted and tightly matched with the second conical portions 12 of the inner walls of the grooves of the heater body 1. The top of the U-shaped sheet 10 is clamped on the heater body 1 through the folded ear portion, and the heat energy generated by the PTC heating pack group 4 is efficiently and quickly transferred to the heater body 1.

[0035] The composite electrode plates 5 on both sides of the heater body 1 connect several PTC heating pack groups 4 in series, and then connect and conduct with the PCBA 7 to transmit the electrical energy of the entire vehicle to the PTC heating pack group 4 and convert it into thermal energy.

[0036] The side cover 6 and the rear cover 8 are fixedly connected to the heater body 1 by means of the snap fasteners 9 and then sealed by glue to form a closed chamber to protect the internal components and prevent external moisture and dust from entering the interior of the heater body 1.

[0037] The outer groove wall of the groove of the heater body 1 and the inlet and outlet baffles 2 and the waterway baffle 3 form a flow channel 13, and the flow channel 13 is equipped with a liquid inlet and a liquid outlet. The coolant can flow in the flow channel 13 and take away the heat energy generated by the PTC heating pack group 4, thereby achieving heating of the entire vehicle cockpit or battery pack.

[0038] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An ultra-high power density PTC heater, comprising a heater body (1), a liquid inlet and outlet baffle (2) and a waterway baffle (3), characterized in that: The heater body (1) is an integrally formed structural member. A number of cavities are provided in the heater body (1), and the number of cavities are symmetrically distributed on both sides inside the heater body (1). A PTC heating pack group (4) is correspondingly assembled in each cavity. On both sides corresponding to the cavities in the heater body (1), a multi-contact electrode plate (5) is installed, and a number of PTC heating pack groups (4) are connected in series by using the multi-contact electrode plate (5). The inlet / outlet baffle (2) and the water channel baffle (3) and the heater body (1) are an integral part. A flow channel (13) is provided inside the heater body (1), and both ends of the flow channel (13) correspond to the inlet / outlet baffle (2) and the water channel baffle (3) respectively.

2. The ultra-high power density PTC heater according to claim 1, characterized in that: The side of the inlet / outlet baffle (2) is provided with an inlet and an outlet, and both the inlet and the outlet are in communication with the flow channel (13).

3. The ultra-high power density PTC heater according to claim 2, characterized in that: The flow channels (13) are distributed in a "field" shape, and a number of the flow channels (13) are in communication with each other.

4. An ultra-high power density PTC heater according to any one of claims 1 to 3, characterized in that: A U-shaped piece (10) is provided outside the PTC heating pack group (4), and the U-shaped piece (10) is press-fitted inside the cavity. Folded ear parts are turned outwards on both sides of the U-shaped piece (10), and the folded ear parts are stuck on the heater body (1).

5. The ultra-high power density PTC heater according to claim 4, characterized in that: The outer side wall of the U-shaped piece (10) is provided as a first tapered portion (11), and the inner cavity wall of the cavity is provided as a second tapered portion (12), and the first tapered portion (11) and the second tapered portion (12) are adapted to each other.

6. The ultra-high power density PTC heater according to claim 5, characterized in that: The second tapered portions (12) in two cavities horizontally corresponding to each other on both sides inside the heater body (1) are symmetrically distributed, and the two second tapered portions (12) are integrally connected, and a through-channel (14) is provided in the middle of the two cavities.

7. The ultra-high power density PTC heater according to claim 6, characterized in that: Both the first tapered portion (11) and the second tapered portion (12) are inclined surfaces, and the included angles between the first tapered portion (11), the second tapered portion (12) and the horizontal plane are 1-5°.

8. An ultra-high power density PTC heater according to any one of claims 5 to 7, characterized in that: Side covers (6) are installed on both sides of the heater body (1) corresponding to the multi-contact electrode plate (5). A buckle member (9) is provided at the connection between the side cover (6) and the heater body (1). The side cover (6) is fixedly connected to the heater body (1) through the buckle member (9), and an adhesive layer is filled at the connection between the side cover (6) and the heater body (1).

9. The ultra-high power density PTC heater according to claim 8, characterized in that: A PCBA (7) is provided on the side of the water channel baffle (3) away from the heater body (1), and the PCBA (7) is electrically connected to the multi-contact electrode plates (5) on both sides of the heater body (1). A rear cover (8) is provided on the side of the PCBA (7) away from the water channel baffle (3). A buckle member (9) is provided at the connection between the rear cover (8) and the heater body (1). The rear cover (8) is fixedly connected to the heater body (1) through the buckle member (9), and an adhesive layer is filled at the connection between the rear cover (8) and the heater body (1).

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