Efficient high-voltage liquid heating rod for vehicle
Through the heating rod designed with aluminum alloy tube shell and fin, the problems of complex production, large weight and poor thermal conductivity in the prior art are solved, and efficient and low-cost heating effect is achieved.
Patent Information
- Application Number
- CN202421950040.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-13
- Publication Date
- 2025-07-04
- Estimated Expiration
- 2034-08-13
AI Technical Summary
The existing high-voltage liquid heaters for automotive use have problems such as difficulty in making, large weight, poor thermal conductivity, high cost and low thermal efficiency, especially due to the complex processing caused by the use of stainless steel materials and the difficulty in increasing fins.
The aluminum alloy tube shell is used to make heating rods through integrated extrusion molding, combined with wavy, threaded wrap-around or grooved fin design, eliminating laser welding and improving thermal conductivity and heating area.
Simplify processing technology, reduce costs, improve thermal efficiency, enhance the reliability and thermal conductivity of heating rods, and ensure product qualification rate.
Smart Images
Figure CN223067218U_ABST
Abstract
Description
Technical Field
[0001] The utility model belongs to the technical field of vehicle electric heaters, and particularly relates to a high-efficiency vehicle high-voltage liquid heating rod. Background Art
[0002] At present, the electric heaters applied to new energy vehicles on the market include high-voltage liquid heaters with a resistance wire structure, high-voltage liquid heaters with a thick film structure, high-voltage liquid heaters with a PTC structure, etc. Among them, the high-voltage liquid heater with a resistance wire structure is the most widely used. Considering the environmental use factors of the heater, the heating rods inside the current high-voltage liquid heaters with a resistance wire structure are all heating rods 1 made of stainless steel as the base material. See Figure 1 , and its structure mainly includes a high-resistance electrothermal alloy wire 2, a steel pipe shell 3, magnesium powder 4, a rubber plug cover 5, a nickel rod 6, a magnesium powder rod 7, a magnesium powder fixing cover 8, a magnesium powder base 9, and a stainless steel end cover 10. Due to the material characteristics of the hardness of steel, the stainless steel end cover and the steel pipe shell are generally connected by a laser welding process. See Figure 2 , including the steel pipe shell 3, the stainless steel end cover 10, and the laser weld 101. This structure and process of the heating rod have various problems: First, it is difficult to manufacture the heating rod in terms of process; second, using steel results in a relatively large gravity of the heating rod; third, the thermal conductivity of the steel pipe is lower than that of other metals such as aluminum and copper, which limits the heat conduction performance of the heating rod; fourth, it is difficult to add fins to the steel pipe, and the thermal efficiency of the heater cannot be further improved; fifth, the steel pipe of the heating rod generally uses a stainless steel pipe to solve corrosion prevention, resulting in a higher cost. Summary of the Utility Model
[0003] Aiming at the deficiencies of the prior art, the utility model provides a high-efficiency vehicle high-voltage liquid heating rod with a simple manufacturing process, low cost, and high heating efficiency.
[0004] The above object of the utility model is achieved by the following technical solutions:
[0005] An efficient high-voltage liquid heating rod for vehicles. The heating rod has a single-ended lead structure and includes a high-resistance electrothermal alloy wire, an aluminum alloy tube housing, magnesium powder, a rubber plug cover, two nickel rods, a magnesium powder rod, a magnesium powder fixing cover, and a magnesium powder base. The aluminum alloy tube housing is of an integrally extruded structure, including a tube body part and an end cover part integrally connected to one end inside the tube body. An installation cavity is formed between the end cover and the other end of the tube body part. The magnesium powder base, the magnesium powder rod, the magnesium powder fixing cover, and the rubber plug cover are sequentially and tightly arranged in the installation cavity from the inside to the outside, and the rubber plug cover forms a sealed contact with the inner wall of the tube body. Magnesium powder is filled between the outer part of the magnesium powder rod and the inner wall of the tube body. The two nickel rods are inserted into two lead rod insertion holes on the magnesium powder rod, and the outer ends of the two nickel rods sequentially pass through two reserved holes in the magnesium powder fixing cover and the rubber plug cover in a sealed manner and extend out from one end of the aluminum alloy tube housing to form two external connection terminals.
[0006] Moreover, the outer diameter of the aluminum alloy tube housing is greater than 18 mm, and the wall thickness of the aluminum alloy tube housing is 1.2 mm - 2 mm.
[0007] Moreover, fins are integrally formed on the outer surface of the tube body part of the aluminum alloy tube housing.
[0008] Moreover, the fins are wavy fins extending along the tube length direction.
[0009] Moreover, the fins are spiral-wound fins extending along the tube length direction.
[0010] Moreover, the fins are grooved fins uniformly distributed along the circumferential direction.
[0011] The advantages and positive effects of the present utility model are as follows:
[0012] 1. The outer housing of the heating rod of the present utility model adopts an extruded aluminum alloy tube structure. The aluminum alloy material has good thermal conductivity, thus greatly improving the thermal efficiency of the heating rod.
[0013] 2. The outer housing of the heating rod of the present utility model adopts an extruded aluminum alloy tube structure. Based on the good ductility of the aluminum alloy material, fins of various structures can be shrink-pressed on the surface of the housing. By adding fins, the heating area of the heating rod can be increased, further improving the efficiency of the heating rod.
[0014] 3. The tube body part and the end cover part of the heating rod of the present utility model are of an integrally extruded structure, simplifying the processing technology and avoiding the problems of difficult processing and high welding quality requirements in the laser welding process of the end cover and the steel pipe in the traditional heating rod processing.
[0015] 4. During the processing of traditional heating rods, the welded part of the end cap will be under pressure during the tube shrinking process, posing a risk of cracks and a high rejection rate. In contrast, the present utility model uses an integrally extruded aluminum alloy tube with the end cap extruded, which has strong rigidity and strength, can avoid the risk of cracks during the tube shrinking process, ensure the qualified rate of product production, and also increase the reliability during the use of the heating rod. BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Figure 1 FIG. 6 is a schematic view of an existing heating rod with an end cap made of steel as the base material;
[0017] Figure 2 FIG. 7 is a schematic view of the welding of the end cap of an existing heating rod and the heating rod housing;
[0018] Figure 3 FIG. 8 is an exploded view of the aluminum alloy heating rod of the present utility model;
[0019] Figure 4 FIG. 9 is a schematic cross-sectional view of the aluminum alloy heating rod of the present utility model;
[0020] Figure 5 FIG. 10 is a cross-sectional view of the integrally formed aluminum alloy tube of the present utility model;
[0021] Figure 6 FIG. 11 is an external view of the heating rod with wavy fins of the present utility model;
[0022] Figure 7 FIG. 12 is a cross-sectional view of the heating rod with wavy fins of the present utility model;
[0023] Figure 8 FIG. 13 is an external view of the heating rod with thread-wound fins of the present utility model;
[0024] Figure 9 FIG. 14 is a cross-sectional view of the heating rod with thread-wound fins of the present utility model;
[0025] Figure 10 FIG. 15 is an external view of the heating rod with grooved fins of the present utility model;
[0026] Figure 11 FIG. 16 is a cross-sectional view of the heating rod with grooved fins of the present utility model;
[0027] Figure 12 is Figure 11 right view of. DETAILED DESCRIPTION OF THE EMBODIMENTS
[0028] The structure of the present utility model will be further described below with reference to the drawings and through embodiments. It should be noted that this embodiment is narrative rather than restrictive.
[0029] An efficient high-voltage liquid heating rod for vehicles, please refer to Figure 3-12, the novelty of the utility model is as follows: The heating rod is a single-head rod, that is, two lead rods extend from the same end. It mainly includes a high-resistance electrothermal alloy wire 2, an aluminum alloy tube shell 3A, magnesium powder 4, a rubber plug cover 5, a nickel rod 6, a magnesium powder rod 7, a magnesium powder fixing cover 8, and a magnesium powder base 9. The aluminum alloy tube shell adopts an integrally extruded structure, including a tube body part and an end cover part integrally connected to the inside of the tube body near one end. An installation cavity is formed between the end cover and the other end of the tube body part. The magnesium powder base, the magnesium powder rod, the magnesium powder fixing cover, and the rubber plug cover are sequentially and tightly arranged in the installation cavity from the inside to the outside, and form a sealed contact with the inner wall of the tube body through the rubber plug cover. Magnesium powder is filled between the outside of the magnesium powder rod and the inner wall of the tube body. The two nickel rods are inserted into two lead rod insertion holes on the magnesium powder rod, and the outer ends of the two nickel rods are hermetically passed through two reserved holes on the magnesium powder fixing cover and the rubber plug cover, and extend out from one end of the aluminum alloy tube shell to form two external wiring terminals.
[0030] The cross-section of the heating rod is shown in Figure 4 . It is required that the diameter of the aluminum alloy tube shell 3A of the heating rod is greater than 18 mm.
[0031] Because the hardness of aluminum alloy is between HB60 and 150HB, compared with the hardness of stainless steel between 180HB and 190HB, the hardness is much smaller, so aluminum alloy has good ductility.
[0032] In the manufacturing process of the traditional heating rod 1, during the processing of the steel pipe shell 3, it is necessary to weld a stainless steel end cover 10, usually by laser welding, which makes the processing technology of the heating rod complex. While using the aluminum alloy tube shell 3A can eliminate the need for welding the end cover. The aluminum alloy tube shell 3A can be integrally formed by the existing mature extrusion process, as shown in Figure 5 , the wall thickness of the aluminum alloy tube shell is usually controlled between 1.2 mm and 2 mm. Among them, the inner walls 3A1 and 3A2 at both ends of the end cover are both extruded. When extruding aluminum alloy, an inner mold and an outer mold are used, a total of one set. When extruding, the aluminum alloy cylinder is placed in the outer mold, a release agent is added, and the inner mold is pressed into the aluminum alloy cylinder by a hydraulic press, controlling the speed and direction. The aluminum alloy cylinder will automatically fill the gap between the inner and outer molds under pressure. Using the extrusion process to obtain the aluminum alloy tube shell 3A can sufficiently ensure the strength and stiffness of the aluminum alloy tube.
[0033] There is a tube shrinking process in the processing of the heating rod 1. For a hard tube with an outer diameter greater than 18 mm, according to the tube shrinking process, the outer diameter of the hard tube usually needs to be reduced by 3 - 5 mm. The tube shrinking process of the heating rod is to ensure that the magnesium oxide magnesium powder 4 inside the hard tube is compacted without voids.
[0034] Due to the characteristics of stainless steel materials, it is not conducive to forming fins on the surface of steel pipes during tube shrinking with stainless steel pipes. However, by using aluminum alloy pipes through the tube shrinking process, finned aluminum alloy pipe shells with various different flow resistances can be formed on the surface of the aluminum pipes, such as the wavy aluminum alloy pipe shell 3B, as shown in Figure 6 and Figure 7 , the threaded-wrapped aluminum alloy pipe shell 3C, as shown in Figure 8 and Figure 9 ), the grooved aluminum alloy pipe shell 3D, as shown in Figure 9 and Figure 10 . Through actual measurement, the heat transfer area of the heating rod surface of the wavy fin 3B1 is 1.1 to 1.3 times that of the heating rod with the same length dimension; the heat transfer area of the heating rod surface of the threaded-wrapped fin 3C1 (as shown in Figure 9 ) is 1.3 to 1.6 times that of the heating rod with the same length dimension; the heat transfer area of the heating rod surface of the grooved fin 3D1 (as shown in Figure 10 ) is more than 1.5 times that of the heating rod with the same length dimension.
[0035] The thermal conductivity of the aluminum alloy pipe material is 230 W / (m*k) - 240 W / (m*k); the thermal conductivity of the stainless steel pipe material is 40 W / (m*k) - 50 W / (m*k). The thermal conductivity of the aluminum alloy pipe material is 4 to 5 times that of the stainless steel pipe material. After calculation, for heating rods of the same size, the thermal efficiency of the heating rods made of aluminum alloy pipes is 2 to 5 times that of the heating rods made of stainless steel pipes.
[0036] According to the advantages of the thermal conductivity characteristics of aluminum alloy pipes, usually in actual use, for heating rods with relatively low power, in the tube shrinking process, fins do not need to be processed, and by adopting the structure of the aluminum alloy pipe shell 3A, the actual thermal efficiency requirements can be met.
[0037] Although the embodiments and drawings of the present invention are disclosed for illustrative purposes, those skilled in the art can understand that within the spirit of the present invention and the appended claims, various substitutions, changes, and modifications are possible. Therefore, the scope of the present invention is not limited to the content disclosed in the embodiments and drawings.
Claims
1. An efficient high-voltage liquid heating rod for vehicles, the heating rod being of a single-ended lead structure, characterized in that: It includes a high-resistance electrothermal alloy wire, an aluminum alloy tube housing, magnesium powder, a rubber plug cover, two nickel rods, a magnesium powder rod, a magnesium powder fixing cover, and a magnesium powder base; the aluminum alloy tube housing adopts an integrally extruded structure, including a tube body part and an end cover part integrally connected to one end inside the tube body; an installation cavity is formed between the end cover and the other end of the tube body part; the magnesium powder base, the magnesium powder rod, the magnesium powder fixing cover, and the rubber plug cover are sequentially and tightly arranged in the installation cavity from the inside to the outside, and the rubber plug cover forms a sealed contact with the inner wall of the tube body; magnesium powder is filled between the outside of the magnesium powder rod and the inner wall of the tube body; the two nickel rods are inserted into two lead rod insertion holes on the magnesium powder rod, and the outer ends of the two nickel rods sequentially pass through two reserved holes on the magnesium powder fixing cover and the rubber plug cover in a sealed manner and extend out from one end of the aluminum alloy tube housing to form two external connection terminals.
2. The high-efficiency vehicle high-voltage liquid heating rod according to claim 1, wherein: The outer diameter of the aluminum alloy tube housing is greater than 18 mm, and the wall thickness of the aluminum alloy tube housing is 1.2 mm to 2 mm.
3. The high-efficiency vehicle high-voltage liquid heating rod according to claim 1, characterized in that: Fins are integrally formed on the outer surface of the tube body part of the aluminum alloy tube housing.
4. The high-efficiency vehicle-mounted high-voltage liquid heating rod according to claim 3, wherein: The fins are wavy fins extending along the tube length direction.
5. The high-efficiency vehicle high-voltage liquid heating rod according to claim 3, characterized in that: The fins are screw-wound fins extending along the tube length direction.
6. The high-efficiency vehicle high-voltage liquid heating rod according to claim 3, characterized in that: The fins are grooved fins evenly distributed along the circumferential direction.