High-pressure water heating PTC heater structure

Abstract

The utility model discloses a high-pressure water heating PTC heater structure. The top of the water tank body is open, the water tank body is sealed through an upper cover plate, a water flow channel is formed in the water tank body, the middle of the bottom face of the water tank body is sunken inwards to form a mounting cavity, a plurality of mounting grooves penetrating into the water flow channel are formed in the mounting cavity, and the heating core assemblies are perpendicularly inserted into the mounting grooves. An electrode in the heating core assembly is electrically connected with a confluence plate below, the lower portion of the confluence plate is sealed through a lower cover plate, a high-voltage connector and a low-voltage connector are arranged at one end of the upper surface of the water tank body, and a water flow inlet and outlet is formed in the front side of the water tank body. And a lead groove is formed in the rear side of the electrode and is used for connecting the electrode with a high-voltage connector and a low-voltage connector. The utility model has the advantages that the design of the mounting groove improves the assembly precision and the heat transfer efficiency, the heating core assembly is compact in structure, the occupied space is reduced, the use requirements under various complex working conditions are met, and the later maintenance is convenient.

Description

Technical Field

[0001] The utility model relates to the water heating technology of new energy vehicles, in particular to a high-pressure water heating PTC heater structure. Background Technique

[0002] The water heating PTC heater is a heating device driven by current and is widely used in vehicle heating systems. Its main working principle is to use PTC (positive temperature coefficient) ceramic elements as the heating core, convert electrical energy into heat energy, heat the antifreeze or other liquids flowing through the water tank, and then transport the heated liquid to the area to be heated through the pipeline system to achieve the heating effect. Existing water heating PTC heaters usually include heating elements, cast aluminum or plastic water tanks, controllers and related connection components. This type of heater is widely used for its advantages such as fast heating speed and stable temperature.

[0003] In the prior art, the control system of the water heating PTC heater is usually managed by an independent electronic controller, which is responsible for adjusting the heating power, temperature control and other functions. For example, a utility model patent with the publication number CN 204547670 U and the name of "a water heater for electric vehicles" is disclosed in the Chinese patent. This utility model relates to a water heater for electric vehicles. This design uses a ceramic PTC heater as the core heating element, conducts heat to the antifreeze, and then transfers the heat to the air through the in-vehicle evaporator to provide stable and comfortable warm air. However, the design of the water flow channel is relatively simple, which may affect the overall thermal efficiency and heating effect of the system, and may also face the problem of insufficient sealing during long-term use. Therefore, there is still room for further improvement to meet the changing market demands. Summary of the Invention

[0004] The technical problem to be solved by the utility model is to provide a high-pressure water heating PTC heater structure, which solves the problems of large overall size, difficult later maintenance and low heat transfer efficiency of the heater by optimizing the installation method of the heating core assembly and the design of the water flow channel.

[0005] To solve the above technical problems, the structure of the high-pressure water-heating PTC heater of the present utility model includes a water tank body with an open top and sealed by an upper cover plate, a heating core assembly, and a busbar plate. The interior of the water tank body has a water flow channel, and the middle part of the bottom surface is recessed inward to form an installation cavity. There are a plurality of installation grooves extending into the water flow channel in the installation cavity. The heating core assembly is vertically inserted into the installation grooves, and the electrodes in the heating core assembly are electrically connected to the busbar plate below. The lower part of the busbar plate is closed by a lower cover plate. One end of the upper surface of the water tank body is provided with a high-voltage connector and a low-voltage connector. A water inlet and outlet are provided on the front side of the water tank body, and a lead wire groove is provided inside the rear side for connecting the busbar plate to the high-voltage connector and the low-voltage connector.

[0006] The heating core assembly includes electrodes, ceramic sheets for heat conduction and mechanical support, PTC heating sheets, and a PTC sheet frame arranged around the electrodes and the PTC heating sheets.

[0007] At least one wedge block is provided between each installation groove and the heating core assembly.

[0008] The water flow channel and the upper cover plate are sealed by friction stir welding.

[0009] A water pipe sealing ring and a φ20 water pipe are installed at the water inlet and outlet.

[0010] The number of the installation grooves is not less than six.

[0011] A wire harness fixing bracket is arranged in the lead wire groove to fix the circuit of the electrode.

[0012] Advantages of the present utility model: First, the wedge blocks ensure that the heating core assembly can be automatically aligned and tightly fitted when inserted into the installation grooves, simplifying the installation process, improving the assembly accuracy and heat transfer efficiency. At the same time, the heating core assembly has a compact structure, reducing the occupied space and the size of the heater. Second, the water flow channel and the upper cover plate are sealed by friction stir welding, combined with the design of the water pipe sealing ring and the φ20 water pipe, ensuring that the heater can maintain excellent waterproof performance under high-pressure environments, meeting the sealing standards of IP67&IP6K9K, increasing the insulation, and adapting to the usage requirements under various complex working conditions and facilitating later maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 It is a schematic structural diagram of the high-pressure water-heating PTC heater of the present utility model;

[0014] Figure 2 It is a schematic structural diagram of the heating core assembly in the structure of the high-pressure water-heating PTC heater of the present utility model;

[0015] Figure 3 It is a schematic diagram of the first installation state of the structure of the high-pressure water-heating PTC heater of the present utility model;

[0016] Figure 4 This is a schematic diagram of the installation state two of the high - pressure water - heating PTC heater structure of the present utility model. Specific embodiments

[0017] The following further details the high - pressure water - heating PTC heater structure of the present utility model in conjunction with the accompanying drawings and specific embodiments. Embodiment

[0018] As Figure 1 shown, the high - pressure water - heating PTC heater structure includes a water - tank body 1 with an open top and sealed by an upper cover plate 4, a heating core assembly 2, and a current - collecting plate 3. The interior of the water - tank body 1 has a water flow channel 5, and the middle part of the bottom surface is recessed inward to form an installation cavity. There are six installation slots 7 extending into the water flow channel 5 in the installation cavity. The heating core assembly 2 is vertically inserted into the installation slots 7. A wedge - shaped block 15 is provided between each installation slot 7 and the heating core assembly 2, so that the heating core assembly 2 can be automatically aligned and tightly fitted when inserted. The electrode 6 in the heating core assembly 2 forms an electrical connection with the current - collecting plate 3 below. The lower part of the current - collecting plate 3 is enclosed by a lower cover plate 19. A high - voltage connector 9 and a low - voltage connector 10 are provided at the rear end of the upper surface of the water - tank body 1. The current - collecting plate 3 is connected to the high - voltage connector 9 and the low - voltage connector 10. The high - voltage input end uses 2 high - voltage wires, and the low - voltage input end uses 2 signal wires of sensors. The other ends of the high - voltage wire harness and the low - voltage sensor signal wires are respectively connected to the high - voltage end and the control end of the compressor, and are integrally controlled by a compressor controller located at a remote end. A water flow inlet and outlet 8 is provided at the front side of the water - tank body 1, and a lead - wire groove 11 is provided inside the rear side for connecting the electrode 6 to the high - voltage connector 9 and the low - voltage connector 10; As Figure 2 shown, the heating core assembly 2 includes an electrode 6, a ceramic sheet 12 for heat conduction and mechanical support, a PTC heating sheet 13, and a PTC sheet frame 14 arranged around the electrode 6. The electrode 6 can be welded to the current - collecting plate 3 below the cast - aluminum water tank 1 through wave - soldering to form an electrical connection. This structure reduces the size of the heater, greatly reducing the overall weight and cost. As Figure 3 shown, a wire - harness fixing bracket 18 is provided in the lead - wire groove 11 to fix the circuit of the electrode 6. When the heating core assembly 2 is placed in the installation slot 7, an interference - fit method is adopted. The compression part relies on a thermal - conductive silica gel sheet and a thermal - conductive adhesive for buffering and filling and fitting. Subsequently, the electrode of the heating core is welded to the current - collecting plate through wave - soldering to form a current - collecting, and is connected by a high - voltage wire harness. After being led out, it can be directly connected to the high - voltage and control ends of the compressor and controlled by the controller of the compressor, integrating the two in one.

[0019] Further, as Figure 4As shown in the figure, a water flow inlet and outlet 8 is provided on the front side of the water tank body 1. A water pipe sealing ring 16 and a φ20 water pipe 17 are installed at the water flow inlet and outlet 8 to achieve the introduction and sealing of water flow. Friction stir welding is used for sealing on the flow channel waterproof structure of the heater. After the welding is completed, 100% airtightness and helium leak detection are carried out to ensure good water side sealing. After installing the heating core assembly 2 into the water tank body 1, potting glue sealing is carried out on the water tank cover 19 to ensure the IP67&IP6K9K performance requirements of the heater. This method makes the sealing more reliable, simplifies the processability, and improves the production efficiency.

[0020] Of course, the number of installation grooves 7 of the water tank body 1 and the tight fixing structure with the heating core assembly 2 can be adjusted adaptively according to actual needs. For example, although the present utility model preferably uses six installation grooves 7 to ensure the stability of the heating core assembly 2, under specific conditions, more or fewer installation grooves can also be considered, or some geometric fixing structures can be adopted to meet the requirements of different application scenarios. The above adjustments to the number of installation grooves and the fixing structure are all within the protection scope of the present utility model.

Claims

1. A structure of a high-pressure water-heating PTC heater, comprising a water tank body (1) with an opening at the top and sealed by an upper cover plate (4), a heating core assembly (2), and a busbar plate (3), characterized in that: The interior of the water tank body (1) has a water flow channel (5). The middle part of the bottom surface is recessed inward to form a mounting cavity. Multiple mounting grooves (7) that penetrate into the water flow channel (5) are provided in the mounting cavity. The mounting grooves (7) are used to vertically insert the heating core assembly (2). The electrodes (6) in the heating core assembly (2) are electrically connected to the lower bus bar (3). The lower part of the bus bar (3) is closed by a lower cover plate (19). A high-voltage connector (9) and a low-voltage connector (10) are provided at the rear end of the upper surface of the water tank body (1). A water flow inlet and outlet (8) is provided on the front side of the water tank body (1). A lead wire groove (11) is provided inside the rear side of the water tank body (1) to connect the bus bar (3) to the high-voltage connector (9) and the low-voltage connector (10).

2. The structure of the high-pressure water-heating PTC heater according to claim 1, characterized in that: The heating core assembly (2) includes electrodes (6), ceramic sheets (12) for heat conduction and mechanical support, PTC heating sheets (13), and a PTC sheet frame (14) arranged around the electrodes and the PTC heating sheets.

3. The high-pressure water heating PTC heater structure according to claim 1 or 2, characterized in that: At least one wedge block (15) is provided between each mounting groove (7) and the heating core assembly (2).

4. The structure of the high-pressure water-heating PTC heater according to claim 1, wherein: The water flow channel (5) and the upper cover plate (4) are sealed by friction stir welding.

5. The structure of the high-pressure water-heating PTC heater according to claim 1, wherein: A water pipe sealing ring (16) and a φ20 water pipe (17) are installed at the water flow inlet and outlet (8).

6. The structure of the high-pressure water heating PTC heater according to claim 1, wherein: The number of the mounting grooves (7) is not less than six.

7. The structure of the high-pressure water heating PTC heater according to claim 1, characterized in that: A wire harness fixing bracket (18) is arranged in the lead wire groove (11) to fix the circuit of the electrode (6).

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