Liquid heater

Abstract

The utility model discloses a liquid PTC (Positive Temperature Coefficient) heating device. The water heater comprises a plastic base, a cast aluminum core seat, a PTC (Positive Temperature Coefficient) heating module, a control assembly and an upper cover, a detection convex cavity is formed in the cast aluminum core seat, a water outlet water temperature sensor is arranged in the detection convex cavity, and an inductive head of the water outlet water temperature sensor is just located at a water outlet; the plastic base is provided with a plurality of slots, the heating modules are inserted into the slots and are bonded and fixed in the corresponding slots by adopting a high-temperature-resistant organic silicon adhesive, a liquid cavity is formed between the inner cavity of the plastic base and the outer surface of the cast aluminum core seat, heat dissipation fins are arranged on the bottom surface of the cast aluminum core seat, and an IGBT power module is arranged in the cast aluminum core seat. The utility model has the advantages that the purposes of improving the heat efficiency of the PTC sheets and reducing the use quantity of the PTC sheets are achieved. The heat dissipation capability of the IGBT is greatly improved, the overheating risk in the use process of the IGBT is reduced, the surface temperature of the IGBT is reduced, and the reliability of the liquid heater is improved. The water temperature can be rapidly detected, and the purpose of real-time water temperature detection is achieved.

Description

Technical Field

[0001] The utility model relates to a liquid heater device for providing heat for new energy vehicle air conditioners, batteries and energy storage products, specifically a liquid heater. Background Art

[0002] At present, there is a patent application for invention with the publication number CN105091350A and the name of "High-efficiency and energy-saving PTC liquid electric heater for new energy vehicles" in the new energy vehicle and energy storage markets. This patent application essentially discloses a PTC heater with a soldered water tank. Specifically, it discloses a flat tube water channel with parallel flow, and at the same time, uses polyimide film as an insulating material to ensure the separation of water and electricity. Through practical application, it has been proved that although the PTC heater with the above structure achieves the above purposes, when in use, there are still problems due to its unreasonable structural design. For example, the heat dissipation efficiency of the PTC chip is not high, resulting in a small thermal power of the heater with the same volume; the sensor is attached to the surface of the water chamber, resulting in a lag in the sensor temperature detection compared to the real-time water temperature; at the same time, the heat dissipation surface of the IGBT is far from the water channel, resulting in poor heat dissipation of the IGBT and a high IGBT temperature. Therefore, how to improve the heat dissipation ability of the PTC ceramic chip, improve the heating efficiency of the heater, quickly detect the water temperature, and at the same time improve the heat dissipation ability of the IGBT and reduce the overheating risk during the use of the IGBT has become an urgent technical problem to be solved. Summary of the Invention

[0003] The technical problem to be solved by the utility model is to provide a liquid heater that can not only improve the heat dissipation ability of the PTC ceramic chip so as to improve the thermal efficiency of the PTC chip, but also improve the accuracy of water temperature detection and increase the heat dissipation ability of the IGBT, and reduce the overheating risk during the use of the IGBT.

[0004] In order to solve the above technical problems, the liquid heater of the utility model comprises a plastic base with a water inlet and a water outlet, a cast aluminum core seat arranged in the plastic base, a PTC heating module for heating, a control component located above the PTC heating module, and an upper cover installed on the top of the cast aluminum core seat for encapsulating the PTC heating module and the control component. The cast aluminum core seat is provided with a detection convex cavity corresponding to the position of the water outlet for accommodating a water outlet water temperature sensor. The water outlet water temperature sensor is arranged in the detection convex cavity and its sensing head is exactly at the water outlet. A slot for plugging in the PTC heating module is provided in the inner cavity of the cast aluminum core seat. The heating module is plugged in correspondingly. The heating modules are bonded and fixed in the corresponding slots with high-temperature resistant silicone adhesive, and a liquid cavity for dissipating the heat generated by the PTC heating module is formed between the inner cavity of the plastic base and the outer surface of the cast aluminum core seat. The bottom surface of the cast aluminum core seat is provided with heat dissipation fins extending into the liquid cavity, and an IGBT power module located at the heat dissipation fins and connected to the control component is arranged in the cast aluminum core seat. By controlling the on and off of the IGBT power module through the control component, the PTC heating module can generate heat and conduct it to the outer surface of the cast aluminum core seat, and then the heat is transferred to the equipment requiring heat through the water outlet through the flow of liquid in the liquid cavity.

[0005] The control assembly comprises a control board for controlling the PTC heating module, an adapter board for cooperating with the control board, and an isolation board arranged between the adapter board and the PTC heating module. The PTC heating module is fixed to the adapter board by welding.

[0006] A base sealing ring groove is provided on the top inner edge of the plastic base, and a sealing ring is placed in the base sealing ring groove for pressing between the plastic base and the cast aluminum core seat; a core seat sealing ring groove is provided on the top inner edge of the cast aluminum core seat, and a two-component liquid sealant is placed in the core seat sealing ring groove for pressing between the upper cover and the cast aluminum core seat, and the cast aluminum core seat and the upper cover are sealed by the two-component liquid sealant to form a control cavity, and a breathable valve is provided on the back of the cast aluminum core seat and the air pressure in the control cavity can be balanced through the breathable valve.

[0007] An isolation frame for installing a control board is arranged in the control cavity, the control board is stacked on the control board isolation frame, and the IGBT power module is installed and fixed by an elastic pressing plate.

[0008] A water inlet boss is arranged at the water inlet of the plastic base, and the water inlet boss corresponds to the position of the heat dissipation fin.

[0009] On the side wall of the cast aluminum core seat, there are high-voltage connectors and low-voltage connectors. The wire of the high-voltage connector is connected to the high-voltage input port of the control board through fasteners, and the low-voltage connector is connected to the low-voltage input port of the control board through an adapter wire. Through the high-voltage connector, a high-voltage power supply can be accessed, and at the same time, through the low-voltage connector, a control signal and a power supply can be introduced to the control board.

[0010] Each slot of the cast aluminum core seat forms an S-shaped bending flow channel in the plastic base.

[0011] An IGBT sensor corresponding to the water inlet position is installed in the cast aluminum core seat.

[0012] The electrodes of the PTC heating module are inserted into the isolation board and then fixedly connected to the adapter board.

[0013] On the bottom surface of the cast aluminum core seat, there are positioning bosses corresponding to the heat dissipation fins, and a heat-conducting insulating pad is attached to the positioning bosses.

[0014] The advantages of the present utility model are as follows:

[0015] (1) The heating module is inserted into the corresponding slots and is adhesively fixed in each corresponding slot by using a high-temperature resistant silicone adhesive, thereby greatly increasing the heat dissipation capacity, so as to achieve the purpose of improving the thermal efficiency of the PTC sheet and reducing the number of PTC sheets used.

[0016] (2) Through the heat dissipation fins arranged on the bottom surface of the cast aluminum core seat and extending into the liquid cavity, the IGBT power module is arranged at the heat dissipation fins, which greatly increases the heat dissipation capacity of the IGBT, reduces the overheating risk during the use of the IGBT and reduces the surface temperature of the IGBT, and increases the reliability of the liquid heater.

[0017] (3) The water outlet temperature sensor is arranged in the detection convex cavity and its sensing head is exactly at the water outlet, so that the water temperature can be quickly detected, and the purpose of real-time water temperature detection can be achieved. Description of the Drawings

[0018] Figure 1 is a perspective view of the liquid heater of the present utility model;

[0019] Figure 2 is an exploded view of the liquid heater of the present utility model;

[0020] Figure 3 is a sectional view of the liquid heater (removing the upper cover) of the present utility model;

[0021] Figure 4 is a top view of the liquid heater (removing the upper cover) of the present utility model;

[0022] Figure 5 For Figure 4 Schematic diagram of the A-A sectional structure Specific implementation mode

[0023] The following further describes the liquid heater device of the present utility model in detail with reference to the drawings and specific implementation modes

[0024] As shown in the figure, the liquid heater device of the present utility model includes a plastic base 1 having a water inlet 21 and a water outlet 22, an aluminum casting core base 3 placed in the plastic base 1, a PTC heating module 16 for heating, a control assembly located above the PTC heating module 16, and an upper cover 9 installed on the top of the aluminum casting core base 3 for encapsulating the PTC heating module and the control assembly. Consisting of Figure 2It can be seen that the plastic base can be made of PA66+GF30 nylon plastic with hydrolysis resistance characteristics; the mounting feet of the plastic base are embedded with hollow metal tubes; the water inlet 21 and the water outlet 22 on the plastic base are used for the liquid to enter and exit to dissipate the heat generated by the PTC heating pack; the inner edge of the top of the plastic base 1 is provided with a base sealing ring groove 29, and a sealing ring 2 for pressing between the plastic base 1 and the cast aluminum core seat 3 is arranged in the base sealing ring groove 29. A fastener passes through the mounting hole of the plastic base and is tightened and fixed with the corresponding threaded hole of the cast aluminum core seat; the inner edge of the top of the cast aluminum core seat 3 is provided with a core seat sealing ring groove 30, and a two-component liquid sealant 10 for pressing between the upper cover 9 and the cast aluminum core seat 3 is arranged in the core seat sealing ring groove 30. During specific installation, the controller upper cover 9 is snap-fitted into the corresponding core seat sealing ring groove 30 of the cast aluminum core seat 3, and at the same time, the two-component liquid sealant 10 is used to fill and seal the gap of the core seat sealing ring groove 30, so that a control cavity 31 is sealed between the cast aluminum core seat 3 and the upper cover 9 through the two-component liquid sealant 10. A breather valve 4 is arranged on the back of the cast aluminum core seat 3 and can balance the air pressure in the control cavity through the breather valve; a back threaded hole is arranged on the back of the cast aluminum core seat 3, and the breather valve 4 can be screwed into the back threaded hole of the cast aluminum core seat 3 through its thread. An IGBT sensor 8 corresponding to the position of the water inlet is installed in the cast aluminum core seat 3. A detection convex cavity 26 for arranging the water outlet water temperature sensor 12 corresponding to the position of the water outlet 22 is arranged on the cast aluminum core seat 3. The water outlet water temperature sensor 12 is arranged in the detection convex cavity and its sensing head is exactly at the water outlet 22. Due to the position design of the IGBT sensor 8 and the water outlet water temperature sensor 12, the resistance value change of the sensor caused by the temperature and flow rate changes in the liquid cavity can be quickly detected; a slot 27 for plugging the PTC heating module is arranged in the inner cavity of the cast aluminum core seat 3. The heating module 16 is plugged into the corresponding slots, and the heating module is adhesively fixed in each corresponding slot by heating with a high-temperature silicone adhesive. A liquid cavity 28 for the liquid to flow through to dissipate the heat generated by the PTC heating module 16 is formed between the inner cavity of the plastic base 1 and the outer surface of the cast aluminum core seat 3. The slots of the cast aluminum core seat 3 protrude into the plastic base 1 to form an S-shaped curved flow channel; heat dissipation fins 25 extending into the liquid cavity are arranged on the bottom surface of the cast aluminum core seat 3. The heat dissipation fins 25 are integrally die-cast strip-shaped heat dissipation fins; an IGBT power module 23 located at the heat dissipation fins and connected to the control component is arranged in the cast aluminum core seat 3. By controlling the on and off of the IGBT power module 23 through the control component, the PTC heating module 16 can generate heat and conduct it to the outer surface of the cast aluminum core seat 3, and then the heat is flowed into the equipment that needs heat through the water outlet through the liquid flow in the liquid cavity.

[0025] Further, the control component includes a control board 6 for controlling the PTC heating module 16, an adapter board 14 for cooperating with the control board, and an isolation board 15 disposed between the adapter board 14 and the PTC heating module 16. The control board employs 4 IGBT power modules; the heating element of the PTC heating module 16 is fixed to the adapter board 14 by soldering. An isolation bracket 13 for mounting the control board is provided in the control cavity 31. The control board 6 is stacked on the control board isolation bracket 13. The IGBT power module 23 can be installed and fixed by an elastic pressing plate 7. There are positioning bosses on the bottom surface of the cast aluminum core base 3 corresponding to the heat dissipation fins 25, and a heat-conducting insulating pad 5 is attached to the positioning bosses. During specific installation, after the PTC heating module 16 is placed in and fixed to the socket of the cast aluminum core base 3, its exposed electrodes are inserted into the isolation board 15 with a guide, and at the same time, the exposed electrodes pass through the adapter board 14 placed on the isolation board 15, and the electrodes are soldered to the adapter board with tin; the heat-conducting insulating pad 5 is attached to the positioning bosses of the cast aluminum core base 3, and at the same time, the isolation bracket 13 is placed on the adapter board 14 and fixed inside the cast aluminum core base; the control board 6 is stacked on the isolation bracket 13, and then the elastic pressing plate 7 is installed on the surfaces of the IGBT power module 23 and the control board isolation bracket. Fasteners are used to fix the elastic pressing plate 7, the control board 6 to the cast aluminum core base together and to fix the control board 6 to the adapter board 14 together; after the IGBT sensor 8 is installed, the temperature sensing head of the water outlet temperature sensor 12 passes through the fixing bracket 11 and is fixed in the detection convex cavity 26. The other ends of the wires of the IGBT sensor 8 and the water outlet temperature sensor 12 are connected to the corresponding temperature detection sockets of the control board 6 through plugs, and the temperature signal values detected by the sensors are transmitted to the single-chip microcomputer of the control board 6.

[0026] Still further, an inlet boss 24 is provided at the water inlet of the plastic base 1, and the position of the inlet boss 24 corresponds to that of the heat dissipation fins 25, as Figure 4 shown. The liquid enters the liquid cavity 28 through the water inlet 21. The inlet boss 24 at the plastic base 1 changes the flow direction of the entering liquid, and the liquid comes into full contact with the protruding IGBT heat dissipation fins 25 of the cast aluminum core base 3, and at the same time quickly takes away the heat generated when the IGBT power module works.

[0027] Furthermore, high-voltage connectors 17 and low-voltage connectors 18 are provided on the side wall of the cast aluminum core seat 3. During installation, the cast aluminum core seat is fixedly connected to the high-voltage connector and the low-voltage connector respectively through fasteners; the wire of the high-voltage connector 17 is connected to the high-voltage input port of the control board 6 through a fastener 20, and the low-voltage connector 18 is connected to the low-voltage input port of the control board 6 through an adapter wire. A high-voltage power supply can be accessed through the high-voltage connector 17, and at the same time, a control signal (CAN\LIN\PWM\EN) and a power supply can be introduced through the low-voltage connector to the control board 6. The on-off of the IGBT of the control board is controlled by an external control signal, and the energy of the high-voltage power supply is transmitted to the PTC heating element (the heating element with the publication number CN214592012U can be used) of the PTC heating module 16 through the adapter board. Through the communication signal of the control component, the control board 6 controls the on-off of its power device IGBT. After the IGBT is turned on, the corresponding PTC heating module heats up, and the generated heat is transferred to the equipment that requires heat through the liquid in the cast aluminum liquid cavity.

[0028] Certainly, the above description is not a limitation of the present invention, and the present invention is not limited to the above examples. Changes, modifications, additions, or substitutions made by those skilled in the art within the essence of the present invention should also fall within the protection scope of the present invention.

Claims

1. A liquid heater, comprising a plastic base (1) having a water inlet (21) and a water outlet (22), a cast aluminum core seat (3) disposed within the plastic base (1), a PTC heating module (16) for heating, a control assembly located above the PTC heating module (16), and an upper cover (9) mounted on the top of the cast aluminum core seat (3) for encapsulating the PTC heating module and the control assembly, characterized in that: The cast aluminum core seat (3) is provided with a detection convex cavity (26) corresponding to the position of the water outlet (22) for placing the water outlet temperature sensor (12). The water outlet temperature sensor (12) is placed in the detection convex cavity and its sensing head is exactly at the water outlet (22). A slot (27) for plugging in the PTC heating module is provided in the inner cavity of the cast aluminum core seat (3). The heating module (16) is plugged into the corresponding slots and is adhesively fixed in each corresponding slot by a high-temperature resistant silicone adhesive. A liquid cavity (28) for dissipating the heat generated by the PTC heating module (16) is formed between the inner cavity of the plastic base (1) and the outer surface of the cast aluminum core seat (3). Heat dissipation fins (25) extending into the liquid cavity are provided on the bottom surface of the cast aluminum core seat (3). An IGBT power module (23) located at the heat dissipation fins and connected to the control component is arranged in the cast aluminum core seat (3). By controlling the on-off of the IGBT power module (23) through the control component, the PTC heating module (16) can generate heat and conduct it to the outer surface of the cast aluminum core seat (3), and then the heat flows through the water outlet into the equipment that requires heat through the flow of the liquid in the liquid cavity.

2. The liquid heater according to claim 1, characterized in that: The control component includes a control board (6) for controlling the PTC heating module (16), an adapter board (14) for cooperating with the control board, and an isolation board (15) provided between the adapter board (14) and the PTC heating module (16). The PTC heating module (16) is fixedly welded to the adapter board (14).

3. The liquid heater according to claim 2, wherein: A base sealing ring groove (29) is provided at the inner edge of the top of the plastic base (1), and a sealing ring (2) for pressing between the plastic base (1) and the cast aluminum core seat (3) is placed in the base sealing ring groove (29); a core seat sealing ring groove (30) is provided at the inner edge of the top of the cast aluminum core seat (3), and a two-component liquid sealant (10) for pressing between the upper cover (9) and the cast aluminum core seat (3) is placed in the core seat sealing ring groove (30). The cast aluminum core seat (3) and the upper cover (9) are sealed by the two-component liquid sealant (10) to form a control cavity (31). A breather valve (4) is provided on the back of the cast aluminum core seat (3) and can balance the air pressure in the control cavity through the breather valve.

4. The liquid heater according to claim 3, characterized in that: An isolation rack (13) for installing the control board is provided in the control cavity (31). The control board (6) is stacked on the control board isolation rack (13), and the IGBT power module (23) is installed and fixed by an elastic pressing plate (7).

5. The liquid heater according to any one of claims 1 to 4, characterized in that: An inlet convex platform (24) is provided at the water inlet of the plastic base (1), and the inlet convex platform (24) corresponds to the position of the heat dissipation fins (25).

6. The liquid heater according to claim 5, wherein: On the side wall of the cast aluminum core base (3), a high-voltage connector (17) and a low-voltage connector (18) are provided. The wire of the high-voltage connector (17) is connected to the high-voltage input port of the control board (6) through a fastener (20). The low-voltage connector (18) is connected to the low-voltage input port of the control board (6) through an adapter wire. Through the high-voltage connector (17), a high-voltage power supply can be accessed. At the same time, through the low-voltage connector, a control signal and a power supply can be introduced and supplied to the control board (6).

7. The liquid heater according to claim 1, 2, 3, 4 or 6, characterized in that: Each slot of the cast aluminum core base (3) forms an S-shaped curved flow channel in the plastic base (1).

8. The liquid heater according to claim 7, characterized in that: An IGBT sensor (8) corresponding to the water inlet position is installed in the cast aluminum core base (3).

9. The liquid heater according to claim 2, wherein: The electrodes of the PTC heating module (16) are inserted into the isolation board (15) and then fixedly connected to the adapter board (14).

10. The liquid heater according to claim 1, characterized in that: On the bottom surface of the cast aluminum core base (3), there are positioning bosses corresponding to the heat dissipation fins (25), and a heat-conducting insulating pad (5) is attached to the positioning bosses.

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