Integrated PTC (Positive Temperature Coefficient) water heater shell

The injection molding technology of the integrated PTC water heater shell solves the problems of metal base leakage and poor sealing, achieves lightweight design and improved insulation performance, and reduces failure rate and cost.

CN223345671UActive Publication Date: 2025-09-16WUXI SHENGBANG ELECTRONICS CO LTD
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Patent Information

Application Number
CN202421688244.9
Authority / Receiving Office
CN · China
Patent Type
Utility models(China)
Current Assignee / Owner
Filing Date
2024-07-17
Publication Date
2025-09-16
Estimated Expiration
2034-07-17

AI Technical Summary

Technical Problem

Existing PTC water heaters have problems such as leakage of cold shutoff in the metal base die-cast cavity, poor sealing of the sealing ring, poor torque of screw assembly and excessive weight of the product, resulting in high product failure rate, high cost and inconvenience of lightweight design.

Method used

The integrated PTC water heater shell is formed into a metal base and a shell through the clinker injection molding process, omitting screws and sealing rings to form an integrated structure, simplifying the assembly process and improving the insulation performance.

Benefits of technology

It solves the problems of metal base leakage and poor sealing, reduces product failure rate and cost, achieves lightweight design, and improves insulation performance and safety.

✦ Generated by Eureka AI based on patent content.

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Abstract

The utility model relates to an integrated PTC water heater shell, which comprises two medium inlets and outlets which are integrally formed and are arranged at the top, a shell main body, a connector mounting seat, a shell back plate and a product mounting hole, the shell main body comprises two runners in bilateral symmetry, a plurality of groups of parallel heating bag mounting holes distributed in bilateral symmetry and heating bag shell inserts embedded in the heating bag mounting holes, the heating bag mounting holes in the left row and the right row are not communicated, the bottoms of the heating bag mounting holes are communicated, and the heating bag mounting holes in the left row and the right row are arranged in a staggered mode to form the runners. The bottoms of the two flow channels are communicated with each other, and a heating bag is installed in each row of heating bag shell inserts. According to the utility model, the weight of the product is reduced, the problems of sealing and leakage of the traditional metal die casting and the sealing ring are solved, parts such as the sealing ring and screws of the traditional PTC water heater are omitted, the assembly process is reduced, the cost of the product and the labor cost are reduced, and the product is more popular; insulation, voltage resistance and other electrical properties of the product are improved, and the use is safer and more reliable.
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Description

Technical Field

[0001] The utility model relates to the technical field of new energy PTC water heaters, in particular to an integrated PTC water heater housing. Background Art

[0002] The PTC water heater housing is an important component of the PTC water heater. It usually protects the internal components, improves insulation performance, and dissipates heat. The water side cavity of a conventional PTC water heater consists of a metal base, a sealing ring, and a plastic injection molded body fastened with screws to form a sealed water heating cavity.

[0003] However, the current PTC water heater housing has the following shortcomings:

[0004] (1) Metal bases are generally die-cast at high speeds, which can easily lead to cold shuts and depressions during the molding process, causing leakage in the water heater and resulting in product failure, and short circuits in the application, causing the product to stop working.

[0005] (2) A sealing ring is used to seal the base and the shell. Since the sealing ring is made of rubber material and is exposed to high temperature for a long time, it is easy to cause poor sealing, so that the coolant leaks out of the product, causing poor insulation of the product and stopping the application.

[0006] (3) As PTC water heaters are currently widely used in new energy places such as passenger cars, strict requirements are placed on product lightweighting. Traditional metal die-cast PTC water heaters are heavy and not convenient for lightweight design in application places.

[0007] (4) Since traditional PTC water heater components are connected by threads, the torque and the number and quality of screws need to be precisely controlled, and the process of tightening is relatively complicated. Utility Model Content

[0008] Technical problems solved: In response to the existing problems in the prior art, such as cold insulation leakage of the die-cast cavity of the traditional PTC water heater metal base, poor calibration of the screw assembly torque and thread stripping of the assembly screws, the market demand for lightweighting, poor sealing of the sealing ring and poor electrical insulation, this new type of PTC water heater shell is proposed. By utilizing the clinker injection molding process, the traditional metal die-cast base and the shell are injection molded as one, eliminating the need for multiple mold development of the product, saving development time and cost, omitting screws, sealing rings and other components, and correspondingly reducing storage space, assembly personnel and assembly processes, avoiding failure points and risk points in the product development process, making the product lightweight and more widely used, and reducing overall costs and later after-sales costs.

[0009] Technical solution: An integrated PTC water heater housing includes an integrally formed first medium inlet and outlet, a second medium inlet and outlet, a housing body, a connector mounting seat, a housing back plate, and a product mounting hole. The first medium inlet and outlet are respectively provided on both sides of the top of the housing body, one for medium inlet and the other for medium outlet. The inlet and outlet media are interchangeable, providing better versatility.

[0010] The connector mounting seat is provided at the bottom of the housing body and is used to support and connect the connector;

[0011] The shell back plate is arranged at the rear side of the shell body and is used to protect the shell body;

[0012] The product installation hole is provided on the side wall of the shell body for installing the shell body;

[0013] A closed cavity is formed inside the shell body, including two left-right symmetrical flow channels, several groups of parallel two left-right symmetrically distributed heating pack installation holes, and heating pack shell inserts embedded in the heating pack installation holes. The left and right columns of heating pack installation holes are not interconnected, but are connected at the bottom, and the heating pack installation holes in each column are staggered. The outer side of the heating pack installation hole and the inner wall of the shell body form a flow channel (i.e., a water channel). The bottoms of the two flow channels are interconnected, and the tops are respectively connected to the first medium inlet and outlet and the second medium inlet and outlet. A heating pack is installed in each column of the heating pack shell insert.

[0014] Preferably, the shell body includes 6 groups of parallel heating pack installation holes that are symmetrically distributed on the left and right.

[0015] Preferably, one end of the heating pack mounting hole is connected to the front side wall of the shell body, and the other end points to the rear side wall of the shell body but does not touch it, and each row of heating pack mounting holes is staggered on both sides of the shell body, and a baffle is provided between the two rows of heating pack mounting holes. The heating pack mounting hole does not contact the left and right side walls of the shell body and the baffle, so that the flow channels on both sides are "Z" shaped, and the heating pack shell insert is embedded in the heating pack mounting hole.

[0016] Preferably, a chamfered structure is provided at the corner of the heating pack installation hole.

[0017] Preferably, the outer wall of the heating pack installation hole in contact with the medium is inclined along the direction of the flow channel with an inclination angle of 1.5° to drain the medium.

[0018] Preferably, two through holes are provided on one side of the connector mounting seat, which are used to connect the high-voltage connector and the low-voltage connector respectively.

[0019] Preferably, a positioning hole is provided on the other side of the connector mounting seat for positioning the production tooling.

[0020] Preferably, the connector mounting seat further includes a grounding mounting hole, which is provided on one side of the connector mounting seat.

[0021] Preferably, the first medium inlet and outlet, the second medium inlet and outlet, the heating pack mounting hole, the connector mounting seat, the shell back plate and the product mounting hole are made of insulating plastic, and the heating pack shell insert is made of metal.

[0022] Beneficial effects: The cooling liquid (water) of this new type passes through the integral injection-molded PTC shell, and the heating pack contacts the cooling liquid through the heating pack shell insert and the heating pack installation hole, and the cold water circulates from the inlet to the outlet to become hot water. The specific advantages are as follows:

[0023] 1. The PTC water heater shell is made of one-piece injection molding to solve the leakage problem such as cold insulation and depression of the die-casting cavity of the metal base of the product.

[0024] 2. The PTC water heater shell is integrally injection molded. The water channel shell and the heating cavity are integrally molded, which omits the subsequent screw torque calibration and assembly process, reducing labor and material costs.

[0025] 3. Traditional PTC water heaters require sealing rings. After the one-piece injection molding is adopted, the sealing ring material is omitted, and the sealing problem of poor sealing and fool-proof installation is solved, which reduces the assembly cost and alleviates the problems of warehousing and after-sales failure rate.

[0026] 4. The use of one-piece injection molding reduces the overall weight of the product, and after injection molding, the insulation performance is significantly improved due to the absence of metal parts. The insulation and voltage resistance performance of the product is greatly enhanced, making the product more widely applicable, reducing the failure rate and improving safety performance.

[0027] In summary, the utility model reduces the weight problem of the product, making the product lightweight, solves the sealing and leakage problems of traditional metal die-casting and sealing rings, omits traditional PTC water heater sealing rings and screws and other parts, reduces the assembly process, reduces the cost of the product and labor costs, makes the product more popular among the public, improves the insulation and voltage resistance and other electrical properties of the product, and is safer and more reliable to use. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 This is the main view of the housing of the new integrated PTC water heater;

[0029] Figure 2 for Figure 1 Rear view;

[0030] Figure 3 for Figure 1 A top view of

[0031] Figure 4 for Figure 2 perspective drawing;

[0032] Figure 5 is a schematic diagram of the flow channel (the arrows in the figure indicate the flow direction);

[0033] Figure 6 This is a cross-sectional view of the heat-generating package insert in the housing of the new integrated PTC water heater;

[0034] Figure 7 This is the disassembly and explosion diagram and installation diagram of the new integrated PTC water heater shell;

[0035] The numbers in the figure are as follows: 1. First medium inlet and outlet; 2. Second medium inlet and outlet; 3. Connector mounting seat; 4. Shell back plate; 5. Product mounting hole; 6. Heating pack mounting hole; 7. Grounding mounting hole; 8. Heating pack shell insert; 9. Through hole; 10. Positioning hole; 11. Heating pack shell; 12. Cover I; 13. Cover II. DETAILED DESCRIPTION

[0036] In the description of the present invention, it should be understood that the terms "left side," "right side," "upper," "lower," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate the description of the present invention and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Terms such as "first" and "second" do not indicate the importance of a component and therefore should not be construed as limiting the present invention. The specific dimensions used in this embodiment are merely for illustrative purposes and do not limit the scope of protection of the present invention.

[0037] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0038] The medium in the embodiments of this specification is water. Example 1

[0039] Integrated PTC water heater housing, see Figure 1-2 , including an integrally formed first medium inlet and outlet 1, a second medium inlet and outlet 2, a housing body, a connector mounting seat 3, a housing back plate 4, and a product mounting hole 5. The first medium inlet and outlet 1 and the second medium inlet and outlet 2 are respectively provided on both sides of the top of the housing body, one for medium inlet and the other for medium outlet. In this embodiment, the first medium inlet and outlet 1 is used for medium inlet, and the second medium inlet and outlet 2 is used for medium outlet, and the two are interchangeable;

[0040] The connector mounting seat 3 is provided at the bottom of the housing body and is used to support and connect the connector;

[0041] The housing back plate 4 is provided on the rear side of the housing body;

[0042] The product installation hole 5 is provided on the side wall of the shell body, and a thread is provided inside, which is used to connect the integrated PTC water heater shell to the client through bolts that match the thread;

[0043] See also Figure 3-5 A closed cavity is formed inside the shell body, including two left-right symmetrical flow channels, several groups of parallel two left-right symmetrically distributed heating pack installation holes 6, and a heating pack shell insert 8 embedded in the heating pack installation holes 6. The left and right rows of heating pack installation holes 6 are not interconnected, but are connected at the bottom, and the heating pack installation holes 6 in each row are staggered. The outer side of the heating pack installation hole 6 forms a flow channel with the inner wall of the shell body. The bottoms of the two flow channels are connected to each other, and the tops are respectively connected to the first medium inlet and outlet 1 and the second medium inlet and outlet 2. A heating pack is installed in each row of heating pack shell insert 8.

[0044] The integrated PTC water heater shell cavity adopts the clinker injection molding process to integrate the traditional metal die-cast base and the shell into one injection molding, eliminating the development of multiple molds for the product, saving development time and cost, omitting screws, sealing rings and other components, and correspondingly reducing storage space, assembly personnel and assembly processes. It avoids failure points and risk points in the product development process, making the product lightweight and more widely used, reducing overall costs and later after-sales costs. Example 2

[0045] The embodiment is the same as the embodiment 1, but differs in that the shell body includes 6 groups of parallel heating pack installation holes 6 that are symmetrically distributed on the left and right.

[0046] See also Figure 6 One end of the heating pack installation hole 6 is connected to the front side wall of the shell body, and the other end points to the rear side wall of the shell body but does not touch it (forming a small gap with the shell, 1.5mm in this embodiment). Each row of heating pack installation holes 6 is staggered and tilted on both sides of the shell body. A baffle is provided between the two rows of heating pack installation holes 6. The heating pack installation holes 6 do not contact the left and right side walls of the shell body and the baffle, so that the water channels on both sides are "Z" shaped. The heating pack shell insert 8 is embedded in the heating pack installation hole 6. The center distance between two adjacent heating pack installation holes 6 in the column direction is 16.5 mm, and the center distance between two adjacent heating pack installation holes 6 in the row direction is 60 mm.

[0047] The corners of the heating pack installation hole 6 are provided with chamfered structures.

[0048] The outer wall of the heating pack installation hole 6 in contact with water is inclined along the direction of the flow channel with an inclination angle of 1.5° to facilitate drainage.

[0049] Two through holes 9 are provided on one side of the connector mounting base 3, which are used to connect the high-voltage connector and the low-voltage connector respectively.

[0050] A positioning hole 10 is provided on the other side of the connector mounting seat 3 for positioning the production tooling.

[0051] The connector mounting base 3 further includes a grounding mounting hole 7, which is provided on one side of the connector mounting base 3 and serves as a safety accessory for the high-voltage connector.

[0052] The first medium inlet and outlet 1, the second medium inlet and outlet 2, the heating pack installation hole 6, the connector installation seat 3, the shell back plate 4 and the product installation hole 5 are made of insulating plastic, and the heating pack shell insert 8 is made of metal.

[0053] The installation method of the above-mentioned integrated PTC water heater housing is as follows: As shown in the exploded diagram (see Figure 7 ) first put the heating pack into the heating pack shell 11, then install it into the heating pack shell insert 8, and then install the cover I 12; then install the high and low voltage connectors into the two through holes 9 of the connector mounting seat 3, and then put the PCB board into the connector mounting seat 3, under the two high and low voltage connectors, weld the high and low voltage connectors to the PCB board and then cover it with cover II 13. After the application end is fixed to the vehicle through the four product mounting holes 5, connect the water pipe to the water inlet and outlet (the first medium inlet and outlet 1 and the second medium inlet and outlet 2), turn on the power (after connecting the high and low voltage connectors to the power supply) and it can be used.

[0054] Note: Cover plate I 12 and cover plate II 13 are not integrally formed with the housing of the integrated PTC water heater, so they are not included in the technical solution. Those skilled in the art can adjust them according to actual needs.

[0055] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some or all of the technical features therein. These modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. Integrated PTC water heater housing, characterized in that, It comprises an integrally formed first medium inlet and outlet (1), a second medium inlet and outlet (2), a housing body, a connector mounting seat (3), a housing back plate (4) and a product mounting hole (5), The first medium inlet and outlet (1) and the second medium inlet and outlet (2) are respectively provided on both sides of the top of the housing body, one for medium inlet and the other for medium outlet; A connector mounting seat (3) is provided at the bottom of the housing body and is used to support and connect the connector; The housing back plate (4) is arranged on the rear side of the housing body; The product mounting hole (5) is provided on the side wall of the housing body; A closed cavity is formed inside the shell body, including two left-right symmetrical flow channels, a plurality of parallel groups of two left-right symmetrically distributed heating pack installation holes (6), and a heating pack shell insert (8) embedded in the heating pack installation holes (6). The left and right rows of heating pack installation holes (6) are not interconnected, but are connected at the bottom, and each row of heating pack installation holes (6) are staggered. The outer sides of the heating pack installation holes (6) form flow channels with the inner wall of the shell body. The bottoms of the two flow channels are interconnected, and the tops are respectively connected to the first medium inlet and outlet (1) and the second medium inlet and outlet (2). A heating pack is installed in each row of heating pack shell insert (8).

2. The integrated PTC water heater housing according to claim 1, characterized in that: The shell body comprises six groups of parallel heating pack mounting holes (6) that are symmetrically distributed on both sides.

3. The integrated PTC water heater housing according to claim 1, characterized in that: One end of the heating pack installation hole (6) is connected to the front side wall of the shell body, and the other end points to the rear side wall of the shell body but does not touch it. Each row of heating pack installation holes (6) is staggered on both sides of the shell body. A baffle is provided between the two rows of heating pack installation holes (6). The heating pack installation hole (6) does not touch the left and right side walls of the shell body and the baffle, so that the flow channels on both sides are "Z"-shaped. The heating pack shell insert (8) is embedded in the heating pack installation hole (6).

4. The integrated PTC water heater housing according to claim 3, characterized in that: The corners of the heating pack installation hole (6) are provided with chamfered structures.

5. The integrated PTC water heater housing according to claim 3, characterized in that: The outer wall of the heating pack installation hole (6) in contact with the medium is inclined along the direction of the flow channel, with an inclination angle of 1.5°.

6. The integrated PTC water heater housing according to claim 1, characterized in that: Two through holes (9) are provided on one side of the connector mounting seat (3), respectively used for connecting a high-voltage connector and a low-voltage connector.

7. The integrated PTC water heater housing according to claim 6, characterized in that: A positioning hole (10) is provided on the other side of the connector mounting seat (3).

8. The integrated PTC water heater housing according to claim 6, characterized in that: The connector mounting seat (3) further comprises a grounding mounting hole (7), and the grounding mounting hole (7) is arranged on one side of the connector mounting seat (3).

9. The integrated PTC water heater housing according to claim 1, characterized in that: The first medium inlet and outlet (1), the second medium inlet and outlet (2), the heating pack installation hole (6), the connector installation seat (3), the shell back plate (4) and the product installation hole (5) are made of insulating plastic, and the heating pack shell insert (8) is made of metal.