High-power-density PTC (Positive Temperature Coefficient) water heater
By employing thermally conductive adhesive bonding and an alumina ceramic sheet insulation design in the PTC water heater, combined with cast aluminum parts and a modular structure, the problems of poor thermal conductivity of the PI insulation film and structural gaps are solved, thus achieving a high power density and low cost PTC water heater.
Patent Information
- Application Number
- CN202520303740.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Priority Date
- 2024-12-26
- Filing Date
- 2025-02-25
- Publication Date
- 2025-11-21
- Estimated Expiration
- 2035-02-25
AI Technical Summary
The PI insulation film of existing PTC water heaters has poor thermal conductivity, resulting in poor heat transfer and dissipation. In addition, the structural gaps lead to reduced power stability, low power density, heavy weight, and high cost.
The PTC heating core and electrode sheet are bonded together with thermally conductive adhesive and wrapped with an insulating protective frame. Combined with the design of alumina ceramic sheet and cast aluminum parts, a compact structure is formed, which increases thermal conductivity and insulation. The liquid flow channel is optimized through modular design to reduce gaps and volume.
It achieves a high power density of 58W/cm2, reduces heater size and weight, improves power stability and thermal conductivity, and reduces costs.
Smart Images
Figure CN223580219U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The utility model relates to the field of heater, concretely relates to a high power density PTC water heater. BACKGROUND
[0002] At present, PTC water heater is widely used in various electrical, new energy vehicles and other equipment with high safety requirements due to its advantages of no open flame, dry burning resistance, low dry burning temperature and the like. The traditional fuel automobile air conditioning system is heated by engine waste heat, and since the pure electric vehicle has no engine, the heating is mainly realized through the PTC water heater. The existing PTC water heater comprises a PTC heating body, a shell and a wire harness, the PTC heating body comprises a PTC sheet in the middle and electrode sheets on both sides, and the outside is wrapped with 2-4 layers of PI insulating film to play a main insulation role, but the heat conduction effect of the PI insulating film itself is relatively poor, and after wrapping several layers, the PTC transmission and heat dissipation are poor, the conversion rate of the temperature of the PTC and the outside temperature is poor, and the PI insulating film is easy to be punctured. The shell is a U-shaped piece, and the PTC heating body is put into the shell through a wedge-shaped block, because the three components are independently assembled together, there will be a gap, and after assembly, the tight fit effect cannot be achieved, in other words, the product is made through the "tight" process (the plug can be pulled out after being inserted), and the ideal state of cooperation is not achieved, so that the power stability of the product is also reduced, thereby affecting the performance of the PTC power. Moreover, the existing PTC water heater has a heavy quality, the heating temperature is low, so the power density is low, and the maximum can only reach about 35W / cm 2 (PTC thermistor area), when high power is needed, the volume of the heater often needs to be increased, or a complex heat dissipation structure needs to be designed, and the processing cost is high. UTILITY MODEL CONTENTS
[0003] In view of the defects of the prior art, the utility model provides a high power density PTC water heater, through the innovative design of the heater structure, insulation, heat dissipation and liquid flow channel, the overall structure is simple, the volume is small, and the maximum power density can reach 58W / cm 2 (PTC thermistor area), and the volume, weight and cost of the heater are effectively reduced.
[0004] In order to achieve the above object, the utility model provides the following technical scheme: a kind of high power density PTC water heater, including PTC heating body, shell and wiring harness, the PTC heating body includes PTC heating core and cast aluminum piece, the PTC heating core includes PTC sheet, electrode sheet and insulation protection frame, the PTC sheet is adhered with electrode sheet by heat-conducting adhesive above and below, and insulation protection frame is equipped around PTC sheet and electrode sheet after adhering, and the electrode sheet end is equipped with pin;The cast aluminum piece includes PTC heating core mounting seat, upper cover and flange I, the middle of PTC heating core mounting seat is equipped with installation cavity matched with PTC heating core installation, and the bottom surface of PTC heating core mounting seat and the upper surface of upper cover are all equipped with flow guide ribs;The shell includes cavity containing PTC heating body, water inlet and flange II, and liquid flow channel is formed between flow guide rib and cavity.
[0005] As further improvement, the PTC heating core is equipped with alumina ceramic sheet between PTC heating core and PTC heating core mounting seat and upper cover.
[0006] As further improvement, the PTC heating core mounting seat is equipped with sealing ring I between PTC heating core mounting seat and upper cover, and is fixedly connected by screw.
[0007] As further improvement, the shell side is equipped with temperature sensing probe.
[0008] As further improvement, the flange I is equipped with protection box outside, and temperature controller and temperature fuse are equipped in protection box.
[0009] As further improvement, the flange I is equipped with sealing ring II between flange I and flange II.
[0010] As further improvement, the shell is further equipped with mounting ear.
[0011] The utility model PTC sheet is formed by one or more PTC sheets arranged side by side, and the PTC sheets are connected in parallel, and the PTC sheet and electrode sheet can be bonded by silicone or other high-temperature adhesive, or can be directly clamped.
[0012] The utility model has the advantages that: through the innovative design of heater structure, insulation, heat dissipation and liquid flow channel, the modular structure is made, and the connection is close, since the heated liquid completely wraps the PTC heating body, the shell temperature is low (will not exceed the heated liquid), the influence on surrounding components is small, and there is no need to design additional temperature insulation protection structure, the volume is reduced, and the cost is greatly reduced. The overall structure is simple, the volume is small, and the maximum can realize 58W / cm 2The power density of the PTC thermistor area effectively reduces the volume, weight and cost of the heater. The alumina ceramic sheet is a good carrier for insulation and heat conduction in the heater, and has a better effect than the PI insulation film, and achieves insulation and good heat conduction. BRIEF DESCRIPTION OF DRAWINGS
[0013] Figure 1 It is a structural schematic view of an embodiment of the present application;
[0014] Figure 2 It is a schematic view of a PTC heating core of an embodiment of the present application;
[0015] Figure 3 It is a schematic view of a PTC heating core installation of an embodiment of the present application;
[0016] Figure 4 It is a schematic view of a PTC heating body of an embodiment of the present application;
[0017] Figure 5 It is a schematic view of a PTC heating body installation of an embodiment of the present application;
[0018] Figure 6 It is a schematic view of a shell of an embodiment of the present application;
[0019] In the figure: 1, PTC sheet; 2, electrode sheet; 3, insulation protection frame; 4, PTC heating core; 5, pin; 6, PTC heating core mounting seat; 7, upper cover; 8, flange I; 9, flow guide rib; 10, sealing ring I; 11, screw; 12, cavity; 13, water inlet and outlet; 14, flange II; 15, alumina ceramic sheet; 16, temperature sensing probe; 17, protection box; 18, sealing ring II; 19, mounting lug; 20, sleeve. DETAILED DESCRIPTION
[0020] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.
[0021] In combination with the drawings, a high-power-density PTC water heater comprises a PTC heating body, a shell and a wire harness, the PTC heating body comprises a PTC heating core 4 and an aluminum casting, the PTC heating core 4 comprises PTC sheets 1, electrode sheets 2 and an insulating protection frame 3, the whole PTC sheets 1 are arranged in parallel by 8 PTC sheets, each PTC sheet is connected in parallel, the electrode sheets 2 are made of aluminum material, copper material or other conductive metal materials, the thickness is set according to the working current, the electrode sheets 2 are provided with pins 5 or pin type structures, which are convenient for connection in the form of wires, welding and the like, and an insulating high-temperature sleeve 20 is sleeved outside the pins 5. The PTC sheets are adhered to the electrode sheets 2 through heat-conducting glue, the PTC sheets 1 and the electrode sheets 2 are provided with the insulating protection frame 3 around, the insulating protection frame 3 is made of high-temperature-resistant plastic or other insulating high-temperature-resistant materials, is used for positioning when being installed into the aluminum casting and is insulated around.
[0022] The aluminum casting comprises a PTC heating core mounting seat 6, an upper cover 7 and a flange I 8, the PTC heating core mounting seat 6 is provided with an installation cavity matched with the PTC heating core 4 in the middle, and alumina ceramic sheets 15 are arranged between the PTC heating core 4 and the PTC heating core mounting seat 6 and the upper cover 7, so as to achieve insulation and good heat conduction. The bottom surface of the PTC heating core mounting seat 6 and the upper surface of the upper cover 7 are each provided with three flow guide ribs 9; the PTC heating core mounting seat 6 is provided with wire leading-out holes, so that the wires or pins on the electrode sheets 2 can be led out to the outside.
[0023] As shown in the drawings, Figure 6 The shell comprises a cavity 12 accommodating the PTC heating body, a water inlet and outlet 13 and a flange II 14, the flow guide ribs 9 on the aluminum casting form a liquid flow channel between the flow guide ribs 9 and the cavity 12, and the flow guide ribs 9 can also increase the heat dissipation area. The PTC heating core mounting seat 6 and the upper cover 7 are provided with a sealing ring I 10 and are fixedly connected through a screw 11, so as to prevent water leakage. The PTC heating core mounting seat 6 and the upper cover 7 can also be fixed by buckles. One side of the shell is provided with a temperature sensing probe 16, a protection box 17 is arranged outside the flange I 8, the protection box 17 is provided with a temperature controller and a temperature fuse, the shell is further provided with a pair of mounting ears 19 matched with a terminal, and the flange I 8 and the flange II 14 are provided with a sealing ring II 18, so as to prevent the liquid in the cavity 12 from leaking.
[0024] The parameters of the existing conventional PTC water heater are as follows:
[0025]
[0026] The parameters of the utility model are as follows:
[0027]
Claims
1. A high power density PTC water heater comprising a PTC heating element, a housing and a wiring harness, characterized in that: The PTC heating body comprises a PTC heating core (4) and a cast aluminum part, the PTC heating core (4) comprises a PTC sheet (1), an electrode sheet (2) and an insulating protection frame (3), the PTC sheet (1) is bonded with the electrode sheet (2) through a heat-conducting adhesive from top to bottom, the bonded PTC sheet (1) and electrode sheet (2) are provided with the insulating protection frame (3) around, and the electrode sheet (2) is provided with a pin (5) at an end; the cast aluminum part comprises a PTC heating core mounting seat (6), an upper cover (7) and a flange I (8), the PTC heating core mounting seat (6) is provided with a mounting cavity matched with the PTC heating core (4) in the middle, the PTC heating core mounting seat (6) bottom surface and the upper cover (7) upper surface are both provided with a flow guide rib (9); the shell comprises a cavity (12) containing the PTC heating body, a water inlet / outlet (13) and a flange II (14), and the flow guide rib (9) and the cavity (12) form a liquid flow channel.
2. A high power density PTC water heater as claimed in claim 1, wherein: The PTC heating core (4) is provided with an alumina ceramic sheet (15) between the PTC heating core (4) and the PTC heating core mounting seat (6) and the upper cover (7).
3. A high power density PTC water heater as claimed in claim 1, wherein: The PTC heating core mounting seat (6) and the upper cover (7) are provided with a sealing ring I (10) and are fixedly connected through a screw (11).
4. A high power density PTC water heater as claimed in claim 1, wherein: One side of the shell is provided with a temperature sensing probe (16).
5. A high power density PTC water heater as claimed in claim 1, wherein: The flange I (8) is provided with a protection box (17) outside, the protection box (17) is provided with a temperature controller and a temperature fuse inside.
6. A high power density PTC water heater as claimed in claim 1, wherein: The flange I (8) and the flange II (14) are provided with a sealing ring II (18) therebetween.
7. A high power density PTC water heater as claimed in claim 1, wherein: The shell is further provided with a mounting lug (19).