Liquid heater for vehicle

Abstract

The utility model relates to a liquid heater for a vehicle. The liquid heater comprises a shell connecting unit, a heat exchange unit, a control unit, a low-voltage plug connector, a high-voltage plug connector and a grounding bolt, the shell connecting unit is formed by buckling and bonding an upper cover and a main shell, and a mounting cavity is formed inside; a hole communicated with the mounting cavity is formed in the front end of the main shell; a two-way flow path is formed in the heat exchange unit; the heat exchange unit is fixedly connected with the shell connecting unit in an inserted mode in the mode that the front end of the water inlet and outlet pipe module is exposed. The control unit comprises a PCB and an IGBT. The PCB is fixed in the main shell and located above the heat exchange unit, the center of the PCB is welded to a terminal strip connected with the heating unit, the rear end of the PCB is connected with the IGBT in a welded mode, and the IGBT is fixed above the water return chamber through a pressing plate; and the low-voltage plug-in, the high-voltage plug-in and the grounding bolt are fixedly arranged at the low-voltage plug-in fixing hole, the high-voltage plug-in fixing hole and the grounding terminal fixing hole at the front end of the water inlet and outlet pipe module respectively. The heater is good in sealing performance and high in heat exchange efficiency.

Description

Technical Field

[0001] This utility model belongs to the field of automotive air conditioning technology, and in particular relates to a liquid heater for vehicles. Background Technology

[0002] Automotive liquid heaters are core components in the thermal management system of new energy vehicle batteries. Existing automotive liquid heaters have complex structures, and most of their water circuits use a sealing ring structure. During long-term use, the sealing rings are prone to failure, leading to coolant leakage and affecting the reliability of the entire vehicle. In addition, existing automotive liquid heaters also have shortcomings such as low heat exchange efficiency. Utility Model Content

[0003] This utility model addresses the aforementioned technical problems by proposing a vehicle liquid heater that achieves better water circuit sealing, improved heat exchange efficiency, high reliability, and wide applicability.

[0004] The above-mentioned objective of this utility model is achieved through the following technical solution:

[0005] A vehicle-mounted liquid heater includes a housing connection unit, a heat exchange unit, a control unit, a low-voltage connector, a high-voltage connector, and a grounding bolt;

[0006] The outer shell connection unit includes a main shell and a top cover. The top cover and the main shell are fixedly connected by a snap-fit ​​adhesive, forming an internal mounting cavity. A hole communicating with the mounting cavity is provided at the front end of the main shell.

[0007] The heat exchange unit includes an inlet / outlet water pipe module, a flat tube, a return water chamber, and a heating unit. The inlet / outlet water pipe module has a grounding terminal fixing hole, a low-pressure plug fixing hole, and a high-pressure plug fixing hole at its front end. The left and right sides of the front end of the inlet / outlet water pipe module are the outlet and inlet, respectively. At the rear end of the inlet / outlet water pipe module, there are separate inlet and outlet water chambers, which are connected to the inlet and outlet water ports, respectively. The inlet / outlet water pipe module is connected to the front end of the flat tube by welding, and the return water chamber is connected to the rear end of the flat tube by welding. The heating unit is printed and sintered onto the lower surface of the flat tube. A two-way flow path is formed inside the heat exchange unit. The heat exchange unit is fixedly connected to the outer shell connecting unit through holes at the front end of the outer shell connecting unit, with the front end of the inlet / outlet water pipe module exposed.

[0008] The control unit includes a PCB board and an IGBT. The PCB board is fixed inside the main housing and located above the heat exchange unit. The center of the PCB board is welded to the terminal block connecting the heating unit, and the rear end of the PCB board is welded to the IGBT. The IGBT is fixed above the return water chamber by a pressure plate. The low-pressure plug, the high-pressure plug, and the grounding bolt are respectively fixedly installed at the low-pressure plug fixing hole, the high-pressure plug fixing hole, and the grounding terminal fixing hole at the front end of the inlet and outlet water pipe module. The low-pressure plug and the high-pressure plug are connected to the PCB board by plug-in or lead wire.

[0009] Furthermore, a conformal sealing groove is provided on the front face of the front protruding ring edge located outside the hole at the front end of the main housing. A sealing ring is installed in the sealing groove. Outer protrusions are arranged on the outer ring edge, and threaded holes are vertically provided on each outer protrusion. Screw through holes are provided on the outer periphery of the inlet and outlet water pipe modules, and the screw through holes correspond one-to-one with the threaded holes at the front end of the main housing. A mounting platform is formed between the front and rear parts of the inlet and outlet water pipe modules. The shape of the rear part of the inlet and outlet water pipe modules matches the shape of the front hole on the main housing. The inlet and outlet water pipe modules are pressed into contact with the front protruding ring edge on the main housing through the mounting platform, and the heat exchange unit and the outer shell connection unit are fixedly connected by screws installed in the corresponding screw through holes and threaded holes.

[0010] Furthermore, main positioning protrusions of equal height are provided in the inner cavity of the main housing against the two side walls, and threaded holes are vertically provided on the main positioning protrusions; the outer ring of the PCB board is provided with screw through holes that correspond one-to-one with the threaded holes on the main positioning protrusions in the main housing, and the control unit is supported on the main positioning protrusions on both sides and is fixedly connected by screws installed in the corresponding threaded through holes and threaded holes.

[0011] Furthermore, auxiliary positioning protrusions of equal height are provided on the left and right sides of the inner side of the main housing, which are close to the rear wall, and threaded holes are provided vertically on the two auxiliary positioning protrusions; external protrusions are provided on both sides of the rear end of the return water chamber, and screw through holes corresponding to the threaded holes on the auxiliary positioning protrusions are provided on the external protrusions. The return water chamber is supported on the auxiliary positioning protrusions on both sides and is fixedly connected by screws installed in the corresponding screw through holes and threaded holes.

[0012] Furthermore, four turbulence columns are distributed laterally on the rear side of the return water chamber.

[0013] Furthermore, the flat tube has flow channel holes inside, and heat dissipation protrusions are arranged around the flow channel holes, which can increase the heat exchange area.

[0014] Furthermore, the heating unit includes an insulating layer, a resistive layer, a conductive layer, and a protective layer; wherein the protective layer is the outermost layer, the insulating layer is in contact with the surface of the flat tube, and the resistive layer and the conductive layer are disposed between the insulating layer and the protective layer; the board temperature sensor is bonded to the solder pad interface position reserved in the middle of the terminal block in the heating unit by conductive structural adhesive, the terminal block is fixed to the lower middle position of the flat tube, one end of the terminal block passes through the through hole set in the middle of the flat tube and is soldered to the PCB board, and the other end of the terminal block is soldered to the solder pad interface reserved in the resistive layer.

[0015] The advantages and positive effects of this utility model are as follows:

[0016] 1. The water circuit structure of this vehicle liquid heater is completed by laser welding, realizing the use of zero sealing rings in the water circuit structure, avoiding the problem of coolant leakage during long-term use, and improving the reliability of water circuit sealing;

[0017] 2. The main housing and top cover of this vehicle liquid heater are sealed with a snap-fit ​​adhesive structure, making it safer and more reliable.

[0018] 3. The water circuit of the liquid heater in this vehicle adopts a two-pass flow channel, which has high heat exchange efficiency. Furthermore, the flat tube adopts a high-efficiency heat exchange flow channel structure, achieving better heat exchange efficiency.

[0019] 4. The liquid heater for this vehicle has a high degree of integration of components, a compact structure, lighter weight, fewer types of parts, and simple and quick assembly.

[0020] 5. This vehicle liquid heater has a wide applicable voltage range, suitable for voltage requirements of DC800V and above, and the power can be matched according to the customer's heating power requirements, up to 10kW and above. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the heater assembly of this utility model;

[0022] Figure 2 This is an exploded view of the heater assembly of this utility model;

[0023] Figure 3 This is a schematic diagram of the internal structure of the heater of this utility model;

[0024] Figure 4 This is a schematic diagram of the outer shell connection unit of this utility model;

[0025] Figure 5 This is an exploded view of the outer shell connection unit of this utility model;

[0026] Figure 6 This is a schematic diagram of the heat exchange unit of this utility model;

[0027] Figure 7This is an exploded view of the heat exchange unit of this utility model;

[0028] Figure 8 This is a schematic diagram of the heating unit of this utility model;

[0029] Figure 9 This is a schematic diagram of the control unit of this utility model;

[0030] Figure 10 This is an exploded view of the control unit of this utility model;

[0031] Figure 11 This is a cross-sectional view of the two-stage water circuit of this utility model;

[0032] Figure 12 This is a schematic diagram of the inlet and outlet water pipe module of this utility model;

[0033] Figure 13 This is a cross-sectional view of the inlet and outlet water pipe module of this utility model;

[0034] Figure 14 This is a schematic diagram of the cross-section of the flat tube of this utility model;

[0035] In the diagram: 1. Outer shell connection unit; 2. Heat exchange unit; 3. Control unit; 1.1 Upper shell; 1.2 Main shell; 2.1 Heating unit; 2.2 Flat tube; 2.3 Return water chamber; 2.4 Inlet and outlet water pipe module; 2.4.1 Outlet; 2.4.2 Low-pressure plug-in fixing hole; 2.4.3 High-pressure plug-in fixing hole; 2.4.4 Inlet; 2.4.5 Grounding terminal fixing hole; 2.4.6 Outlet chamber; 2.4.7 Inlet chamber; 2.5 High-pressure plug-in; 2.6 Low-pressure plug-in; 2.7 Grounding terminal; 2.8 Pressure plate; 3.1 PCB board; 3.2 IGBT ; 1.2.1 Auxiliary positioning protrusion; 1.2.2 Main positioning protrusion; 1.2.3 Hole; 1.2.4 Front protruding ring edge; 2.1.1 Insulating layer; 2.1.2 Resistive layer; 2.1.3 Conductive layer; 2.1.4 Protective layer; 2.1.5 Terminal block; 2.1.6 Board temperature sensor; 2.1.7 Solder pad interface; 2.3.1 Flushing column; 2.4.1 Water outlet; 2.4.2 Low-pressure plug-in fixing hole; 2.4.3 High-pressure plug-in fixing hole; 2.4.4 Water inlet; 2.4.5 Grounding terminal fixing hole; 2.4.6 Water outlet chamber; 2.4.7 Water inlet chamber. Detailed Implementation

[0036] The structure of this utility model will be further described below with reference to the accompanying drawings and embodiments. It should be noted that these embodiments are descriptive and not limiting.

[0037] A vehicle liquid heater, please see Figures 1-14 It mainly includes an outer shell connection unit 1, a heat exchange unit 2, and a control unit 3.

[0038] The outer casing connection unit mainly includes an upper cover 1.1 and a main casing 1.2. The upper cover 1.1 and the main casing 1.2 are connected together by a snap-fit ​​method, and then sealed around the perimeter with sealant, forming an internal mounting cavity. The main casing adopts an integral injection-molded structure or an integral cast aluminum structure. Its front end has a hole 1.2.3 connecting to the mounting cavity and a front protruding ring 1.2.4 surrounding the hole. A conformal sealing groove is provided on the front surface of the front protruding ring for installing a sealing ring. Outer protrusions are arranged around the outer ring, and each outer protrusion has a vertically threaded hole for positioning and fixing the water inlet and outlet parts of the heat exchange unit.

[0039] The main housing has equal-height main positioning protrusions 1.2.2 positioned against the side walls of the inner cavity. Threaded holes are vertically provided on these main positioning protrusions for positioning, supporting, and fixing the control unit. Auxiliary positioning protrusions 1.2.1 of equal height are located on the left and right sides of the inner side of the main housing against the rear wall. Threaded holes are vertically provided on these auxiliary positioning protrusions for supporting and fixing the rear recovery section of the heat exchange unit. The upper housing is constructed using a one-piece injection molding structure or a cast aluminum structure. The outer shell connecting unit 1 primarily serves to fix and protect the control unit and the heat exchange unit.

[0040] The heat exchange unit mainly includes an inlet / outlet water pipe module 2.4, a flat tube 2.2, a return water chamber 2.3, and a heating unit 2.1. The inlet / outlet water pipe module 2.4 is connected to the front end of the flat tube 2.2 by welding, and the return water chamber 2.3 is connected to the rear end of the flat tube 2.2 by welding. The heating unit 2.1 is printed and sintered on the lower surface of the flat tube 2.2 to achieve the heating function.

[0041] Furthermore, the front end of the inlet / outlet water pipe module 2.4 has three holes: a grounding terminal fixing hole 2.4.5, a low-voltage plug fixing hole 2.4.2, and a high-voltage plug fixing hole 2.4.3, mainly for connecting and fixing the grounding terminal 2.7, low-voltage plug 2.6, and high-voltage plug 2.5. The left and right sides of the front end of the inlet / outlet water pipe module are the outlet 2.4.1 and the inlet 2.4.4, respectively, mainly for the inflow and outflow of coolant. The grounding terminal 2.7 is connected to the inlet / outlet water pipe module 2.4 by bolting, and the low-voltage plug 2.6 and high-voltage plug 2.5 are fixed to the inlet / outlet water pipe module 2.4 by bolts. Screw holes are provided around the outer perimeter of the inlet / outlet water pipe module, corresponding one-to-one with the threaded holes on the front end of the main housing. At the rear end of the inlet / outlet water pipe module, there are separate inlet chambers 2.4.7 and 2.4.6, which are connected to the inlet and outlet respectively. An installation platform is formed between the front and rear of the inlet and outlet water pipe module to achieve positioning and engagement with the front protruding ring edge of the main housing. The shape of the rear of the inlet and outlet water pipe module matches the shape of the front hole on the main housing to achieve insertion and engagement between the two.

[0042] Furthermore, to better guide the flow, the flat tube 2.2 has flow channel holes inside, and heat dissipation protrusions are arranged around the flow channel holes to increase the heat exchange area. The flat tube is divided into left and right double water paths. One water path is aligned with the water inlet chamber on the inlet / outlet water pipe module and flows into the coolant; the other water path is aligned with the water outlet chamber on the inlet / outlet water module and flows out the coolant. A row of through holes is spaced at the center of the flat tube 2.2 between the double water paths. Threaded holes are formed at both ends of the row of through holes. The main function of the row of rectangular through holes and threaded holes is to fix the terminal block 2.1.5 of the heating unit 2.1, and to allow one end of the terminal block 2.1.5 to pass through the through holes and be soldered to the PCB board 3.1. The shape of the row of through holes can be changed according to the shape and size of the end of the terminal block 2.1.5, for example, it can be rectangular, elliptical, etc. In this utility model, a rectangle is preferred.

[0043] Furthermore, the return water chamber 2.3 is an open-front water chamber structure, with its opening width matching the width of the flat tube. Four flow-deflecting pillars 2.3.1 are laterally distributed inside the return water chamber, spaced 25mm–30mm apart, primarily guiding the incoming coolant. Raised bolt holes (not shown in the attached diagram) are located above these pillars, mainly providing support and fixation for the IGBT 3.1 of the control unit. The return water chamber, together with the inlet and outlet water pipe modules and the flat tube, forms a two-way flow path, constituting a complete water flow loop. External protrusions are located on both sides of the rear end of the return water chamber, with screw through holes corresponding to the threaded holes on the auxiliary positioning pillars.

[0044] Furthermore, the heating unit 2.1 mainly consists of an insulating layer 2.1.1, a resistive layer 2.1.2, a conductive layer 2.1.3, and a protective layer 2.1.4. It is formed through multiple furnace sintering and printing processes. The protective layer is the outermost layer, the insulating layer is in contact with the surface of the flat tube, and the resistive and conductive layers are positioned between the insulating and protective layers. The board temperature sensor 2.1.6 is bonded to the pre-reserved solder pad interface position of the terminal block in the middle of the heating unit using conductive structural adhesive. Then, the other end of the terminal block 2.1.5 is welded to the pre-reserved solder pad interface 2.17 of the resistive layer, and both ends are fixed to the flat tube with screws to achieve the heating function. The working process is as follows: coolant flows in from the inlet pipe of the inlet / outlet water pipe module 2.4, enters the inlet chamber of the inlet / outlet water pipe module 2.4, flows into the inlet flow of the flat pipe 2.2, is heated by the heating unit 2.1, reaches the return water chamber 2.3, is guided from the return water chamber 2.3 into the outlet flow of the flat pipe 2.2, reaches the outlet chamber of the inlet / outlet water pipe module 2.4, and flows out from the outlet pipe of the inlet / outlet water pipe module 2.4.

[0045] The temperature sensor 2.1.6 is integrated with the terminal block 2.1.5, saving space for the printed thick film heating resistors, thereby allowing for the placement of more heating resistors and increasing the overall power of the heater. At the same time, this integrated structure can reduce the number of terminals on the terminal block, facilitating the connection of the subsequent control board.

[0046] Furthermore, the control unit 3 mainly includes a PCB board 3.2 and an IGBT 3.1. The outer ring of the PCB board is provided with screw through holes that correspond one-to-one with the threaded holes on the main positioning post inside the main housing. The PCB board 3.2 is mainly fixed inside the main housing 1.2 by screws and is located above the heat exchange unit. The center of the PCB board is welded to the terminal block 2.1.5 of the heating unit 2.1, and the rear end is welded to the IGBT 3.1. The IGBT 3.1 is fixed above the return water chamber 2.3 by a pressure plate 2.8. The low-pressure plug 2.6 and the high-pressure plug 2.5 are connected to the PCB board 3.2 by plug-in or lead wire. The control unit 3 adjusts the heating power and realizes various functions and protection functions of the heater. It can meet different heating power requirements according to the heating needs of the whole vehicle, and is equipped with multiple protection functions to protect the heater from working abnormally.

[0047] The front end of heat exchange unit 2 is fixedly connected to the outer casing connection unit 1 by a ring of screws. The rear end of the heat exchange unit is supported on two auxiliary positioning protrusions and connected by screws. Except for the inlet and outlet water pipe modules, the rest of the heat exchange unit 2 is fixed inside the outer casing connection unit 1. The control unit 3 is fixed to the outer casing connection unit 1 and the heat exchange unit 2 by screws and pressure plates 2.8. The outer casing connection unit 1 protects and fixes the control unit 3 and the heat exchange unit 2. The heat exchange unit 2 heats the incoming coolant before it flows out to achieve the heating function. The control unit 3 adjusts the heating power of the heat exchange unit and realizes various functions and protection functions of the heater.

[0048] Although embodiments and drawings of the present invention have been disclosed for illustrative purposes, those skilled in the art will understand that various substitutions, variations and modifications are possible without departing from the spirit and scope of the present invention and the appended claims. Therefore, the scope of the present invention is not limited to the contents disclosed in the embodiments and drawings.

Claims

1. A vehicle liquid heater, characterized in that: It includes an outer casing connection unit, a heat exchange unit, a control unit, a low-voltage connector, a high-voltage connector, and a grounding bolt; The outer shell connection unit includes a main shell and a top cover. The top cover and the main shell are fixedly connected by a snap-fit ​​adhesive, forming an internal mounting cavity. A hole communicating with the mounting cavity is provided at the front end of the main shell. The heat exchange unit includes an inlet / outlet water pipe module, a flat tube, a return water chamber, and a heating unit. The inlet / outlet water pipe module has a grounding terminal fixing hole, a low-pressure plug fixing hole, and a high-pressure plug fixing hole at its front end. The left and right sides of the front end of the inlet / outlet water pipe module are the outlet and inlet, respectively. At the rear end of the inlet / outlet water pipe module, there are separate inlet and outlet water chambers, which are connected to the inlet and outlet water ports, respectively. The inlet / outlet water pipe module is connected to the front end of the flat tube by welding, and the return water chamber is connected to the rear end of the flat tube by welding. The heating unit is printed and sintered onto the lower surface of the flat tube. A two-way flow path is formed inside the heat exchange unit. The heat exchange unit is fixedly connected to the outer shell connecting unit through holes at the front end of the outer shell connecting unit, with the front end of the inlet / outlet water pipe module exposed. The control unit includes a PCB board and an IGBT. The PCB board is fixed inside the main housing and located above the heat exchange unit. The center of the PCB board is welded to the terminal block connecting the heating unit, and the rear end of the PCB board is welded to the IGBT. The IGBT is fixed above the return water chamber by a pressure plate. The low-pressure plug, the high-pressure plug, and the grounding bolt are respectively fixedly installed at the low-pressure plug fixing hole, the high-pressure plug fixing hole, and the grounding terminal fixing hole at the front end of the inlet and outlet water pipe module. The low-pressure plug and the high-pressure plug are connected to the PCB board by plug-in or lead wire.

2. The vehicle liquid heater according to claim 1, characterized in that: A front protruding ring is located at the front end of the main housing, surrounding the hole. A conformal sealing groove is provided on the front surface of the front protruding ring, and a sealing ring is installed in the sealing groove. Outer protruding posts are arranged on the outer ring, and threaded holes are vertically provided on each outer protruding post. Screw through holes are provided on the outer periphery of the inlet and outlet water pipe modules, and the screw through holes correspond one-to-one with the threaded holes at the front end of the main housing. A mounting platform is formed between the front and rear parts of the inlet and outlet water pipe modules, and the shape of the rear part of the inlet and outlet water pipe modules matches the shape of the front hole on the main housing. The inlet and outlet water pipe modules are pressed into contact with the front protruding ring on the main housing through the mounting platform, and the heat exchange unit and the outer shell connection unit are fixedly connected by screws installed in the corresponding screw through holes and threaded holes.

3. The vehicle liquid heater according to claim 1, characterized in that: Main positioning protrusions of equal height are provided in the inner cavity of the main housing against the two side walls, and threaded holes are vertically provided on the main positioning protrusions; the outer ring of the PCB board is provided with screw through holes that correspond one-to-one with the threaded holes on the main positioning protrusions in the main housing; the control unit is supported on the main positioning protrusions on both sides and is fixedly connected by screws installed in the corresponding threaded through holes and threaded holes.

4. The vehicle liquid heater according to claim 1, characterized in that: Equal-height auxiliary positioning protrusions are provided on the left and right sides of the inner side of the main housing, which are close to the rear wall, and threaded holes are provided vertically on the two auxiliary positioning protrusions; external protrusions are provided on both sides of the rear end of the return water chamber, and screw through holes corresponding to the threaded holes on the auxiliary positioning protrusions are provided on the external protrusions. The return water chamber is supported on the auxiliary positioning protrusions on both sides and is fixedly connected by screws installed in the corresponding screw through holes and threaded holes.

5. The automotive liquid heater according to claim 1, characterized in that: There are four turbulence columns distributed laterally on the rear side of the return water chamber.

6. The vehicle liquid heater according to claim 1, characterized in that: The flat tube has flow channel holes inside, and heat dissipation protrusions are arranged around the flow channel holes.

7. The vehicle liquid heater according to claim 1, characterized in that: The heating unit includes an insulating layer, a resistive layer, a conductive layer, and a protective layer; the protective layer is the outermost layer, the insulating layer is in contact with the surface of the flat tube, and the resistive layer and the conductive layer are disposed between the insulating layer and the protective layer; the board temperature sensor is bonded to the solder pad interface position reserved in the middle of the terminal block in the heating unit by conductive structural adhesive, the terminal block is fixed to the lower middle position of the flat tube, one end of the terminal block passes through the through hole set in the middle of the flat tube and is soldered to the PCB board, and the other end of the terminal block is soldered to the solder pad interface reserved in the resistive layer.

Images