PTC heater with high-voltage wiring harness structure

Abstract

The utility model discloses a PTC (Positive Temperature Coefficient) heater with a high-voltage wiring harness structure, which comprises a heating assembly, a temperature control assembly and a temperature control assembly, and is characterized in that the heating assembly comprises a heating pipe and radiating fins, a heating element is arranged in the heating pipe, and electrode plates are arranged on two sides of the heating element; the wiring terminal comprises a main body part, the side surface of the main body part is provided with a plurality of connecting parts, and the connecting parts are provided with connecting grooves for accommodating the electrode plates; and the high-voltage wiring harness is connected with the wiring terminal and is also connected with a fuse. The beneficial effects of the utility model lie in that the condition of pseudo soldering of the terminals is reduced, the safety and reliability of the heater in long-term use are improved, the production efficiency of the product is greatly improved, and the cost is further reduced.

Description

Technical Field

[0001] This utility model relates to the field of heater technology, specifically to a PTC heater with a high-voltage wire harness structure. Background Technology

[0002] Currently, heaters use two or three copper electrodes to connect each heating element in parallel. A high-voltage wiring harness is then connected to the copper electrodes, and subsequently to a power source. This energizes the PTC ceramic elements, causing them to heat up. The heat is transferred to the air through the metal electrodes, insulation layer, aluminum tube, and thermally conductive aluminum components, and finally, a fan delivers the hot air into the vehicle, raising the interior temperature. Because the electrode heads and electrode strips of the PTC heating core are perpendicular, the traditional electrode strip welding method involves first welding an L-shaped terminal to each end of the electrode strip, then welding the L-shaped terminals to the electrode strip, and finally welding the electrode strip to the high-voltage wiring harness terminals. This welding method has drawbacks such as numerous processing steps, many weld points, and structural instability. Since heaters in new energy vehicles operate under high-voltage DC, any poor welding can cause continuous arcing between the two electrodes, leading to heater burnout and ultimately, vehicle fire. Utility Model Content

[0003] To address the aforementioned technical problems, this utility model provides a PTC heater with a high-voltage wiring harness, which reduces the occurrence of poor soldering at the terminals, improves the safety and reliability of the heater during long-term use, and greatly increases the production efficiency of the product, thereby further reducing costs.

[0004] Specifically, this utility model discloses a PTC heater with a high-voltage wiring harness structure, comprising:

[0005] A heating assembly includes a heating tube and a heat sink, wherein a heating element is disposed inside the heating tube and electrode plates are disposed on both sides of the heating element;

[0006] A terminal block includes a main body, and a plurality of connecting portions are provided on the side of the main body, and the connecting portions are provided with connecting grooves for accommodating the electrode plates;

[0007] The high-voltage wiring harness is connected to the terminal block and also to a fuse.

[0008] The advantages of adopting the above technical solution are that it reduces the occurrence of poor soldering at the terminals, improves the safety and reliability of the heater in long-term use, and greatly improves the production efficiency of the product, thereby further reducing costs.

[0009] Furthermore, the electrode sheet is provided with an extended end, which extends into the connecting groove and is pressed together by current welding or resistance welding.

[0010] The advantage of adopting the above technical solution is that the connection groove is set to first press and connect with the electrode sheet to ensure that the electrode sheet and the terminal are in close contact. Then, current welding or resistance welding is used to make it melt and connect, ensuring a tight connection without any false welds.

[0011] Furthermore, the terminal block is provided with a connecting part, which is connected to the high-voltage wiring harness.

[0012] The advantage of adopting the above technical solution is that the connection part is designed to connect with the high-voltage wire harness, ensuring a tight connection.

[0013] Furthermore, the fuse is disposed on the side of the heating assembly, and a ceramic tube cap is sleeved on the outside. The side of the heating assembly is provided with a fixing workpiece for fixing the high-voltage wire harness. The fixing workpiece is provided with a wire pass slot, and the high-voltage wire harness is installed and fixed in the wire pass slot.

[0014] The advantages of adopting the above technical solution are that the ceramic pipe cap plays a role in preventing leakage and waterproofing, ensuring safe use, and the pre-installation of the fuse and ceramic pipe cap reduces the number of steps during installation, improves sealing performance, and the wire pass slot facilitates the connection of high-voltage wire harnesses.

[0015] Furthermore, the terminal block includes a positive terminal and two negative terminals. The negative terminals are located at the upper and lower ends of the heating assembly. The positive terminal is connected to the positive terminal on the high-voltage harness, and the fuse is connected to the positive terminal.

[0016] The advantage of adopting the above technical solution is that the positive terminal is connected to the positive terminal and the negative terminal is connected to the negative terminal. When the current exceeds the specified value, the positive terminal connection will be melted to avoid safety accidents.

[0017] Furthermore, the electrode sheet is divided into a positive electrode sheet and a negative electrode sheet. The positive electrode sheet is connected to the positive terminal, and the negative electrode sheet is connected to the negative terminal. Each heating tube is provided with two negative electrode sheets.

[0018] The advantage of adopting the above technical solution is that, since each heater includes multiple heating tubes, multiple positive electrode plates are connected through the positive terminal, and the negative terminal is connected to the negative electrode plate, and the number of negative electrode plates is two, the entire heater is divided into upper and lower parts, and the heating area can be changed as needed.

[0019] Furthermore, insulating plates are provided on both sides of the electrode sheet.

[0020] The advantage of adopting the above technical solution is that the insulating board provides insulation and ensures safe use.

[0021] Furthermore, the heat sink is wavy and is alternately arranged with the heating tube.

[0022] The advantage of adopting the above technical solution is that the alternating arrangement of heat sinks and heating tubes can ensure the heating temperature of the heater and ensure the heat utilization rate.

[0023] Furthermore, the connecting portion is formed by bending the main body portion to the side, and the plurality of connecting portions are parallel to each other.

[0024] The advantages of adopting the above technical solution are that the integrally molded terminal block is easy to process and easy to press the electrode pieces together, and the parallel connecting parts can connect multiple electrode pieces to ensure connection safety. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of this utility model, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below.

[0026] Figure 1 This is a schematic diagram of the overall structure of the PTC heater with a high-voltage wiring harness according to this utility model.

[0027] Figure 2 This is an enlarged view of section A of this utility model.

[0028] Figure 3 This is an exploded view of the high-voltage wiring harness of this utility model.

[0029] Figure 4 This is a schematic diagram of the workpiece fixing structure of this utility model.

[0030] Figure 5 This is a cross-sectional view of the heating element of this utility model.

[0031] The reference numerals used in the attached figures are as follows:

[0032] Heating tube 1; heat sink 2; heating element 21; protruding end 221; electrode plate 22; positive electrode plate 222; negative electrode plate 223; insulating plate 23; wiring terminal 3; main body 31; connecting part 32; connecting groove 33; connecting terminal 34; positive terminal 35; negative terminal 36; high voltage wire harness 4; fuse 41; ceramic tube cap 42; fixed workpiece 5; wire guide slot 51. Detailed Implementation

[0033] The present invention will now be described in further detail with reference to the accompanying drawings.

[0034] like Figure 1-5 As shown, this utility model discloses a PTC heater with a high-voltage wiring harness structure, comprising:

[0035] The heating assembly includes a heating tube 1 and a heat sink 2. A heating element 21 is disposed inside the heating tube 1. The heating element is a PTC heating element. Electrode plates 22 are disposed on both sides of the heating element 21.

[0036] The terminal block 3 includes a main body 31, and a plurality of connecting parts 32 are provided on the side of the main body 31. The connecting parts 32 are provided with connecting grooves 33 for accommodating the electrode sheet 22.

[0037] The high-voltage wiring harness 4 is connected to the terminal block 3 and is also connected to a fuse 41.

[0038] The advantages of adopting the above technical solution are that it reduces the occurrence of poor soldering at the terminals, improves the safety and reliability of the heater in long-term use, and greatly improves the production efficiency of the product, thereby further reducing costs.

[0039] In some implementations, the electrode 22 is provided with a protruding end 221, and the connecting groove 33 has a small overall width to accommodate the insertion of the protruding end 221 of the electrode 22. After insertion, a certain force is applied to both sides of the connecting part 32 to press it tight. Then, the electrode 22 is connected to the connecting part 32 by current welding or resistance welding to ensure that the electrode 22 and the terminal are in close contact. Then, current welding or resistance welding is used to make it fused together. The electrode 22 and the connecting terminal are both made of copper to ensure a tight connection without any false solder joints.

[0040] Furthermore, the terminal block 3 is provided with a connecting terminal 34, which is integrally formed with the high-voltage wire harness 4. The connecting terminal 34 is provided with a receiving groove for accommodating the high-voltage wire harness 4. The high-voltage wire harness 4 extends into the receiving groove, is pressed tightly, and then welded to ensure a tight connection.

[0041] In some implementations, the fuse 41 is located on the side of the heating assembly, and a ceramic cap 42 is fitted on the outside. The ceramic cap 42 is fixed to the side of the heating assembly with adhesive. The side of the heating assembly is provided with a fixing workpiece 5 for fixing the high-voltage wire harness 4. The fixing workpiece 5 can be fixed to the side of the heating assembly by welding. It is located on both sides of the fuse 41. The fixing workpiece is provided with a wire-passing slot 51. The high-voltage wire harness 4 is installed and fixed in the wire-passing slot 51. There are three wire-passing slots 51 to accommodate the high-voltage wire harness 4. After the high-voltage wire harness 4 is placed in the wire-passing slot 51, it is fixed with adhesive to ensure the fixed position of the high-voltage wire harness 4.

[0042] The advantages of adopting the above technical solution are that the ceramic cap 42 plays a role in preventing leakage and waterproofing, ensuring safe use. Furthermore, the fuse 41 and the ceramic cap 42 are pre-encapsulated, so they are installed as soon as they arrive, eliminating the need for re-sealing and reducing installation steps. This also improves sealing performance. The wire guide slot 51 facilitates the connection of the high-voltage wire harness 4.

[0043] Furthermore, the terminal block 3 includes a positive terminal 35 and two negative terminals 36. The negative terminals 36 are located at the upper and lower ends of the heating assembly. The positive terminal 35 is connected to the positive terminal of the high-voltage wiring harness 4. The fuse 41 is connected to the positive terminal. The negative terminals 36 are connected to the two negative terminals of the high-voltage wiring harness 4.

[0044] The advantage of adopting the above technical solution is that the positive terminal 35 is connected to the positive terminal wire and the negative terminal 36 is connected to the negative terminal wire. When the current exceeds the specified value, the positive terminal wire will be melted to avoid safety accidents.

[0045] Furthermore, the electrode plate 22 is divided into a positive electrode plate 222 and a negative electrode plate 223. The positive electrode plate 222 is connected to the positive terminal 35, and the negative electrode plate 223 is connected to the negative terminal 36. Each heating tube 1 is provided with two negative electrode plates 223. The positive electrode plate 222 is in contact with one side of the heating element 21, and the negative electrode plate 223 is provided on the other side of the heating element 21. They are also in contact, but the two negative electrode plates 223 are not in contact with each other. The negative electrode plates 223 extend to both ends and are connected to the negative terminals 36 at both ends. The negative terminals 36 are also connected to the negative wires.

[0046] Since each heater includes multiple heating plates, multiple positive electrode plates 222 are connected through the positive terminal 35, and negative electrode plates 223 are connected through the negative terminal 36, and the number of negative electrode plates 223 is two, the entire heater is divided into upper and lower parts. The heating area can be changed as needed. When both negative electrode lines are connected, the entire heater starts to heat up. When one negative electrode plate 223 is connected, half of the heater is heated, and the heating temperature can be changed.

[0047] Furthermore, insulating plates 23 are provided on both sides of the electrode sheet 22. The insulating plates 23 are connected to the electrode sheet 22 by thermally conductive adhesive and are installed securely to ensure safe use.

[0048] Furthermore, the heat sink 2 is wavy, with a fixing plate on the outside for fixation. It is alternately arranged with the heating tube 1 and fixed with the heating tube 1 by adhesive. The wavy heat sink 2 can increase the heat dissipation area, and the alternating arrangement of the heat sink 2 and the heating tube 1 can ensure the heating temperature of the heater and ensure the heat utilization rate.

[0049] In some implementations, the connecting part 32 is formed by bending the main body 31 to the side. The entire connecting part 32 is U-shaped, and multiple connecting parts 32 are parallel to each other and the spacing between the connecting parts 32 is equal. The integrally formed terminal 3 is convenient to process and convenient to press the electrode sheet 22. The parallel connecting parts 32 can connect multiple electrode sheets 22 to ensure connection safety.

[0050] For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of this utility model, and these modifications and improvements all fall within the protection scope of this utility model.

Claims

1. A PTC heater with a high-voltage wiring harness structure, characterized in that, include: The heating assembly includes a heating tube (1) and a heat sink (2). A heating element (21) is provided inside the heating tube (1), and electrode plates (22) are provided on both sides of the heating element (21). The terminal block (3) includes a main body (31), and a plurality of connecting parts (32) are provided on the side of the main body (31). The connecting parts (32) are provided with connecting grooves (33) for accommodating the electrode sheet (22). The high-voltage wiring harness (4) is connected to the terminal block (3) and is also connected to a fuse (41).

2. The PTC heater with a high-voltage wiring harness structure according to claim 1, characterized in that, The electrode sheet (22) is provided with an extension end (221), which extends into the connecting groove (33) and is pressed tightly, using current welding or resistance welding.

3. The PTC heater with a high-voltage wiring harness structure according to claim 1, characterized in that, The terminal block (3) is provided with a connection terminal (34), which is connected to the high-voltage harness (4).

4. The PTC heater with a high-voltage wiring harness structure according to claim 1, characterized in that, The fuse (41) is located on the side of the heating assembly, and a ceramic tube cap (42) is sleeved on the outside. A fixing workpiece (5) for fixing the high voltage wire harness (4) is provided on the side of the heating assembly. A wire pass slot (51) is provided on the fixing workpiece (5), and the high voltage wire harness (4) is fixed in the wire pass slot (51).

5. The PTC heater with a high-voltage wiring harness structure according to claim 1, characterized in that, The terminal block (3) includes a positive terminal (35) and two negative terminals (36). The negative terminals (36) are located at the upper and lower ends of the heating assembly. The positive terminal (35) is connected to the positive terminal of the high-voltage harness (4). The fuse (41) is connected to the positive terminal.

6. The PTC heater with a high-voltage wiring harness structure according to claim 5, characterized in that, The electrode sheet (22) is divided into a positive electrode sheet (222) and a negative electrode sheet (223). The positive electrode sheet (222) is connected to the positive terminal (35), and the negative electrode sheet (223) is connected to the negative terminal (36). Each heating tube (1) is provided with two negative electrode sheets (223).

7. The PTC heater with a high-voltage wiring harness structure according to claim 6, characterized in that, Insulating plates (23) are provided on both sides of the electrode sheet (22).

8. The PTC heater with a high-voltage wiring harness structure according to claim 1, characterized in that, The heat sink (2) is wavy and is alternately arranged with the heating tube (1).

9. The PTC heater with a high-voltage wiring harness structure according to claim 1, characterized in that, The connecting part (32) is formed by bending the main body part (31) to the side, and the multiple connecting parts (32) are parallel to each other.

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