Novel-structure high-power-density PTC (Positive Temperature Coefficient) water heater

Abstract

The utility model discloses a PTC water heater with a novel structure and high power density, and belongs to the field of heaters. Comprising a PTC heating core, an aluminum casting, a water pipeline and a wire harness, the PTC heating core comprises a PTC sheet, an electrode sheet and an insulation protection layer, and a pin is arranged at the end of the electrode sheet; the aluminum casting comprises an upper aluminum part, a second aluminum part, a third aluminum part and a lower aluminum part, the second aluminum part and the third aluminum part are used for fixing the PTC heating core, the water passing pipeline is an integrated continuous U-shaped pipe, and two ports of the water passing pipeline are blunt; the water passing pipeline is installed outside the second aluminum piece and the third aluminum piece and fixed through the upper aluminum piece and the lower aluminum piece. According to the utility model, the whole structure is simple, the size is small, the maximum power density of 60W / cm < 2 > (PTC thermistor area) can be realized, and the size, the weight and the cost of the heater are effectively reduced.

Description

Technical Field

[0001] This utility model relates to the field of heaters, specifically to a novel high-power-density PTC water heater. Background Technology

[0002] PTC water heaters are widely used in various electrical and new energy vehicle equipment with high safety requirements due to their advantages such as no open flame, resistance to dry burning, and low dry burning temperature. However, because of their low heating temperature, their power density is low, reaching a maximum of only 35W / cm². 2 The area of ​​a PTC thermistor is approximately [area missing]. When high power is required, the heater is often large or designed with a complex heat dissipation structure, resulting in high manufacturing costs. How to achieve high power density while keeping the size small is a major problem at present. Utility Model Content

[0003] To address the shortcomings of existing technologies, this invention provides a novel high-power-density PTC water heater with a simple overall structure, small size, and a maximum power density of 60W / cm². 2 The power density of (PTC thermistor area) effectively reduces the size, weight and cost of the heater.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a novel high-power-density PTC water heater, comprising a PTC heating core, a cast aluminum component, a water pipe, and a wiring harness. The PTC heating core includes a PTC plate, an electrode plate, and an insulating protective layer. The electrode plate has leads at its ends. The cast aluminum component includes an upper aluminum component, a second aluminum component, a third aluminum component, and a lower aluminum component. The second and third aluminum components are used to fix the PTC heating core. The water pipe is an integral continuous U-shaped pipe with blunt ends at both ends. The water pipe is installed outside the second and third aluminum components and fixed by the upper and lower aluminum components.

[0005] As a further improvement, the contact surfaces of the second and third aluminum parts with the PTC heating core are provided with thermally conductive adhesive layers; the contact surfaces of the upper and lower aluminum parts with the water pipe are provided with thermally conductive adhesive layers.

[0006] As a preferred embodiment, the water pipes include 4 or 6 rows.

[0007] As a preferred option, the insulating protective layer is a polyimide layer, with 3-4 layers provided.

[0008] As a further improvement, a protective box is provided at the upper end of the cast aluminum part.

[0009] As a preferred embodiment, the cast aluminum part is provided with several bolt connection holes on both sides and in the middle.

[0010] This invention achieves maximum heat dissipation by using a central heating core for heating and two side tubes for heat dissipation. It is the first to boldly adopt a structure combining aluminum and aluminum tubes, adding high-quality tube bending technology and a novel product structure. Because the heater dissipates heat from both sides simultaneously and the heat dissipation area is maximized, it can achieve the effect of high power in a small size. Due to the good heat dissipation, the PTC center temperature is low (it will not exceed the temperature of the heated liquid), which has little impact on surrounding components. There is no need to design an additional heat insulation protective shell, which reduces the size and significantly lowers the cost.

[0011] The beneficial effects of this utility model are: 1. The innovative design of the heater structure, insulation, heat dissipation, and liquid flow channel results in a simple structure that can accommodate a maximum of 60W / cm². 2 With a power density exceeding (PTC thermistor area), it effectively reduces heater volume, weight, and cost; it also features structural innovations.

[0012] 2. For the first time, aluminum cylindrical tubes are bent into a single piece, with blunt ends integrally formed, effectively solving the common industry problems of water leakage risk and assembly difficulties caused by the combination of inner and outer spiral structures.

[0013] 3. It is made primarily of aluminum and can heat air under certain airflow conditions, thus achieving the dual function of heating both water and air. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of an embodiment of the present utility model;

[0015] Figure 2 This is a schematic diagram of the PTC heating core structure according to an embodiment of the present invention;

[0016] Figure 3 This is a schematic diagram of the structure of the cast aluminum part according to an embodiment of the present utility model;

[0017] Figure 4 This is a schematic diagram of the assembled structure of the cast aluminum parts according to an embodiment of the present invention;

[0018] Figure 5 This is a schematic diagram of the water pipe structure according to an embodiment of the present utility model;

[0019] Figure 6 This is an installation diagram of an embodiment of the present invention;

[0020] Figure 7 This is a schematic diagram of the wire harness installation according to an embodiment of the present utility model.

[0021] In the diagram: 1. PTC plate; 2. Electrode plate; 3. Insulating protective layer; 4. Pin; 5. Cast aluminum part; 6. Water pipe; 7. Upper aluminum part; 8. Second aluminum part; 9. Third aluminum part; 10. Lower aluminum part; 11. Wiring harness; 12. Protective box; 13. Thermally conductive silicone layer; 14. Bolt connection hole; 15. Water pipe mounting hole; 16. PTC heating core mounting cavity; 17. Fuse; 18. Grounding wire; 19. NTC; 20. AC line; 21. Terminal; 22. Thermostat; 23. PTC connection harness. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0023] As shown in the accompanying drawings, a novel high-power-density PTC water heater includes a PTC heating core, a cast aluminum component 5, a water pipe 6, and a wiring harness 11. The PTC heating core comprises multiple PTC plates 1 arranged in parallel, electrode plates 2, and a three-layer polyimide insulating protective layer 3. The PTC plates are connected in parallel, and the electrode plates 2 and PTC plates 1 are bonded together with a thermally conductive silicone layer 13. The electrode plates 2 are provided with leads 4 at their ends. The cast aluminum component 5 includes an upper aluminum component 7, a second aluminum component 8, a third aluminum component 9, and a lower aluminum component 10. A PTC heating core mounting cavity 16 is formed between the second aluminum component 8 and the third aluminum component 9 to fix the PTC heating core. The water pipe 6 is an integral continuous U-shaped pipe, including four rows, with blunt ends at both ends. It is generally made of aluminum profiles (such as AL6063) or die-cast aluminum using a special pipe bending equipment. The water pipe 6 is installed outside the second aluminum part 8 and the third aluminum part 9, and is fixed through the water pipe mounting hole 15 formed between the upper aluminum part 7 and the lower aluminum part 10. In order to reduce costs and product weight, some through holes can be set in the cast aluminum part 5, or the structure can be pre-laid to facilitate the installation of key components such as NTC;

[0024] A thermally conductive adhesive layer is provided on the contact surfaces of the second aluminum component 8 and the third aluminum component 9 with the PTC heating core; a thermally conductive adhesive layer is also provided on the contact surfaces of the upper aluminum component 7 and the lower aluminum component 10 with the water pipe 6. The thermally conductive adhesive layer can maximize its heat dissipation effect, thereby increasing the product power to meet the customer's high-density power requirements.

[0025] like Figure 7As shown, the upper end of the cast aluminum part 5 is provided with a protective box 12. The wiring harness includes a fuse 17, a grounding wire 18, an NTC 19, an AC wire 20, a terminal 21, a thermostat 22, and a PTC connection harness 23, etc. Among them, the protective components such as the thermostat 22 and the temperature fuse are protected by the protective box 12 and fixed to the cast aluminum part 5 with screws. Several bolt connection holes 14 are provided on both sides and in the middle of the cast aluminum part 5 to facilitate screw fixing.

Claims

1. A novel high-power-density PTC water heater, comprising a PTC heating core, a cast aluminum component (5), a water pipe (6), and a wiring harness (11), wherein the PTC heating core comprises a PTC plate (1), an electrode plate (2), and an insulating protective layer (3), and the electrode plate (2) has leads (4) at its ends; characterized in that: The cast aluminum part (5) includes an upper aluminum part (7), a second aluminum part (8), a third aluminum part (9) and a lower aluminum part (10). The second aluminum part (8) and the third aluminum part (9) are used to fix the PTC heating core. The water pipe (6) is an integral continuous U-shaped pipe with blunt ends at both ends. The water pipe (6) is installed outside the second aluminum part (8) and the third aluminum part (9) and is fixed by the upper aluminum part (7) and the lower aluminum part (10).

2. The novel high-power-density PTC water heater as described in claim 1, characterized in that: The second aluminum part (8) and the third aluminum part (9) are provided with a thermally conductive adhesive layer on their contact surfaces with the PTC heating core; the upper aluminum part (7) and the lower aluminum part (10) are provided with a thermally conductive adhesive layer on their contact surfaces with the water pipe (6).

3. The novel high-power-density PTC water heater as described in claim 1, characterized in that: The water pipes (6) include 4 or 6 rows.

4. The novel high-power-density PTC water heater as described in claim 1, characterized in that: The insulating protective layer (3) is a polyimide layer, with 3-4 layers.

5. A novel high-power-density PTC water heater as described in claim 1, characterized in that: The upper end of the cast aluminum part (5) is provided with a protective box (12).

6. A novel high-power-density PTC water heater as described in claim 1, characterized in that: The cast aluminum part (5) has several bolt connection holes (14) on both sides and in the middle.

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