Water heater for round tube vehicle

Abstract

The utility model discloses a water heater for a round tube vehicle. The water heater comprises a shell, a water chamber formed along the interior of the shell, a flange for sealing the open end of the water chamber, and a round tube heating tube arranged in the flange in a penetrating mode. The round heating tube is composed of an inner tube and an outer tube, a PTC heating sheet and an electrode sheet which are wrapped by insulation paper are arranged in the inner tube, and the PTC heating sheet and the electrode sheet are fixed through a glue layer. All parts of the circular heating pipe can be tightly attached, so that the power is improved, and the heat conduction efficiency is improved; and the electrode plate is wrapped in the insulating paper and then arranged in the inner tube, so that the potential safety hazard existing when the electrode plate is inserted into an insulating spacer in the prior art is avoided, and the electrical safety is enhanced. And meanwhile, the insulation paper is adopted as the insulation material, so that the manufacturing cost is reduced, and the market competitiveness of the product is improved. Besides, the electric control device is arranged outside the water chamber and is connected with the power line, so that the risk that the electric control device is in direct contact with water is avoided, and the safety of the product is further enhanced.

Description

Technical Field

[0001] This utility model relates to the field of water heater technology, and in particular to a water heater for a circular tube vehicle. Background Technology

[0002] PTC heaters, due to their unique positive temperature coefficient characteristics, are widely used in in-vehicle air conditioning systems, defrosting, and battery thermal management in new energy vehicles. PTC water heaters, using PTC ceramic as the core heating element, offer advantages such as automatic temperature control, wide voltage range applicability, no open flame, safety and reliability, and long lifespan. Furthermore, PTC water heaters are also suitable for residential underfloor heating systems, electric water heaters, SPA pools, liquid heating in the chemical, food, and pharmaceutical industries, as well as hot water supply for medical disinfection and cleaning equipment.

[0003] The existing PTC water heater works on the following principle: A PTC ceramic element and electrode plates are wrapped with insulating gaskets and inserted into a U-shaped aluminum clamp. A wedge-shaped block is added to one side of the U-shaped clamp to fill the volume, thus forming a single heating source. Multiple heating sources are then inserted into a large aluminum shell, and thermally conductive silicone grease is used to fill the gaps for heat conduction. The large aluminum shell is placed in the water chamber. The heat generated by the PTC ceramic element after power-on is transferred through the electrode plates, insulating layer, U-shaped clamp, wedge-shaped block, and thermally conductive silicone grease, heating the water flowing through the chamber and raising its temperature.

[0004] The existing PTC water heaters have the following drawbacks: the contact surfaces between the PTC ceramic element and the electrode plate, as well as between the electrode plate and the insulating gasket, cannot be guaranteed to fit properly, affecting power output; the insulating gaskets used for insulation are expensive, and the insulating gaskets are easily damaged during electrode plate insertion, posing a safety hazard; after power is applied, the heat from the heating element must pass through multiple media such as U-shaped aluminum clips, single-sided wedge blocks, and thermal grease before being dissipated, making it difficult to guarantee thermal conductivity; the electrode busbars are located inside the large aluminum shell, and the electrical control is placed directly above the water chamber, in close proximity to it. If there are gaps in the water chamber, the water flow can easily come into direct contact with the electrical control, leading to product failure and safety issues. Utility Model Content

[0005] This application provides a water heater for a circular tube vehicle to solve the technical problems of low power, high cost, difficulty in guaranteeing heat conduction efficiency, and safety hazards in the prior art.

[0006] To solve the above-mentioned technical problems, this utility model provides a water heater for a circular tube vehicle, comprising:

[0007] case;

[0008] A water chamber is formed within the housing along a first direction. The housing is provided with an inlet and an outlet communicating with the water chamber. One end of the water chamber is open. The first direction is a horizontal direction.

[0009] A flange, a housing installed at the open end of the water chamber and sealing the open end of the water chamber; and,

[0010] A circular heating tube is inserted into the flange. One end of the circular heating tube located outside the water chamber is connected to a power cord, and the remaining part of the circular heating tube is housed inside the water chamber. The circular heating tube includes a circular inner tube and an outer tube, with an adhesive layer between the inner and outer tubes. The inner tube contains a PTC heating element wrapped with insulating paper and an electrode plate.

[0011] In one embodiment of this utility model, multiple circular heating tubes are provided, and the multiple circular heating tubes are evenly distributed with the center of the flange as the center.

[0012] In one embodiment of the present invention, a connector is further included. The connector includes a base plate installed on the inner wall of the water chamber and a plurality of snap-fit ​​holes. The plurality of snap-fit ​​holes are snapped into the plurality of heating tubes in a one-to-one manner. The snap-fit ​​holes are formed by a plurality of snap-fit ​​pieces uniformly disposed on the base plate.

[0013] In one embodiment of this utility model, the shell at the open end of the water chamber is provided with a stepped hole, and the flange is disposed in the stepped hole.

[0014] In one embodiment of this utility model, an electronic control device is also included, which is located outside the water tank and connected to the power supply line.

[0015] In one embodiment of the present invention, an electrical control room is further included. An electrical control room is formed inside the housing and is arranged along the first direction. The electrical control room is located above the water chamber, and the electrical control device is disposed inside the electrical control room.

[0016] In one embodiment of this utility model, a connector is also included. The connector is located outside the water tank. One end of the connector is soldered to the power cord, and the other end of the connector is connected to the electronic control device.

[0017] In one embodiment of this utility model, one end of the connector plug is sealed with glue at the solder joint with the power cord.

[0018] In one embodiment of the present invention, a transfer chamber is further included, which is formed within the housing and located on one side of the flange. The transfer chamber is isolated from the water chamber by the flange, and the connector is located inside the transfer chamber.

[0019] In one embodiment of this utility model, a thermally conductive film is provided in the electrical control room.

[0020] Compared with the prior art, the above-mentioned technical solution of this utility model has at least the following advantages:

[0021] The heating tube used in this utility model is a round tube heating tube, which consists of an inner tube and an outer tube. The inner tube contains a PTC heating element wrapped with insulating paper and an electrode plate. The round tube design facilitates the tight fitting of the internal components through the tube shrinking method. The inner tube and the outer tube are fixed together by an adhesive layer, which increases the power and improves the heat conduction efficiency.

[0022] The electrode sheet is wrapped in insulating paper and then placed in the inner tube, which avoids the safety hazards that exist when the electrode sheet is inserted into the insulating pad in the prior art, thus enhancing electrical safety; using insulating paper as the insulating material also reduces manufacturing costs and improves the product's market competitiveness.

[0023] By placing the electronic control device outside the water tank and connecting it to the power cord, the risk of direct contact between the electronic control device and water is avoided, further enhancing the safety of the product.

[0024] Furthermore, the circular heating element employs an inner tube and insulating paper to wrap the PTC heating element and electrode plates, which are then placed inside a glue-filled outer tube. This design achieves uniform temperature distribution. Specifically, the PTC heating element is evenly wrapped with insulating paper, allowing heat from the heating element to be evenly transferred to the surrounding electrode plates and the surface of the inner tube, preventing heat concentration at any point and thus avoiding localized overheating. The glue layer in the glue-filled outer tube acts as a heat conduction medium, evenly transferring heat from the inner tube to the entire circumference of the outer tube. Due to the heat conduction properties of the glue, heat can be evenly distributed along the circumference. The geometric characteristics of the circular tube allow heat to be evenly transferred from the inner tube to every point of the outer tube. Because of the symmetry of the circle, the heat transfer path is of equal length along the circumference, which contributes to uniform heat distribution. Attached Figure Description

[0025] To make the content of this utility model easier to understand, the present utility model will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0026] Figure 1 This is a schematic diagram of the cross-sectional structure of the circular heating tube in this utility model;

[0027] Figure 2 This is a schematic diagram of the longitudinal section structure of the circular heating tube in this utility model;

[0028] Figure 3This is a schematic diagram of the structure of the round tube water heater in this utility model;

[0029] Figure 4 This is a side view of the round tube water heater of this utility model;

[0030] Figure 5 This is a top view of the water heater for the circular tube vehicle in this utility model;

[0031] Figure 6 This is a schematic diagram of the transfer chamber in this utility model;

[0032] Figure 7 This is a schematic diagram of the structure of the water chamber, the transfer chamber, and the electrical control chamber in this utility model;

[0033] Figure 8 This is a schematic diagram of the connector and the circular heating tube in this utility model;

[0034] Figure 9 This is a schematic diagram of the connector in this utility model.

[0035] Explanation of reference numerals in the accompanying drawings: 10. Housing; 11. Inlet; 12. Outlet; 13. Stepped hole; 20. Water chamber; 30. Flange; 40. Round heating element; 41. PTC heating element; 42. Electrode plate; 43. First insulating paper; 44. Aluminum foil; 45. Second insulating paper; 46. Inner tube; 47. Adhesive layer; 48. Outer tube; 49. Power cord; 50. Connector; 51. Base plate; 52. Snap-fit ​​hole; 53. Snap-fit ​​piece; 60. Electrical control device; 70. Electrical control chamber; 71. First cover plate; 80. Connecting strip; 81. Pin; 90. Adapter chamber; 91-Second cover plate. Detailed Implementation

[0036] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0037] See Figures 1 to 5 As shown, this utility model embodiment provides a circular tube water heater, including a housing 10, a water chamber 20, a flange 30, and a circular tube heating pipe 40. The water chamber 20 is formed inside the housing 10 along a first direction. The housing 10 is provided with an inlet 11 and an outlet 12 communicating with the water chamber 20. One end of the water chamber 20 is open. The flange 30 is installed on the housing 10 at the open end of the water chamber 20 and closes the open end of the water chamber 20. The circular tube heating pipe 40 passes through the flange 30. One end of the circular tube heating pipe 40 located outside the water chamber 20 is connected to a power line 49. The remaining part of the circular tube heating pipe 40 is housed inside the water chamber 20. The first direction can be horizontal.

[0038] The circular heating tube 40 includes a PTC heating element 41, an electrode 42, a first insulating paper 43, an aluminum foil 44, a second insulating paper 45, an inner tube 46, an adhesive layer 47, and an outer tube 48. The inner tube 46 and the outer tube 48 are circular tubes and are made of aluminum. The PTC heating element 41 and the electrode 42 are wrapped by the first insulating paper 43. Then, aluminum foil 44 and second insulating paper 45 are wrapped around the outside of the first insulating paper 43. The PTC heating element 41 and the electrode 42, after being wrapped layer by layer, are placed inside the inner tube 46. The inner tube 46 is placed inside the outer tube 48. An adhesive layer 47 is formed between the inner tube 46 and the outer tube 48 by filling with adhesive.

[0039] Specifically, two electrode plates 42 sandwich multiple PTC heating elements 41 within them, and the cross-sections of the two electrode plates 42 and the multiple PTC heating elements 41 are approximately circular. This allows them to fit better with the inner tube 46 after being wrapped, thus forming a circular heating tube 40 with each component tightly fitted together.

[0040] In this embodiment, the heating tube used in the round tube water heater is a round tube heating tube 40, which consists of an inner tube 46 and an outer tube 48. The inner tube 46 is provided with a PTC heating element 41 wrapped with insulating paper 43 and an electrode plate 42. The round tube design makes it easy to tightly fit the internal components by shrinking the tube. The inner tube 46 and the outer tube 48 are fixed by an adhesive layer 47. This structure increases the power and improves the heat conduction efficiency.

[0041] The electrode sheet 42 is wrapped in insulating paper 43 and then placed in the inner tube 46, which avoids the safety hazards that exist when the electrode sheet 42 is inserted into the insulating pad in the prior art, and thus enhances electrical safety.

[0042] Using insulating paper 43 as the insulating material reduces manufacturing costs and enhances the product's market competitiveness. By placing the electronic control device 60 outside the water chamber 20 and connecting it to the power line 49, the risk of the electronic control device 60 coming into direct contact with water is avoided, further enhancing the product's safety.

[0043] In addition, the round tube heating tube 40 uses an inner tube 46 and insulating paper 43 to wrap the PTC heating element 41 and electrode plate 42, and then puts them into the glued outer tube 48, which can achieve uniform temperature distribution.

[0044] Specifically, the PTC heating element 41 is uniformly wrapped with insulating paper 43, which allows the heat on the heating element 41 to be evenly transferred to the surrounding electrode plates 42 and the surface of the inner tube 46, avoiding heat concentration at a certain point and causing local overheating. The glue layer 47 in the glue-filled outer tube 48 acts as a heat conduction medium, which can evenly transfer heat from the inner tube 46 to the entire circumference of the outer tube 48. Due to the heat conduction properties of the glue layer 47, the heat can be evenly distributed along the circumference. The geometric characteristics of the circular tube allow heat to be evenly transferred from the inner tube 46 to every point of the outer tube 48. Because of the symmetry of the circle, the heat transfer path is of equal length on the circumference, which helps to distribute the heat evenly.

[0045] See Figure 3 As shown, in some embodiments of the heating tube water heater of this utility model, multiple round heating tubes 40 are provided, and the multiple round heating tubes 40 are evenly distributed with the center of the flange 30 as the center.

[0046] In this embodiment, by setting multiple circular heating tubes 40 and evenly distributing them with the center of flange 30 as the center, the heat source in water chamber 20 is evenly distributed, thereby improving heating efficiency and thermal energy utilization. This ensures that water can be evenly heated when it flows through the water chamber, improves the overall heating performance, and reduces the heat load of a single heating tube, which helps to extend the service life of the equipment and enhance the reliability and safety of the product.

[0047] See Figures 8 to 9 As shown, in some embodiments of the heating tube water heater of this utility model, a connector 50 is also included. The connector 50 includes a base plate 51 installed on the inner wall of the water chamber 20 and a plurality of snap-fit ​​holes 52. The plurality of snap-fit ​​holes 52 are snapped into a plurality of heating tubes one by one. The snap-fit ​​holes 52 are formed by a plurality of snap-fit ​​pieces 53 evenly arranged on the base plate 51.

[0048] In this embodiment, the introduction of connector 50 achieves a stable connection between the heating tube 40 and the inner wall of the water chamber 20, ensuring the positional stability of the heating tube during operation, improving the structural integrity and reliability of the entire heater, and facilitating installation and maintenance, as each heating tube can be independently snapped into connector 50, simplifying the assembly process, reducing maintenance difficulty, and enhancing the practicality and durability of the product.

[0049] See Figure 7 As shown, in some embodiments of the heating tube water heater of this utility model, the housing 10 at the open end of the water chamber 20 is provided with a stepped hole 13, and the flange 30 is disposed in the stepped hole 13.

[0050] In this embodiment, the flange 30 is installed in the stepped hole 13. This structural design not only enhances the sealing performance and structural stability of the water chamber 20, but also achieves precise positioning and fastening through the cooperation between the stepped hole 13 and the flange 30, ensuring the sealing effect between the water chamber 20 and the flange 30, preventing direct contact between water and electricity, thereby improving the safety of the heater.

[0051] See Figure 3 As shown, in some embodiments of the heating tube water heater of this utility model, an electronic control device 60 is also included. The electronic control device 60 is located outside the water chamber 20 and is connected to the power supply line 49; wherein, the electronic control device 60 includes a PCB board.

[0052] In this embodiment, an electronic control device 60 is provided to achieve more functions. By placing the electronic control device 60 outside the water chamber 20 and connecting it to the power line 49, physical isolation between the electronic control device and the water is achieved, greatly improving the safety of the heater and preventing water leakage or electric shock risks caused by electrical faults or short circuits. Furthermore, this layout facilitates the maintenance and repair of the electronic control device, allowing direct access to the electronic components without opening the water chamber, simplifying the maintenance process and reducing maintenance costs.

[0053] See Figures 6 to 7 As shown, in some embodiments of the heating tube water heater of this utility model, an electrical control chamber 70 is also included. An electrical control chamber 70 is formed in the housing 10 and is arranged along a first direction (horizontal direction). The electrical control chamber 70 is located above the water chamber 20, and an electrical control device 60 is provided in the electrical control chamber 70.

[0054] By setting the electrical control chamber 70 inside the housing 10 and placing it above the water chamber 20, the electrical control device 60 is physically isolated from the water chamber 20, ensuring that the electrical control does not come into contact with water, thus enhancing safety and reliability.

[0055] Specifically, the side of the electrical control room 70 away from the water chamber 20 is open, and a first cover plate 71 for sealing the electrical control room 70 is installed at the open part. The first cover plate 71 facilitates the installation of electrical control devices in the electrical control room 70 before sealing the water chamber 20.

[0056] The design of the electrical control room 70 allows it to be opened from the side away from the water chamber and closed by the first cover plate 71. This structure not only facilitates the installation and maintenance of the electrical control device 60 in front of the closed water chamber 20, avoiding the risk of water leakage or electrical components getting damp, but also improves the convenience of maintenance operations and the accessibility of the electrical control system, thereby reducing maintenance costs and improving maintenance efficiency.

[0057] See Figures 6 to 8As shown, in some embodiments of the heating tube water heater of this utility model, a connecting plug 80 is also included. The connecting plug 80 is located outside the water chamber 20. The connecting plug 80 is set vertically, that is, it is set in a direction perpendicular to the horizontal direction. One end of the connecting plug 80 is welded to the power cord 49, and the other end of the connecting plug 80 is connected to the plug 81 of the electrical control device 60.

[0058] In this embodiment, by positioning the connector 80 outside the water chamber 20, with one end soldered to the power cord 49 and the other end's pin 81 connected to the electrical control device 60, this design achieves modularity and simplification of electrical connections, facilitating installation and maintenance. Simultaneously, placing the connection point between the power cord and the electrical control device outside the water chamber enhances safety, preventing water leakage or electric shock risks due to electrical faults or short circuits. Furthermore, this layout helps reduce the likelihood of electrical components getting damp or directly contacting water, lowering the probability of electrical faults, improving system reliability and stability, and making the entire heater operation safer and more efficient.

[0059] In some embodiments of the heating tube water heater of this utility model, one end of the connector 80 is sealed with glue at the welding point between it and the power cord 49.

[0060] In this embodiment, the connection point 80 is sealed with glue at the weld joint with the power cord 49. This effectively enhances the waterproof performance and mechanical stability of the electrical connection, preventing moisture and impurities from entering the weld joint, thereby reducing the risk of electrical failure and improving the overall safety and reliability of the heater. This sealing measure also helps extend the service life of electrical components, reduces maintenance costs, and ensures stable electrical performance under various environmental conditions, enhancing the product's durability and environmental adaptability.

[0061] See Figure 7 As shown, in some embodiments of the heating tube water heater of this utility model, the heating tube water heater further includes a transition chamber 90, which is formed in the housing 10 and located on one side of the flange 30. The transition chamber 90 is isolated from the water chamber 20 by the flange 30, and the connecting plug 80 is located in the transition chamber 90.

[0062] Specifically, the side of the transfer chamber 90 away from the water chamber 20 and the electrical control chamber 70 is open, and a second cover 91 is installed at this opening to close it. The second cover 91 facilitates the installation of connectors, sockets, etc., inside the transfer chamber 9 before it is closed.

[0063] In this embodiment, by positioning the transition chamber 90 on one side of the flange 30 and isolating the transition chamber 90 from the water chamber 20 through the flange 30, and placing the connector 80 within the transition chamber 90, this design not only optimizes the internal space layout and improves the compactness and overall integrity of the structure, but also enhances the safety of the electrical components (connector 80) through the isolation effect of the flange, preventing direct contact between water and electrical components and reducing the risk of leakage and short circuits. Furthermore, placing the connector 80 within the transition chamber 90 facilitates the management and protection of electrical connections, reduces the impact of the external environment on the electrical system, improves the stability and reliability of the system, and also provides convenience for the maintenance and replacement of electrical components, reducing maintenance difficulty and costs.

[0064] See Figure 3 As shown, in order to ensure the heat dissipation capacity of the electrical control area, in some embodiments of the heating tube water heater of this utility model, a thermally conductive film 61 is attached inside the electrical control chamber 70, and the thermally conductive film 61 can be attached to the side of the electrical control chamber 70 near the water chamber 20.

[0065] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the protection scope of this invention.

Claims

1. A water heater for a circular tube vehicle, characterized in that, include: case; A water chamber is formed within the housing along a first direction. The housing is provided with an inlet and an outlet communicating with the water chamber. One end of the water chamber is open. The first direction is a horizontal direction. A flange, a housing installed at the open end of the water chamber and sealing the open end of the water chamber; and, A circular heating tube is inserted into the flange. One end of the circular heating tube located outside the water chamber is connected to a power cord, and the remaining part of the circular heating tube is housed inside the water chamber. The circular heating tube includes a circular inner tube and an outer tube, with an adhesive layer between the inner and outer tubes. The inner tube contains a PTC heating element wrapped with insulating paper and an electrode plate.

2. The water heater for the circular tube vehicle according to claim 1, characterized in that, The circular heating tube is provided in multiple forms, and the multiple circular heating tubes are evenly distributed with the center of the flange as the center.

3. The water heater for the circular tube vehicle according to claim 2, characterized in that, It also includes a connector, which includes a base plate installed on the inner wall of the water chamber and multiple snap-fit ​​holes. The multiple snap-fit ​​holes are snapped into the multiple heating tubes one by one. The snap-fit ​​holes are formed by multiple snap-fit ​​pieces evenly arranged on the base plate.

4. The water heater for the circular tube vehicle according to claim 1, characterized in that, The shell at the open end of the water chamber is provided with a stepped hole, and the flange is disposed in the stepped hole.

5. The water heater for the circular tube vehicle according to claim 1, characterized in that, It also includes an electronic control device located outside the water tank and connected to the power supply line.

6. The water heater for the circular tube vehicle according to claim 5, characterized in that, It also includes an electrical control room, which is formed inside the housing and is arranged along the first direction. The electrical control room is located above the water chamber and the electrical control device is installed inside the electrical control room.

7. The water heater for a circular tube vehicle according to claim 5, characterized in that, It also includes a connector strip located outside the water tank, one end of which is soldered to the power cord and the other end of which is connected to the electronic control device.

8. The water heater for a circular tube vehicle according to claim 7, characterized in that, One end of the connector is sealed by applying glue to the solder joint where it is welded to the power cord.

9. The water heater for a circular tube vehicle according to claim 7, characterized in that, It also includes a transfer chamber formed within the housing and located on one side of the flange, the transfer chamber being isolated from the water chamber by the flange, and the connector being located within the transfer chamber.

10. The water heater for a circular tube vehicle according to claim 6, characterized in that, The electrical control room is equipped with a thermally conductive film.

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