Waterproof PTC heater for heating refrigerant

Abstract

The utility model discloses a heating refrigerant waterproof type PTC heater, which comprises PTC heating core bodies and a pipe body group, the pipe body group is made of corrosion-resistant and heat-conducting materials, an inlet and an outlet are arranged on the pipe body group, the pipe body group comprises carriers and pipe fittings, a gap is arranged between two adjacent groups of carriers, the PTC heating core bodies are arranged in the gaps, the pipe fittings are provided with pipe cavities, and the pipe cavities are communicated with the PTC heating core bodies. Two adjacent groups of carriers are communicated with each other through a pipe fitting, a shell is arranged outside the pipe body group, the shell is provided with an inner cavity, the through hole is communicated with the inner cavity, the shell is provided with an assembly opening communicated with the inner cavity, the assembly opening is provided with a sealing cover plate, the sealing cover plate is provided with a wire through hole for a wire to penetrate out, and the wire of the PTC heating core body penetrates out of the wire through hole. And a sealant is at least filled between one end of the lead of the PTC heating core body and the sealing cover plate. Compared with the prior art, the whole size is reduced while the heating effect is guaranteed, the whole product is sealed, and the waterproof effect is achieved.

Description

Technical Field

[0001] This utility model relates to a PTC heater, and more particularly to a waterproof PTC heater for heating refrigerant. Background Technology

[0002] Currently, cooling and thermal management systems in new energy vehicles, industrial applications, and household appliances generally use coolant to control system temperature. This involves pumping cooled or heated coolant to the components requiring temperature control through a refrigeration and heating system, maintaining the component temperature within a suitable range. However, these liquid cooling systems are complex in structure, heavy and costly, space-consuming, difficult to install, and pose a risk of leakage. Therefore, existing technologies have evolved to eliminate the liquid cooling system, directly placing the original refrigeration system (generally referring to a refrigeration system with a compressor) at the location of the components requiring temperature control. This involves using the refrigerant from the refrigeration system to directly cool or heat the components. However, in extremely cold environments, the refrigerant cannot vaporize during the heating process to absorb heat, significantly reducing heating efficiency. Furthermore, due to the chemical properties of the refrigerant, the contact materials must possess corrosion resistance and good thermal conductivity to meet the safety requirements of automotive and other applications; currently, no such products exist. Utility Model Content

[0003] The purpose of this invention is to provide a waterproof PTC heater for heating refrigerant. The technical problem to be solved is to achieve heating of refrigerant while having a high level of protection.

[0004] To solve the above problems, this utility model adopts the following technical solution: a waterproof PTC heater for heating refrigerant, comprising a PTC heating core and a tube assembly. The tube assembly is made of a corrosion-resistant and thermally conductive material, and has an inlet and an outlet. The tube assembly includes multiple sets of carriers with heating cavities and fittings. The multiple sets of carriers are arranged in parallel arrays, with gaps between adjacent sets. The PTC heating core is disposed in the gaps to heat the multiple sets of carriers. The inlet is located on the outermost carrier of one set, and the outlet is located on the outermost carrier of another set. The fittings have cavities. Two adjacent carrier groups are interconnected through pipe fittings to allow the heated medium to flow through each carrier group. An outer shell is provided outside the tube group, and the outer shell has through holes for the inlet and outlet to extend out. The inlet and outlet are sealed with the through holes. The outer shell has an inner cavity, and the through holes communicate with the inner cavity. An assembly opening is provided on the outer shell, which is connected to the inner cavity. A sealing cover is provided on the assembly opening to seal it. The sealing cover has a wire through hole for the wire to pass through. The wire of the PTC heating core passes through the wire through hole, and at least one end of the wire of the PTC heating core is filled with sealant between it and the sealing cover.

[0005] Furthermore, a temperature controller is provided on the PTC heating core.

[0006] Furthermore, a fuse is provided on the wires of the PTC heating core.

[0007] Furthermore, the outlet and inlet are provided with a first sealing ring, and the through hole is provided with a groove, with the first sealing ring disposed in the groove.

[0008] Furthermore, the carrier in each tube group consists of at least two straight tubes, and a heat-conducting seat is provided outside the carrier. The heat-conducting seat is sandwiched outside the carrier, and a gap is provided between the heat-conducting seats. The PTC heating core is placed in the gap.

[0009] Furthermore, one end of the wire of the PTC heating core is provided with a bracket, and the bracket is provided with a support column opposite to the position of the PTC heating core. The support column is provided with a support column through hole for the wire to pass through. The support column abuts against one end of the wire of the PTC heating core, and sealant is filled between the bracket and one end of the wire of the PTC heating core.

[0010] Furthermore, the carrier is a harmonica tube, with fittings respectively disposed at opposite ends of the carrier. Each fitting is hollow, with one end being a closed surface and the other end having a connecting hole that communicates with the inner cavity of the fitting. The end of the fitting opposite to the carrier has an insertion fixing cavity equal in number to the carrier, which communicates with the inner cavity of the fitting. Both ends of the carrier are inserted into the insertion fixing cavities and sealed and fixedly connected to them. The inlet and outlet are sealed and fixedly connected to the connecting holes, so that the medium enters the fitting connected to the inlet from the inlet, flows through the carrier to another fitting, and then flows out from the outlet.

[0011] Furthermore, the carrier has a flat structure with two surfaces, and the heating surface of the PTC heating core is in close contact with the surface of the carrier.

[0012] Compared with the prior art, this utility model uses tube assemblies made of corrosion-resistant and thermally conductive materials. The carriers are arranged in parallel arrays in the tube assemblies, and the PTC heating cores are set between the tube assemblies to form a stacked structure. This reduces the overall volume while ensuring the heating effect. The entire product is sealed to achieve waterproofing. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the external structure of Embodiment 1 of this utility model.

[0014] Figure 2 This is an exploded view of Embodiment 1 of this utility model.

[0015] Figure 3 This is a schematic diagram of the internal structure of Embodiment 1 of this utility model.

[0016] Figure 4This is a three-dimensional schematic diagram of the internal structure of Embodiment 1 of this utility model.

[0017] Figure 5 This is a schematic diagram of the external structure of Embodiment 2 of this utility model.

[0018] Figure 6 This is an exploded view of Embodiment 2 of this utility model.

[0019] Figure 7 This is a schematic diagram of the connection between the carrier and the pipe in Embodiment 2 of this utility model.

[0020] Figure 8 This is a schematic diagram of the internal relationship between the pipe fitting and the carrier in Embodiment 2 of this utility model. Detailed Implementation

[0021] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0022] Example 1

[0023] like Figures 1 to 4 As shown, this embodiment 1 discloses a waterproof PTC heater for heating refrigerant, comprising the following main components: PTC heating core 1, tube assembly 2, and outer shell 21, wherein:

[0024] The tube assembly 2 is made of corrosion-resistant and thermally conductive material, specifically copper. It comprises multiple sets of carriers 5 with heating cavities and fittings 6. The carriers 5 are arranged in parallel arrays, each consisting of two straight pipes. The tube assembly 2 has an inlet 3 and an outlet 4. One straight pipe from the outermost carrier in one set is connected to the inlet 3, and another straight pipe from the outermost carrier in the other set is connected to the outlet 4. As shown in the diagram, the inlet 3 and outlet 4 are on the same side but not on the corresponding straight pipes. The fitting 6 is an elbow with a cavity. The fitting 6 at one end of a carrier 5 connects to two straight pipes from one set of tube assemblies. The fitting 6 at the other end of a carrier 5, in addition to the straight pipes already connected to the inlet 3 and outlet 4, connects to one straight pipe from each of the remaining carriers 5. This creates a spiral structure for the tube assembly 2, allowing the heated medium to flow through each set of carriers 5.

[0025] A gap is provided between the carriers 5 of two adjacent tube groups 2. Each carrier 5 of the tube group is provided with a heat-conducting seat 13. The heat-conducting seat 13 is composed of two symmetrically arranged heat-conducting plates. A semi-circular through groove 23 adapted to the carrier 5 is provided on the opposite side of the plate so that the heat-conducting seat 13 clamps the carrier 5 therein. A straight tube is set in the semi-circular through groove 23. A gap is provided between the heat-conducting seats 13. The PTC heating core 1 is set in the gap of the heat-conducting seat 13 so that the two heating surfaces of the PTC heating core 1 are in contact with the surface of the plate so as to heat multiple groups of carriers 5. The heat-conducting seat 13 can be made of metal materials such as aluminum alloy.

[0026] An outer shell 21 is provided outside the tube assembly 2. The outer shell 21 is an integral structure and can be made of plastic or metal. The outer shell 21 has through holes 7 for the inlet 3 and outlet 4 to extend out. The inlet 3 and outlet 4 are sealed with the through holes 7. The outer shell 21 has an inner cavity. The tube assembly 2 and the PTC heating core 1 are placed in the inner cavity of the outer shell 21. The through holes 7 communicate with the inner cavity. The outer shell 21 has an assembly opening 8 that communicates with the inner cavity. The assembly opening 8 is provided with a sealing cover plate 9 to seal the assembly opening 8. The sealing cover plate 9 has a wire through hole 10 for the wire to pass through. The wire of the PTC heating core 1 passes through the wire through hole 10. Sealant is filled between one end of the wire of the PTC heating core 1 and the sealing cover plate 9 to achieve waterproofing.

[0027] like Figure 3 and Figure 4 As shown, one end of the wire of the PTC heating core 1 is provided with a bracket 14. The bracket 14 is provided with a support column 15 opposite to the position of the PTC heating core 1. The support column 15 is provided with a support column through hole 16 for the wire to pass through. The support column 15 abuts against one end of the wire of the PTC heating core 1. After the wire of the PTC heating core 1 passes through the support column through hole 16, the PTC heating core 1 is connected in series or parallel through positive and negative power lines. The positive and negative power lines pass out through the wire through hole 10. The space between the positive and negative power lines and the wire through hole 10, and between the bracket 14 and one end of the wire of the PTC heating core 1, is filled with sealant to achieve waterproof sealing.

[0028] like Figure 3 and Figure 4 As shown, a second sealing ring 24 is also provided between the sealing cover 9 and the assembly opening 8 of the outer shell 21 to further improve the waterproof effect. The sealing cover 9 is connected and fixed to the outer shell 21 by screws.

[0029] like Figure 2As shown, a temperature controller 11 is provided on the heat-conducting seat 13 outside one of the PTC heating cores 1. The temperature controller 11 is electrically connected to an external controller through a wire to achieve first-level thermal protection. Of course, a temperature controller 11 can also be provided on the heat-conducting seat 13 outside each PTC heating core 1 to improve the monitoring effect.

[0030] like Figure 2 As shown, a fuse 12 is provided on one of the wires of each PTC heating core 1 to achieve secondary thermal protection and further improve the thermal protection effect.

[0031] like Figure 3 and Figure 4 As shown, a first sealing ring 17 is provided on the outlet 4 and the inlet 3, and a groove 18 is provided on the through hole 7. The first sealing ring 17 is located in the groove 18, and the groove 18 is also filled with sealant to further achieve waterproofing and prevent water from entering the housing 21, thereby achieving the IP67 protection level.

[0032] In this embodiment, the pipe fitting 6 and the straight pipe in the carrier 5 adopt an integral molding structure, that is, it is directly formed by bending copper pipe, thus avoiding the risk of leakage.

[0033] like Figure 3 and Figure 4 As shown, a glue-filling groove 22 is provided on the surface of the bracket 14 opposite to the sealing cover plate 9, and sealant is filled into it to improve the sealing effect.

[0034] In this embodiment, the heat-conducting base 13 is composed of two symmetrically arranged heat-conducting plates. Except for the two outermost plates, the other plates are connected by a pressing deformation part to form an inner cavity to accommodate the PTC heating core 1. The plates are pressed together to make them fit tightly against the PTC heating core 1.

[0035] Example 2

[0036] like Figures 5 to 8 As shown, this embodiment 2 provides a different structure of a waterproof PTC heater for heating refrigerant. The biggest difference between this and embodiment 1 is the different structures of the pipe 6 and the carrier 5.

[0037] The carrier 5 is a harmonica tube made of aluminum alloy. It has a flat structure. The tube fittings 6 are set at both ends of the carrier 5 and also serve to fix the carrier 5. The tube fittings 6 have a cuboid structure and are hollow inside. The long side of the tube fitting is perpendicular to the long side of the carrier 5. One end of the tube fitting 6 is a closed surface, and the other end is provided with a connecting hole 20. The connecting hole 20 communicates with the inner cavity of the tube fitting 6. On the end of the tube fitting 6 opposite to the carrier 5, there are a number of insertion fixing cavities 19 equal to the number of carrier 5. The insertion fixing cavities 19 communicate with the inner cavity of the tube fitting 6. The inlet 3 and the outlet 4 are respectively sealed and fixed to one of the connecting holes 20. The carrier 5 is inserted into the insertion fixing cavity 19 and sealed and fixed. The inlet 3 and the outlet 4 extend out from the through hole 7 on the outer shell 21.

[0038] The inlet 3 and outlet 4 can be welded to the connecting hole 20 to form a whole.

[0039] The medium enters the inner cavity of the pipe 6 connected to it from the inlet 3, and then enters each carrier 5 through the inner cavity. At the same time, after being heated by the PTC heating core 1, it flows out from the outlet 4 on another pipe 6.

[0040] The PTC heating core 1 is directly set in the gap between the two carriers 5. It can be fixed by adhesive. The carrier 5 has two surfaces, and the PTC heating core 1 has two heating surfaces. The heating surfaces are in close contact with the surfaces of the carriers 5. Since the harmonica tube has a surface that can be in contact with the heating surfaces of the PTC heating core 1, there is no need to set a heat conduction seat, reducing accessories and lowering costs. Of course, an aluminum tube can also be set outside the PTC heating core 1. After it is set in the space, it is pressed by a press to make the aluminum tube in close contact with the two heating surfaces of the PTC heating core 1 and the surface of the carrier 5, thereby forming heat conduction.

[0041] A temperature controller 11 is provided outside one of the PTC heating cores 1. The temperature controller 11 is electrically connected to an external controller via a wire to achieve first-level thermal protection. Alternatively, a temperature controller 11 can be provided on the heat-conducting base 13 outside each PTC heating core 1 to improve the monitoring effect.

[0042] A fuse 12 is provided on one of the wires of each PTC heating core 1 to achieve secondary thermal protection and further improve the thermal protection effect.

[0043] The same first sealing ring 17 as in embodiment 1 can also be provided on outlet 4 and inlet 3. A groove 18 is provided on through hole 7, and the first sealing ring 17 is provided in the groove 18. At the same time, the groove 18 is also filled with sealant to further achieve waterproofing and prevent water from entering the housing 21, thereby achieving the IP67 protection level.

[0044] In Example 2, the wires of the PTC heating core 1 are led out from the surface of one of the fixing bases and pass through the wire through holes 10 on the sealing cover plate via positive and negative wires. Of course, the inner cavity of the outer shell on this side is filled with sealant for sealing.

[0045] The structure of the outer shell 21 and the sealing cover 9 is the same as that of the outer shell 21 and the sealing cover 9 in Embodiment 1, and will not be repeated here.

[0046] In this utility model, the PTC heating core 1 typically includes components such as a PTC heating element, an electrode plate, and insulating paper, which are existing technologies and are not specifically limited here.

[0047] This utility model has the following advantages:

[0048] The carrier adopts a parallel array method, which optimizes the structure to reduce the volume as much as possible while greatly increasing the heatable area of ​​the carrier. This allows the medium to be repeatedly heated, ensuring the product's power stability and heat transfer efficiency.

[0049] The tube assembly is made of copper or aluminum alloy, ensuring corrosion resistance and good thermal conductivity.

[0050] Except for necessary openings, the outer casing is a single, integrated structure. Grooves are provided in the through-holes of the casing, where tightly fitted sealing rings are placed. Sealing is then achieved through potting. A support post is installed on the bracket at the cable exit end, with its end face aligned with one end face of the PTC heating element. After sealing one end of the PTC heating element's wire, a potting space is created between the bracket and one end of the PTC heating element, where sealant is applied for a secondary seal. A potting groove is provided at the opposite end of the bracket and the sealing cover. After multiple PTC heating elements are wired together, potting is applied for protection. The wires exit through the through-hole in the sealing cover, and the assembly opening is finally covered by the sealing cover. A sealing ring is placed around the outer circumference of the sealing cover, and the screws are tightened for a final seal. Through multiple potting processes and the action of multiple sealing rings, the product forms a sealed whole, achieving an IP67 protection rating, thus protecting all internal components.

[0051] The design incorporates two levels of thermal protection: a primary thermal protection thermostat and a secondary thermal protection fuse, both installed inside the product. This provides the entire PTC heater with independent thermal protection devices and also allows it to be connected to the system control terminal. When the system detects an excessively high temperature signal, it promptly cuts off the power supply to the heater, greatly enhancing safety performance.

Claims

1. A waterproof PTC heater for heating refrigerant, comprising a PTC heating core (1) and a tube assembly (2), Its features are: The tube assembly (2) is made of a corrosion-resistant and thermally conductive material. The tube assembly (2) is provided with an inlet (3) and an outlet (4). The tube assembly (2) includes multiple sets of carriers (5) with heating cavities and tube fittings (6). The multiple sets of carriers (5) are arranged in parallel arrays, and gaps are provided between adjacent sets of carriers (5). The PTC heating core (1) is located in the gaps to heat the multiple sets of carriers (5). The inlet (3) is located on the outermost carrier (5) of one set, and the outlet (4) is located on the outermost carrier (5) of another set. The tube fittings (6) have cavities, and adjacent sets of carriers are interconnected through the tube fittings (6) so that the heated medium can flow through each set of carriers (5). (2) An outer shell (21) is provided. The outer shell (21) is provided with a through hole (7) for the inlet (3) and outlet (4) to extend out. The inlet (3) and outlet (4) are sealed with the through hole (7). The outer shell (21) has an inner cavity. The through hole (7) communicates with the inner cavity. An assembly opening (8) communicating with the inner cavity is provided on the outer shell (21). A sealing cover plate (9) is provided on the assembly opening (8) to seal the assembly opening (8). A wire through hole (10) is provided on the sealing cover plate (9) for the wire to pass through. The wire of the PTC heating core (1) passes through the wire through hole (10). At least one end of the wire of the PTC heating core (1) and the sealing cover plate (9) are filled with sealant.

2. The waterproof PTC heater with heating refrigerant according to claim 1, characterized in that: A temperature controller (11) is provided on the PTC heating core (1).

3. The waterproof PTC heater with heating refrigerant according to claim 2, characterized in that: A fuse (12) is provided on the wire of the PTC heating core (1).

4. The waterproof PTC heater with heating refrigerant according to claim 1, characterized in that: The outlet (4) and inlet (3) are provided with a first sealing ring (17), and the through hole (7) is provided with a groove (18), with the first sealing ring (17) located in the groove (18).

5. The waterproof PTC heater with heating refrigerant according to any one of claims 1-4, characterized in that: Each tube group (2) consists of a carrier (5) made up of at least two straight tubes. A heat-conducting seat (13) is provided outside the carrier (5). The heat-conducting seat (13) is sandwiched outside the carrier (5). A gap is provided between the heat-conducting seats (13). The PTC heating core (1) is placed in the gap.

6. The waterproof PTC heater with heating refrigerant according to claim 5, characterized in that: The PTC heating core (1) has a bracket (14) at one end of the wire. The bracket (14) has a support column (15) opposite to the PTC heating core (1). The support column (15) has a support column through hole (16) for the wire to pass through. The support column (15) abuts against one end of the PTC heating core (1). Sealant is filled between the bracket (14) and one end of the PTC heating core (1).

7. The waterproof PTC heater with heating refrigerant according to any one of claims 1-4, characterized in that: The carrier (5) is a harmonica tube, and the fittings (6) are respectively set on the opposite ends of the carrier (5). The fittings (6) are hollow, with one end being a closed surface and the other end having a connecting hole (20). The connecting hole (20) communicates with the inner cavity of the fitting (6). The end of the fitting (6) opposite to the carrier (5) has an insertion fixing cavity (19) equal in number to the carrier (5). The insertion fixing cavity (19) communicates with the inner cavity of the fitting (6). The two ends of the carrier (5) are respectively inserted into the insertion fixing cavity (19) and sealed and fixed with the insertion fixing cavity (19). The inlet (3) and outlet (4) are respectively sealed and fixed with the connecting hole (20) so that the medium enters the fitting (6) connected to the inlet (3) from the inlet (3) and flows through the carrier (5) to another fitting (6) and then flows out from the outlet (4).

8. The waterproof PTC heater with heating refrigerant according to claim 7, characterized in that: The carrier (5) has a flat structure with two surfaces, and the heating surface of the PTC heating core (1) is in close contact with the surface of the carrier (5).

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