Stable air inlet preheater

Abstract

The utility model discloses a stable air inlet preheater. The stable air inlet preheater comprises a preheater seat, an electric heating belt and at least two binding posts, an accommodating cavity is formed in the preheater seat, and at least two through holes communicated with the accommodating cavity are formed in the surface of the preheater seat; the electric heating belt is fixedly contained in the containing cavity and comprises a plurality of wave-shaped electric heating pieces, the electric heating pieces are arranged in the containing cavity in parallel, a plurality of fixing holes are formed in the electric heating pieces at intervals, a plurality of fixing columns are arranged in the containing cavity at intervals, the electric heating pieces are fixed to the fixing columns through the fixing holes, and the fixing columns are sleeved with isolation pads. The isolation pads are configured to at least separate every two adjacent electric heating pieces, and the electric heating pieces are electrically connected end to end in sequence in the current flowing direction. Wherein the two electric heating pieces are both electrically connected with connecting belts, one connecting belt is fixedly installed on one binding post, the other connecting belt is fixedly installed on the other binding post, and the binding posts are installed on the corresponding through holes. The ribbon heater is composed of a plurality of electric heating pieces, and the electric heating pieces are wave-shaped electric heating pieces, so that stress deformation is buffered.

Description

Technical Field

[0001] This utility model relates to the field of intake preheaters, and more particularly to a robust intake preheater. Background Technology

[0002] Generally, car intake manifolds are equipped with intake air preheaters to heat the intake air during engine startup, reducing engine wear and improving combustion efficiency. Intake air preheaters are frequently used at high temperatures, which can easily cause deformation or even damage to components, especially the heating element.

[0003] Traditional preheaters have no protective measures for the preheater base, which can easily lead to electro-corrosion of the preheater base during use, affecting the product's performance and service life.

[0004] Therefore, considering the aforementioned technical problems, it is necessary to provide a new technical solution. Utility Model Content

[0005] To address at least one of the technical problems existing in the prior art, this utility model provides a stable air intake preheater. Its heating tape is composed of multiple heating elements, and these heating elements are corrugated to buffer stress deformation. Multiple fixing columns are also provided to stabilize each heating element, increasing the product's stability, reliability, and service life. The specific technical solution is as follows:

[0006] This utility model provides a robust intake preheater, which includes a preheater base, an electric heating tape, and at least two terminals;

[0007] The preheater base has a receiving cavity with at least one opening, and the surface of the preheater base has at least two through holes, both of which are connected to the receiving cavity.

[0008] The heating tape is fixedly housed in the receiving cavity. The heating tape includes multiple corrugated heating elements arranged in parallel in the receiving cavity. Multiple fixing holes are spaced apart on the heating elements. Multiple fixing posts are spaced apart in the receiving cavity. The heating elements are fixed to the fixing posts through the fixing holes. Spacers are fitted on the fixing posts. The spacers are configured to separate at least two adjacent heating elements. The heating elements are electrically connected end to end in sequence along the direction of current flow.

[0009] Both heating elements are electrically connected by connecting strips with mounting holes. One connecting strip is fixedly installed on a terminal block through the mounting hole, and the other connecting strip is fixedly installed on another terminal block through the mounting hole. The terminals are installed on their respective through holes.

[0010] As a preferred embodiment of the air intake preheater described in this utility model, the wavy bending direction of the heating element is consistent with the length direction of the fixed column.

[0011] As a preferred embodiment of the air intake preheater described in this utility model, the thickness of the heating element is greater than or equal to 0.8 mm.

[0012] As a preferred embodiment of the air intake preheater described in this utility model, the thickness of the heating element is between 1.0 mm and 1.2 mm.

[0013] As a preferred embodiment of the air intake preheater described in this utility model, at the non-head-to-tail electrical connection of the heating element, the spacer includes a mica sheet and a metal gasket, the mica sheet and the metal gasket are sleeved on the fixed post, and the adjacent heating elements are separated by the mica sheet and the metal gasket.

[0014] At the electrical connection points of the heating elements, metal gaskets are used as spacers, and these metal gaskets are fitted between adjacent heating elements.

[0015] As a preferred embodiment of the air intake preheater described in this utility model, a Teflon insulation layer is provided on the surface of the preheater base.

[0016] As a preferred embodiment of the air intake preheater described in this utility model, the thickness of the Teflon insulation layer is 0.019mm to 0.051mm.

[0017] As a preferred embodiment of the air intake preheater described in this utility model, the terminal block includes a first bolt, a first insulating sleeve, a first mica sheet, a first flat washer, and a first nut. A connecting strip is fitted onto the first bolt through the mounting hole. After the first insulating sleeve is fitted onto the first bolt with the connecting strip, it passes through the through hole and extends out of the preheater seat. The first bolt is insulated from the preheater seat by the first insulating sleeve. The first mica sheet, the first flat washer, and the first nut are fitted onto the extended end of the first bolt in sequence. The first nut is configured to fix the first bolt onto the preheater seat.

[0018] As a preferred embodiment of the air intake preheater described in this utility model, the bottom wall of the receiving cavity is provided with a through first mounting hole, and the top wall of the receiving cavity is provided with a threaded hole.

[0019] The fixing column includes a fixing bolt, a second flat washer, a second mica sheet, a second insulating sleeve, a mica tube, a spacer, and a mica washer. The fixing bolt is sequentially fitted with the second flat washer, the second mica sheet, the second insulating sleeve, and the mica tube. The fixing bolt is inserted into the first mounting hole from outside the preheater seat and extends into the receiving cavity. The second flat washer and the second mica sheet are stopped outside the preheater seat. The second insulating sleeve is housed in the first mounting hole. The mica tube is located in the receiving cavity. The spacer and the heating element are sequentially fitted on the mica tube. The heating element is isolated from the bottom wall of the receiving cavity by the spacer. The heating elements are also isolated from each other by spacers. The fixing bolt is fitted with a mica washer located on the side of the mica tube away from the second insulating sleeve. One end of the fixing bolt is screwed into a threaded hole.

[0020] As a preferred embodiment of the air intake preheater described in this utility model, at the non-head-to-tail electrical connection of the heating element, the spacer includes a mica sheet and a metal gasket, the mica sheet and the metal gasket are sleeved on the fixed post, and the adjacent heating elements are separated by the mica sheet and the metal gasket.

[0021] At the electrical connection points of the heating elements, metal gaskets are used as spacers, and these metal gaskets are fitted between adjacent heating elements.

[0022] As a preferred embodiment of the air intake preheater described in this utility model, the first bolt is a conductive bolt, and the fixing bolt is a conductive bolt.

[0023] As a preferred embodiment of the air intake preheater described in this utility model, the fixing column further includes an insulating cover, which covers the bolt head of the fixing bolt.

[0024] Compared with the prior art, the technical solution of this utility model has at least one or more of the following beneficial effects:

[0025] This patent utilizes a corrugated heating element, improving the product's durability and reliability. During the cold start phase, the temperature of the preheater gradually increases along the flow direction, especially at the center of the corrugated metal element, while the temperature on the outer side of the preheater base gradually decreases. In the absence of ventilation, the center of the corrugated metal element can reach a maximum temperature of 1200℃. Therefore, the use of a corrugated heating element mitigates thermal expansion and contraction during heating, with the corrugations acting as a buffer to prevent deformation of the heated metal element and subsequent failure. This also reduces post-assembly stress and increases the product's stability, reliability, and service life.

[0026] The corrugated metal heating elements are separated by mica and metal gaskets and fixed by bolts passing through them, which avoids localized heating problems, ensures its reliability, and improves the service life of the product.

[0027] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0028] To more clearly illustrate the technical solution of this utility model, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0029] Figure 1 This is a schematic diagram of the main structure of the air intake preheater described in this patent;

[0030] Figure 2 yes Figure 1 A cross-sectional view of the air intake preheater in the position of a fixed column;

[0031] Figure 3 yes Figure 1 A partially enlarged three-dimensional structural diagram of the air intake preheater;

[0032] Figure 4 This is an electron microscope schematic diagram of the Teflon insulation layer on the surface of the preheater seat described in this patent;

[0033] Figure 5 This is an electron microscope schematic diagram of the Teflon insulation layer on the surface of the preheater seat described in this patent.

[0034] Among them, 1-preheater base, 2-heating tape, 3-terminal, 11-receiving cavity, 12-Teflon insulation layer, 13-fixing post, 131-fixing bolt, 132-second flat washer, 133-second mica sheet, 134-second insulating sleeve, 135-mica sleeve, 136-mica washer, 137-insulating cover, 138-spacer, 21-heating element, 22-connecting strip, 31-first bolt, 32-first insulating sleeve, 33-first mica sheet, 34-first flat washer, 35-first nut. Detailed Implementation

[0035] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without inventive effort are within the scope of protection of this utility model.

[0036] In the description of this utility model, it should be understood that the terms "upper," "lower," "top," "bottom," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this utility model. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0037] In the description of this utility model, unless otherwise explicitly specified and limited, the terms "provided with," "equipped with," "connected," "installed," "sleeved," "opened," and "fixed," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0038] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.

[0039] Please refer to Figure 1-5 .like Figure 1-5 As shown, this utility model provides a robust air intake preheater, which includes a preheater base 1, an electric heating tape 2, and at least two terminals 3.

[0040] The preheater base 1 has a receiving cavity 11 with openings on both sides. The receiving cavity 11 has at least one opening. The surface of the preheater base 1 has at least two through holes, both of which are connected to the receiving cavity 11.

[0041] The heating tape 2 is fixedly housed in the receiving cavity 11. The heating tape 2 includes multiple corrugated heating elements 21, which are arranged in parallel in the receiving cavity 11. Multiple fixing holes are spaced apart on the heating elements 21. Multiple fixing posts 13 are spaced apart in the receiving cavity 11. The heating elements 21 are fixed to the fixing posts through the fixing holes. Spacers are sleeved on the fixing posts. The spacers are configured to separate at least two adjacent heating elements. The heating elements are electrically connected end to end along the direction of current flow.

[0042] Both heating elements 21 are electrically connected to connecting strips 22, each with mounting holes. One connecting strip 22 is fixedly mounted to a terminal block 3 through the mounting hole, and the other connecting strip 22 is fixedly mounted to another terminal block 3 through the mounting hole. The terminal blocks 3 are mounted in their respective through holes. In this example, the heating elements that are in direct electrical contact with the connecting strips are preferably located on either side of the heating strip. In this example, the connecting strip 22 and its corresponding heating element 21 are electrically connected by being sleeved on a fixing post.

[0043] In the example, openings are provided on both sides of the receiving cavity 11.

[0044] This patent utilizes a corrugated heating element, improving the product's durability and reliability. During the cold start phase, the temperature of the preheater gradually increases along the flow direction, especially at the center of the corrugated metal element, while the temperature on the outer side of the preheater base gradually decreases. In the absence of ventilation, the center of the corrugated metal element can reach a maximum temperature of 1200℃. Therefore, the use of a corrugated heating element mitigates thermal expansion and contraction during heating, with the corrugations acting as a buffer to prevent deformation of the heated metal element and subsequent failure. This also reduces post-assembly stress and increases the product's stability, reliability, and service life.

[0045] Preferred embodiments, such as Figure 1 As shown, the wavy bending direction of the heating element 21 is consistent with the length direction of the fixed column.

[0046] Preferably, the thickness of the heating element 21 is greater than or equal to 0.8 mm. More preferably, the thickness of the corrugated heating element 21 is between 1.0 mm and 1.2 mm.

[0047] In a preferred embodiment, such as Figure 1-2 As shown, at the non-terminal electrical connection points of the heating elements, the spacers consist of mica sheets and metal gaskets, which are fitted onto the fixing posts. Adjacent heating elements are separated by these spacers. At the terminal electrical connection points, the spacers are metal gaskets, fitted between adjacent heating elements. Corrugated metal heating elements are separated from each other by mica sheets and metal gaskets, and secured by bolts passing through them. This prevents localized overheating, ensures reliability, and extends the product's lifespan.

[0048] Specifically, the bottom wall of the receiving cavity 11 has a through first mounting hole, and the top wall of the receiving cavity 11 has a threaded hole; the fixing column 13 includes a fixing bolt 131, a second flat washer 132, a second mica sheet 133, a second insulating sleeve 134, a mica sleeve 135, a spacer, and a mica washer 136; the fixing bolt 131 is sequentially fitted with the second flat washer 132, the second mica sheet 133, the second insulating sleeve 134, and the mica sleeve 135, and the fixing bolt 131 is inserted from outside the preheater seat 1 into the first mounting hole and extends into the receiving cavity 11, the second flat washer 132, the second mica sheet 133, the second insulating sleeve 134, and the mica sleeve 135, the second flat washer 132, the second mica sheet 133, the second insulating sleeve 134, and the second insulating sleeve 135, the second flat washer 132, the second mica sheet 133, the second insulating sleeve 134, and the second insulating sleeve 135, the second insulating sleeve 136 ...7, the second insulating sleeve 138, the second insulating sleeve 139, the second insulating sleeve 130, the second insulating sleeve 136, the second insulating sleeve 139, the second insulating sleeve 130, the second insulating sleeve 139, the second insulating sleeve 130, the second insulating sleeve 139, the second insulating sleeve 139, the second insulating sleeve 139, the second insulating sleeve Two flat washers 132 and a second mica sheet 133 are positioned outside the preheater base 1. A second insulating sleeve 134 is housed within a first mounting hole. A mica sleeve 135 is located within a receiving cavity 11. A spacer and a heating element 21 are sequentially threaded onto the mica sleeve 135. The heating element is isolated from the bottom wall of the receiving cavity by a spacer, and the heating elements are also isolated from each other by spacers. A mica washer 136 is fitted onto the fixing bolt 131, located on the side of the mica sleeve 135 away from the second insulating sleeve 134. One end of the fixing bolt 131 is screwed into a threaded hole. In this example, the second mica sheet 133 is configured to insulate the fixing bolt 131 from the preheater base 1, the second insulating sleeve 134 is configured to insulate the fixing bolt 131 from the first mounting hole of the preheater base 1, and the mica sleeve 135 is configured to insulate the heating element 21 from the fixing bolt 131. In the example, the fixing bolt 131 is a conductive internal hexagon socket head cap screw. In the example, the lowermost heating element is also separated from the bottom wall of the receiving cavity by a spacer.

[0049] In a further preferred embodiment, the fixing post 13 also includes an insulating cover 137, which covers the bolt head of the fixing bolt 131.

[0050] In a preferred embodiment, such as Figure 4-5 As shown, a Teflon insulation layer 12 is provided on the surface of the preheater base 1. In this example, the thickness of the Teflon insulation layer 12 is 0.019 mm to 0.051 mm.

[0051] In a preferred embodiment, such as Figure 1 As shown, the terminal block 3 includes a first bolt 31, a first insulating sleeve 32, a first mica sheet 33, a first flat washer 34, and a first nut 35. A connecting band 22 is fitted onto the first bolt 31 through the mounting hole. After the first insulating sleeve 32 is fitted onto the first bolt 31 with the connecting band 22, it passes through the through hole and extends out to the outside of the preheater base 1. The first bolt 31 is insulated from the preheater base 1 by the first insulating sleeve 32. The first mica sheet 33, the first flat washer 34, and the first nut 35 are fitted onto the extended end of the first bolt 31 in sequence. The first nut 35 is configured to fix the first bolt 31 onto the preheater base 1.

[0052] In the example, the first bolt 31 is a conductive hexagonal head bolt.

[0053] In the example, at least one of the two terminals 3 is the positive terminal and the other is the negative terminal.

[0054] Preferably, one terminal 3 is installed on the upper side of the preheater base 1, and the other terminal 3 is installed on the bottom side of the preheater base 1, with the two terminals 3 arranged correspondingly above and below each other.

[0055] During operation, after the engine starts, the intake preheater located in the intake manifold begins to work and gradually heats up. If the surface of the preheater housing is not coated with a Teflon insulating layer, an electrolyte will form when the preheater housing comes into contact with the incoming gas (such as oil vapor, moisture, dust, or sulfides and chlorides in other pollutants). The preheater housing itself contains elements such as copper and iron, and there will be a potential difference between different metal materials, causing current to flow between the two materials. When the current flows, atoms on the anode material will lose electrons (oxidation), forming ions that dissolve into the electrolyte and undergo a metal reaction, causing initial corrosion. In humid conditions, the heating creates a high-temperature and high-humidity environment, and the electrolyte adhering to the surface of the preheater housing is more likely to accelerate metal oxidation, thereby affecting circuit performance and the mechanical properties of components, and in severe cases, may even cause a short circuit. The Teflon insulation layer, applied to the preheater base, interrupts current flow and prevents the formation of a potential difference, thus combating electro-corrosion caused by high temperature and humidity environments. Furthermore, the extremely low surface energy of the Teflon insulation layer reduces contaminant adhesion, and its excellent chemical resistance provides strong resistance to most chemicals. The superior corrosion resistance, impermeability, water swelling resistance, and shock resistance of the Teflon insulation layer significantly extend the service life and operating environment of the preheater base after coating it with the Teflon insulation layer.

[0056] The heating tape formed by the corrugated metal heating element is connected to the power supply through the electrode (i.e., the first bolt on the terminal block), forming a predetermined current path to ensure uniform heating of the corrugated heating tape. The electrode is isolated from the preheater base through the first mica sheet and Teflon insulation layer to prevent electrical short circuits.

[0057] It should be noted that, unless otherwise specified, all features in the above embodiments or embodiments described herein can be combined arbitrarily.

[0058] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "yet another embodiment," "another embodiment," "other embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Furthermore, those skilled in the art can combine and integrate the different embodiments or examples described in this specification.

[0059] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications and variations to the above embodiments within the scope of the present invention.

Claims

1. A robust air intake preheater characterized by, It includes a preheater seat (1), an electric heating band (2) and at least two terminal posts (3); The preheater seat (1) is provided with a receiving cavity (11) having at least one opening, and at least two through holes are formed on the surface of the preheater seat (1) and are in communication with the receiving cavity (11); The electric heating band (2) is fixedly arranged in the receiving cavity (11), and the electric heating band (2) comprises a plurality of wave-shaped electric heating sheets (21). The plurality of electric heating sheets (21) are arranged in parallel in the receiving cavity (11). A plurality of fixing holes are formed on the electric heating sheet (21) at intervals. A plurality of fixing columns (13) are arranged in the receiving cavity (11) at intervals. The electric heating sheet (21) is fixed on the fixing column through the fixing hole. A spacer is sleeved on the fixing column. The spacer is configured to separate at least two adjacent electric heating sheets. The electric heating sheets are sequentially electrically connected in the current flow direction. Two electric heating sheets (21) are electrically connected with a connecting band (22). The connecting band (22) is provided with a mounting hole. One connecting band (22) is fixedly mounted on one terminal post (3) through the mounting hole. The other connecting band (22) is fixedly mounted on the other terminal post (3) through the mounting hole. The terminal post (3) is mounted on the corresponding through hole.

2. The air intake preheater of claim 1, wherein The wave bending direction of the electric heating sheet (21) is consistent with the length direction of the fixing column.

3. The air intake preheater of claim 1, wherein, The thickness of the electric heating sheet (21) is greater than or equal to 0.8 mm.

4. The air intake preheater of claim 3, wherein The thickness of the electric heating sheet (21) is between 1.0 mm and 1.2 mm.

5. The air intake preheater of claim 1, wherein The surface of the preheater seat (1) is provided with a Teflon insulating layer (12).

6. The air intake preheater of claim 5, wherein, The thickness of the Teflon insulating layer (12) is 0.019 mm to 0.051 mm.

7. The air intake preheater of claim 1, wherein The terminal post (3) comprises a first bolt (31), a first insulating sleeve (32), a first mica sheet (33), a first flat gasket (34) and a first nut (35). One connecting band (22) is sleeved on the first bolt (31) through the mounting hole. The first bolt (31) with the sleeved connecting band (22) is sleeved with the first insulating sleeve (32), then passes through the through hole and extends out of the preheater seat (1). The first bolt (31) is insulated from the preheater seat (1) through the first insulating sleeve (32). The first bolt (31) is sequentially sleeved with the first mica sheet (33), the first flat gasket (34) and the first nut (35) on the extending end. The first nut (35) is configured to fix the first bolt (31) on the preheater seat (1).

8. The air intake preheater of claim 1, wherein, A first mounting hole is formed in the bottom wall of the receiving cavity (11), and a threaded hole is formed in the top wall of the receiving cavity (11); The fixing column (13) comprises a fixing bolt (131), a second flat washer (132), a second mica sheet (133), a second insulating sleeve (134), a mica sleeve (135), a spacer and a mica washer (136); the fixing bolt (131) is sequentially sleeved with the second flat washer (132), the second mica sheet (133), the second insulating sleeve (134) and the mica sleeve (135), the fixing bolt (131) is inserted into the first mounting hole from the outside of the preheater base (1) and extends into the accommodating cavity (11), the second flat washer (132) and the second mica sheet (133) are stopped outside the preheater base (1), the second insulating sleeve (134) is accommodated in the first mounting hole, the mica sleeve (135) is located in the accommodating cavity (11), the spacer and the electric heating sheet (21) are sequentially sleeved on the mica sleeve (135), the electric heating sheet is isolated from the bottom wall of the accommodating cavity by the spacer, the electric heating sheets are isolated from each other by the spacer, the mica washer (136) is sleeved on the fixing bolt (131), the mica washer (136) is located on the side of the mica sleeve (135) away from the second insulating sleeve (134), and one end of the fixing bolt (131) is screwed into the threaded hole.

9. The air intake preheater of claim 1 or 8, wherein, The spacer comprises a mica sheet and a metal gasket, the mica sheet and the metal gasket are sleeved on the fixing column, and every two adjacent electric heating sheets are separated by the mica sheet and the metal gasket; The spacer is a metal gasket, and the metal gasket is sleeved between every two adjacent electric heating sheets.

10. The air intake preheater of claim 8, wherein, The first bolt (31) is a conductive bolt, and the fixing bolt (131) is a conductive bolt; and / or The fixing column (13) further comprises an insulating cover (137), and the insulating cover (137) covers the bolt head of the fixing bolt (131).

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