Lightweight vehicle heater

Abstract

The utility model relates to the technical field of vehicle air heating heaters, and discloses a light-weight vehicle heater, which comprises a ceramic resistance heating core body and a shell, the two side surfaces of the ceramic resistance heating core body are coated with bonding layers, the ceramic resistance heating core body is fixedly connected with radiating fins through the bonding layers, and the radiating fins are arranged in the shell. The plurality of radiating fins and the plurality of ceramic resistance heating core bodies are sequentially and alternately connected to form the heating core body assembly, and the heating core body assembly is arranged in the shell; the height of the ceramic resistance heating core body is larger than that of the heat dissipation fins, the top of the ceramic resistance heating core body is provided with a welding point, and the single side of the top end, higher than the heat dissipation fins, of the ceramic resistance heating core body is provided with the welding point with the concave hole, so that during assembly, the thickness of the welding position is not increased additionally, and the heat dissipation efficiency is improved. Furthermore, the heating core assembly is integrally ultrathin and flat, so that the compact and light-weight design of the structure of the heater is realized.

Description

Technical Field

[0001] This utility model relates to the technical field of automotive air heaters, specifically a lightweight automotive heater. Background Technology

[0002] In new energy vehicles such as electric vehicles and hybrid vehicles, cabin heating and battery thermal management are critical aspects. In cold operating conditions, when the system's own heating capacity is insufficient, additional electric heating devices are usually required to supplement the heat.

[0003] Currently, most mainstream air-cooled heaters use positive temperature coefficient thermistors, i.e., metal PTC materials, as heating elements. Since metal PTC materials are inherently conductive, an insulating layer is required between the heating element and the heat sink fins to achieve electrical isolation. This insulating layer is typically formed by coating an insulating medium, which not only increases the complexity of the manufacturing process and material costs, but may also lead to uneven coating, causing localized heat accumulation, reducing thermal efficiency, and affecting the long-term reliability of the system. Therefore, existing air-cooled heaters suffer from problems such as complex manufacturing processes and large size and weight.

[0004] Therefore, since it does not meet the existing requirements, we propose a lightweight automotive heater. Utility Model Content

[0005] This invention provides a lightweight automotive heater that features low manufacturing cost, compact structure, convenient packaging, higher heat exchange efficiency, and shorter heating time, thus solving the problems mentioned in the background art.

[0006] This utility model provides the following technical solution: a lightweight automotive heater, comprising a ceramic resistance heating core and a shell. Both sides of the ceramic resistance heating core are coated with an adhesive layer. Heat dissipation fins are fixedly connected to the ceramic resistance heating core via the adhesive layer. A plurality of heat dissipation fins and a plurality of ceramic resistance heating cores are sequentially and alternately connected to form a heating core assembly, which is disposed within the shell. The height of the ceramic resistance heating core is greater than the height of the heat dissipation fins. A welding point is provided at the top of the ceramic resistance heating core, and the welding point is located at the core portion of the ceramic resistance heating core that exceeds the height of the heat dissipation fins.

[0007] Specifically, the outermost layers on both sides of the heating core assembly are heat dissipation fins, and the number of ceramic resistance heating cores can be increased or decreased as needed.

[0008] More specifically, the thickness of the ceramic resistance heating core is less than 1.5 mm. The ultra-thin ceramic resistance heating core helps to reduce the weight of the heater, thereby achieving a lightweight heater.

[0009] Specifically, the adhesive layer is a thermally conductive silicone layer applied by screen printing.

[0010] More specifically, the thickness of the thermally conductive silicone layer is less than 0.1 mm. The thermally conductive silicone layer can bond and fix the ceramic resistance heating core and the heat dissipation fins. At the same time, its own thermal conductivity will not affect the transfer of heat from the ceramic resistance heating core to the heat dissipation fins.

[0011] Specifically, two welding points are symmetrically arranged along the outer wall of the ceramic resistance heating core, and positive and negative electrode conductors are welded to the welding points.

[0012] More specifically, the end face structure of the welding point is a rectangular concave hole structure. During welding, the concave hole at the welding point can accommodate solder, making the welding point flat and the welding firm.

[0013] Specifically, the outer shell includes a bottom shell with an internal cavity, a cover shell for sealing the cavity is installed on the top of the bottom shell, bolts for fixing the bottom of the front shell and the rear shell are provided, and the cover shell and the bottom shell are connected by a snap-fit ​​structure.

[0014] More specifically, the cover is provided with a connecting opening.

[0015] Specifically, the bottom shell is divided into two parts along its centerline: a front shell and a rear shell, which are connected by a snap-fit ​​structure.

[0016] More specifically, a rib structure for positioning and supporting the ceramic resistance heating core is provided between the front shell and the rear shell.

[0017] More specifically, several rib structures are arranged in a central shape along the inner wall of the bottom shell and the bottom wall, and the rib structures cooperate with each other to three-dimensionally position and fix the ceramic resistance heating core.

[0018] This utility model has the following beneficial effects:

[0019] 1. In this utility model, a ceramic resistance heating core is used to provide a heat source. The ceramic resistance heating core itself has good insulation performance and stable resistance-temperature characteristics. No additional insulation treatment is required. It can be directly combined with the heat dissipation structure, thereby simplifying the manufacturing process, reducing costs, and improving heat conduction efficiency and system reliability.

[0020] 2. In this utility model, the thickness of the ceramic resistance heating core is less than 1.5mm, and a welding point with a concave hole is provided on one side of the top of the heat dissipation fins. Thus, during assembly, the welding point can be made without adding extra thickness, thereby achieving the overall ultra-thin and flat characteristics of the heating core assembly, so as to realize the compact and lightweight design of the heater structure.

[0021] 3. In this utility model, the number of ceramic resistance heating cores can be increased or decreased according to needs. When adjusting the number of ceramic resistance heating cores, the number of heat dissipation fins needs to be adjusted accordingly to increase or decrease the power of the heater so that it can be used in vehicles with different spaces. The outer ends of the heating core assembly are fixedly set as heat dissipation fins to avoid the ceramic resistance heating cores from directly contacting the outer shell.

[0022] 4. In this utility model, the bottom shell is formed by snap-fit ​​connection of the front shell and the rear shell, and the bottom of the front shell and the rear shell are fixed by bolt structure. After the heating core assembly is housed in the inner cavity of the bottom shell, the cover shell is snapped on the top of the bottom shell to lock the top of the front shell and the rear shell, thereby quickly encapsulating the heating core assembly in the outer shell. Attached Figure Description

[0023] Figure 1 This is a three-dimensional structural diagram of a lightweight automotive heater according to the present invention;

[0024] Figure 2 This is a three-dimensional structural diagram of the heating core assembly of this utility model;

[0025] Figure 3 This is a three-dimensional structural diagram of the heat dissipation fins of this utility model;

[0026] Figure 4 This is a partial three-dimensional structural diagram of the ceramic resistance heating core of this utility model;

[0027] Figure 5 This is a schematic diagram of the structure of this utility model;

[0028] Figure 6 This is an exploded view of a lightweight automotive heater according to this utility model;

[0029] Figure 7 This is a structural comparison diagram between the present invention and an existing heater of the same power.

[0030] Figure 8 This is a comparison diagram of the air flow resistance of this utility model and an existing heater of the same power.

[0031] Figure 9 This is a structural comparison diagram between the present invention and an existing heater of the same volume;

[0032] Figure 10 This is a comparison diagram of the airflow resistance of this utility model and an existing heater of the same volume.

[0033] In the diagram: 1. Heating core assembly; 10. Ceramic resistance heating core; 11. Heat dissipation fins; 12. Adhesive layer; 13. Welding point; 130. Positive and negative electrode conductors; 2. Outer shell; 20. Bottom shell; 21. Cover shell; 22. Rib structure; 200. Front shell; 201. Rear shell; 202. Bolt; 210. Wiring opening. Detailed Implementation

[0034] 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.

[0035] like Figures 1-6 As shown, a lightweight automotive heater includes a ceramic resistance heating core 10. Both sides of the ceramic resistance heating core 10 are coated with an adhesive layer 12. The ceramic resistance heating core 10 is fixedly connected to heat dissipation fins 11 through the adhesive layer 12. The ceramic resistance heating core 10 itself has good insulation properties and does not require additional insulation treatment. It can be directly combined with the heat dissipation fins 11. Several heat dissipation fins 11 and several ceramic resistance heating cores 10 are sequentially and alternately connected to form a heating core assembly 1.

[0036] In this embodiment, the heating core assembly 1 has a multi-layer composite structure, specifically composed of heat dissipation fins 11 and ceramic resistance heating core 10 bonded together alternately. The heat dissipation fins 11 are made of aluminum foil of a specific thickness, corrugated and welded by brazing process to maximize the effective heat dissipation area and improve heat exchange efficiency.

[0037] like Figure 3 As shown, the adhesive layer 12 is a thermally conductive silicone layer set by screen printing. The thermally conductive silicone layer itself has excellent thermal conductivity, thereby avoiding the adhesive layer 12 from affecting heat transfer. The thickness of the thermally conductive silicone layer is less than 0.1mm. The smaller the thickness of the thermally conductive silicone layer, the smaller the overall width of the device. In order to maintain the stability of its adhesive performance, a thermally conductive silicone layer with a thickness of 0.1mm is the best.

[0038] When assembling the heating core assembly 1: Before connecting the ceramic resistance heating core 10 and the heat dissipation fins 11 through the adhesive layer 12, the surfaces of the ceramic resistance heating core 10 and the heat dissipation fins 11 are thoroughly cleaned with a suitable ethanol solution. After the surface solution evaporates, thermally conductive silicone is screen-printed onto both sides of the heat dissipation fins 11 to form an adhesive layer 12 with a thickness of 0.1 mm. The heat dissipation fins 11 and the ceramic resistance heating core 10 are stacked in sequence. After stacking, the assembly is cured at 130°C for 90 minutes to form a heating core assembly 1 with a solid structure and stable thermal conductivity.

[0039] like Figures 1-3 As shown, the thickness of the ceramic resistance heating core 10 is less than 1.5 mm. The ultra-thin ceramic resistance heating core 10 helps to reduce the weight of the heater, thereby achieving the lightweight design of the heater. The height of the ceramic resistance heating core 10 is greater than the height of the heat dissipation fins 11. A welding point 13 is provided on the top of the ceramic resistance heating core 10. Two welding points 13 are symmetrically arranged along the outer wall of the ceramic resistance heating core 10. Positive and negative electrode conductors 130 are welded to the welding points 13. The welding points 13 are located at the core of the ceramic resistance heating core 10 that exceeds the height of the heat dissipation fins 11, thereby separating the electrode welding points and the connection ends of the electrode wires of the heating core assembly 1 from the heating core assembly 1.

[0040] In this embodiment, a welding point 13 is provided at the position where the ceramic resistance heating core 10 is higher than the heat dissipation fins 11 to reduce the thickness of the welding point. At the same time, a ceramic resistance heating core 10 with a thickness of less than 1.5 mm is selected to form a heating core assembly 1 with the heat dissipation fins 11, so as to greatly reduce the width of the heating core assembly 1. This makes the heating core assembly 1 have ultra-thin and flat characteristics, so as to achieve a compact and lightweight design of the heater structure.

[0041] like Figure 4 As shown, the end face structure of the solder point 13 is a rectangular concave cavity structure. The concave cavity on the solder point 13 can accommodate solder, which helps with assembly and soldering, and can also hide the solder point 13 to prevent it from being exposed.

[0042] In this embodiment, the welding point 13 is higher than the top of the heat dissipation fin 11, thereby avoiding the welding end from affecting the thickness of the heating core assembly 1. Moreover, the welding point 13 has a concave cavity, which can accommodate solder and hide the welding point, so that the welding part of the ceramic resistance heating core 10 is flat and smooth.

[0043] like Figure 2 As shown, the outermost layers on both sides of the heating core assembly 1 are heat dissipation fins 11. The number of ceramic resistance heating cores 10 and heat dissipation fins 11 can be increased or decreased according to requirements.

[0044] like Figure 2As shown, in this embodiment, a heating core assembly 1 of a 3.6kW air heater is composed of ten ceramic resistance heating cores 10 and eleven heat dissipation fins 11. It is suitable for 400V electrical platforms to be compatible with most new energy vehicles on the market.

[0045] like Figures 1-6 As shown, a lightweight vehicle heater also includes a housing 2, and a heating core assembly 1 is disposed inside the housing 2. The housing 2 includes a bottom shell 20 with an internal cavity. A cover shell 21 for sealing the cavity is installed on the top of the bottom shell 20. A wiring opening 210 is provided on the cover shell 21. The bottom shell 20 is divided into two parts, a front shell 200 and a rear shell 201, along its center line. Bolts 202 for fixing the front shell 200 and the rear shell 201 are provided at the bottom.

[0046] In this embodiment, the outer shell 2 is composed of a bottom shell 20 consisting of a front shell 200 and a rear shell 201, and a cover shell 21. When assembling the outer shell 2, the front shell 200 and the rear shell 201 are spliced ​​together and fixed to the bottom of the two by bolts 202. When the cover shell 21 is installed on the top of the bottom shell 20, the top of the front shell 200 and the rear shell 201 can be fixed. Thus, the front shell 200, the rear shell 201 and the cover shell 21 together with a heating core assembly 1 constitute a complete heater.

[0047] like Figures 5-6 As shown, the front shell 200 and the rear shell 201 are connected by a snap-fit ​​structure, and the cover shell 21 and the bottom shell 20 are connected by a snap-fit ​​structure.

[0048] In this embodiment, the front shell 200, rear shell 201 and bottom shell 20 are all installed using a snap-fit ​​structure that allows for quick disassembly, thereby achieving convenient assembly, simplifying the installation steps and reducing production costs.

[0049] like Figure 6 As shown, a rib structure 22 for positioning and supporting the ceramic resistance heating core 10 is provided between the front shell 200 and the rear shell 201. After the front shell 200 and the rear shell 201 are spliced ​​together, the rib structures 22 fit together. Several rib structures 22 are arranged in a central shape along the inner wall and bottom wall of the bottom shell 20. The rib structures 22 form at least three support points on the two side walls and the bottom wall of the inner cavity of the bottom shell 20. The three rib structures 22 cooperate with each other to position and fix the ceramic resistance heating core 10 in three dimensions.

[0050] In this embodiment, to prevent the heating core assembly 1 from becoming loose inside the outer shell 2, and to ensure a stable connection between the airflow channel inside the vehicle and the heating core assembly 1, the heating core assembly 1 is positioned and supported by at least three support points. This ensures that after forming a closed flow channel structure with the vehicle, the cold air flows through the gaps between all the heat dissipation fins 11 and exchanges heat with the heat generated by the ceramic resistance heating core 10 in a sufficient and uniform manner. The heated airflow is then transported to the passenger compartment or other areas that require heating, thus achieving the function of efficient temperature control.

[0051] like Figure 7 As shown, Figure 7 The diagram shows a comparison of the structure of the present invention and an existing heater under the same power conditions. The heater of the present invention is located on the left, while the existing heater is located on the right. It is clear that, under the same heating power of the heat dissipation fins 11, the structure of the present invention is more compact, and the overall volume is reduced by nearly one-third.

[0052] Figure 8 As shown, Figure 8 For the same power, Figure 7 The simulation comparison diagram of air flow resistance at section AA is shown. The air flow resistance diagram of this invention is located on the left, while the air flow resistance diagram of the existing heater is located on the right. It is clear that, under the same heating power of heat dissipation fins 11, the air flow resistance of this invention is significantly reduced.

[0053] like Figure 1 As shown, Figure 1 The diagram shows a structural comparison between the present invention and an existing heater of the same volume. The heater of the present invention is located on the left, while the existing heater is located on the right. It is clear that the present invention has a larger effective air intake area.

[0054] like Figure 10 As shown, Figure 10 For the same volume, Figure 9 The simulation comparison diagrams of air flow resistance at the BB section are shown. The air flow resistance diagram of this invention is located on the left, while the air flow resistance diagram of the existing heater is located on the right. It is clear that this invention has lower air flow resistance and higher power density.

[0055] In summary, in this utility model:

[0056] 1. A ceramic resistance heating core 10 is used to provide a heat source. The ceramic resistance heating core 10 itself has good insulation properties and does not require additional insulation treatment. It can be directly combined with the heat dissipation structure, thereby simplifying the manufacturing process and reducing costs. At the same time, a welding point 13 is set at the point where the ceramic resistance heating core 10 is higher than the heat dissipation fins 11 to reduce the thickness of the welding point. Moreover, the ceramic resistance heating core 10 itself is also relatively thin. Therefore, when the ceramic resistance heating core 10 and the heat dissipation fins 11 form the heating core assembly 1, the width of the heating core assembly 1 can be greatly reduced to achieve a compact and lightweight design of the heater structure.

[0057] 2. After the front shell 200 and the rear shell 201 are spliced ​​together, the rib structure 22 fits together and forms three support points on the two side walls and the bottom wall of the inner cavity of the bottom shell 20 to fix the ceramic resistance heating core 10 in three directions. Moreover, when the cover shell 21 is fastened to the bottom shell 20 by the snap-fit ​​structure, it will abut against the top of the heating core assembly 1, thereby fixing the heating core assembly 1 stably and firmly inside the outer shell 2.

[0058] Third, the ceramic resistance heating core 10 is directly bonded to the side wall of the heat dissipation fins 11 through the adhesive layer 12. The adhesive layer 12, which uses a thermally conductive silicone layer, has high thermal conductivity. While performing the bonding and fixing function, it does not affect the heat transfer, thus enabling it to conduct heat to the heat dissipation fins 11 and improve the heat conduction efficiency. At the same time, the screen-printed adhesive layer 12 can conduct heat evenly when the ceramic resistance heating core 10 is transferring heat, thereby avoiding the problem of local heat accumulation and increasing the long-term reliability of this type of heater.

Claims

1. A lightweight automotive heater, comprising a ceramic resistance heating core (10) and a shell (2), characterized in that: Both sides of the ceramic resistance heating core (10) are coated with an adhesive layer (12). The ceramic resistance heating core (10) is fixedly connected to heat dissipation fins (11) through the adhesive layer (12). A plurality of heat dissipation fins (11) and a plurality of ceramic resistance heating cores (10) are sequentially and alternately connected to form a heating core assembly (1). The heating core assembly (1) is disposed inside the outer shell (2). The height of the ceramic resistance heating core (10) is greater than the height of the heat dissipation fins (11). A welding point (13) is provided on the top of the ceramic resistance heating core (10), and the welding point (13) is located at the core of the ceramic resistance heating core (10) that exceeds the height of the heat dissipation fins (11).

2. The lightweight automotive heater according to claim 1, characterized in that: Two welding points (13) are symmetrically arranged along the outer wall of the ceramic resistance heating core (10), and positive and negative electrode conductors (130) are welded to the welding points (13).

3. A lightweight automotive heater according to claim 1, characterized in that: The outer shell (2) includes a bottom shell (20) with an internal cavity, and a cover shell (21) for closing the cavity is mounted on the top of the bottom shell (20).

4. A lightweight automotive heater according to claim 1, characterized in that: The adhesive layer (12) is a thermally conductive silicone layer formed by screen printing, and the thickness of the thermally conductive silicone layer is less than 0.1 mm.

5. A lightweight automotive heater according to claim 1, characterized in that: The outermost layers on both sides of the heating core assembly (1) are the heat dissipation fins (11), and the thickness of the ceramic resistance heating core (10) is less than 1.5 mm.

6. A lightweight automotive heater according to claim 2, characterized in that: The end face structure of the welding point (13) is a rectangular concave hole structure.

7. A lightweight automotive heater according to claim 3, characterized in that: The bottom shell (20) is divided into two parts along its center line: a front shell (200) and a rear shell (201). The front shell (200) and the rear shell (201) are connected by a snap-fit ​​structure. The bottom of the front shell (200) and the rear shell (201) are provided with bolts (202) for fixed connection.

8. A lightweight automotive heater according to claim 7, characterized in that: The cover (21) and the bottom shell (20) are connected by a snap-fit ​​structure, and the cover (21) is provided with a connection opening (210).

9. A lightweight automotive heater according to claim 8, characterized in that: A rib structure (22) for positioning and supporting the ceramic resistance heating core (10) is provided between the front shell (200) and the rear shell (201).

10. A lightweight automotive heater according to claim 9, characterized in that: The rib structure (22) is arranged in a central shape along the inner wall and bottom wall of the bottom shell (20). The rib structure (22) cooperates with each other to position and fix the ceramic resistance heating core (10) in three dimensions.

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