Cooling module assembly with electric heater

Abstract

The utility model relates to a cooling module assembly with an electric heater, which comprises a core body and two intercooler air chambers, the electric heater is arranged in at least one intercooler air chamber, a lead of the electric heater penetrates out of the intercooler air chamber in a sealed manner, a temperature sensor is arranged in the intercooler air chamber, and the temperature sensor is connected with the core body. The electric heater is arranged at the bottom in the air chamber of the intercooler, connected with the vehicle-mounted power supply and provided with the temperature sensor, target temperature can be set according to user requirements, when the internal temperature is smaller than the set temperature, the electric heater starts to work, the temperature in the air chamber of the intercooler is increased, and freezing and melting are achieved; water can be discharged through a water drain valve at the lower end of the air chamber of the intercooler, and when the temperature reaches the set temperature, the electric heater can automatically cut off a power supply to stop heating; therefore, the internal temperature is kept stable, and resource waste caused by continuous action of the electric heater is avoided.

Description

Technical Field

[0001] This utility model relates to the field of intercooler technology, specifically to a cooling module assembly with an electric heater. Background Technology

[0002] Intercoolers are typically installed in turbocharged engines. Turbocharging leads to increased intake air temperature, affecting the engine's charging efficiency. Intercoolers cool the pressurized air, lowering its temperature and thus improving engine power output and fuel economy. Specifically, intercoolers lower the intake air temperature, increasing intake air density and consequently the amount of air entering the cylinders, improving fuel combustion efficiency and thus increasing engine power output. Furthermore, intercoolers also reduce fuel consumption, decrease knocking and nitrogen oxide emissions, and improve the engine's environmental adaptability.

[0003] The pressurized air entering the intercooler contains moisture. In humid regions, the moisture content is higher, and this moisture adheres to the intercooler walls and drips down, accumulating at the bottom of the chamber. To drain this moisture, a drain valve is added to the bottom of the chamber. However, in winter or low-temperature environments, when the vehicle is idling or at low speeds, the moisture in the chamber freezes, clogging the drain valve's drain hole. This prevents the moisture from draining, causing it to accumulate and freeze. Once frozen, the increased volume can damage the radiator pipes, leading to intercooler leaks and shortening the lifespan of the cooling module. Utility Model Content

[0004] This invention addresses the shortcomings of existing technologies by providing a cooling module assembly with an electric heater. Through the coordinated control of the electric heater and a temperature sensor, it prevents moisture inside the air chamber from freezing and optimizes energy consumption.

[0005] This utility model is achieved through the following technical solution: a cooling module assembly with an electric heater is provided, including a core and two intercooler chambers, at least one of which is equipped with an electric heater, the wires of which are sealed through the intercooler chamber, and a temperature sensor is installed in the intercooler chamber.

[0006] As an optimization, the intercooler chamber is arranged vertically, and the electric heater is located at the bottom of the intercooler chamber.

[0007] As an optimization, a drain valve is installed at the lower end of the intercooler chamber.

[0008] As an optimization, the wire exits the intercooler chamber from the side of the intercooler chamber away from the core.

[0009] As an optimization, the electric heater is located in the intercooler chamber on the outlet side.

[0010] As an optimization, the electric heater includes heating wires arranged in a serpentine pattern.

[0011] As an optimization, the electric heater also includes a metal housing that encloses the heating wire.

[0012] The beneficial effects of this utility model are as follows: This utility model provides a cooling module assembly with an electric heater. An electric heater is installed at the bottom of the intercooler chamber. The electric heater is connected to the vehicle's power supply and is equipped with a temperature sensor. A target temperature can be set according to user needs. When the internal temperature is lower than the set temperature, the electric heater starts working, raising the temperature inside the intercooler chamber, melting ice, and allowing moisture to drain through the drain valve at the bottom of the intercooler chamber. When the temperature reaches the set temperature, the electric heater automatically cuts off the power and stops heating; thus maintaining a stable internal temperature and avoiding continuous operation of the electric heater, which would otherwise waste resources.

[0013] This invention can actively defrost, prevent heat pipes from freezing and cracking, extend the life of the intercooler, reduce energy consumption through closed-loop temperature control, save ≥30% energy compared to continuous heating solutions, and its modular design is compatible with existing intercooler structures, resulting in low retrofit costs. Attached Figure Description

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

[0015] Figure 2 This is a front view of the present utility model;

[0016] Figure 3 This is a schematic diagram of the internal structure of the intercooler chamber of this utility model;

[0017] Figure 4 This is a side view of the intercooler chamber of this utility model;

[0018] Figure 5 This is a schematic diagram of the intercooler chamber of this utility model;

[0019] Figure 6 This is the control flowchart of this utility model;

[0020] As shown in the figure:

[0021] 1. Core, 2. Intercooler chamber, 3. Electric heater, 4. Wire, 5. Drain valve, 6. Temperature sensor. Detailed Implementation

[0022] To clearly illustrate the technical features of this solution, the following detailed implementation method will be used to explain the solution.

[0023] like Figures 1-6As shown, the present invention provides a cooling module assembly with an electric heater, comprising a core 1 and two intercooler chambers 2. The two intercooler chambers 2 are respectively connected to the two ends of the core 1. The high-temperature air from the turbocharger enters from the intercooler chamber 2 on the intake side and exits from the intercooler chamber 2 on the exhaust side, thereby cooling the high-temperature air.

[0024] To prevent the condensate from freezing in low-temperature environments, an electric heater 3 is provided in at least one intercooler chamber 2. In this embodiment, the electric heater 3 is located in the intercooler chamber 2 on the outlet side.

[0025] The intercooler chamber 2 is vertically arranged to facilitate the flow of condensate to the lower end. In this embodiment, a drain valve 5 is installed at the lower end of the intercooler chamber 2 to periodically drain the condensate.

[0026] Because the bottom of the intercooler chamber 2 is prone to icing, the electric heater 3 is located at the bottom of the intercooler chamber 2. The height of the icing-prone area is H, and the height of the electric heater 3 is H1, where H1 ≤ H.

[0027] The electric heater 3 includes heating wires arranged in a serpentine pattern. The heating power of the heating wires is 200-500W. The electric heater 3 is attached to the inner wall of the intercooler chamber 2, so as not to affect the air entering the core 1. For insulation, an insulating layer is wrapped around the heating wires. In addition, to protect the heating wires, the electric heater 3 also includes a metal shell that encloses the heating wires. The surface of the metal shell is coated with an anti-corrosion coating. The metal shell is made of 304 stainless steel and the thickness of the anti-corrosion coating is ≥50μm.

[0028] A temperature sensor is installed inside the intercooler chamber 2. The temperature sensor is mounted inside the intercooler chamber 2 and above the electric heater 3, and is used to detect the internal temperature. The electric heater 3 is connected to the temperature sensor 6 to achieve automatic control of heating start-up and shutdown. The temperature sensor 6 communicates with the vehicle ECU and supports setting temperature thresholds from 0℃ to 50℃.

[0029] The wire 4 of the electric heater 3 passes through the intercooler chamber 2 in a sealed manner. In this embodiment, the wire passes through the intercooler chamber 2 from the side away from the core 1, which facilitates the arrangement of the wire. A sealing ring is installed on the hole to prevent the leakage of high-pressure gas in the intercooler chamber 2.

[0030] How to use this utility model:

[0031] Because the bottom heat pipes of the intercooler are prone to icing, the electric heater 3 is placed at the bottom of the intercooler chamber 2. The electric heater 3 is connected to the vehicle power supply, which provides power to the electric heater.

[0032] The intercooler chamber 2 is equipped with a temperature sensor, allowing users to set a target temperature. When the internal temperature is lower than the set temperature (typically 0°C), the electric heater starts working, raising the temperature inside the intercooler chamber 2, melting any ice, and allowing moisture to drain through the drain valve 5 at the bottom of the intercooler chamber 2. When the temperature at the measuring point reaches the set temperature, the electric heater automatically cuts off the power and stops heating, thus maintaining a stable internal temperature and preventing the electric heater from running continuously and wasting resources.

[0033] Of course, the above description is not limited to the examples above. Technical features of this utility model not described can be implemented by or using existing technology, and will not be repeated here. The above embodiments and drawings are only used to illustrate the technical solution of this utility model and are not intended to limit this utility model. This utility model has been described in detail with reference to preferred embodiments. Those skilled in the art should understand that any changes, modifications, additions or substitutions made by those skilled in the art within the scope of this utility model do not depart from the spirit of this utility model and should also fall within the protection scope of the claims of this utility model.

Claims

1. A cooling module assembly with an electric heater, comprising a core (1) and two intercooler chambers (2), characterized in that: An electric heater (3) is provided in at least one intercooler chamber (2), the wires of the electric heater (3) are sealed through the intercooler chamber (2), and a temperature sensor (6) is installed in the intercooler chamber (2).

2. The cooling module assembly with an electric heater according to claim 1, characterized in that: The intercooler chamber (2) is arranged vertically, and the electric heater (3) is arranged at the bottom of the intercooler chamber (2).

3. The cooling module assembly with an electric heater according to claim 1, characterized in that: The lower end of the intercooler chamber (2) is equipped with a drain valve (5).

4. The cooling module assembly with an electric heater according to claim 1, characterized in that: The wire passes through the intercooler chamber (2) from the side away from the core (1).

5. A cooling module assembly with an electric heater according to claim 1, characterized in that: The electric heater (3) is installed in the intercooler chamber (2) on the outlet side.

6. A cooling module assembly with an electric heater according to claim 1, characterized in that: The electric heater (3) includes heating wires arranged in a serpentine pattern.

7. A cooling module assembly with an electric heater according to claim 6, characterized in that: The electric heater (3) also includes a metal casing that encloses the heating wire.

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