Pipeline heater structure

Abstract

The utility model discloses a pipeline heater structure. The PTC heater comprises a pipe body with a central flow channel and a heater shell arranged outside the pipe body in a sleeving mode, the outer contour of the pipe body is of a rectangular section structure, flat grooves which are located in the periphery of the pipe body and used for being connected with PTC heating cores in an inserted mode are machined in all the side faces of the pipe body, and connecting faces formed in all corner portions of the pipe body are arranged between the adjacent flat grooves. The edge of the root of each flat groove is provided with a pair of folds sunken towards an inner cavity of the flat groove, the PTC heating cores are inserted into the flat grooves and can be pressed, held and fixed by extruding the folds, and the two ends of the central flow channel of the pipe body are provided with connectors with annular protrusions. The utility model has the advantages that the volume of the whole structure is smaller, the application range is expanded, meanwhile, the structural design is simple, the processing technology is relatively simple, the manufacturing cost is lower, the stress stability is good especially in the deformation process of the pressing pipe, and the pressing reliability is ensured.

Description

Technical Field

[0001] This utility model relates to a battery thermal management structure for use in new energy vehicles and energy storage, specifically a pipe heater structure. Background Technology

[0002] Since the optimal operating temperature for batteries in electric vehicles is 25-35℃, battery thermal management activities have been developed to cope with extreme hot and cold weather conditions, reduce damage to batteries during the use of new energy vehicles, and improve battery life. Furthermore, with the imbalance between power generation and consumption in different regions and the varying power demands at different times of the year, energy storage heating has found its application. Although there are many battery water heating and energy storage products on the market, liquid heaters have unique advantages compared to them. Most existing products on the market use chuck-type heaters, which typically have the following drawbacks:

[0003] Conventional chuck-type pipe heaters have several drawbacks. First, they require matching chucks for installation; errors in the chuck result in poor sealing and inconvenient assembly. Second, conventional chuck-type heaters are relatively large, requiring significant space. Third, their complex manufacturing process leads to higher costs. Fourth, the aluminum tube profiles often lack pressure relief grooves on their side walls, or have poorly designed grooves, causing irregular deformation of the tube wall during pressing, often resulting in misalignment and insufficient compression. This leads to unstable power output and significant power dispersion in PTC products. Finally, the numerous and messy wires easily cause wiring errors. For example, a common design on the market features a PTC coil wrapped around six sides with water flowing through the center. Each of the six sides has six heating elements, each with two wires, totaling 12 wires. These 12 wires are connected end-to-end in a delta configuration, resulting in three groups of exiting the coils. This wiring method is time-consuming and prone to errors, ultimately causing the PTC liquid heater to malfunction. Summary of the Invention

[0004] The technical problem to be solved by this utility model is to provide a pipeline heater structure that is relatively simple in structure, small in size, wide in application range, easy to assemble, and has reliable PTC heating core clamping, thereby effectively ensuring product quality.

[0005] To solve the above-mentioned technical problems, the pipe heater structure of this utility model includes a pipe body with a central flow channel and a heater shell fitted outside the pipe body. The outer contour of the pipe body is a rectangular cross-section structure. Each side of the pipe body is machined with a flat groove for inserting a PTC heating element. Adjacent flat grooves are provided with connecting surfaces formed at the corners of the pipe body. The root edge of each flat groove is provided with a pair of folds that are recessed into the inner cavity of the flat groove. The PTC heating element is inserted into each flat groove and can be pressed and fixed by squeezing each pair of folds. The two ends of the central flow channel of the pipe body are provided with joints with annular protrusions.

[0006] The distance between the crease and the root of the groove is one-third of the height of the groove.

[0007] Each PTC heating element has two wires: the neutral wire of each PTC heating element forms one group, and the live wire of each PTC heating element forms another group, forming two sets of outgoing wires.

[0008] The thickness of the sidewall of each of the flat grooves is less than the thickness of the top of the flat groove.

[0009] The connecting surface is joined at the root of the adjacent flat groove, and the indentation is located at the edge of the connecting surface.

[0010] The tube body is also fitted with a connector housing that mates with the outer shell, and the connector housing is provided with a wire outlet terminal for the heating element to exit.

[0011] A sealing element is provided between the connector housing and the connector.

[0012] The advantages of this utility model are:

[0013] (1) By setting the outer contour of the tube as a rectangular cross section and setting a pair of folds that are recessed into the inner cavity of the flat groove at the root edge of each flat groove, the PTC heating core can be inserted into each flat groove and the PTC heating core can be pressed and fixed by squeezing each pair of folds. The overall structure is small in volume, which expands the application range. At the same time, its structural design is simple and the processing technology is relatively simple, so the manufacturing cost is low. In particular, by setting a pair of folds that are recessed into the inner cavity of the flat groove at the root edge of each flat groove, the material at the bottom is more pulled by the profile during the compression deformation process, while the material at the top is less pulled by the profile at the bottom. The folds are close to the bottom, the stress stability is good, and the pressing reliability is guaranteed.

[0014] (2) By directly setting joints with annular protrusions at both ends of the central flow channel of the pipe body, the hose can be directly put on the inlet and outlet and fixedly connected through the annular protrusions. The assembly method is simple and the sealing is better.

[0015] (3) The distance between the root of the crease and the flat groove is one-third of the height of the flat groove, which makes the stress stability better and the deformation of the compression tube more controllable, further ensuring the reliability of the compression. This makes the power output of the PTC product very stable when it is working, and the product power value has small dispersion.

[0016] (4) The neutral wire of each PTC heating element is used as one group and the live wire of each PTC heating element is used as another group to form two sets of outgoing wires. The outgoing wire method is simpler and clearer, the wiring is easy and there will be no mistakes. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the pipeline heater of this utility model;

[0018] Figure 2 This is an exploded structural diagram of the pipe heater structure of this utility model;

[0019] Figure 3 This is a three-dimensional structural diagram of the tube body of this utility model;

[0020] Figure 4 This is a side view of the tube body of this utility model. Detailed Implementation

[0021] The structure of the pipe heater of this utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0022] As shown in the figure, the pipe heater structure of this utility model includes a pipe body 2 with a central flow channel 1 and a heater shell 3 fitted outside the pipe body. The two ends of the central flow channel of the pipe body 1 are provided with joints 7 with annular protrusions. The outer contour of the pipe body 1 is a rectangular cross-section structure. Each side of the pipe body 1 is machined with a flat groove 4 for inserting a PTC heating element. The thickness of the side wall of each flat groove 4 is less than the thickness of the top of the flat groove. Between adjacent flat grooves 4, there are connecting surfaces 5 formed at the corners of the pipe body 1. As can be seen from the figure, the connecting surfaces 5 are connected to the root position of the adjacent flat grooves. Each flat groove 4 has a pair of creases 6 that are recessed into the inner cavity of the flat groove at the root edge. The creases 6 are located at the edge of the connecting surface. The PTC heating element is inserted into each flat groove 4 and can be pressed and fixed by squeezing each pair of creases.

[0023] Furthermore, the distance between the crease 6 and the root of the flat groove 4 is one-third of the height of the flat groove, and the connecting surface 5 is exactly connected to the crease 6. This structural design, on the one hand, utilizes the characteristic that the thickness of the side wall of the flat groove 4 is less than the thickness of the top of the flat groove to form a stress relief groove at the crease, which is easy to deform and easier to press. On the other hand, the symmetrical deformation allows it to tightly press the PTC heating core, and the pressing is very reliable.

[0024] Furthermore, each PTC heating element has two wires. The neutral wires of each PTC heating element form one group, and the live wires of each PTC heating element form another group. Specifically, each heating element has two wires, for a total of eight wires. The four neutral wires form one group, and the four live wires form another group, thus forming two groups of output wires. This structure is simple and clear, and will not cause errors.

[0025] Furthermore, the tube body 2 is also fitted with a connector housing 8 that is installed in conjunction with the outer shell 3. The connector housing 8 is provided with a wire outlet terminal 9 for the heating core to exit. A sealing element 10 is provided between the connector housing 8 and the connector 7.

[0026] Of course, the above description is not intended to limit the present utility model, and the present utility model is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present utility model should also fall within the protection scope of the present utility model.

Claims

1. A pipe heater structure comprising a pipe body (2) having a central flow channel (1) and a heater housing (3) which is fitted outside the pipe body, characterized in that: The outer contour of the pipe body (2) is rectangular section structure, each side of the pipe body (2) is processed with flat groove (4) for inserting PTC heating core at the pipe body periphery, the adjacent flat groove (4) is provided with the link surface (5) shaped in each corner position of the pipe body (2), the root edge of each flat groove (4) is provided with a pair of creases (6) recessed to the flat groove inner cavity, the PTC heating core is inserted in each flat groove (4) and can be fixed by extruding each pair of creases to the PTC heating core, the center flow passage of the pipe body (2) is provided with the joint (7) with annular protrusion at both ends.

2. The pipe heater structure of claim 1, wherein: The distance between the crease (6) and the root of the flat groove (4) is one third of the height of the flat groove.

3. A pipe heater structure according to claim 1 or 2, characterised in that: Each PTC heating core has two wires, the zero line of each PTC heating core is a group, the fire line of each PTC heating core is a group, forming two groups of outgoing wires.

4. A pipe heater arrangement according to claim 3, characterised in that: The thickness of the side wall of each flat groove (4) is less than the thickness of the top of the flat groove.

5. A pipe heater arrangement according to claim 1, 2 or 4, characterised in that: The link surface (5) links at the root position of the adjacent flat groove, and the crease (6) is at the edge of the link surface.

6. A pipe heater arrangement according to claim 5, characterised in that: The pipe body (2) is further sleeved with the joint shell (8) matched with the shell (3), and the joint shell (8) is provided with outgoing terminal (9) for outgoing wire of the heating core.

7. A pipe heater arrangement according to claim 6, characterised in that: The sealing element (10) is arranged between the joint shell (8) and the joint (7).

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