PTC (Positive Temperature Coefficient) heating device for electric automobile

Abstract

The utility model discloses a PTC heating device for an electric automobile, which comprises a PTC heater main body and a controller arranged on one side of the PTC heater main body, the PTC heater main body comprises a lower shell and an upper cover which are sequentially connected from top to bottom, an installation cavity is formed between the lower shell and the upper cover, a PTC heating assembly is arranged in the installation cavity, and the PTC heating assembly is arranged in the installation cavity. A PTC heating assembly is arranged in the lower shell, a liquid flow cavity is formed between the PTC heating assembly and the bottom of the inner wall of the lower shell, a liquid inlet and a liquid outlet which are communicated with the liquid flow cavity are further formed in the two ends of the lower shell, the PTC heating assembly comprises a plurality of heating aluminum bases which are connected side by side, a heating cavity is formed above each heating aluminum base, and a heating element electrically connected with a controller is arranged in each heating cavity. The weight and the cost are reduced through single-cavity punch forming, meanwhile, the heating element layout and the heating cavity structure are optimized, the heat transfer efficiency is improved, light weight, cost control and efficient heating are achieved, the endurance of the electric automobile is prolonged, and the energy consumption and the manufacturing cost are reduced.

Description

TECHNICAL FIELD

[0001] The utility model relates to electric automobile heat management system technical field, specifically point to a kind of PTC heating device for electric automobile. BACKGROUND

[0002] Traditional fuel automobile utilizes engine waste heat to heat coolant, and then heat is transferred to the vehicle cabin through components such as a heater, achieving the function of heating. However, electric vehicles lack engines and cannot directly utilize waste heat, so independent heating systems are needed. Currently, PTC (Positive Temperature Coefficient) heating devices are widely used in electric vehicle thermal management systems due to their stable performance and rapid response.

[0003] However, existing PTC heating devices still have some problems. First, conventional PTC heating devices use a shell and aluminum base die casting structure, which has a complex manufacturing process and requires a large amount of aluminum material, resulting in high costs and heavy weight. Second, due to the structural limitations of the die casting, the wall thickness of the heating cavity is large, and the heat transfer efficiency is not high, which cannot meet the demand of electric vehicles for high-efficiency heating systems. In addition, the assembly process of the conventional scheme is complicated and requires a large assembly space, which is not conducive to the lightweight design of electric vehicles.

[0004] To solve the above problems, the present application provides a PTC heating device for electric vehicles, which aims to overcome the shortcomings of the prior art through innovative design, improve the heating performance of the electric vehicle thermal management system, reduce weight and cost. SUMMARY

[0005] The technical problem to be solved by the utility model is to overcome the above technical defects and provide a PTC heating device for electric vehicles.

[0006] To solve the above technical problems, the technical scheme provided by the utility model is as follows: a PTC heating device for electric vehicles, comprising a PTC heater main body and a controller arranged on one side of the PTC heater main body, the PTC heater main body comprising a lower shell and an upper cover connected in sequence from bottom to top, an installation cavity is formed between the lower shell and the upper cover, and a PTC heating assembly is arranged in the installation cavity, the PTC heating assembly and the bottom of the inner wall of the lower shell form a liquid flow cavity, the lower shell is further provided with a liquid inlet and a liquid outlet communicating with the liquid flow cavity at both ends, and the PTC heating assembly comprises a plurality of heating aluminum bases connected side by side, a heating cavity is arranged above each heating aluminum base, and a heating element electrically connected to the controller is arranged in the heating cavity.

[0007] Preferably, the heating element comprises a PTC ceramic sheet vertically arranged inside the heating cavity, and the PTC ceramic sheet is provided with a positive electrode sheet and a negative electrode sheet on two sides respectively, and the positive electrode sheet and the negative electrode sheet are respectively clamped with an insulating film between the positive electrode sheet and the negative electrode sheet and the inner wall of the heating cavity.

[0008] Preferably, the wall thickness of the heating cavity is 0.3-0.6mm.

[0009] Preferably, an adapter plate is arranged above the heating aluminum seat, the adapter plate is made of conductive material and is electrically connected with the controller through a lead wire, a plurality of positive electrode sheet docking grooves and negative electrode sheet docking grooves are arranged on the adapter plate, the positive electrode sheet and the negative electrode sheet of each group of heating elements are fixed in the corresponding positive electrode sheet docking groove and negative electrode sheet docking groove through soldering respectively, and a plurality of heating elements are connected with each other in series through the conductive path on the adapter plate.

[0010] Preferably, a plurality of the heating aluminum seats are connected in sequence into an integrated body through welding.

[0011] Preferably, the bottom of the inner cavity of the lower shell is upwardly protruded to form a plurality of protruding portions, and adjacent two protruding portions directly form a clamping groove for placing the heating aluminum seat.

[0012] Compared with the prior art, the heating shell split-welding electric heating device proposed in the application has significant technical advantages in the electric vehicle thermal management system.

[0013] Firstly, aiming at the problems of heavy weight and high cost of the PTC heating device in the prior art, the application adopts a single-cavity stamping forming heating cavity design, which significantly reduces the overall weight and reduces the amount of aluminum material, thereby realizing the dual goals of lightweight and cost control. This not only improves the endurance of electric vehicles, but also helps to reduce energy consumption and manufacturing cost.

[0014] Secondly, aiming at the problem of low heat transfer efficiency in the prior art, the application optimizes the layout of the heating element and the structure of the heating cavity to improve the heat transfer efficiency. The vertically arranged PTC ceramic sheet can directly and efficiently transfer heat to the surrounding medium, and the thin wall thickness of the heating cavity further accelerates the diffusion of heat, ensuring the rapid response and efficient operation of the heating system.

[0015] In summary, the application overcomes the shortcomings of weight, cost and heat transfer efficiency in the prior art through innovative design, and provides a more efficient, lightweight and cost-controllable heating solution for the electric vehicle thermal management system. These advantages not only improve the overall performance of electric vehicles, but also give them greater advantages in future market competition. BRIEF DESCRIPTION OF DRAWINGS

[0016] Figure 1 is a schematic diagram of an external structure of a PTC heating device for an electric vehicle.

[0017] Figure 2 is a schematic diagram of an internal structure of a PTC heating device for an electric vehicle.

[0018] Figure 3 is a schematic diagram of an internal split structure of a PTC heating device for an electric vehicle.

[0019] Figure 4 is a schematic diagram of an internal structure of a heating aluminum seat.

[0020] Figure 5 is a schematic diagram of a structure of a PTC heating device for an electric vehicle equipped with an adapter plate.

[0021] As shown in the figure: 1, PTC heater main body, 101, lower shell, 102, upper cover, 2, controller, 3, PTC heating assembly, 31, heating aluminum seat, 32, heating cavity, 33, heating element, 331, PTC ceramic sheet, 332, positive electrode sheet, 333, negative electrode sheet, 334, insulating film, 4, liquid flow cavity, 5, liquid inlet, 6, liquid outlet, 7, adapter plate, 8, protruding part, 9, clamping groove. DETAILED DESCRIPTION

[0022] The utility model will be further described in detail below with reference to the drawings.

[0023] The specific implementation of the utility model will be further described below with reference to the drawings. The same parts are denoted by the same reference numerals.

[0024] It should be noted that the words "front", "back", "left", "right", "up" and "down" used in the following description refer to the directions in the drawings, and the words "inner" and "outer" refer to the directions towards or away from the geometric center of a particular component.

[0025] In order to make the content of the utility model more easily understood clearly, the technical solutions in the utility model embodiments will be described clearly and completely below with reference to the drawings in the utility model embodiments.

[0026] Referring to the drawings Figure 1 - the drawings Figure 3The utility model provides a kind of PTC heating device for electric vehicle, including PTC heater main body 1 and the controller 2 being arranged in PTC heater main body 1 side, PTC heater main body 1 includes lower shell 101 and upper cover 102 connected in turn from bottom to top, lower shell 101 and upper cover 102 form mounting cavity between and be equipped with PTC heating assembly 3 in mounting cavity, PTC heating assembly 3 forms liquid flow cavity 4 with lower shell 101 inner wall bottom, lower shell 101 both ends are also equipped with with liquid flow cavity 4 communication inlet 5 and outlet 6, PTC heating assembly 3 includes several side-by-side connection heating aluminum base 31, every heating aluminum base 31 top is equipped with heating cavity 32 and heating cavity 32 is equipped with with the heating element 33 of electric connection with controller 2.

[0027] Combine with attached Figure 4 In a specific embodiment of the present application, the heating element 33 of the present application uses a PTC ceramic sheet 331 vertically arranged inside the heating cavity 32 as the core heating material. This arrangement ensures that heat can be directly and efficiently transferred to the surrounding medium. In order to ensure stable transmission of current and prevent short circuit, positive electrode sheet 332 and negative electrode sheet 333 are arranged on both sides of PTC ceramic sheet 331. In order to further enhance safety, positive electrode sheet 332 and negative electrode sheet 333 are each sandwiched with an insulating film 334 between the inner wall of the heating cavity 32. This design not only ensures electrical safety, but also avoids heat loss due to direct contact.

[0028] Combine with attached Figure 5 In order to realize the cooperative work of multiple heating elements 33, the present application sets a switching plate 7 above the heating aluminum base 31. The switching plate 7 is made of conductive material and is electrically connected to the controller 2 through wires. The switching plate 7 is provided with a plurality of positive electrode sheet docking grooves and negative electrode sheet docking grooves, and the positive electrode sheet 332 and the negative electrode sheet 333 of each group of heating elements 33 are fixed in the corresponding docking groove by soldering. In this way, the controller 2 can send current to each heating element 33 in series through the conductive path on the switching plate 7, so as to realize the cooperative work of multiple heating elements 33.

[0029] In one specific embodiment, the heating aluminum bases 31 are connected in sequence by welding. Specifically, the heating aluminum bases 31 and the heating elements 33 in the heating cavities 32 can be assembled separately during the manufacturing process. Each heating aluminum base 31 is equipped with an independent heating cavity 32, which is manufactured by single-cavity stamping forming technology. This forming method not only ensures the accuracy and dimensional stability of the heating cavity 32, but also greatly simplifies the manufacturing process. More importantly, multiple stamping-formed heating cavities 32 are welded together at the abutting position of the heating aluminum base 31, which is easy to process and has strong operability. Compared with traditional die castings, the stamping-formed heating cavities 32 have a thinner wall thickness, which is controlled within the range of 0.3-0.6 mm. This not only significantly reduces the amount of aluminum material used and achieves lightweight, but also improves the heat transfer efficiency.

[0030] Meanwhile, in order to improve assembly efficiency and reduce assembly space, the application designs a protruding part 8 at the bottom of the inner cavity of the lower shell 101. The card slot 9 for placing the heating aluminum base 31 is formed between the two adjacent protruding parts 8. This design not only simplifies the assembly process and reduces the assembly difficulty, but also further reduces the assembly space and achieves compact structure.

[0031] Working principle: During the heating process, the controller 2 sends a heating signal to the PTC heating assembly 3. This signal is transmitted to the adapter plate 7 through the wire. The adapter plate 7 is provided with a positive electrode sheet butt joint groove and a negative electrode sheet butt joint groove. The positive electrode sheet 332 and the negative electrode sheet 333 of each heating element 33 are fixed in the corresponding butt joint groove by soldering. In this way, the controller 2 can send current to each heating element 33 in series through the conductive path on the adapter plate 7.

[0032] When the current passes through the PTC ceramic sheet 331, according to the material characteristics (i.e. positive temperature coefficient effect), the resistance of the PTC ceramic sheet 331 will increase with the temperature rise. During this process, the PTC ceramic sheet 331 generates heat, which is transferred to the heating aluminum base 31 through the heating cavity 32, and then heats the cooling liquid in the entire liquid flow cavity 4.

[0033] After the cooling liquid is heated in the liquid flow cavity 4, it circulates through the liquid inlet 5 and the liquid outlet 6 at both ends of the lower shell 101. During this process, the cooling liquid transfers heat to the components of the vehicle's heating system, and then sends the heat to the vehicle cabin, thereby increasing the temperature in the vehicle cabin and achieving the purpose of heating.

[0034] The above has described the utility model and its implementation mode, which is not restrictive, and the drawings only show one of the implementation modes of the utility model, and the actual structure is not limited thereto. In summary, if a person skilled in the art is inspired thereby, without departing from the creative purpose of the utility model, similar structural modes and embodiments are not creatively designed, which should belong to the protection scope of the utility model.

Claims

1. A PTC heating device for electric vehicles, comprising a PTC heater body (1) and a controller (2) arranged on one side of the PTC heater body (1), wherein the PTC heater body (1) comprises a lower shell (101) and an upper cover (102) connected in sequence from bottom to top, a mounting cavity is formed between the lower shell (101) and the upper cover (102), and a PTC heating assembly (3) is arranged in the mounting cavity; the PTC heating assembly (3) and the bottom of the inner wall of the lower shell (101) form a liquid flow cavity (4); and the lower shell (101) is further provided with a liquid inlet (5) and a liquid outlet (6) which are in communication with the liquid flow cavity (4). The PTC heating assembly (3) comprises a plurality of heating aluminum bases (31) connected side by side, each of the heating aluminum bases (31) is provided with a heating cavity (32) above and is provided with a heating element (33) electrically connected with the controller (2) in the heating cavity (32); The heating element (33) comprises a PTC ceramic sheet (331) vertically arranged in the heating cavity (32), the PTC ceramic sheet (331) is provided with a positive electrode sheet (332) and a negative electrode sheet (333) on two sides respectively, and the positive electrode sheet (332) and the negative electrode sheet (333) are respectively clamped with the inner wall of the heating cavity (32) through an insulating film (334); The heating aluminum base (31) is provided with an adapter plate (7) above, the adapter plate (7) is made of conductive material and is electrically connected with the controller (2) through a wire, the adapter plate (7) is provided with a plurality of positive electrode sheet butt grooves and negative electrode sheet butt grooves, the positive electrode sheet (332) and the negative electrode sheet (333) of each group of heating elements (33) are respectively fixed in the corresponding positive electrode sheet butt groove and negative electrode sheet butt groove through soldering, and a plurality of heating elements (33) are connected with each other in series through the conductive path on the adapter plate (7).

2. The PTC heating device for an electric vehicle according to claim 1, characterized by The wall thickness of the heating cavity (32) is 0.3-0.6mm.

3. The PTC heating device for an electric vehicle according to claim 1 or 2, characterized by A plurality of the heating aluminum bases (31) are connected in sequence into an integrated body through welding.

4. The PTC heating device for an electric vehicle according to claim 3, characterized by The bottom of the inner cavity of the lower shell (101) is upwardly protruded to form a plurality of protruding portions (8), and adjacent two protruding portions (8) directly form clamping grooves (9) for placing the heating aluminum bases (31).

Images