Thick film heating module for new energy automobile

Abstract

The utility model provides a thick film heating module for a new energy automobile. The thick film heating module comprises a surface protection layer, a heating resistance layer, a conductor material layer, an insulating medium layer and a composite substrate which are arranged in sequence, a through hole is formed in the surface protection layer, and an avoiding part matched with the through hole is arranged on the heating resistance layer, so that the conductor material layer corresponds to the through hole; the composite substrate comprises a first substrate and a second substrate, and the thermal conductivity of the second substrate is larger than that of the first substrate. The technical scheme can adapt to various shapes and sizes and meet different application scenes, warping and stripping are avoided, good heat conductivity, heat conduction uniformity, material compatibility and reliability are achieved, and heat conduction efficiency is improved.

Description

Technical Field

[0001] This utility model relates to the field of medical device technology, specifically to a thick film heating module for new energy vehicles. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the demand for efficient and stable heating elements in vehicle thermal management systems is increasing. Current mainstream thick-film heating technology uses stainless steel plates as substrates, forming thick-film heating elements through electronic paste printing and high-temperature sintering processes, achieving liquid heating through electrothermal conversion. However, this technology faces the following technical bottlenecks in practical applications:

[0003] 1. Heat conduction efficiency and uniformity defects

[0004] Traditional flat stainless steel substrates have a planar heating surface, and the heating wire pattern is limited by the printing process, making it difficult to achieve a three-dimensional distribution. This leads to the coexistence of localized high-temperature and low-temperature areas when heat is conducted to the edge of the substrate. Uneven heating not only causes energy loss but also generates abnormal noise due to the violent vaporization of liquids, significantly increasing the operating noise of the heating system.

[0005] 2. Insufficient material compatibility and reliability

[0006] The heating system pipes in new energy vehicles are mostly made of aluminum alloy, but the difference in physical and chemical properties between stainless steel substrates and aluminum makes direct welding difficult. Even if a connection is achieved through special processes, stainless steel... With aluminum The mismatch in thermal expansion coefficients can still cause stress concentration at the interface, which can easily lead to peeling or even failure of the welded parts after long-term use, seriously affecting the life and safety of the heating element.

[0007] In summary, developing a novel thick-film heating element that combines high efficiency, low noise, and high reliability, while overcoming limitations in material systems and structural design, has become a pressing technical challenge in the field of thermal management for new energy vehicles. Utility Model Content

[0008] To address the shortcomings of existing technologies, the purpose of this utility model is to provide a thick-film heating module for new energy vehicles that can adapt to various shapes and sizes, meet different application scenarios, avoid warping and peeling, and possesses good thermal conductivity, uniform heat conduction, material compatibility and reliability, thereby improving heat conduction efficiency.

[0009] To solve the above-mentioned technical problems, this utility model provides a thick film heating module for new energy vehicles, comprising a surface protective layer, a heating resistance layer, a conductor material layer, an insulating dielectric layer, and a composite substrate arranged sequentially; the surface protective layer has through holes, and the heating resistance layer has clearance portions matching the through holes, so that the conductor material layer corresponds to the through holes; the composite substrate includes a first substrate and a second substrate, wherein the thermal conductivity of the second substrate is greater than that of the first substrate.

[0010] Furthermore, the surface protective layer includes at least one first insulating medium.

[0011] Furthermore, the insulating dielectric layer comprises at least four layers of second insulating dielectric.

[0012] Further, the heating resistance layer includes a plurality of first resistors and two second resistors. The upper surfaces of the plurality of first resistors and the upper surfaces of the two second resistors are located on the same horizontal plane, and the lower surfaces of the plurality of first resistors and the two second resistors are located on the same horizontal plane. The two second resistors are located on the left and right sides of the plurality of first resistors. The conductor material layer includes a plurality of first conductors that match the first resistors and two sets of second conductors that match the second resistors. The plurality of first conductors are located at the front and rear ends of the plurality of first resistors and are electrically connected to the plurality of first resistors. The two sets of second conductors are located at the front and rear ends of the two second resistors and are electrically connected to the two second resistors. The clearance portion corresponds to the first resistors and the second resistors, or the clearance portion corresponds to the second resistors. The second conductors correspond to the through holes.

[0013] Furthermore, the first insulating medium and the second insulating medium may be the same or different.

[0014] Furthermore, the surface protective layer includes one or two layers of the first insulating medium.

[0015] Furthermore, the insulating dielectric layer comprises four or five layers of the second insulating dielectric.

[0016] Furthermore, the thickness of the second substrate is less than that of the first substrate.

[0017] Furthermore, the first substrate is made of stainless steel.

[0018] Furthermore, the second substrate is a nickel plate.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] (1) By setting the surface protective layer and the insulating dielectric layer as a multi-layer structure, the thickness of each screen printing layer can be reduced, the process difficulty of each layer can be reduced, the stress concentration during the drying / sintering process can be reduced, the yield can be improved, and the layered structure can be precisely adjusted in shape through the layer-by-layer construction method, which makes it easy to make the thick film heating module three-dimensional to adapt to various shapes and sizes, especially to adapt to substrates with complex curved surfaces or three-dimensional shapes, thereby meeting different application scenarios, especially suitable for scenarios that need to be bonded to curved surfaces, avoiding the problem of thick layer cracking or peeling. In addition, it is also easy to adjust the number of layers according to different needs, enhancing design flexibility.

[0021] (2) Since this application achieves three-dimensional distribution through multi-layer design, compared with the flat plate design of traditional thick film heating modules, it avoids the phenomenon of local high temperature area and low temperature area coexisting when heat is conducted to the edge of the substrate, that is, uneven heating, which leads to energy loss and significantly increases the operating noise of the heating system, and has good heat conduction uniformity.

[0022] (3) By dividing the composite substrate into a first substrate and a second substrate, and designing the thermal conductivity of the second substrate to be greater than that of the first substrate, the heat conduction efficiency is improved.

[0023] (4) By adopting a design of stainless steel plate + nickel plate, the problem of warping and peeling caused by inconsistent material expansion coefficients during the welding of stainless steel and aluminum can be solved, thereby improving the compatibility and reliability of the materials. Attached Figure Description

[0024] Other features, objects, and advantages of this invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0025] Figure 1 A schematic diagram of the structure of a thick film heating module for new energy vehicles provided in this embodiment of the present invention;

[0026] Figure 2 An exploded view of the structure of a thick-film heating module for new energy vehicles provided in this embodiment of the present invention;

[0027] Figure 3 This is a schematic diagram of the structure of a composite substrate for a thick-film heating module for new energy vehicles, provided as an embodiment of the present invention.

[0028] In the picture:

[0029] 1. Surface protective layer; 101. Through hole; 2. Heating resistor layer; 201. First resistor; 202. Second resistor; 3. Conductor material layer; 301. First conductor; 302. Second conductor; 4. Insulating dielectric layer; 5. Composite substrate; 501. First substrate; 502. Second substrate. Detailed Implementation

[0030] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the present invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0031] Example:

[0032] Please see Figures 1-3 This utility model provides a thick film heating module for new energy vehicles, which includes a surface protective layer 1, a heating resistance layer 2, a conductor material layer 3, an insulating dielectric layer 4 and a composite substrate 5 arranged sequentially from top to bottom;

[0033] The surface protective layer 1 includes at least one first insulating medium, and the insulating medium layer 4 includes at least four second insulating mediums. The first insulating medium and the second insulating medium may be the same or different. Preferably, the surface protective layer 1 includes 1-2 layers of first insulating medium, and the insulating medium layer 4 includes 4-5 layers of second insulating medium.

[0034] A through hole 101 is provided on the surface protective layer 1, and a clearance portion matching the through hole 101 is provided on the heating resistance layer 2 so that the conductor material layer 3 corresponds to the through hole 101; preferably, the heating resistance layer 2 includes a plurality of first resistors 201 and two second resistors 202, the upper end surfaces of the plurality of first resistors 201 and the upper end surfaces of the two second resistors 202 are located on the same horizontal plane, the lower end surfaces of the plurality of first resistors 201 and the lower end surfaces of the two second resistors 202 are located on the same horizontal plane, and the two second resistors 202 are located on the left and right sides of the plurality of first resistors 201; conductor material Layer 3 includes multiple sets of first conductors 301 that match the first resistors 201 and two sets of second conductors 302 that match the second resistors 202. The multiple sets of first conductors 301 are located at the front and rear ends of the multiple first resistors 201 and are electrically connected to the multiple first resistors 201 respectively. The two sets of second conductors 302 are located at the front and rear ends of the two second resistors 202 and are electrically connected to the two second resistors 202 respectively. The clearance portion corresponds to the first resistors 201 and the second resistors 202, or the clearance portion corresponds to the second resistors 202. The second conductors 302 correspond to the through holes 101.

[0035] The composite substrate 5 includes a first substrate 501 and a second substrate 502 arranged sequentially from top to bottom. The thermal conductivity of the second substrate 502 is greater than that of the first substrate, and the thickness of the second substrate 502 is less than that of the first substrate 501. Preferably, the first substrate 501 is made of stainless steel plate, and the second substrate 502 is made of nickel plate.

[0036] In this embodiment, paste is printed on the composite substrate 5 using a thick-film screen printing process. The insulating dielectric layer 4 is typically printed 4 or 5 times. The surface protective layer 1 is typically printed 1 or 2 times. Then, the entire thickness of the thick-film heating module is sintered at high temperature to a film layer ranging from tens of micrometers to hundreds of micrometers.

[0037] In this embodiment, a composite substrate 5 is used instead of the conventional stainless steel substrate. The composite substrate 5 is composed of, but is not limited to, a stainless steel plate and a nickel plate.

[0038] The thermal conductivity of stainless steel 430 is 23.9 W / (m·K).

[0039] Nickel, with a thermal conductivity of 90.9 W / (m·K), is a hard and ductile metal exhibiting ferromagnetism and good thermal and electrical conductivity. It is chemically stable and has strong oxidation resistance. It serves as a welding material and surface agent between stainless steel and copper. Nickel also shows excellent welding properties with aluminum.

[0040] The specific embodiments of this utility model have been described above. It should be understood that this utility model is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the substantive content of this utility model. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A thick film heating module for a new energy vehicle, characterized in that, The material comprises a surface protective layer (1), a heating resistance layer (2), a conductor material layer (3), an insulating dielectric layer (4), and a composite substrate (5) arranged sequentially. The surface protective layer (1) has a through hole (101), and the heating resistance layer (2) has a clearance portion that matches the through hole (101), so that the conductor material layer (3) corresponds to the through hole (101). The composite substrate (5) includes a first substrate (501) and a second substrate (502), and the thermal conductivity of the second substrate (502) is greater than that of the first substrate.

2. The thick film heating module for a new energy vehicle according to claim 1, characterized in that, The surface protective layer (1) includes at least one first insulating medium.

3. The thick film heating module for a new energy vehicle according to claim 2, characterized in that, The insulating dielectric layer (4) includes at least four layers of second insulating dielectric.

4. The thick film heating module for a new energy vehicle according to claim 3, characterized in that, The heating resistance layer (2) includes a plurality of first resistors (201) and two second resistors (202). The upper surfaces of the plurality of first resistors (201) and the upper surfaces of the two second resistors (202) are located on the same horizontal plane. The lower surfaces of the plurality of first resistors (201) and the lower surfaces of the two second resistors (202) are located on the same horizontal plane. The two second resistors (202) are located on the left and right sides of the plurality of first resistors (201). The conductor material layer (3) includes a plurality of first conductors (301) that match the first resistors (201) and two sets of conductors that match the second resistors (202). 2) Matching second conductors (302), multiple sets of first conductors (301) are respectively located at the front and rear ends of multiple first resistors (201) and are electrically connected to multiple first resistors (201) respectively, two sets of second conductors (302) are respectively located at the front and rear ends of two second resistors (202) and are electrically connected to two second resistors (202) respectively; the clearance part corresponds to the first resistor (201) and the second resistor (202), or the clearance part corresponds to the second resistor (202); the second conductor (302) corresponds to the through hole (101).

5. The thick film heating module for a new energy vehicle according to claim 3, characterized in that, The first insulating medium and the second insulating medium may be the same or different.

6. A thick-film heating module for new energy vehicles according to claim 5, characterized in that, The surface protective layer (1) includes one or two layers of the first insulating medium.

7. The thick film heating module for a new energy vehicle according to claim 5, characterized in that, The insulating dielectric layer (4) includes four or five layers of the second insulating dielectric.

8. The thick film heating module for a new energy vehicle according to any one of claims 1 to 7, characterized in that, The thickness of the second substrate (502) is less than that of the first substrate (501).

9. The thick film heating module for a new energy vehicle according to claim 8, characterized in that, The first substrate (501) is made of stainless steel.

10. The thick film heating module for a new energy vehicle according to claim 9, characterized in that, The second substrate (502) is made of nickel plate.

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