Novel automotive electric heating tube heating core

Abstract

The utility model relates to the technical field of electric heating, and discloses a novel automotive electric heating tube heating core which comprises at least one single-head electric heating tube, a fin sleeve is sleeved outside the single-head electric heating tube, fins are arranged on the outer surface of the fin sleeve to form a flow channel structure, the single-head electric heating tube is fixedly connected with the fin sleeve, and the fin sleeve is fixedly connected with the single-head electric heating tube. An outer tube and an end cover are arranged in the single-head electric heating tube, the end cover is fixed to the tail end of the outer tube in a sealed mode, and the end cover and the fin sleeve form an integrated packaging structure. The problems that in the prior art, the size is too large, the heat transfer efficiency is low and cost is high are solved, and the purposes of low cost, small size and high heat transfer efficiency are achieved.

Description

Technical Field

[0001] This utility model relates to the field of electrothermal technology, and in particular to a heater element that is structurally combined with a coupling element or a support. Background Technology

[0002] Currently, automotive electric heating element-based water heaters on the market mainly fall into two categories: one where the heating element is assembled into a specially structured flow channel cavity, with the coolant in direct contact with the heating element surface; and the other where the heating element is used as an insert, directly die-cast. Both structures have the following problems: **Heating element plus shell and flow channel:** 1. The heating element diameter is generally quite small, with voltage ratings mostly between 2000V / min and 3000V / min, and the contact area with the coolant is limited, resulting in low heat transfer efficiency; 2. To avoid excessively high contact surface temperatures leading to coolant carbonization and failure, a longer heating element is required under the same power conditions, corresponding to a larger flow channel shell volume, increasing cost. **Die-cast heater:** As an insert, the heating element, due to the high casting pressure in automotive products, is prone to uncontrollable displacement during die-casting, resulting in relatively poor consistency in temperature measurement response feedback during subsequent temperature control setup. For example, Chinese Patent CN211481504U discloses an air-heating finned electric heating tube, providing the following technical solution. This utility model belongs to the field of heating equipment technology, and specifically to an air-heating finned electric heating tube. During prolonged use, a layer of dust accumulates on the surface of the fins. By moving a sliding rod outwards, the fins slide in a sliding groove, disengaging from the positioning block. The fins can then be moved left and right to increase the distance between them, facilitating wiping and cleaning, thus removing the dust from the fin surface. A support spring then resets the fins, and pulling the spring causes the sliding rod to engage and fix the fins via the positioning block, completing the installation. This method effectively cleans the dust from the fin surface, preventing the dust from being blown away by a blower, ensuring a clean heating environment, and improving the efficiency of fin cleaning. However, the aforementioned air-heating finned electric heating tube is mainly used for air convection and does not directly contact the coolant. It does not belong to the same heat transfer medium scenario, and its overall structure is relatively large, making it unsuitable for the compact structure and small size requirements of automotive applications. Utility Model Content

[0003] This invention solves the problems of excessive size, low heat transfer efficiency, and high cost in the prior art, and proposes a new type of automotive electric heating tube core that achieves the goals of low cost, small size, and high heat transfer efficiency.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A novel automotive electric heating element includes at least one single-ended heating element. The single-ended heating element is fitted with a finned sleeve, and the outer surface of the finned sleeve has fins forming a flow channel structure. The single-ended heating element is fixedly connected to the finned sleeve. The single-ended heating element has an outer tube and an end cap inside. The end cap is sealed and fixed to the end of the outer tube, forming an integrated encapsulation structure with the finned sleeve.

[0006] This structure significantly improves pressure resistance through a large-diameter single-ended heating tube, greatly increases the heat exchange area through the flow channel structure formed by the finned sleeve, reduces the overall size and manufacturing cost through the integrated packaging design, and enhances leak-proof reliability through end cap sealing.

[0007] Preferably, the outer tube includes an inner filling layer, which includes a magnesium powder base at the bottom and a magnesium powder cover at the top, with a magnesium powder rod between them, and magnesium powder filling the outside of the magnesium powder rod.

[0008] The combination of magnesium powder rods and filler layers ensures the stability of the internal heat conduction path while improving the overall structural strength of the heating element.

[0009] Preferably, the magnesium powder rod is surrounded by a resistance wire, the top of the magnesium powder cover is provided with sealing silicone, the outer tube is in the shape of a long hollow round tube, and the single-ended heating tube is also provided with an extension rod.

[0010] The design of the resistance wire surrounding the magnesium powder rod improves heating efficiency, the sealing silicone ensures airtightness under high-temperature conditions, and the hollow round tube structure enhances mechanical support.

[0011] Preferably, the resistance wire is connected to the lead-out rod, and the lead-out rod passes through the magnesium powder rod and the sealing silicone.

[0012] Direct connection reduces the risk of contact resistance, while the through-type structure ensures the stability of the electrical connection and reduces the possibility of excessive local temperature rise.

[0013] Preferably, the magnesium powder cap has a through hole in the center for the lead-out rod to pass through, with one end of the lead-out rod extending to the magnesium powder bottom and the other end extending to the end of the outer tube.

[0014] Preferably, the single-head heating element and the finned sleeve are fixedly connected by riveting or laser welding, and their axes coincide.

[0015] Press riveting or laser welding ensures structural robustness, while the axial alignment design optimizes the heat conduction path, reducing energy loss and improving thermal efficiency.

[0016] Preferably, the outer surface of the finned sleeve is provided with a continuous or discontinuous fin structure, specifically in the shape of a ring, vertical or spiral.

[0017] Diverse fin shapes adapt to different fluid flow requirements, increasing the heat exchange area while optimizing fluid disturbance within the flow channel, thereby improving overall heat exchange efficiency.

[0018] Preferably, the single-head heating tubes are arranged in parallel, and the outer finned sleeves form a flow channel structure, forming an integrated heating module.

[0019] Parallel arrangement allows for flexible expansion of power requirements, integrated modular design simplifies the installation process, and optimized flow channel structure enables efficient thermal management.

[0020] Compared with the prior art, the beneficial effects of this utility model are as follows.

[0021] 1. This utility model adopts an integrated packaging design. The single-head heating element and the finned sleeve are fixedly connected by riveting or laser welding, ensuring a robust structure and aligned axes, reducing energy loss in the heat conduction path. The end cap seal and the fixed end of the outer tube form a leak-proof barrier, significantly improving pressure resistance and sealing reliability. The annular, vertical, or spiral fins distributed on the outer surface of the finned sleeve form a multi-morphological flow channel structure, increasing the heat exchange area and enhancing heat exchange efficiency by optimizing fluid turbulence. In addition, the hollow circular tubular outer tube and internal filling layer design further strengthen mechanical support capabilities, making the overall structure more compact and durable, while reducing manufacturing costs.

[0022] 2. In the internal filling layer of this utility model, the bottom magnesium powder base, the top magnesium powder cover, and the magnesium powder rod form a stable axial heat conduction path. Combined with the magnesium powder filling on the outside, this ensures uniform heat distribution and enhances structural strength. The resistance wire is arranged around the magnesium powder rod and directly connected to the through-type lead-out rod, reducing the risk of contact resistance and optimizing heating efficiency. The sealing silicone maintains its seal at high temperatures, preventing internal components from becoming damp or oxidized. The diverse fin structure design adapts to different fluid flow characteristics, achieving rapid heat transfer by enhancing turbulence and expanding the contact area, meeting the high-efficiency heating requirements of automotive environments.

[0023] 3. This utility model includes solutions for single electric heating tubes and multiple electric heating tubes arranged in parallel to form multiple electric heating tubes. In the multiple electric heating tube solution, the flow channel structure of the outer finned sleeve forms an integrated heating module, supporting flexible expansion of power requirements. The modular design simplifies the installation process, while achieving efficient thermal management through unified flow channel optimization, adapting to complex vehicle space layouts. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of a single-ended electric heating tube of a novel automotive electric heating tube heating core according to this utility model.

[0025] Figure 2This is a cross-sectional view of a single-head electric heating tube of a novel automotive electric heating tube heating core according to this utility model.

[0026] Figure 3 This is a schematic diagram of the structure of a combination of multiple electric heating tubes in a novel automotive electric heating tube heating core according to this utility model.

[0027] Illustration:

[0028] 1. Finned sleeve, 2. Outer tube, 3. End cap, 4. Lead-out rod, 5. Sealing silicone, 6. Magnesium powder cap, 7. Magnesium powder rod, 8. Magnesium powder, 9. Resistance wire, 10. Magnesium powder base, 11. Single-ended heating element, 12. Flow channel structure. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of this disclosure clearer, the embodiments of this disclosure will be further described in detail below with reference to the accompanying drawings. The proportions of the components are not drawn to scale, and the proportions and dimensions shown in the drawings should not limit the essential technical solutions of this utility model. These embodiments do not exhaustively describe all details, nor do they limit this utility model to merely the specific embodiments described.

[0030] See Figures 1 to 3 As shown, a novel automotive electric heating element includes at least one single-ended heating element. The single-ended heating element is fitted with a finned sleeve, and the outer surface of the finned sleeve has fins forming a flow channel structure. The single-ended heating element is fixedly connected to the finned sleeve. The single-ended heating element has an outer tube and an end cap inside. The end cap is sealed and fixed to the end of the outer tube, forming an integrated encapsulation structure with the finned sleeve.

[0031] like Figure 1 In one embodiment shown, Figure 1 This is a schematic diagram of the structure of a single-ended electric heating tube of a novel automotive electric heating element according to this utility model. The novel automotive electric heating element designed in this utility model consists of at least one single-ended electric heating tube 11 as its core component, which is externally fitted with a finned sleeve 1. The outer surface of the finned sleeve 1 forms a flow channel structure 12 through fins of a specific shape. The single-ended electric heating tube 11 and the finned sleeve 1 are axially aligned and fixedly connected using a press-fit or laser welding process. Internally, the single-ended electric heating tube 11 includes an outer tube 2 and a sealed end cap 3. The end cap 3 is precision-machined to form an integrated encapsulation structure with the end of the outer tube 2, and a through-type lead-out rod 4 serves as an electrical connection carrier. The finned structure's morphological design is engineering-adaptable, supporting three typical configurations: annular, vertical, or spiral, and can be arranged continuously or intermittently.

[0032] This invention achieves a performance breakthrough in the field of automotive heaters through multi-dimensional innovation. In terms of structural strength, the use of a large-diameter single-head heating element 11 increases its pressure resistance to 3500V / min, a significant improvement over traditional solutions. Simultaneously, the axial fixing process using riveting or laser welding ensures minimal assembly precision deviation between the heating element and the finned sleeve 1. This directly brings two technical advantages: firstly, the coincident axis design shortens the heat conduction path, effectively reducing energy loss; secondly, precise alignment ensures uniform temperature field distribution when multiple heating elements are connected in parallel, keeping the response feedback error of the temperature control system within a small range. Regarding heat exchange efficiency, the finned structure utilizes turbulence enhancement technology to increase the effective heat exchange area to several times that of traditional structures. Combined with the guiding effect of spiral or annular fins on the coolant, the heat transfer coefficient is significantly improved compared to existing solutions. This high thermal efficiency allows for a substantial reduction in the heating core volume under the same power output conditions, making it suitable for automotive environments.

[0033] like Figure 2 In one embodiment shown, Figure 2 This is a cross-sectional view of a single-ended electric heating element of a novel automotive electric heating element according to this utility model. The core of this novel automotive electric heating element is composed of a single-ended electric heating element 11, which is externally encased in a finned sleeve 1. The outer surface of the finned sleeve 1 is precision-machined to form a flow channel structure 12 with specific geometric features. The fins can be annular, vertical, or spiral, supporting continuous or intermittent distribution patterns. The single-ended electric heating element 11 and the finned sleeve 1 are axially aligned and fixed using riveting or laser welding processes, with their axes coinciding to form a highly integrated encapsulated structure. Internally, the single-ended electric heating element 11 includes an outer tube 2 and an end cap 3. The outer tube 2 adopts a long, hollow circular tube structure, and the end cap 3 provides an airtight seal at its end.

[0034] The core heat conduction system of this device consists of an internal filling layer: a magnesium powder base 10 at the bottom serves as a heat-conducting base, and a magnesium powder cover 6 with through holes is positioned at the top. An axial heat transfer channel is established between the two through a magnesium powder rod 7. Magnesium powder 8 fills the outer side of the magnesium powder rod 7 to form a radial heat transfer medium, with precisely arranged resistance wires 9 spirally surrounding its periphery. The electrical connection system uses a through-type lead-out rod 4. One end of this component extends to the magnesium powder base 10 to form a negative electrode connection, while the other end penetrates the central through hole of the magnesium powder cover 6 and passes through the sealing silicone 5, ultimately forming a positive electrode output terminal with the end of the outer tube 2. All components achieve physical coupling through a gradient press-fit process. The magnesium powder used is magnesium oxide.

[0035] This utility model device features an innovative design that, through systematic engineering optimization, achieves significant technical advantages in structural strength, heat exchange efficiency, sealing reliability, and production economy. Structurally, the combination of the large-diameter single-ended heating element 11 and the hollow circular outer tube 2 significantly enhances pressure resistance. Combined with axial fixing processes such as riveting or laser welding, it ensures a firm connection and precise positioning between components. The coincident axis design optimizes the heat conduction path. Combined with the axial heat transfer system of magnesium powder base 10-magnesium powder rod 7-magnesium powder cover 6, it forms an efficient longitudinal heat flow channel, effectively reducing energy loss. The uniform filling of magnesium powder 8 not only enhances lateral heat diffusion capacity but also improves overall mechanical strength, meeting the vibration resistance requirements of the vehicle environment.

[0036] The flow channel design of the finned sleeve 1 significantly expands the heat exchange surface area. The spiral fins guide the fluid to generate turbulence, significantly enhancing convective heat transfer efficiency. The annular and vertical fins provide adaptable solutions for different flow rate conditions. The spiral coupling layout of the resistance wire 9 and the magnesium powder rod 7 optimizes the contact area between the heating element and the heat transfer medium. Combined with the through-type direct connection structure of the lead-out rod 4, it effectively reduces contact resistance and improves energy conversion efficiency. The sealing system employs a combined mechanical and elastic seal scheme. The rigid sealing interface of the magnesium powder cover 6 and the high-temperature adaptability of the sealing silicone 5 together construct multiple leak-proof barriers, ensuring long-term sealing stability under extreme temperature conditions.

[0037] In terms of manufacturing and scalability, the modular architecture demonstrates significant advantages: standardized single-tube design simplifies production processes, while riveting or laser welding assembly methods improve production consistency and reduce the processing difficulty of complex flow channel structures. When multiple tubes are arranged in parallel, the integrated flow channel design of the finned sleeve 1 achieves linear expansion of power output while maintaining a compact overall size. This modular solution not only supports flexible adaptation to different power requirements but also balances heat distribution uniformity and fluid resistance through optimized flow channel layout, meeting the technical requirements of miniaturization and high power density of thermal management systems in new energy vehicles. Engineering verification has shown that this design exhibits excellent temperature response consistency and structural durability during long-term operation, providing a high-performance and reliable solution for the automotive heating field.

[0038] like Figure 3 In one embodiment shown, Figure 3This is a schematic diagram of the structure of a novel automotive electric heating element core according to this utility model, comprising multiple electric heating tubes. The novel automotive electric heating element core designed in this utility model adopts a modular architecture design, with its core consisting of at least one single-ended electric heating tube 11. Each single-ended electric heating tube 11 is externally equipped with a dedicated finned sleeve 1. The outer surface of this sleeve is precision-machined to form a finned structure with specific geometric features, thereby constructing a functional flow channel structure 12. The single-ended electric heating tube 11 and the finned sleeve 1 are physically fixed by riveting or laser welding. An outer tube 2 is set internally as the main support structure, and the end is hermetically sealed by an end cap 3, forming an integrated encapsulation system together with the finned sleeve 1. In extended application scenarios, multiple single-ended electric heating tubes 11 can be combined in a parallel arrangement. The outer finned sleeve 1, through topology optimization of the flow channel structure 12, forms an integrated heating module, realizing a multi-heat source collaborative working mode.

[0039] This utility model's modular design supports flexible configuration of single to multiple heating elements. The parallel arrangement allows for linear expansion of power output, while the integrated flow channel structure ensures uniform heat distribution when multiple heat sources work together, preventing localized overheating. In terms of manufacturing, riveting or laser welding simplifies assembly, and the aligned axis design reduces machining accuracy requirements. Combined with standardized component design, this significantly improves production consistency. This highly integrated structural solution, while maintaining a compact size, enables efficient operation of the thermal management system. It meets the stringent requirements of lightweight and miniaturization in new energy vehicles and, through its scalable architecture, adapts to the power needs of different vehicle models, providing a high-performance and highly adaptable solution for the automotive heating field.

[0040] In another embodiment, this utility model relates to a vehicle water heating element with a built-in flow channel, which uses a single-ended heating element and a finned sleeve, and combines the two by means of riveting, welding, etc. Structurally, it can be referenced Figure 1 and Figure 2 A single-ended heating element, or refer to Figure 3 It is a combination of multiple single-ended heating tubes, and the shape of the fins on the surface of the outer sleeve can be, but is not limited to, spiral, annular, vertical, etc.

[0041] Compared to conventional automotive water heaters, this design uses a large-diameter single-ended heating element, enabling the product to withstand higher pressure ratings. The finned structure on the outer layer of the heating element significantly increases the heat exchange area with the coolant, resulting in more efficient heat transfer and allowing the product to handle higher power output. The product is also smaller and less expensive. Compared to cast heaters, this design combines the flow channel structure with the heating element through riveting and welding, resulting in better uniformity of the heating element position compared to integral die casting. This allows for more precise response feedback during subsequent temperature control setup.

[0042] Compared with the two existing mainstream heater designs, this utility model device adopts a combination of single-head electric heating tubes and finned tubes through processes such as riveting and welding. The electric heating tubes have a larger diameter and a higher voltage rating, reaching 3500V / min. At the same time, the finned structure provides a larger contact area during heating, resulting in better heat transfer. It can also effectively prevent the contact surface temperature from becoming too high even at high power output, achieving a lightweight and miniaturized design. Furthermore, the current design provides better consistency in the position of the electric heating tubes, which is conducive to obtaining more accurate temperature measurement response feedback and achieving precise temperature control. The combination of multiple single-head electric heating tubes allows for more flexible combinations to achieve multi-level power output.

[0043] In summary, this utility model designs a novel automotive electric heating element core, whose core structure consists of a single-ended electric heating tube 11 and a finned sleeve 1. The single-ended electric heating tube 11 adopts a large-diameter design, and the finned sleeve 1 is externally fitted. Precise fixation with aligned axes is achieved through riveting or laser welding processes, forming an integrated encapsulation system. The outer surface of the finned sleeve 1 is precision-machined to form annular, vertical, or spiral fin structures, constructing a flow channel structure 12, significantly expanding the heat exchange surface area and optimizing fluid turbulence. Internally, the sealing fit between the outer tube 2 and the end cap 3 enhances leak-proof reliability. The axial heat transfer channel formed by the magnesium powder base 10, magnesium powder rod 7, and magnesium powder cap 6, combined with the magnesium powder 8 filling the outer side, forms an efficient longitudinal heat flow conduction path. The spiral arrangement of the resistance wire 9 around the magnesium powder rod 7 improves energy conversion efficiency, and the through-type lead-out rod 4 directly connects to the resistance wire 9, reducing the risk of contact resistance. When multiple single-ended heating tubes 11 are arranged in parallel, the integrated flow channel structure 12 of the finned sleeve 1 forms a modular heating unit through topology optimization, supporting flexible power expansion. The innovative advantages of this design are reflected in multi-dimensional synergistic improvements: In terms of structural strength, the combination of the large-diameter single-head heating tube 11 and the hollow outer tube 2 enables it to withstand a pressure rating of 3500V / min. The riveting or laser welding process ensures the positioning accuracy and connection firmness of the components. The axis coincidence design shortens the heat conduction path, and combined with the uniform heat diffusion characteristics of the magnesium powder filling layer, it effectively reduces energy loss. In terms of heat exchange performance, the fin structure enhances convective heat transfer efficiency through turbulence effect, the spiral fins optimize the fluid movement trajectory, and the annular and vertical fins adapt to different flow velocity conditions, significantly improving heat transfer efficiency compared to traditional solutions. The modular architecture supports linear power expansion from single tube to multiple tubes, and the integrated flow channel design balances the thermal field distribution and fluid resistance, meeting the requirements of new energy vehicles for compact layout and high power density. In terms of production economy, standardized component design and automated assembly process reduce manufacturing costs, riveting / laser welding simplifies the processing flow, and the flexible configuration of multiple tube combinations improves production line compatibility.

[0044] This utility model is not limited to the above-described embodiments. Any changes made to its shape or material composition, as long as the structural design provided by this utility model is adopted, are considered a variation of this utility model and should be regarded as within the protection scope of this utility model.

Claims

1. A novel automotive electric heating element, characterized in that, It includes at least one single-ended heating tube (11), the single-ended heating tube (11) is covered with a finned sleeve (1), the outer surface of the finned sleeve (1) is provided with a finned flow channel structure (12), the single-ended heating tube (11) is fixedly connected to the finned sleeve (1), the single-ended heating tube (11) is provided with an outer tube (2) and an end cap (3), the end cap (3) is sealed and fixed at the end of the outer tube (2), and forms an integrated encapsulation structure with the finned sleeve (1).

2. The novel automotive electric heating element according to claim 1, characterized in that, The outer tube (2) includes an inner filling layer, which includes a magnesium powder base (10) at the bottom and a magnesium powder cover (6) at the top, with a magnesium powder rod (7) between them, and magnesium powder (8) filling the outside of the magnesium powder rod (7).

3. A novel automotive electric heating element according to claim 2, characterized in that, The magnesium powder rod (7) is surrounded by a resistance wire (9), the top of the magnesium powder cover (6) is provided with a sealing silicone (5), the outer tube (2) is in the shape of a long hollow round tube, and the single-head heating tube (11) is also provided with a lead-out rod (4).

4. A novel automotive electric heating element according to claim 3, characterized in that, The resistance wire (9) is connected to the lead-out rod (4), and the lead-out rod (4) passes through the magnesium powder rod (7) and the sealing silicone (5).

5. A novel automotive electric heating element according to claim 3 or 4, characterized in that, The magnesium powder cap (6) has a through hole in the center for the lead-out rod (4) to pass through. One end of the lead-out rod (4) extends to the magnesium powder bottom (10), and the other end extends to the end of the outer tube (2).

6. A novel automotive electric heating element according to claim 3 or 4, characterized in that, The single-head heating element (11) and the finned sleeve (1) are fixedly connected by riveting or laser welding, and their axes coincide.

7. A novel automotive electric heating element according to claim 6, characterized in that, The outer surface of the finned sleeve (1) is provided with a continuous or discontinuous fin structure, specifically in the shape of a ring, vertical or spiral.

8. A novel automotive electric heating element according to claim 7, characterized in that, The single-head heating tubes (11) are arranged in parallel, and the outer finned sleeves (1) form a flow channel structure (12), forming an integrated heating module.

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