Heating module for PTC (Positive Temperature Coefficient) air heater and PTC air heater

Abstract

The utility model discloses a heating module for a PTC air heater and the PTC air heater, and relates to the technical field of heating equipment. The heating module comprises a first electrode plate, a second electrode plate and a plurality of PTC heating resistors, one end of the first electrode plate is provided with a first extending end, one end of the second electrode plate is provided with a second extending end, and the first extending end and the second extending end are located on the same side of the heating module. And the plurality of terminals are detachably connected with the convergence sheet. The PTC heating resistors are arranged between the first electrode plate and the second electrode plate and abut against the first electrode plate and the second electrode plate. Based on the technical scheme disclosed by the utility model, local heating can be prevented from occurring between the confluence sheet and the heating module, the service life of the heating module is ensured, unnecessary wiring can be reduced, and the internal structure of the PTC air heater is effectively simplified.

Description

Technical Field

[0001] This utility model relates to the field of heating equipment technology, specifically to a heating module and a PTC air heater for a PTC air heater. Background Technology

[0002] A PTC air heater is a heating device whose core function is to achieve rapid and stable heating by combining the self-limiting temperature characteristics of PTC ceramic material with forced convection from a fan.

[0003] PTC air heaters typically include a PTC heating module, an electrical control system, and a mechanical protection structure. Internally, multiple heating elements are usually connected in series using a busbar, and a sensor is used to detect the temperature and provide feedback to the electrical control system to ensure that the outlet air temperature remains stable at the set value.

[0004] In related technologies, existing PTC air heaters typically use laser welding to weld the busbars to the heating core, achieving series connection of multiple heating modules. This method requires high precision in laser welding, and poor welding can lead to localized overheating. Furthermore, the sensors in existing PTC air heaters are generally housed within a mechanical protective structure, which requires additional wiring, making the process cumbersome. Utility Model Content

[0005] The purpose of this invention is to overcome the above-mentioned technical deficiencies and propose a heating module and a PTC air heater for PTC air heaters, which solves the technical problems in the prior art where poor welding between the busbar and the heating core easily leads to local heating and the sensor wiring is complicated.

[0006] To achieve the above-mentioned technical objectives, the present invention adopts the following technical solution:

[0007] In a first aspect, this utility model provides a heating module for a PTC air heater, comprising:

[0008] A first electrode sheet, one end of which is provided with a first protruding end;

[0009] The second electrode plate is arranged parallel to and spaced apart from the first electrode plate, and one end of the second electrode plate has a second protruding end; and

[0010] Multiple PTC heating resistors are disposed between the first electrode plate and the second electrode plate, and the opposite sides of the multiple PTC heating resistors respectively abut against the first electrode plate and the second electrode plate;

[0011] The first protruding end and the second protruding end are located on the same side of the heating module and are both detachably connected to the busbar.

[0012] In some embodiments, the plurality of PTC heating resistors are arranged sequentially in the same direction between the first electrode plate and the second electrode plate.

[0013] In some embodiments, dummy plates are provided on one or both sides of the arrangement direction of the plurality of PTC heating resistors.

[0014] In some embodiments, a metal shell is provided on the outer side of the first electrode sheet and the second electrode sheet, and an insulating layer is provided between the metal shell and the first electrode sheet and the second electrode sheet.

[0015] In some embodiments, fins are also included, which abut against the outer side of the metal housing.

[0016] Secondly, this utility model also provides a PTC air heater, including a housing, a manifold, and the aforementioned heating module, wherein the manifold is detachably connected to a first protruding end and a second protruding end on the heating module.

[0017] In some embodiments, the PTC air heater further includes:

[0018] A control box, detachably connected to the housing, and equipped with a grounding connection wire; and

[0019] The metal elastic element abuts against the metal housing on one side and against the control box on the other side.

[0020] In some embodiments, a circuit board is fixedly disposed inside the control box, and a temperature sensor for detecting the metal elastic element is integrated on the circuit board.

[0021] In some embodiments, at least two heating modules are arranged side by side on the housing in the same direction, and the metal outer shell of each heating module abuts against the metal elastic element.

[0022] In some embodiments, a heat dissipation opening is provided on one side of the housing; each of the heat-generating modules is arranged side by side in the same direction inside the heat dissipation opening.

[0023] Compared with the prior art, the present invention provides a heating module and a PTC air heater for a PTC air heater. By setting a first protruding end and a second protruding end on the first electrode plate and the second electrode plate respectively, and detachably connecting the first protruding end and the second protruding end to the busbar, the traditional laser welding method is avoided, preventing local heating between the busbar and the heating module and ensuring the service life of the heating module. At the same time, by directly integrating the temperature sensor on the circuit board and using a metal elastic component to detect the temperature of the heating module, unnecessary wiring is reduced, effectively simplifying the internal structure of the PTC air heater. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of the heating module applied in a PTC air heater in one embodiment of the present invention;

[0025] Figure 2 This is a cross-sectional schematic diagram of the PTC heating element in one embodiment of the present invention;

[0026] Figure 3 This is an isometric view of the PTC heating element in one embodiment of the present invention;

[0027] Figure 4 This is a schematic diagram of the overall structure of the PTC air heater in one embodiment of the present invention;

[0028] Figure 5 This is a cross-sectional schematic diagram of a PTC air heater in one embodiment of the present invention;

[0029] Figure 6 yes Figure 5 The enlarged schematic diagram of part A in the middle is mainly used to show the busbar and grounding spring.

[0030] Explanation of reference numerals in the attached drawings: 1. Fin; 2. PTC heating element; 21. First electrode plate; 211. First protruding end; 22. Second electrode plate; 221. Second protruding end; 23. PTC heating resistor; 24. Dummy plate; 25. Metal casing; 26. Insulating layer; 3. Housing; 31. First housing; 32. Second housing; 4. Control box; 41. Cover plate; 42. High voltage connector; 43. Low voltage connector; 44. Grounding connection wire; 5. Heat dissipation opening; 6. Circuit board; 7. Busbar; 71. Metal plate; 8. Grounding spring; 9. Temperature sensor. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.

[0032] To solve the above-mentioned technical problems, this utility model provides a heating module and a PTC air heater for a PTC air heater. It can not only prevent local heating between the busbar 7 and the heating module and ensure the service life of the heating module, but also reduce unnecessary wiring and effectively simplify the internal structure of the PTC air heater.

[0033] Please see Figure 1This utility model provides a heating module for a PTC air heater, which can be applied to the air conditioning heating system of new energy vehicles. It includes a PTC heating element 2 and fins 1. The PTC heating element 2 uses the self-limiting temperature characteristics of PTC ceramic material to achieve heating. The fins 1 can increase the heat dissipation area of ​​the PTC heating element 2, thereby improving the heating effect.

[0034] Specifically, such as Figure 2 As shown, the PTC heating element 2 includes a first electrode plate 21, a second electrode plate 22, and a plurality of PTC heating resistors 23 disposed between the first electrode plate 21 and the second electrode plate 22.

[0035] The first electrode plate 21 and the second electrode plate 22 can be copper electrodes, or other materials can be used as needed; there is no specific limitation on this. The first electrode plate 21 and the second electrode plate 22 can be arranged in parallel and spaced apart, forming a space between them to accommodate multiple PTC heating resistors 23.

[0036] Multiple PTC heating resistors 23 are disposed between the first electrode plate 21 and the second electrode plate 22. Their specific number can be set as needed and is not specifically limited. Taking any one of the PTC heating resistors 23 as an example, electroplated layers (not shown in the figure) are provided on both opposite sides of the PTC heating resistor 23. In actual assembly, multiple PTC heating resistors 23 can be arranged sequentially in the same direction between the first electrode plate 21 and the second electrode plate 22, and each PTC heating resistor 23 abuts against the first electrode plate 21 and the second electrode plate 22 respectively through its electroplated layers on both sides.

[0037] Combination Figure 3 To facilitate connection to the busbar 7 on the PTC air heater, one end of the first electrode 21 extends into a first protruding end 211, and one end of the second electrode 22 extends into a second protruding end 221. The first protruding end 211 and the second protruding end 221 are located on the same side of the heating module. In actual assembly, the first protruding end 211 and the second protruding end 221 can be detachably connected to the busbar 7 on the PTC air heater by snap-fit.

[0038] Meanwhile, in the arrangement direction of the multiple PTC heating resistors 23, dummy plates 24 are provided on both sides of each PTC heating resistor 23. The dummy plates 24 on both sides can block the opening between the first electrode plate 21 and the second electrode plate 22. In practical applications, the dummy plates 24 can protect the multiple PTC heating resistors 23, reduce the risk of damage to the PTC heating resistors 23, and prevent dust and other impurities from entering the heating module, ensuring the cleanliness of the heating module's interior.

[0039] It is understandable that the aforementioned fake film 24 can be set in two as needed, or, provided that the design requirements are met, only one can be set as needed, depending on the design requirements of the specific occasion.

[0040] In this embodiment, a metal shell 25 is also provided on the outer side of the first electrode plate 21 and the second electrode plate 22. The metal shell 25 can be made of aluminum or other materials as needed, and there is no specific limitation on this.

[0041] Meanwhile, an insulating layer 26 is provided between the metal casing 25 and the first electrode plate 21 and the second electrode plate 22. The insulating layer 26 is preferably an insulating film with insulating function. The insulating layer 26 can achieve the insulating effect between the metal casing 25 and the first electrode plate 21 / second electrode plate 22, so as to prevent the metal casing 25 from being charged.

[0042] In this embodiment, the aforementioned fins 1 can be disposed on the outer side of the metal casing 25 and abut against the metal casing 25 to achieve heat dissipation. The material of the fins 1 can be a metal that is easy to conduct heat, and its structure can be a continuously bent metal sheet 71, or other structural forms that can increase the heat dissipation area of ​​the metal casing 25. No specific limitation is made in this regard.

[0043] Please see Figure 4 This utility model also provides a PTC air heater, which can be applied to the air conditioning heating system of new energy vehicles. It includes a housing 3, a control box 4, and the aforementioned heating module. The control box 4 is located on one side of the housing 3, while the heating module is located inside the housing 3.

[0044] Specifically, the housing 3 includes a first housing 31 and a second housing 32. The first housing 31 and the second housing 32 are detachably connected and together form an internal space for accommodating the aforementioned heating module. The connection between the first housing 31 and the second housing 32 can be pre-fixed by snap-fit. In addition, to further ensure the stability of the housing 3 structure, the first housing 31 and the second housing 32 can also be fixed together by screws.

[0045] After the first housing 31 and the second housing 32 are stably connected, they can form an internal space to accommodate the aforementioned heating modules. To facilitate heat dissipation, heat dissipation openings 5 ​​can be provided on opposite sides of the housing 3, meaning that heat dissipation openings 5 ​​can be provided on both the first housing 31 and the second housing 32 simultaneously. In this way, the aforementioned heating modules can be arranged in two rows between the first housing 31 and the second housing 32, with each row consisting of multiple heating modules, and the two rows of heating modules located inside the corresponding heat dissipation openings 5.

[0046] Specifically, taking the heat dissipation opening 5 on the first housing 31 as an example, multiple heating modules can be arranged side by side along the same direction inside the heat dissipation opening 5. During assembly, since the heating module includes a PTC heating element 2 and fins 1, the multiple heating modules can be arranged sequentially inside the heat dissipation opening 5 in the manner of "PTC heating element 2 - fins 1 - PTC heating element 2", that is, any two adjacent PTC heating elements 2 are connected by fins 1. In this way, the performance of multiple PTC heating elements 2 can be fully utilized to ensure the heating effect.

[0047] Meanwhile, since the heating module needs to be connected to the busbar 7, and the busbar 7 is located inside the control box 4, the first protruding end 211 and the second protruding end 221 on the heating module should face the side where the control box 4 is located during actual assembly.

[0048] It is understandable that the assembly structure of the multiple heat-generating modules inside the heat dissipation opening 5 on the second housing 32 can be referenced from the relevant settings on the first housing 31, and will not be elaborated here.

[0049] In other embodiments, the multiple heating modules described above may be arranged in only one row. In this case, a heat dissipation opening 5 may be provided on the first housing 31 or the second housing 32, and the multiple heating modules may be arranged inside the heat dissipation opening 5.

[0050] In this embodiment, the control box 4 is disposed on one side of the housing 3 and is detachably connected to the housing 3. Specifically, the connection method between the control box 4 and the housing 3 can also refer to the connection method between the first housing 31 and the second housing 32, that is, the control box 4 can be pre-fixed to the housing 3 by snap-fit, and then the control box 4 can be fixed to the housing 3 by screws.

[0051] To facilitate the installation of components into the control box 4 and for later maintenance and repair, an opening can be provided on the top of the control box 4, and a cover plate 41 can be detachably installed at this opening. The cover plate 41 can be fixed to the main body of the control box 4 with screws.

[0052] It is understandable that, since the heating module needs to connect to the components inside the control box 4, the control box 4 and the housing 3 should be interconnected after the control box 4 and the housing 3 are assembled.

[0053] Please see Figures 5-6 A circuit board 6 is fixedly installed inside the control box 4, and the circuit board 6 can be fixed inside the control box 4 with screws. In order to facilitate the connection of the heating module below, the circuit board 6 and the heating module below are preferably arranged perpendicularly.

[0054] Correspondingly, the control box 4 is also equipped with a high-voltage connector 42, a low-voltage connector 43, and a grounding connection wire 44, all of which can be fixedly connected to the control box 4 with screws. The high-voltage connector 42 and the low-voltage connector 43 can be respectively located on opposite sides of the control box 4 and are both electrically connected to the circuit board 6.

[0055] During operation, the aforementioned high-voltage connector 42 can be electrically connected to the vehicle's high-voltage power supply system to provide power. The low-voltage connector 43 can be electrically connected to the vehicle's low-voltage system, facilitating connection to external control systems for controlling the PTC air heater. The grounding connection wire 44 is connected to the control box 4, enabling the control box 4 to be grounded.

[0056] In this embodiment, a busbar 7 is also provided inside the control box 4. The aforementioned multiple heating modules are connected to the circuit board 6 through the busbar 7, thereby realizing the power supply to the multiple heating modules.

[0057] Specifically, the busbar 7 can be provided with multiple slots, which can be used to connect the aforementioned multiple heating modules. In actual assembly, when multiple heating modules are arranged side by side inside the housing 3, taking any one of the heating modules as an example, the first protruding end 211 and the second protruding end 221 on the heating module can be inserted into the corresponding slot on the busbar 7, so that the multiple heating modules and the busbar 7 can be connected to form a whole through a snap-fit ​​method.

[0058] To connect to the circuit board 6, the busbar 7 can be provided with multiple metal pieces 71. These metal pieces 71 extend upward and engage with the slots on the circuit board 6. In this way, the busbar 7 can be electrically connected to the circuit board 6 through the multiple metal pieces 71, and thus the busbar 7 can be powered by the circuit board 6.

[0059] It is understandable that since there are multiple heating modules and they are arranged neatly inside the housing 3, when multiple heating modules are connected to the busbar 7 at the same time, the multiple heating modules are actually equivalent to forming an overall arrangement on the busbar 7.

[0060] Meanwhile, since the busbar 7 can be powered by the circuit board 6, and multiple heating modules are connected to the busbar 7 through the first protruding end 211 and the second protruding end 221, multiple heating modules can be powered by the busbar 7.

[0061] In this embodiment, in order to ground multiple heating modules, a metal elastic element is also provided on the inner side of the control box 4. The metal elastic element can be a grounding spring 8, and the grounding spring 8 can be made of any elastic conductive metal material, without specific limitations.

[0062] Specifically, since multiple heating modules can be arranged in two rows inside the housing 3, two grounding springs 8 can also be provided accordingly. The two grounding springs 8 are used to ground the two rows of heating modules respectively.

[0063] Taking the multiple heating modules inside the first housing 31 as an example, the grounding spring 8 can be embedded between the multiple heating modules and the inner wall of the control box 4. One side of the grounding spring 8 abuts against the metal shell 25 on the multiple heating modules, while the opposite side abuts against the inner wall of the control box 4.

[0064] Thus, because the grounding spring 8 itself is elastic, after it abuts against multiple heating modules and the inner wall of the control box 4 on both sides, it will be stably stuck between the multiple heating modules and the inner wall of the control box 4 under the combined action of elastic recovery force and friction.

[0065] Understandably, since multiple heating modules are arranged side by side, the grounding spring 8 is preferably arranged perpendicularly to the heating modules to achieve simultaneous grounding of multiple heating modules. In this way, the grounding spring 8 can simultaneously abut against multiple heating modules on the same side. At this time, the multiple heating modules on the same side can also be regarded as arranged sequentially along the extension direction of adjacent grounding springs 8.

[0066] After the grounding spring 8 is set, since the control box 4 can be grounded through the grounding connection line 44, and the grounding spring 8 connects the control box 4 to the metal shell 25 of multiple heating modules, multiple heating modules on the same side can be grounded through the grounding spring 8 to ensure safety and reliability.

[0067] In this embodiment, a temperature sensor 9 may also be installed inside the control box 4 to detect the heating status of multiple heating modules.

[0068] Specifically, the temperature sensor 9 can be integrated onto the circuit board 6 and placed close to the aforementioned grounding spring 8. Thus, in conjunction with the matching control system, the temperature sensor 9 can detect the temperature of the grounding spring 8 in real time. Since the grounding spring 8 directly contacts multiple heating modules, it is equivalent to real-time detection of the heating status of multiple heating modules, facilitating the adjustment of the power of multiple heating modules through the matching control system.

[0069] To better understand this utility model, the technical solution of this utility model will be described in detail below with reference to the accompanying drawings:

[0070] First, by setting a first protruding end 211 and a second protruding end 221 on the first electrode plate 21 and the second electrode plate 22 on the heating module, the first protruding end 211 and the second protruding end 221 can form a snap-fit ​​with the slot on the busbar 7, avoiding the use of traditional laser welding operation, thereby preventing local overheating between the busbar 7 and the heating module due to poor welding, so as to ensure the service life of the heating module.

[0071] Secondly, the heating modules described above are applied to the PTC air heater, with multiple heating modules arranged side-by-side inside the heat dissipation opening 5 on the housing 3. These multiple heating modules are connected to the circuit board 6 via a busbar 7 for power supply. Simultaneously, the multiple heating modules can also be connected to the inner wall of the control box 4 via a grounding spring 8. Since the inner wall of the control box 4 is connected to a grounding connection wire 44, the multiple heating modules can be grounded to ensure safety and reliability.

[0072] In addition, by directly integrating a temperature sensor 9 on the circuit board 6, the temperature sensor 9 can detect the temperature of the grounding spring 8, thereby indirectly detecting the heating status of multiple heating modules, and facilitating the adjustment of the power of multiple heating modules through the matching control system.

[0073] Therefore, by means of the above method, this utility model can not only prevent local heating between the busbar 7 and the heating module, thus ensuring the service life of the heating module, but also reduce unnecessary wiring, effectively simplify the internal structure of the PTC air heater, and facilitate real-time monitoring and adjustment of the heating status of multiple heating modules.

[0074] In the description of this application, it should be noted that the terms "upper" and "lower," etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0075] It should be noted that in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0076] The specific embodiments of this utility model described above do not constitute a limitation on the scope of protection of this utility model. Any other corresponding changes and modifications made based on the technical concept of this utility model should be included within the scope of protection of the claims of this utility model.

Claims

1. A heating module for a PTC air heater, characterized in that, include: A first electrode sheet, one end of which is provided with a first protruding end; The second electrode plate is arranged parallel to and spaced apart from the first electrode plate, and one end of the second electrode plate has a second protruding end; and Multiple PTC heating resistors are disposed between the first electrode plate and the second electrode plate, and the opposite sides of the multiple PTC heating resistors respectively abut against the first electrode plate and the second electrode plate; The first protruding end and the second protruding end are located on the same side of the heating module and are both detachably connected to the busbar.

2. The heating module according to claim 1, characterized in that, The plurality of PTC heating resistors are arranged sequentially in the same direction between the first electrode plate and the second electrode plate.

3. The heating module according to claim 2, characterized in that, A dummy circuit is provided on one or both sides of the arrangement direction of the plurality of PTC heating resistors.

4. The heating module according to claim 1, characterized in that, The first electrode and the second electrode are covered with a metal shell, and an insulating layer is provided between the metal shell and the first electrode and the second electrode.

5. The heating module according to claim 4, characterized in that, It also includes fins that abut against the outer side of the metal casing.

6. A PTC air heater, characterized in that, It includes a housing, a busbar, and a heating module as described in any one of claims 1-5, wherein the busbar is detachably connected to a first protruding end and a second protruding end on the heating module.

7. The PTC air heater according to claim 6, characterized in that, Also includes: A control box, detachably connected to the housing, and equipped with a grounding connection wire; and The metal elastic element abuts against the metal housing on one side and against the control box on the other side.

8. The PTC air heater according to claim 7, characterized in that, A circuit board is fixedly installed inside the control box, and a temperature sensor for detecting the metal elastic component is integrated on the circuit board.

9. The PTC air heater according to claim 7, characterized in that, At least two heating modules are arranged side by side on the housing in the same direction, and the metal outer shell of each heating module abuts against the metal elastic element.

10. The PTC air heater according to claim 9, characterized in that, A heat dissipation opening is provided on one side of the housing; each of the heating modules is arranged side by side in the same direction inside the heat dissipation opening.

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