A car heater

Abstract

This utility model relates to a vehicle-mounted air heater, characterized by: multiple sets of PTC heating tube external terminals connected in series and parallel via connecting plates, forming three lead wires; the connecting plates are fixedly connected to the bracket; the bottom of the potting frame is inserted into the heating core near one end of the external terminal, and potting compound is injected to seal the PTC heating tube external terminals, connecting plates, bracket, and lead wire connectors; the temperature sensing wire assembly is fixed to one side of the heat dissipation fins; the main body of the heating unit is inserted into the heating unit housing; the bottom of the control unit housing is inserted into and fixedly connected to the top of the heating unit housing, the top cover is fixed to the upper opening of the control unit housing, and the PCB control board assembly is fixedly installed inside the control unit housing; the three lead wires and the lead wires of the temperature sensing wire assembly are connected to the PCB control board assembly; one end of the grounding wire is connected to the heating core, and one end of each of the high and low voltage wire harnesses is connected to the PCB control board assembly; the other ends of all three are sealed and pass through the wire outlet hole of the top cover. This heater can be installed inside the air conditioning unit.

Description

Technical Field

[0001] This utility model belongs to the field of automotive air conditioning technology, specifically relating to a vehicle-mounted air heater. Background Technology

[0002] For new energy vehicles, since there is no waste heat generated by the engine to utilize, or during the warm-up phase of a traditional fuel vehicle engine, a separate, efficient heating device is needed to provide warm air. The PTC heater perfectly meets this need, as it can quickly start working after the car is started, providing warm air and reducing the time passengers have to wait for the interior to warm up.

[0003] Currently, the structure of PTC air heaters on the market mainly includes a heating unit, a control unit, a heating unit housing, and a control unit housing. The controller is located in the control housing, and the PTC heating structure is electrically connected to the controller. The PTC heating structure is located in the heating housing.

[0004] Currently, the heating unit and control unit housings on the market are generally located outside the air conditioning unit. The heaters are large, have unreliable sealing or complex structures, which occupy a lot of space inside the dashboard, affect the layout of other components, and limit the flexibility of heater use. Utility Model Content

[0005] This utility model addresses the shortcomings of existing technologies by proposing a vehicle-mounted air heater that is compact in structure, small in size, can be installed inside the air conditioning unit, and improves sealing performance.

[0006] The above-mentioned objective of this utility model is achieved through the following technical solution:

[0007] A vehicle-mounted air heater includes a heating unit body, a heating unit housing, a control unit body, and a control unit housing; characterized in that:

[0008] The main body of the heating unit includes PTC heating tubes, heat dissipation fins, connecting pieces, a bracket, a potting frame, and a temperature sensing wire assembly. Multiple sets of PTC heating tubes and multiple sets of heat dissipation fins are fixedly connected in parallel at intervals to form the heating core. The external terminals of the multiple sets of PTC heating tubes face the same end, with the end of the PTC heating tube furthest from its external terminal aligned with one end of the heat dissipation fin, and the end of the PTC heating tube closest to its external terminal higher than the other end of the heat dissipation fin. The external terminals of the multiple sets of PTC heating tubes are connected in series and parallel through the connecting pieces, forming three lead wires. The connecting pieces are fixedly connected to the bracket. The potting frame is inserted into the heating core near the external terminal through a row of heating tube insertion holes at its bottom. The connecting pieces and the bracket are placed in the inner cavity of the potting frame, and potting compound is injected into the inner cavity of the potting frame to completely seal the external terminals of the PTC heating tubes, the connecting pieces, the bracket, and the lead wire connectors. The temperature sensing wire assembly is fixed on the heat dissipation fins located on one side.

[0009] The heating unit housing is a flat rectangular housing with an opening at the top and ventilation holes on the large flat surfaces on both sides. The main body of the heating unit is inserted into the heating unit housing.

[0010] The control unit body includes a PCB control board assembly, a grounding wire, a low-voltage wiring harness, and a high-voltage wiring harness. The control unit housing includes a control unit outer shell and a top cover. The bottom of the control unit outer shell is fixedly connected to the top of the heating unit outer shell via a rectangular insert frame. A wire-passing hole is provided inside the rectangular insert frame at the bottom of the control unit outer shell. The top cover is sealed and fixedly connected to the upper open end of the control unit outer shell. A wire-out hole is provided on the top cover near one end. The PCB control board assembly is fixedly installed in the inner cavity of the control unit outer shell. The three lead wires of the heating unit and the lead wires of the temperature sensing wire assembly pass through the wire-passing hole at the bottom of the control unit outer shell and are connected to the PCB control board assembly in a sealed manner. One end of the grounding wire is connected to the heating core. The grounding wire passes through the wire-passing hole at the bottom of the control unit outer shell. One end of the high-voltage wiring harness and one end of the low-voltage wiring harness are both connected to the PCB control board assembly. The other ends of the grounding wire, the high-voltage wiring harness, and the low-voltage wiring harness are combined into a single wiring harness and pass through the wire-out hole on the top cover in a sealed manner.

[0011] Furthermore, there are two wire passage holes, which are respectively located at the bottom of the control unit housing near both ends; the three lead wires of the heating unit, the lead wire of the temperature sensing wire assembly, and one end of the ground wire are combined into two wire bundles, which pass through the two wire passage holes at the bottom of the control unit housing.

[0012] Furthermore, perforated sealing plugs are installed in the two wire passage holes of the control unit housing to allow the lead wires to pass through in a sealed manner.

[0013] Furthermore, a sealing sleeve and a plastic wire cover are installed at the cable outlet of the top cover to achieve sealed cable harness exit.

[0014] The advantages and positive effects of this utility model are as follows:

[0015] 1. The present invention has a compact structure and small size, and can be completely installed inside the air conditioning unit, making it more flexible in use.

[0016] 2. The electrical cavity of the heater in this utility model is arranged inside the air conditioning unit, resulting in a higher sealing level;

[0017] 3. This type of heater has a simple structure and fewer parts, resulting in lower manufacturing costs compared to heaters of the same specifications and models. Attached Figure Description

[0018] Figure 1 This is an overall drawing of the vehicle-mounted air heater of this utility model;

[0019] Figure 2 This is an exploded perspective view of the vehicle-mounted air heater of this utility model;

[0020] Figure 3 This is an exploded view of the main body of the heating unit of this utility model;

[0021] Figure 4 This is an assembly diagram of the main body of the heating unit of this utility model;

[0022] Figure 5 This is a schematic diagram of the structure of the control unit of this utility model. Figure 1 ;

[0023] Figure 6 This is a schematic diagram of the structure of the control unit of this utility model. Figure 2 ;

[0024] Figure 7 This is a schematic diagram of the installation of the vehicle air heater of this utility model on the air conditioning unit. 7a is an overall view, and 7b is a partial enlarged view of the installation position. Detailed Implementation

[0025] The structure of this utility model will be further described below with reference to the accompanying drawings and embodiments. It should be noted that these embodiments are descriptive and not limiting.

[0026] Please see the following: A car heater / heater. Figures 1-7 It includes a heating unit body 1, a heating unit shell 2, a control unit body 3, and a control unit shell 4; the heating unit body and the heating unit shell constitute a heating unit, and the control unit body and the control unit shell constitute a control unit.

[0027] The heating unit consists of a PTC heating tube (1.1), heat sink fins (1.2), a potting frame (1.3), a bracket (1.4), a connecting piece (1.5), lead wires (1.6), a temperature sensing wire assembly (1.7), and potting compound (1.8). Multiple sets of PTC heating tubes and heat sink fins are arranged parallel to each other in a staggered manner. The external terminals of the PTC heating tubes face the same direction. The end of the PTC heating tube furthest from its external terminal is aligned with one end of the heat sink fin, and the end of the PTC heating tube closest to its external terminal is higher than the other end of the heat sink fin, allowing for insertion and mating with the potting frame. The PTC heating tubes and heat sink fins are connected together using thermally conductive adhesive or brazing to form the heating core. The external terminals of the multiple PTC heating tubes (including the positive and negative terminals) are connected in series and parallel via the connecting piece (1.5), ultimately forming three lead wires (1.6) for connection to external high voltage. The connecting piece is fixed to the bracket with screws, and the bracket serves to fix and reinforce the connecting piece. The potting frame is a rectangular frame with an opening at the top and a row of heating tube insertion holes at the bottom. Lead wire insertion holes are provided on both side walls of the potting frame for leading out three lead wires and a ground wire. The potting frame is inserted into the heating core near the external terminal via the row of heating tube insertion holes at the bottom. The connecting piece and bracket are placed inside the potting frame. Potting compound 1.8 is injected into the potting frame 1.3 to completely seal the PTC heating tube external terminal, connecting piece, bracket, and lead wire connector. Figure 4 As shown, this ensures a secure seal of the electrical interface of the heating unit. The temperature sensing wire assembly 1.7 is screwed onto the heat sink fins on one side to monitor the temperature of the heating core, as shown. Figure 4 As shown.

[0028] The heating unit housing is a flat rectangular shell with an opening at the top. The shape and size of its inner cavity match the shape and size of the heating unit body. Ventilation holes are provided on the large flat surfaces on both sides of the heating unit housing, aligned with the heating core to allow air from inside the vehicle to pass through for heating. The heating unit body is integrally inserted into the inner cavity of the heating unit housing. Three lead wires, the lead wire of the temperature sensing wire assembly, and the grounding wire extend from both ends of the upper part of the heating unit housing. The three lead wires and the lead wire of the temperature sensing wire assembly are electrically connected to the control unit body.

[0029] The main body of the control unit is composed of a PCB control board assembly 3.1, a grounding wire 3.2, a low-voltage wiring harness 3.3, and a high-voltage wiring harness 3.4. The control unit housing is composed of a control unit outer shell 4.1, a perforated sealing plug (using a silicone plug) 4.2, a top cover 4.3, a sealing sleeve (using a silicone sleeve) 4.4, and a plastic wire cover 4.5. Figure 2 , Figure 5 , Figure 6As shown. The upper end of the control unit housing is open for connection with the top cover. A rectangular insert frame is provided on one side of the bottom of the control unit housing, which is inserted into the upper end of the heating unit housing. Slots are provided on the outer walls of both ends of the rectangular insert frame, and corresponding protrusions are provided on the upper side wall of the heating unit housing. The protrusions are embedded in the corresponding slots, achieving a fixed insertion and connection between the control unit housing and the heating unit housing. A wire passage hole is provided at each end of the rectangular insert frame at the bottom of the control unit housing. The PCB control board assembly is placed inside the cavity of the control unit housing and is fixed to the control unit housing by screws. The top cover is fixed to the upper open end of the control unit housing by screws installed at the four corners. The seal between the top cover and the control unit housing is achieved by sealant or sealing rings, ensuring a tight seal at the interface and sealing the PCB control board assembly inside the control unit housing. A wire outlet hole is provided on one end of the top cover. One end of the grounding wire 3.2 is connected to the heating core, and one end of the high-voltage wire harness and one end of the low-voltage wire harness are both connected to the PCB control board assembly. The other ends of the grounding wire, the high-voltage wire harness, and the low-voltage wire harness are combined into a single wire harness and pass through the outlet hole on the top cover. A sealing sleeve is installed at the outlet hole. The entire wire harness passes through the inner hole of the sealing sleeve to ensure the sealing of the outlet hole on the top cover. Then, it is fixed by the plastic wire cover 4.5 to the outer protrusion at the outlet hole. Specifically, a protrusion is provided on the side of the outer protrusion at the outlet hole, and a groove is provided on the side wall of the plastic wire cover. The groove and the protrusion are inserted and fitted to fix the sealing sleeve.

[0030] The three leads of the heating unit, the lead of the temperature sensing wire assembly, and the grounding wire are combined into two wire bundles. The two wire bundles are introduced into the cavity of the control unit housing through two wire holes at the bottom of the control unit housing. The three leads and the lead of the temperature sensing wire assembly are connected to the PCB control board assembly. At the same time, perforated sealing plugs are installed at the two wire holes for sealing. Thus, the control unit and housing are sealed.

[0031] After the heater is assembled, foam is bonded around its perimeter, and then the entire assembly is inserted into the air conditioner housing slot. Only the bundled wiring harness and corresponding connectors remain on the outside of the air conditioner housing for connection. It is then secured with screws using the heater cover plate. (See attached image.) Figure 7 .

[0032] Although embodiments and drawings of the present invention have been disclosed for illustrative purposes, those skilled in the art will understand that various substitutions, variations and modifications are possible without departing from the spirit and scope of the present invention and the appended claims. Therefore, the scope of the present invention is not limited to the contents disclosed in the embodiments and drawings.

Claims

1. A vehicle-mounted air heater, comprising a heating unit body, a heating unit housing, a control unit body, and a control unit housing; characterized in that: The main body of the heating unit includes PTC heating tubes, heat dissipation fins, connecting pieces, a bracket, a potting frame, and a temperature sensing wire assembly. Multiple sets of PTC heating tubes and multiple sets of heat dissipation fins are fixedly connected in parallel at intervals to form the heating core. The external terminals of the multiple sets of PTC heating tubes face the same end, with the end of the PTC heating tube furthest from its external terminal aligned with one end of the heat dissipation fin, and the end of the PTC heating tube closest to its external terminal higher than the other end of the heat dissipation fin. The external terminals of the multiple sets of PTC heating tubes are connected in series and parallel through the connecting pieces, forming three lead wires. The connecting pieces are fixedly connected to the bracket. The potting frame is inserted into the heating core near the external terminal through a row of heating tube insertion holes at its bottom. The connecting pieces and the bracket are placed in the inner cavity of the potting frame, and potting compound is injected into the inner cavity of the potting frame to completely seal the external terminals of the PTC heating tubes, the connecting pieces, the bracket, and the lead wire connectors. The temperature sensing wire assembly is fixed on the heat dissipation fins located on one side. The heating unit housing is a flat rectangular housing with an opening at the top and ventilation holes on the large flat surfaces on both sides. The main body of the heating unit is inserted into the heating unit housing. The control unit body includes a PCB control board assembly, a grounding wire, a low-voltage wiring harness, and a high-voltage wiring harness. The control unit housing includes a control unit outer shell and a top cover. The bottom of the control unit outer shell is fixedly connected to the top of the heating unit outer shell via a rectangular insert frame. A wire-passing hole is provided inside the rectangular insert frame at the bottom of the control unit outer shell. The top cover is sealed and fixedly connected to the upper open end of the control unit outer shell. A wire-out hole is provided on the top cover near one end. The PCB control board assembly is fixedly installed in the inner cavity of the control unit outer shell. The three lead wires of the heating unit and the lead wires of the temperature sensing wire assembly pass through the wire-passing hole at the bottom of the control unit outer shell and are connected to the PCB control board assembly in a sealed manner. One end of the grounding wire is connected to the heating core. The grounding wire passes through the wire-passing hole at the bottom of the control unit outer shell. One end of the high-voltage wiring harness and one end of the low-voltage wiring harness are both connected to the PCB control board assembly. The other ends of the grounding wire, the high-voltage wiring harness, and the low-voltage wiring harness are combined into a single wiring harness and pass through the wire-out hole on the top cover in a sealed manner.

2. The vehicle-mounted air heater according to claim 1, characterized in that: There are two wire passage holes, which are respectively located at the bottom of the control unit housing near both ends; the three lead wires of the heating unit, the lead wire of the temperature sensing wire assembly, and one end of the ground wire are combined into two wire bundles, which pass through the two wire passage holes at the bottom of the control unit housing.

3. The air heating heater for vehicle according to claim 1, characterized by: Perforated sealing plugs are installed in the two wire passage holes of the control unit housing to allow the lead wires to pass through in a sealed manner.

4. The air heating heater for vehicle according to claim 1, characterized by: A sealing sleeve and a plastic wire cover are installed at the cable outlet of the top cover to ensure the sealed exit of the wire harness.

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