An immersion type thick film heating element based on a new energy vehicle

Abstract

The utility model relates to a kind of immersion type thick film heating element based on new energy vehicle in new energy heating technical field, including substrate and conductor layer and resistance layer, first insulating layer is equipped between substrate and conductor layer, the one end of resistance layer is connected with second insulating layer, substrate, first insulating layer, conductor layer, resistance layer and second insulating layer constitute heating element between, heating element is the immersion type structure of double-face contact coolant;The structure uses the way of double-face contact coolant, improves the pain point disadvantage that traditional single-face contact coolant can only heat coolant from one direction, and the design of double-face contact coolant makes that heating element can heat coolant from two directions simultaneously, improves heating efficiency, the utility model can be used on high voltage version can reach 800VDC, withstand voltage can reach 4000VDC;And thermal efficiency is improved, and heat loss is less;It has the advantage of small assembly space simultaneously.

Description

Technical Field

[0001] This utility model relates to the field of new energy heating technology, and in particular to an immersion thick film heating element based on new energy vehicles. Background Technology

[0002] Thick-film heating elements are heating devices manufactured using thick-film technology and are widely used in various applications requiring localized or rapid heating. This technology involves printing resistive material onto a substrate using methods such as screen printing, followed by high-temperature sintering to form a robust and efficient heating layer. Immersion heating elements, on the other hand, use a coolant to immerse the heating element to reduce the impact of overheating.

[0003] The drawback of existing products is that:

[0004] Firstly, existing products use PTC heating on high-voltage platforms, which has poor insulation. They typically employ a one-time molding coating structure, and when this coating structure is damaged, it can easily lead to short circuits, localized overheating, or even render the product unusable.

[0005] Secondly, the existing heating efficiency is low. Most existing products use single-sided heating. When the coolant comes into contact with the heating element, one end of the heating element can contact the coolant, while the other end is idle, resulting in ineffective heating and wasted energy.

[0006] Thirdly, the assembly space is large, requiring multiple mounting surfaces to allow the heating element to contact the coolant on both sides, which increases manufacturing costs and reduces work efficiency. In addition, the PTC heating method has a brick-like structure, which occupies a large area and is prone to breakage after being heated. Therefore, the inventor of this utility model proposes an immersion thick film heating element based on new energy vehicles to solve the above-mentioned technical problems. Utility Model Content

[0007] In order to overcome the shortcomings mentioned above, the utility model aims to provide a technical solution that can solve the above problems.

[0008] An immersion thick-film heating element for new energy vehicles includes a substrate, a conductor layer, and a resistor layer. The resistor layer is mounted on the surface of the conductor layer. A first insulating layer is provided between the substrate and the conductor layer. One end of the resistor layer is connected to a second insulating layer. The substrate, the first insulating layer, the conductor layer, the resistor layer, and the second insulating layer together constitute a heating element. The heating element is a thick-film structure and is an immersion structure that is in contact with coolant on both sides.

[0009] This structure adopts a double-sided contact with coolant, which improves the shortcomings of the traditional single-sided contact with coolant, which can only heat the coolant from one direction. The double-sided contact with coolant design allows the heating element to heat the coolant from two directions at the same time, improving heating efficiency and making the heating element heat the coolant more effectively.

[0010] Traditional single-sided contact coolant design has limitations in heating efficiency and heat dissipation performance, which can easily lead to uneven heating and poor heat dissipation. In contrast, the double-sided contact coolant design can distribute heat more evenly, reduce thermal stress concentration caused by local overheating, and reduce the risk of material fatigue and damage.

[0011] Firstly, the double-sided contact design can transfer heat to the coolant more evenly, avoiding local overheating or uneven heating, improving the overall heating effect, thereby enhancing heat exchange efficiency, allowing heat to be carried away by the coolant more quickly, preventing the heating element from overheating. Moreover, due to the more efficient heat dissipation, it avoids the phenomenon of overheating caused by one end being heated while the other end is not in contact with the coolant or is not dissipated in time, reducing the risk of aging and damage to the heating element due to overheating and extending its service life.

[0012] Secondly, the double-sided contact coolant design can provide higher heating power within the same volume, optimizing space utilization. This design is specifically designed to fit the limited space environment in new energy vehicles. Furthermore, the size and shape of the heating element can be flexibly adjusted according to actual needs to adapt to different installation positions and requirements, making disassembly and installation easier and improving assembly efficiency.

[0013] Thirdly, this design can transfer heat to the coolant more quickly, achieving rapid heating and improving the user experience. Due to its higher heating efficiency, the system can reach the set temperature in a shorter time, reducing energy consumption and meeting the requirements of energy conservation and environmental protection. By using an immersion double-sided contact with the coolant, the heating element effectively solves the problems of uneven heating and poor heat dissipation that may be encountered in traditional heating methods, further reducing energy consumption and achieving rapid heating.

[0014] On the other hand, the first and second insulation layers provide double insulation protection, ensuring that current does not leak into the coolant or into components adjacent to the heating element, thus improving the safety of the system. By using the first and second insulation layers as a double protection method for insulation, this structure effectively prevents the risk of electrical short circuits or leakage, ensuring the reliability and safety of system operation.

[0015] The heating element in this structure is a thick-film heating element, with a thickness of 500 nanometers to 5 micrometers, which is thicker than that of traditional thin films. The use of thick-film technology can achieve high power density in a smaller area, allowing the heating element to provide more heat output in a limited space. This is suitable for the space-constrained internal heating application scenarios of new energy vehicles. In addition, due to the tight connection of the thick-film heating element, it can respond quickly to temperature changes and provide efficient heating performance. It also has good thermal conductivity, which allows the heating element to quickly convert electrical energy into heat energy and quickly transfer it to the coolant or other media to achieve rapid heating and avoid problems such as local overheating or uneven cooling. Moreover, the thick-film structure has low resistivity, which can achieve high power output at a lower voltage, improving energy utilization efficiency. After high-temperature sintering, the internal structure of the thick-film heating element in this structure is dense, with corresponding mechanical strength and fatigue resistance, and can maintain stable performance during use.

[0016] Furthermore, the substrate, the first insulating layer, the conductor layer, the resistive layer, and the second insulating layer are arranged sequentially. This structural arrangement enhances electrical safety and prevents short circuits and leakage. The first insulating layer is located between the substrate and the conductor layer, and the second insulating layer is located at one end of the resistive layer, ensuring that current does not directly contact the substrate or components adjacent to it, thus effectively preventing short circuits and leakage. The use of two insulating layers, the first and second insulating layers respectively, provides dual electrical isolation protection, further enhancing the system's safety and reliability.

[0017] This structure uses materials arranged in a specific order to form the overall structure of the heating element. This not only enhances the mechanical strength and stability of the entire heating element, but also reduces the risk of delamination caused by temperature changes or external stress, improving the reliability of long-term use. The simple hierarchical structure simplifies the production process, reduces the overall assembly difficulty and time, and improves production efficiency.

[0018] The materials of each layer are arranged in an orderly manner, and appropriate high-temperature resistant materials can be selected according to actual needs to ensure that the heating element can still operate stably in high-temperature environments; the substrate in this structure is one of ceramic substrate, stainless steel substrate or aluminum substrate.

[0019] Furthermore, the first insulating layer, conductor layer, resistive layer and second insulating layer are all screen-printed onto the surface of the substrate, and the resistive layer is arranged in a linear stepped manner on the surface of the substrate.

[0020] This structure uses screen printing technology to achieve patterned deposition, ensuring that each of the first insulating layer, conductor layer, resistive layer and second insulating layer can be printed on the substrate according to the design requirements. Screen printing can ensure the consistency of products between batches, reduce the difference between batches and improve the stability of product quality.

[0021] The linear stepped arrangement of the resistive layer allows the current to be evenly distributed across the entire heating element, avoiding problems such as local overheating or uneven electric field, thus improving the overall electrical performance. Operators can adjust the resistance value as needed to achieve ideal heating power and temperature control, thereby realizing local temperature gradient control and meeting the needs of specific application scenarios. In addition, the linear stepped arrangement of the resistive layer can more effectively disperse heat, making the heat more evenly distributed on the surface of the substrate, thereby improving the heat conduction efficiency.

[0022] Furthermore, the first insulating layer includes a first dielectric layer, a second dielectric layer, a third dielectric layer, and a fourth dielectric layer. The individual thickness of the first dielectric layer, the second dielectric layer, the third dielectric layer, and the fourth dielectric layer is approximately 35 micrometers, and the total film thickness of the first insulating layer is greater than or equal to 110 micrometers.

[0023] Furthermore, when the total thickness is 110 micrometers, sufficient insulation performance is ensured without excessively increasing thermal resistance, ensuring that heat can be efficiently conducted away and preventing overheating. By adjusting the thickness and material combination of each dielectric layer, the insulation performance and thermal conductivity performance can be finely adjusted to meet the needs of different application scenarios.

[0024] Furthermore, the first dielectric layer, the second dielectric layer, the third dielectric layer and the fourth dielectric layer are all coated and connected by screen printing, and it is a composite coating connection structure of coating one layer and sintering one time.

[0025] By coating only one layer of dielectric material at a time and sintering it on top, the uniformity and consistency of each layer can be ensured. This structure helps to avoid problems such as uneven thickness or bubbles caused by coating too much material at once. By coating and sintering layer by layer, the thickness and performance parameters of each layer can be controlled more precisely, thereby ensuring the high quality of the final product.

[0026] Each layer of material is sintered independently, forming a robust bonding interface that enhances the mechanical strength and stability of the overall structure. This layered structure helps to disperse stress, reducing deformation or damage caused by excessive local stress. Furthermore, the composite structure formed by layer-by-layer coating and sintering has better fatigue resistance and can remain stable during long-term use, thus extending the product's service life.

[0027] Furthermore, the second insulating layer includes a first protective layer, a second protective layer, a third protective layer, and a fourth protective layer. The individual thickness of the first, second, third, and fourth protective layers is approximately 35 micrometers, and the total film thickness of the second insulating layer is greater than or equal to 110 micrometers. The material, process, and function of the second insulating layer are consistent with those of the first insulating layer described above.

[0028] Furthermore, the first protective layer, the second protective layer, the third protective layer and the fourth protective layer are all coated and connected by screen printing, and it is a composite coating connection structure in which one layer is coated and sintered at a time.

[0029] Furthermore, the surfaces of the first insulating layer and the second insulating layer are respectively provided with a first reserved hole, a second reserved hole and a third reserved hole, and the resistive layer and the conductor layer are arranged with clearance grooves that are used in conjunction with the first reserved hole, the second reserved hole and the third reserved hole.

[0030] Furthermore, the surface of the substrate is provided with a mounting hole for placing an external temperature probe. The mounting hole passes through the first insulating layer, the conductor layer, the resistive layer and the second insulating layer in sequence. The conductor layer and the resistive layer are provided with a clearance area corresponding to the mounting hole in the middle.

[0031] Furthermore, one end of both the first insulating layer and the second insulating layer is provided with a protruding structure, and the surface of the protruding structure of the second insulating layer is provided with a pad pre-reserved hole, and the surface of the pad pre-reserved hole is filled with a pad structure.

[0032] The conductor layer and the resistor layer are respectively provided with a resistor pin and an extension pin at one end. One end of the resistor pin and the extension pin extends to the surface of the pad structure. An insulating sealing ring is connected to the edge of the pad structure by an externally placed insulating sealing ring that is attached to the surface of the pad structure by an externally placed method.

[0033] The design of the pre-drilled holes and pad structure allows resistor leads and extension leads to be precisely soldered to external circuits, ensuring that current can pass smoothly through each layer and reducing problems such as poor contact or open circuit. It provides electrical connection points to ensure that current can be smoothly transmitted to external circuits. The pad structure enables more reliable electrical interconnection between different layers, simplifies the soldering process and reduces the complexity of manual operation.

[0034] Compared with the prior art, the beneficial effects of this utility model are:

[0035] 1. This structure adopts a double-sided contact with coolant, which improves the shortcomings of the traditional single-sided contact with coolant, which can only heat the coolant from one direction. The double-sided contact with coolant design allows the heating element to heat the coolant from two directions at the same time, improving heating efficiency and making the heating element heat the coolant more effectively.

[0036] 2. This utility model improves upon the limitations of traditional single-sided contact coolant design in terms of heating efficiency and heat dissipation performance, which can easily lead to uneven heating and poor heat dissipation. By adopting a double-sided contact coolant design, heat can be distributed more evenly, reducing thermal stress concentration caused by local overheating and lowering the risk of material fatigue and damage.

[0037] 3. The double-sided contact design can transfer heat to the coolant more evenly, avoiding local overheating or uneven heating, improving the overall heating effect, thereby enhancing heat exchange efficiency, allowing heat to be carried away by the coolant more quickly, preventing the heating element from overheating. In addition, due to the more efficient heat dissipation, it avoids the phenomenon of overheating caused by one end being heated while the other end is not in contact with the coolant or is not dissipated in time. This reduces the risk of aging and damage to the heating element due to overheating and extends its service life.

[0038] 4. The double-sided contact coolant design can provide higher heating power within the same volume, optimize space utilization, and is specifically designed to fit the limited space environment in new energy vehicles. In addition, the size and shape of the heating element can be flexibly adjusted according to actual needs to adapt to different installation positions and requirements, facilitate disassembly and installation, and improve assembly efficiency.

[0039] 5. This design can transfer heat to the coolant more quickly, achieving rapid heating and improving the user experience. Due to its higher heating efficiency, the system can reach the set temperature in a shorter time, reducing energy consumption and meeting the requirements of energy conservation and environmental protection. By using an immersion double-sided contact with the coolant, the heating element effectively solves the problems of uneven heating and poor heat dissipation that may be encountered in traditional heating methods, further reducing energy consumption and achieving rapid heating.

[0040] 6. The first and second insulation layers provide double insulation protection, ensuring that current does not leak into the coolant or into components adjacent to the heating element, thus improving system safety. The use of the first and second insulation layers as a double protection method effectively prevents the risk of electrical short circuits or leakage, ensuring the reliability and safety of system operation.

[0041] 7. The heating element in this structure is a thick film heating element structure, which is thicker than the traditional thin film of 500 nanometers to 5 micrometers. The use of thick film technology can achieve a higher power density in a smaller area, so that the heating element can provide more heat output in a limited space, which is suitable for the application scenario of internal heating of new energy vehicles with limited space.

[0042] 8. Due to the tight connection of the thick film heating element, it can respond quickly to temperature changes and provide efficient heating performance. It has good thermal conductivity, which enables the heating element to quickly convert electrical energy into heat energy and quickly transfer it to the coolant or other media to achieve rapid heating and avoid the problems of local overheating or uneven cooling. In addition, the thick film structure has low resistivity, which can achieve high power output at lower voltage and improve energy utilization efficiency.

[0043] 9. The thick film heating element in this structure undergoes four layers of screen printing and four high-temperature sintering processes, resulting in a dense internal structure with corresponding mechanical strength and fatigue resistance, enabling it to maintain stable performance during use.

[0044] 10. This product can be used in high-voltage versions up to 800VDC, with a withstand voltage of up to 4000VDC; it also has improved thermal efficiency and less heat loss; at the same time, it has the advantage of small assembly space. Under the premise that the electrical connection needs to be sealed, this structure can be immersed in coolant, thereby achieving the effect of insulation operation. Attached Figure Description

[0045] Figure 1 This is a front view of an immersion thick-film heating element based on new energy vehicles;

[0046] Figure 2 This is a front view of the second insulating layer in this embodiment;

[0047] Figure 3 This is a front view of the resistive layer in this embodiment;

[0048] Figure 4 This is a front view of the conductor layer in this embodiment;

[0049] Figure 5 This is a front view of the first insulating layer in this embodiment;

[0050] Figure 6 This is a front view of the substrate in this embodiment;

[0051] Figure 7 This is a partially enlarged view of an immersion thick-film heating element based on new energy vehicles;

[0052] Figure 8 This is an exploded view of an immersion thick-film heating element based on new energy vehicles;

[0053] Figure 9 It is a layered structure of an immersion thick film heating element based on new energy vehicles;

[0054] Figure 10 This is a three-dimensional view of the housing in an immersion thick-film heating element for new energy vehicles;

[0055] Figure 11 This is a modeling and operational reference diagram for an immersion thick film heating element based on new energy vehicles.

[0056] In the diagram: Substrate-1, Conductor layer-2, Resistor layer-3, First insulating layer-4, Second insulating layer-5, First dielectric layer-6, Second dielectric layer-7, Third dielectric layer-8, Fourth dielectric layer-9, First protective layer-10, Second protective layer-11, Third protective layer-12, Fourth protective layer-13, First reserved hole-14, Second reserved hole-15, Third reserved hole-16, Clearance groove-17, Mounting reserved hole-18, Clearance area-19, Raised structure-20, Pad reserved hole-21, Pad structure-22, Resistor pin-23, Extension pin-24, Insulating sealing ring-25, Housing-26, Power contact area-27, Mounting groove-28, Partition-29, Flow channel-30, Inlet-31, Outlet-32, Mounting area-33, Temperature measuring area-34. Detailed Implementation

[0057] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0058] For this embodiment, please refer to Figures 1-11 The specific implementation of this is an immersion thick film heating element based on new energy vehicles, which includes a substrate 1, a conductor layer 2, and a resistor layer 3. The resistor layer 3 is installed on the surface of the conductor layer 2. A first insulating layer 4 is provided between the substrate 1 and the conductor layer 2. One end of the resistor layer 3 is connected to a second insulating layer 5. The substrate 1, the first insulating layer 4, the conductor layer 2, the resistor layer 3, and the second insulating layer 5 constitute a heating element. The heating element is a thick film structure and is an immersion structure that is in double-sided contact with coolant.

[0059] This structure adopts a double-sided contact with coolant, which improves the shortcomings of the traditional single-sided contact with coolant, which can only heat the coolant from one direction. The double-sided contact with coolant design allows the heating element to heat the coolant from two directions at the same time, improving heating efficiency and making the heating element heat the coolant more effectively.

[0060] Traditional single-sided contact coolant design has limitations in heating efficiency and heat dissipation performance, which can easily lead to uneven heating and poor heat dissipation. In contrast, the double-sided contact coolant design can distribute heat more evenly, reduce thermal stress concentration caused by local overheating, and reduce the risk of material fatigue and damage.

[0061] Firstly, the double-sided contact design can transfer heat to the coolant more evenly, avoiding local overheating or uneven heating, improving the overall heating effect, thereby enhancing heat exchange efficiency, allowing heat to be carried away by the coolant more quickly, preventing the heating element from overheating. Moreover, due to the more efficient heat dissipation, it avoids the phenomenon of overheating caused by one end being heated while the other end is not in contact with the coolant or is not dissipated in time, reducing the risk of aging and damage to the heating element due to overheating and extending its service life.

[0062] Secondly, the double-sided contact coolant design can provide higher heating power within the same volume, optimizing space utilization. This design is specifically designed to fit the limited space environment in new energy vehicles. Furthermore, the size and shape of the heating element can be flexibly adjusted according to actual needs to adapt to different installation positions and requirements, making disassembly and installation easier and improving assembly efficiency.

[0063] Thirdly, this design can transfer heat to the coolant more quickly, achieving rapid heating and improving the user experience. Due to its higher heating efficiency, the system can reach the set temperature in a shorter time, reducing energy consumption and meeting the requirements of energy conservation and environmental protection. By using an immersion double-sided contact with the coolant, the heating element effectively solves the problems of uneven heating and poor heat dissipation that may be encountered in traditional heating methods, further reducing energy consumption and achieving rapid heating.

[0064] On the other hand, the first insulating layer 4 and the second insulating layer 5 provide double insulation protection, ensuring that current does not leak into the coolant or into components adjacent to the heating element, thus improving the safety of the system. By using the first insulating layer 4 and the second insulating layer 5 as a double protection method for insulation, this structure effectively prevents the risk of electrical short circuits or leakage, ensuring the reliability and safety of system operation.

[0065] The heating element in this structure is a thick-film heating element, with a thickness of 500 nanometers to 5 micrometers, which is thicker than that of traditional thin films. The use of thick-film technology can achieve high power density in a smaller area, allowing the heating element to provide more heat output in a limited space. This is suitable for the space-constrained internal heating application scenarios of new energy vehicles. In addition, due to the tight connection of the thick-film heating element, it can respond quickly to temperature changes and provide efficient heating performance. It also has good thermal conductivity, which allows the heating element to quickly convert electrical energy into heat energy and quickly transfer it to the coolant or other media to achieve rapid heating and avoid problems such as local overheating or uneven cooling. Moreover, the thick-film structure has low resistivity, which can achieve high power output at a lower voltage, improving energy utilization efficiency. After high-temperature sintering, the internal structure of the thick-film heating element in this structure is dense, with corresponding mechanical strength and fatigue resistance, and can maintain stable performance during use.

[0066] The substrate 1, the first insulating layer 4, the conductor layer 2, the resistive layer 3 and the second insulating layer 5 are arranged in sequence.

[0067] The above-mentioned structural arrangement improves electrical safety and prevents short circuits and leakage. The first insulating layer 4 is located between the substrate 1 and the conductor layer 2, and the second insulating layer 5 is located at one end of the resistive layer 3, ensuring that the current does not directly contact the substrate 1 or the components adjacent to the substrate 1, thereby effectively preventing short circuits and leakage. By setting two insulating layers, namely the first insulating layer 4 and the second insulating layer 5, this structure provides double electrical isolation protection, achieving a double protection effect and further improving the safety and reliability of the system.

[0068] Furthermore, the close contact between conductor layer 2 and resistor layer 3 facilitates more precise temperature control, ensuring that the heating element can operate stably within the set temperature range. At the same time, the heat generated by resistor layer 3 can be quickly conducted to conductor layer 2 and then transferred to coolant through conductor layer 2, optimizing the heat conduction path. This structural design reduces thermal resistance and improves heat conduction efficiency, further achieving the effect of high-efficiency heat conduction. Moreover, conductor layer 2, as an intermediate layer, can not only conduct heat quickly but also distribute heat evenly across the entire surface, avoiding local overheating and extending the service life of the heating element.

[0069] This structure uses materials arranged in a specific order to form the overall structure of the heating element. This not only enhances the mechanical strength and stability of the entire heating element, but also reduces the risk of delamination caused by temperature changes or external stress, improving the reliability of long-term use. The simple hierarchical structure simplifies the production process, reduces the overall assembly difficulty and time, and improves production efficiency.

[0070] The materials arranged in an orderly manner can be selected from suitable high-temperature resistant materials according to actual needs, ensuring that the heating element can still operate stably in high-temperature environments; in this structure, the substrate 1 is one of a ceramic substrate, a stainless steel substrate, or an aluminum substrate:

[0071] The ceramic matrix includes alumina ceramics, aluminum nitride ceramics, and zirconia ceramics, which have good thermal conductivity and mature processing technology;

[0072] Stainless steel matrix has good thermal conductivity, high mechanical strength and good toughness, and does not suffer mechanical damage when subjected to rapid cooling and heating;

[0073] The advantages of aluminum substrate are good thermal conductivity, high mechanical strength and good toughness, and no mechanical damage during rapid cooling and heating;

[0074] The conductor layer 2 is formed by screen printing of conductor paste. The functional phases of the conductor paste include gold, silver, palladium, and platinum in the noble metal system and copper and nickel in the base metal system. One of these can be selected as the conductor for the conductor layer 2.

[0075] The resistive layer 3 is formed by screen printing resistive paste. The functional phase of the resistive paste includes silver, palladium, and ruthenium dioxide in the noble metal system, nickel, tungsten in the noble metal system, or graphene in the graphene carbon system. The resistive layer 3 can be selected as a resistor.

[0076] The first insulating layer 4, the conductor layer 2, the resistive layer 3 and the second insulating layer 5 are all screen printed onto the surface of the substrate 1, and the resistive layer 3 is arranged in a linear stepped manner on the surface of the substrate 1.

[0077] This structure uses screen printing technology to achieve patterned deposition, ensuring that each of the first insulating layer 4, conductor layer 2, resistive layer 3 and second insulating layer 5 can be printed on the substrate 1 according to the design requirements. Screen printing can ensure the consistency of products between batches, reduce the difference between batches, and improve the stability of product quality.

[0078] The linear stepped arrangement of the resistive layer 3 allows the current to be evenly distributed across the entire heating element, avoiding local overheating or uneven electric field, thus improving the overall electrical performance. Operators can adjust the resistance value as needed to achieve ideal heating power and temperature control, thereby realizing local temperature gradient control and meeting the needs of specific application scenarios. In addition, the linear stepped arrangement of the resistive layer 3 can more effectively disperse heat, making the heat more evenly distributed on the surface of the substrate 1, thereby improving the heat conduction efficiency.

[0079] The design of this structure is not only applicable to heating systems in new energy vehicles, but also to the fields of home appliances, medical equipment, and office equipment. In the field of medical equipment, it includes, but is not limited to, far-infrared physiotherapy devices, ventilators, and moxibustion devices; in the field of office equipment, it includes, but is not limited to, laser printers.

[0080] The first insulating layer 4 includes a first dielectric layer 6, a second dielectric layer 7, a third dielectric layer 8 and a fourth dielectric layer 9. The individual thickness of the first dielectric layer 6, the second dielectric layer 7, the third dielectric layer 8 and the fourth dielectric layer 9 is about 35 micrometers, and the total film thickness of the first insulating layer 4 is greater than or equal to 110 micrometers.

[0081] The first insulating layer 4 is formed by screen printing of dielectric paste, which includes barium titanate, high borosilicate, and alumina ceramic. The four dielectric layers can be coated with one of barium titanate, high borosilicate, and alumina ceramic respectively. The design of multiple dielectric layers increases the overall thickness of the insulating layer, thereby improving the electrical insulation performance, ensuring that current does not leak into other components or coolant, and enhancing the safety of the system.

[0082] Each dielectric layer in this structure provides a certain degree of insulation protection. The four dielectric layers work together to form multiple protective barriers, further reducing the risk of leakage. The multi-layer structure can effectively disperse external stress, reduce deformation or damage caused by excessive local stress, and enhance the mechanical strength and stability of the entire insulation layer. Since each dielectric layer can share some of the stress, it helps to distribute heat evenly, avoid local overheating, improve the overall thermal management capability, and at the same time make the overall structure have better durability and fatigue resistance, extending its service life.

[0083] Furthermore, when the total thickness is 110 micrometers, sufficient insulation performance is ensured without excessively increasing thermal resistance, ensuring that heat can be efficiently conducted away and preventing overheating. By adjusting the thickness and material combination of each dielectric layer, the insulation performance and thermal conductivity can be finely adjusted to meet the needs of different application scenarios.

[0084] The conductor paste, resistor paste, and dielectric paste are bonded together by a binder phase, which includes glass powder, oxides, and mixtures of glass powder and oxides. The glass powder is high borosilicate or aluminosilicate. The organic carrier between the conductor paste, resistor paste, and dielectric paste is an organic solvent, a thickening agent, ethyl cellulose, or lecithin. The organic solvent includes one of the following alcohols: terpene propanol, butyl carbitol acetate, or terpineol.

[0085] The first dielectric layer 6, the second dielectric layer 7, the third dielectric layer 8 and the fourth dielectric layer 9 are all coated and connected by screen printing, and it is a composite coating connection structure of coating one layer and sintering one time.

[0086] By coating only one layer of dielectric material at a time and sintering it on top, the uniformity and consistency of each layer can be ensured. This structure helps to avoid problems such as uneven thickness or bubbles caused by coating too much material at once. By coating and sintering layer by layer, the thickness and performance parameters of each layer can be controlled more precisely, thereby ensuring the high quality of the final product.

[0087] Each layer of material is sintered independently to form a strong bonding interface, which enhances the mechanical strength and stability of the overall structure. This layered structure helps to disperse stress and reduce deformation or damage caused by excessive local stress. Furthermore, the composite structure formed by layer coating and sintering has better fatigue resistance and can remain stable during long-term use, thus extending the product's service life.

[0088] Furthermore, each layer of material is sintered independently, which enables better heat conduction and diffusion, avoiding the problem of increased thermal resistance caused by coating too much material at once. This helps improve overall thermal management efficiency and prevents overheating. On the other hand, by adopting the method of coating and sintering layer by layer, operators can adjust the thermal conductivity of each layer of material, thereby achieving more precise temperature gradient control to meet the needs of specific application scenarios. When a defect occurs in a certain layer or needs to be adjusted, the layer can be handled separately without affecting other layers, simplifying the production process and improving production efficiency.

[0089] Each layer of this structure can be made of one of barium titanate, borosilicate, or alumina ceramic as a single-layer structure. This single-layer structure has good vibration resistance and is suitable for use in environments with frequent vibration, such as new energy vehicles, to maintain long-term stable operation.

[0090] Based on this, each dielectric layer provides a certain degree of electrical isolation protection. The four dielectric layers work together to form multiple protective barriers, further reducing the risk of leakage and improving the safety of the system. At the same time, they have good sealing properties, which can effectively prevent moisture and other impurities from entering, thus improving the reliability and durability of the equipment.

[0091] The second insulating layer 5 includes a first protective layer 10, a second protective layer 11, a third protective layer 12, and a fourth protective layer 13. The individual thickness of the first protective layer 10, the second protective layer 11, the third protective layer 12, and the fourth protective layer 13 is approximately 35 micrometers. The total thickness of the second insulating layer 5 is greater than or equal to 110 micrometers. The material, process, and function of the second insulating layer 5 are the same as those of the first insulating layer 4 described above. The function, material, process, and function of the first protective layer 10, the second protective layer 11, the third protective layer 12, and the fourth protective layer 13 are equivalent to those of the first dielectric layer 6, the second dielectric layer 7, the third dielectric layer 8, and the fourth dielectric layer 9.

[0092] The first protective layer 10, the second protective layer 11, the third protective layer 12 and the fourth protective layer 13 are all connected by screen printing coating, and it is a composite coating connection structure of coating one layer and sintering one time. The function, material, process and function of the first protective layer 10, the second protective layer 11, the third protective layer 12 and the fourth protective layer 13 are the same as the function, material, process and function of the first dielectric layer 6, the second dielectric layer 7, the third dielectric layer 8 and the fourth dielectric layer 9.

[0093] The surfaces of the first insulating layer 4 and the second insulating layer 5 are respectively provided with a first reserved hole 14, a second reserved hole 15 and a third reserved hole 16. The resistive layer 3 and the conductor layer 2 are respectively provided with clearance grooves 17 that are used to match the first reserved hole 14, the second reserved hole 15 and the third reserved hole 16. The surface of the substrate 1 is provided with a mounting reserved hole 18 for placing an external temperature probe. The mounting reserved hole 18 passes through the first insulating layer 4, the conductor layer 2, the resistive layer 3 and the second insulating layer 5 in sequence. The middle of the conductor layer 2 and the resistive layer 3 is provided with a clearance area 19 corresponding to the mounting reserved hole 18.

[0094] The first reserved hole 14, the clearance groove 17, the mounting reserved hole 18, and the clearance area 19 constitute the mounting area 33. This mounting area 33 is used to connect external screws or fasteners to define the position of the heating element, thus achieving a fixed installation effect. Figure 1 As shown;

[0095] The second reserved hole 15, the third reserved hole 16, and the clearance groove 17 form a temperature measuring area 34. This temperature measuring area 34 uses an external temperature measuring component for assisted temperature measurement. The temperature measuring area 34 operates by having the external temperature measuring component extend into the housing 26 and contact its surface to obtain temperature data. Figure 1 As shown.

[0096] Both the first insulating layer 4 and the second insulating layer 5 have a protruding structure 20 at one end. The surface of the protruding structure 20 of the second insulating layer 5 has a pad pre-reserved hole 21, and the surface of the pad pre-reserved hole 21 is filled with a pad structure 22.

[0097] The conductor layer 2 and the resistor layer 3 are respectively provided with a resistor pin 23 and an extension pin 24 at one end. One end of the resistor pin 23 and the extension pin 24 extends to the surface of the pad structure 22. An insulating sealing ring 25 placed externally is connected to the edge of the pad structure 22. The insulating sealing ring 25 is externally placed and attached to the surface of the pad structure 22.

[0098] The design of the pad pre-drilled hole 21 and the pad structure 22 allows the resistor pin 23 and the extension pin 24 to be precisely soldered to the external circuit, ensuring that the current can pass smoothly through each layer and reducing the problem of poor contact or open circuit. It provides electrical connection points to ensure that the current can be smoothly transmitted to the external circuit. The pad structure 22 enables more reliable electrical interconnection between different layers, simplifies the soldering steps and reduces the complexity of manual operation.

[0099] The raised structure 20 can disperse external stress and increase heat dissipation area to a certain extent while protecting the product. During installation, if the product falls to the ground due to accident or incorrect operation, the center of gravity change caused by the raised structure 20 will cause the raised structure 20 to contact the ground first and impact the ground when affected by gravity, reducing the probability of forming multiple impact points and further damaging the product, thus protecting the product.

[0100] The design of resistor pin 23 and extension pin 24 can also prevent excessive heat accumulation in specific locations, thereby reducing the formation of hot spots, helping to dissipate heat evenly, and improving the overall thermal management efficiency. Meanwhile, the insulating sealing ring 25 plays a role in filling and blocking, reducing the probability of leakage and coolant seeping into the pad structure 22.

[0101] The key design features of this invention are: it can be used in high-voltage versions up to 800VDC, with a withstand voltage of up to 4000VDC; it also has improved thermal efficiency and less heat loss; it has the advantage of small assembly space; and under the premise that electrical connections must be sealed, this structure can be immersed in coolant to achieve the effect of insulation operation.

[0102] This structure adopts a double-sided contact with coolant, which improves the shortcomings of the traditional single-sided contact with coolant, which can only heat the coolant from one direction. The double-sided contact with coolant design allows the heating element to heat the coolant from two directions at the same time, improving heating efficiency and making the heating element heat the coolant more effectively.

[0103] This invention improves upon the limitations of traditional single-sided contact coolant design in terms of heating efficiency and heat dissipation performance, which can easily lead to uneven heating and poor heat dissipation. By adopting a double-sided contact coolant design, heat can be distributed more evenly, reducing thermal stress concentration caused by local overheating and lowering the risk of material fatigue and damage.

[0104] The double-sided contact design can transfer heat to the coolant more evenly, avoiding local overheating or uneven heating, improving the overall heating effect, thereby enhancing heat exchange efficiency, allowing heat to be carried away by the coolant more quickly, preventing the heating element from overheating. In addition, due to the more efficient heat dissipation, it avoids the phenomenon of one end being heated while the other end is not in contact with the coolant or is not dissipated in time, which can cause overheating. This reduces the risk of aging and damage to the heating element due to overheating and extends its service life.

[0105] The operation process of this utility model is as follows: A heating element is installed inside the housing 26. The housing 26 has a power contact area 27 inside, through which an external power source is connected to the pad structure 22 for electrical connection. This allows the heat generated by the resistive layer 3 to be rapidly conducted to the conductor layer 2 and the substrate 1, and then transferred to the coolant through the conductor layer 2 and the substrate 1. This optimizes the heat conduction path, reduces thermal resistance, and improves heat conduction efficiency. The housing 26 has an installation groove 28 for placing the heating element. A partition 29 is connected inside the installation groove 28, and the area formed between adjacent partitions 29 is a flow channel 30. The installation groove 28 has an inlet 31 and an outlet 32, both of which penetrate the interior of the installation groove 28 and extend beyond the exterior of the housing 26. Figure 11 As shown;

[0106] When the heating element is placed inside the mounting slot 28, coolant enters the slot 28 through the inlet 31. Because the housing 26 has a closed mounting structure, forming a sealed space, the coolant contacts the surface of the heating element through the flow channel 30. When the cooling element is completely submerged in the coolant inside the housing 26, the heating element has also completed heating the coolant. Driven by water pressure, the coolant is discharged from the mounting slot 28 through the outlet 32. Simultaneously, the heated coolant is transported through pipes to the corresponding operating module. The operating modules have a mutual recirculation structure, achieving a circulation effect. Finally, the coolant passes through the operating module and is transported through pipes to a water tank or container for storing the coolant. The container is then pressurized to force the coolant in, completing the recycling process. Figure 11 As shown.

[0107] In this embodiment: the substrate 1 is austenitic stainless iron 4 series;

[0108] The first insulating layer 4 is a high borosilicate glass system, used to insulate against the substrate 1; the conductor layer 2 is a silver-palladium / silver-platinum system, used for conductivity and electrical connection; the resistive layer 3 is a silver-palladium / silver-platinum system, used as a heating layer; the second insulating layer 5 is a high borosilicate glass system, used to insulate against external coolant; the low voltage platform of this heating element is 400VDC, the high voltage platform is 800VDC, and the operating voltage is manually adjusted by the operator according to work or environmental requirements; the rated power is 3500W-7000W; the insulation withstand voltage is 2300Vac / 5mA / 1min, and the maximum temperature it can withstand is 250℃-300℃.

[0109] The test temperatures for the thick-film heating element in this embodiment are 25℃, 60℃, 100℃, and 125℃, and the temperature coefficients are shown in the table below:

[0110] Table 1: Reference Table for TCR Temperature Coefficient

[0111]

[0112] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention. It should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the concept of the present invention, and all such modifications and substitutions should be considered within the scope of protection of the present invention.

Claims

1. An immersion thick-film heating element for new energy vehicles, comprising a substrate, a conductor layer, and a resistive layer, characterized in that: The resistive layer is mounted on the surface of the conductor layer. A first insulating layer is provided between the substrate and the conductor layer. One end of the resistive layer is connected to a second insulating layer. The substrate, the first insulating layer, the conductor layer, the resistive layer, and the second insulating layer together constitute a heating element. The heating element is an immersion structure that is in double-sided contact with the coolant.

2. The immersion thick-film heating element for new energy vehicles according to claim 1, characterized in that: The substrate, the first insulating layer, the conductor layer, the resistive layer, and the second insulating layer are arranged in sequence.

3. The immersion thick-film heating element for new energy vehicles according to claim 1, characterized in that: The first insulating layer, conductor layer, resistive layer and second insulating layer are all screen-printed onto the surface of the substrate, and the resistive layer is arranged in a linear stepped manner on the surface of the substrate.

4. An immersion thick-film heating element for new energy vehicles according to any one of claims 1-3, characterized in that: The first insulating layer includes a first dielectric layer, a second dielectric layer, a third dielectric layer, and a fourth dielectric layer.

5. The immersion thick-film heating element for new energy vehicles according to claim 4, characterized in that: The first dielectric layer, the second dielectric layer, the third dielectric layer and the fourth dielectric layer are all coated and connected by screen printing, and it is a composite coating connection structure in which one layer is coated and sintered at a time.

6. An immersion thick-film heating element for new energy vehicles according to any one of claims 1-3, characterized in that: The second insulating layer includes a first protective layer, a second protective layer, a third protective layer, and a fourth protective layer.

7. The immersion thick-film heating element for new energy vehicles according to claim 6, characterized in that: The first protective layer, the second protective layer, the third protective layer and the fourth protective layer are all coated and connected by screen printing, and it is a composite coating connection structure in which one layer is coated and sintered at a time.

8. An immersion thick-film heating element for new energy vehicles according to any one of claims 1-3, characterized in that: The first insulating layer and the second insulating layer are respectively provided with a first reserved hole, a second reserved hole and a third reserved hole on their surfaces. The resistive layer and the conductor layer are arranged with clearance grooves that are used in conjunction with the first reserved hole, the second reserved hole and the third reserved hole.

9. A submersible thick-film heating element for new energy vehicles according to any one of claims 1-3, characterized in that: The substrate has mounting holes for connecting external screws on its surface. The mounting holes pass through the first insulating layer, the conductor layer, the resistive layer and the second insulating layer in sequence. The conductor layer and the resistive layer have clearance areas in the middle that correspond to the mounting holes.

10. An immersion thick-film heating element for new energy vehicles according to any one of claims 1-3, characterized in that: Both the first insulating layer and the second insulating layer have a protruding structure at one end. The surface of the protruding structure of the second insulating layer has a pre-drilled pad hole, and the surface of the pre-drilled pad hole is filled with a pad structure. The conductor layer and the resistor layer are respectively provided with a resistor pin and an extension pin at one end. One end of the resistor pin and the extension pin extends to the surface of the pad structure. The edge of the pad structure is connected to an externally placed insulating sealing ring.

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