A small volume, low weight compressor heater integrated module
By designing a compressor-heater integrated module with a shared controller in the air conditioning system of an electric vehicle and adopting a series heating tube structure, the high cost and large size problems caused by the separate structure of the heater and compressor are solved, achieving higher integration and lower cost.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SUZHOU ZHONGCHENG NEW ENERGY TECH CO LTD
- Filing Date
- 2025-08-11
- Publication Date
- 2026-07-10
AI Technical Summary
In existing electric vehicle air conditioning systems, the heater and compressor are separate components, resulting in high cost, large size, poor integration, and affecting the overall layout.
A compact, lightweight compressor-heater integrated module is designed. By sharing the same controller for the compressor and heater and adopting a series heating tube structure, the structural volume and heater volume are significantly reduced.
Integrated electrical management of the compressor and heater was achieved, reducing the overall structural volume, increasing heating density and installation efficiency, and reducing costs.
Smart Images
Figure CN224476807U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to a thermal management system, and more particularly to a small-volume, low-weight compressor heater integrated module. Background Technology
[0002] The description in this section provides only background information related to the disclosure of this utility model and does not constitute prior art.
[0003] Currently, under the strong national policy, the popularization of electric vehicles is an inevitable trend. However, in the process of developing electric vehicles, more and more problems are becoming increasingly prominent. For example, in conventional air conditioning systems, the heater and compressor are separate structures, requiring two sets of high-voltage terminals for power supply, which is costly and takes up a large volume.
[0004] At the same time, due to the unreasonable configuration of the heater, the heater is also large in size and has poor integration, which affects the overall layout.
[0005] It should be noted that the above introduction to the technical background is only for the purpose of providing a clear and complete explanation of the technical solutions of this utility model and facilitating understanding by those skilled in the art. It should not be assumed that these technical solutions are known to those skilled in the art simply because they have been described in the background section of this utility model. Utility Model Content
[0006] The purpose of this invention is to provide a small-volume, low-weight compressor-heater integrated module that can share the same controller for the compressor and heater, and significantly reduce the structural volume by using series-connected heating tubes.
[0007] To achieve the above objectives, this utility model discloses a small-volume, low-weight compressor heater integrated module, which includes:
[0008] compressor;
[0009] There is one and only one controller, which is located at one end of the compressor. The controller includes a first connection terminal and a second connection terminal, and the first connection terminal is electrically connected to the compressor.
[0010] The heater includes a metal tube, a heating unit, and a cover plate. The heating unit is electrically connected to the second connection terminal and is used to heat the liquid in the metal tube. The metal tube is covered by the cover plate on the side of the controller away from the compressor.
[0011] As a further description of the above technical solution, the metal tube includes a first drain tube, a first heating tube, a second heating tube, and a second drain tube arranged in series; the first heating tube is provided with a first terminal, and the second heating tube is provided with a second terminal, the first terminal and the second terminal extending toward the controller and being plugged into the controller.
[0012] As a further description of the above technical solution, the first heating tube and the second heating tube are connected by a connecting plate, the first heating tube, the second heating tube, and the connecting plate are configured to be U-shaped connected, and the first terminal and the second terminal extend to the connecting plate.
[0013] As a further description of the above technical solution, the first heating tube and the second heating tube are provided with a spiral flow guiding structure extending along the extension direction of the first heating tube and the second heating tube.
[0014] As a further description of the above technical solution, the first drainage tube passes through the cover plate and is inserted into the first heating tube, and a first sealing ring is provided between the first drainage tube and the cover plate, and a second sealing ring is provided between the first drainage tube and the first heating tube; the second drainage tube passes through the cover plate and is inserted into the second heating tube, and a third sealing ring is provided between the second drainage tube and the cover plate, and a fourth sealing ring is provided between the second drainage tube and the second heating tube.
[0015] As a further description of the above technical solution, the first heating tube is provided with a first mounting groove for mounting a sensor at the connection point with the first drain tube; the second heating tube is provided with a second mounting groove for mounting a sensor at the connection point with the second drain tube, and the first mounting groove and the second mounting groove are opened towards the controller.
[0016] As a further description of the above technical solution, the height of the first drainage tube is higher than the height of the second drainage tube.
[0017] As a further description of the above technical solution, a support plate is provided between the first heating tube and the second heating tube.
[0018] As a further description of the above technical solution, a partition is provided between the first heating tube and the second heating tube.
[0019] As a further description of the above technical solution, the first heating tube and the second heating tube are inclinedly disposed in the cover plate.
[0020] Based on the above technical solutions, the beneficial effects of this utility model are as follows: The small-volume, low-weight integrated compressor-heater module of this utility model significantly reduces the structural volume by using a shared controller for both the compressor and heater, and by employing series-connected heating tubes. Specifically, in this utility model, the compressor and heater are respectively located on both sides of the controller and electrically connected to it. Therefore, two levels of control are achieved with a single controller, resulting in a smaller volume compared to integrated compressor modules with dual controllers. The heater utilizes multiple heating tubes connected in series; the series-connected tubular heating units help increase the heating density within the same volume, indirectly reducing the heater's volume.
[0021] To further understand the features and technical content of this utility model, please refer to the following detailed description and drawings of this utility model. However, the drawings provided are for reference and illustration only and are not intended to limit this utility model. Attached Figure Description
[0022] To more clearly illustrate the technical solutions in the embodiments or prior art of this specification, the drawings used in the description of the embodiments or prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this specification. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0023] Figure 1 This is a schematic diagram illustrating an installation method for a small-volume, low-weight compressor heater integrated module provided in the embodiments of this specification;
[0024] Figure 2 This is a schematic diagram of a small-volume, low-weight compressor heater integrated module provided in the embodiments of this specification;
[0025] Figure 3 This is a schematic diagram of the heating tube assembly of a small-volume, low-weight compressor heater integrated module provided in the embodiments of this specification;
[0026] Figure 4 This is a schematic cross-sectional view of a heater in a small-volume, low-weight compressor heater integrated module provided in the embodiments of this specification;
[0027] Figure 5 This is a three-dimensional schematic diagram of the heating tube of a small-volume, low-weight compressor heater integrated module provided in the embodiments of this specification;
[0028] In the picture:
[0029] 1. Compressor;
[0030] 2. Controller;
[0031] 3. Heater; 31. First drain pipe; 32. First heating pipe; 321. First terminal; 322. First mounting groove; 323. First sealing ring; 324. Second sealing ring; 33. Second heating pipe; 331. Second terminal; 332. Second mounting groove; 333. Third sealing ring; 334. Fourth sealing ring; 34. Second drain pipe; 35. Cover plate; 36. Spiral guide structure; 37. Connecting plate; 38. Support plate; 39. Partition plate. Detailed Implementation
[0032] To enable those skilled in the art to better understand the technical solutions in this specification, the technical solutions in the embodiments of this specification will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this specification, and not all embodiments. Based on the embodiments in this specification, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this specification.
[0033] The following specific embodiments illustrate the implementation of this utility model. Those skilled in the art can understand the advantages and effects of this utility model from the content disclosed in this specification. This utility model can be implemented or applied through other different specific embodiments, and various details in this specification can also be modified and changed based on different viewpoints and applications without departing from the concept of this utility model. Furthermore, the accompanying drawings of this utility model are for simple illustration only and are not depictions of actual dimensions, as stated in advance. The following embodiments will further describe the relevant technical content of this utility model in detail, but the disclosed content is not intended to limit the scope of protection of this utility model.
[0034] It should be understood that while terms such as "first," "second," and "third" may be used in this document to describe various components or signals, these components or signals should not be limited by these terms. These terms are primarily used to distinguish one component from another, or one signal from another. Furthermore, the term "or" as used herein should, as appropriate, include any combination of one or more of the related listed items.
[0035] Please see Figure 1-5 This embodiment provides a small-volume, low-weight compressor heater integrated module, which includes:
[0036] Compressor 1;
[0037] There is one and only one controller 2. Controller 2 is located at one end of compressor 1. Controller includes a first connection end and a second connection end. The first connection end is electrically connected to compressor 1.
[0038] Heater 3, heater package 3 metal tube, heating unit and cover plate 35, heating unit is electrically connected to the second connection end, heating unit is used to heat the liquid in the metal tube, the metal tube is covered by cover plate 35 on the side of controller 2 away from compressor 1.
[0039] Based on the above structure, during installation, such as Figure 1 As shown, with compressor 1 as the center of gravity, controller 2 can be installed at the bottom of compressor 1, and the corresponding wiring harness in compressor 2 can be electrically connected to controller 2 downwards. Then, or simultaneously, heater 3 can be installed at the bottom of controller 2, and the wiring harness in heater 3 can be electrically connected to controller 2.
[0040] Therefore, in the above configuration, the controller 2, located in the middle, can simultaneously serve as the main integrated functional module to manage the electricity of both the compressor 1 above and the heater 3 below. In other words, this embodiment integrates two main component structures simultaneously using a single controller 2 module, achieving extremely high integration density. Furthermore, the top-to-bottom splicing installation method is easier to implement, contributing to improved installation efficiency.
[0041] Based on this utility model, the heater 3 is configured with multiple heating tubes connected in series. Specifically, in this embodiment, the metal tubes are a first drain pipe 31, a first heating tube 32, a second heating tube 33, and a second drain pipe 34 connected in series. The first drain pipe 31 can be configured as a cold water inlet, and the second drain pipe 34 can be configured as a heated hot water outlet. The first heating tube 32 and the second heating tube 33 are provided with a covered heating surface, which can quickly and effectively heat the liquid entering them. Compared with the panel-type heater of a general manifold for heating liquid, its tube structure can be covered with a heating film, achieving a larger heating surface with the three-dimensional space of the tube. Moreover, the assembly and manufacturing process requirements of the tube structure are lower, significantly reducing costs and achieving better cost control. The heating unit can be configured as a heating film or heating wire attached to the inner or outer wall of the first heating tube 32 and the second heating tube 33, or directly placed in the pipe.
[0042] In practical use, cold water is injected into the first drain pipe 31. As the water flows through the first heating pipe 32 and the second heating pipe 33, the water is heated by the contact surfaces of the first heating pipe 32, the second heating pipe 33, and the water itself. Then, the heated water is discharged from the second drain pipe 34 and directed to the area where the corresponding heating element is located.
[0043] By utilizing the small-volume, low-weight integrated compressor-heater module of this invention, the compressor 1 and heater 3 can share the same controller 2, and the structural volume is significantly reduced through the use of series-connected heating tubes. Specifically, in this invention, the compressor 1 and heater 3 are respectively located on both sides of the controller and electrically connected to the controller 2. Therefore, two levels of control are achieved with one controller 2, resulting in a smaller volume compared to integrated compressor modules with dual controllers. The heater utilizes multiple heating tubes connected in series; the series-connected tubular heating units help increase the heating density within the same volume, indirectly reducing the heater's volume.
[0044] The metal tube in this application can be an aluminum alloy tube structure with a circular cross-section, which allows the water inside to receive a 360-degree surrounding heating surface.
[0045] Please see Figure 1-2 In this design, a first terminal 321 is provided on the first heating tube 32, and a second terminal 331 is provided on the second heating tube 33. The first terminal 321 and the second terminal 331 extend toward the controller 2 and are plugged into the controller 2. The first heating tube 32 and the second heating tube 33 are connected by a connecting plate 37, which is configured in a U-shape. The first terminal 321 and the second terminal extend to the connecting plate. Specifically, when installing the heater 3, it is plugged into the controller 2 from bottom to top to achieve electrical connection between the first terminal 321, the second terminal 331, and the controller 2. The first terminal 321 and the second terminal 331 are integrated at the connecting plate 37 where the ends of the first heating tube 32 and the second heating tube 33 are connected, which is relatively close, thus improving the integration of the corresponding docking terminals in the controller 2. The U-shape in the above structure, with the first heating tube 32 and the second heating tube 33 arranged in parallel, can achieve better structural density in the cover plate 35 structure with a certain length.
[0046] Please see Figure 4 and Figure 5 The first heating tube 32 and the second heating tube 33 are internally provided with a spiral flow guiding structure 36 extending along the extension direction of the first heating tube 32 and the second heating tube 33. The spiral flow guiding structure 36 can be regarded as a rotating butterfly-shaped plate extending along the tube body direction of the first heating tube 32 and the second heating tube 33 and conforming to the inner wall of the tube. Under the guidance of the spiral flow guiding structure 36, the liquid flow path in the first heating tube 32 and the second heating tube 33 can be longer and the liquid flow speed can be slower. The spiral flow guiding structure 36 itself can assist in heating the liquid. Therefore, when the liquid comes into contact with the spiral flow guiding structure 36, auxiliary heat exchange is generated, which helps to improve the heat exchange efficiency.
[0047] Please see Figure 4The first drainage tube 32 passes through the cover plate 35 and is inserted into the first heating tube 32. A first sealing ring 323 is provided between the first drainage tube 31 and the cover plate 35, and a second sealing ring 324 is provided between the first drainage tube 31 and the first heating tube 32. The second drainage tube 34 passes through the cover plate 35 and is inserted into the second heating tube 33. A third sealing ring 333 is provided between the second drainage tube 34 and the cover plate 35, and a fourth sealing ring 334 is provided between the second drainage tube 34 and the second heating tube 33. Taking the first drainage tube 32 as an example, its output end is inserted into a matching hole on the cover plate 35. A first sealing ring 323 is filled between the outer wall of the first drainage tube 32 and the inner wall of the hole in the cover plate 35. Therefore, the cover plate 35 can be sealed and isolated from the outside with the help of the first sealing ring 323. Similarly, the output end of the first drainage tube 32 is inserted into the input end of the first heating tube 32. A second sealing ring 324 is filled between the outer wall of the first drainage tube 32 and the inner wall of the first heating tube 32. Therefore, the first heating tube 32 can be sealed and isolated from the inside with the help of the second sealing ring 324. In other words, in this embodiment, the liquid penetration between the outside of the cover plate 5 and the inside of the first heating tube 32 can be effectively limited by the double-layer sealing structure. Its structure is simple, easy to insert and install, and has a low cost. The sealing process of the second heating tube 33 is similar to that of the first heating tube 32, and will not be described in detail here.
[0048] In at least one embodiment, the heating unit is a thick-film heater. However, thick-film heaters are generally not bendable, and their U-shaped design wastes heating space, resulting in lower heating efficiency. This application utilizes a double-stage sealing ring integrated into the compressor to improve the sealing effect. This increases the fluid flow pressure while ensuring reliable sealing. Compared to existing tubular thick-film heaters, it provides better heat exchange efficiency through rapid liquid flow and improved sealing. The heating effect is further improved without increasing the heater's volume.
[0049] Please see Figure 2 and Figure 5 The first heating tube 32 has a first mounting groove 322 for mounting a sensor at its connection with the first drain tube 31; the second heating tube 33 has a second mounting groove 332 for mounting a sensor at its connection with the second drain tube 34. Both the first mounting groove 322 and the second mounting groove 332 face the controller 2. Specifically, a corresponding temperature sensor or temperature / pressure sensor can be installed in the first mounting groove 322 or the second mounting groove 332, with the sensor terminals facing the controller 2. During installation, the sensor is directly inserted into the corresponding sensor port to establish a connection.
[0050] In another embodiment, such as Figure 1As shown, the height of the first drain pipe 31 is higher than the height of the second drain pipe 34. Specifically, the height of the first drain pipe 31 used for liquid outlet is higher than the height of the second drain pipe 34 used for liquid inlet, so as to timely discharge the gas from the heater 3, prevent damage to the heater due to dry burning, and reduce the probability of heater damage.
[0051] Furthermore, a support plate 38 is provided between the first heating tube 32 and the second heating tube 33. For details, please refer to... Figure 3 The support plate 38 is connected between the two heating tubes. It can improve the stability of the heating unit and reduce the probability of resonance between the heater 3 and the flowing liquid. The connection between the support plate and the heating tube can be welding or other methods.
[0052] See also Figure 2 and Figure 4 A partition 39 is provided between the first heating tube 32 and the second heating tube 33. The partition 39 extends directly from the cover plate 35 and is positioned between the first heating tube 32 and the second heating tube 33 along their extension directions, presenting a vertical flat plate structure. The partition 39 serves two purposes: firstly, it guides and limits the installation of the first heating tube 32 and the second heating tube 33 in the heater 3; secondly, it enhances the structural strength of the cover plate 35 and supports the base plate. A corresponding contoured surface can be provided at the contact point between the partition 39 and the heating tubes to assist in installation.
[0053] Please see Figure 2 The first heating tube 32 and the second heating tube 33 are inclinedly arranged in the cover plate 35. In fact, the groove on the cover plate 35 for placing the first heating tube 32 and the second heating tube 33 is inclined relative to the arrangement direction of the compressor 1, the controller 2 and the cover plate 35. This allows for the use of longer heating tubes, improves the space utilization rate inside the cover plate 35 and the heat exchange area of the first heating tube 32 and the second heating tube 33, and further improves the heating efficiency of liquids in a small space.
[0054] The above-disclosed content is only a preferred and feasible embodiment of the present utility model, and is not intended to limit the scope of the patent application of the present utility model. Therefore, all equivalent technical changes made using the contents of the present utility model specification and drawings are included in the scope of the patent application of the present utility model.
[0055] The various embodiments in this specification are described in a progressive manner. The same or similar parts between the various embodiments can be referred to each other. Each embodiment focuses on describing the differences from other embodiments.
[0056] Although this application has been described by way of examples, those skilled in the art will know that this application has many modifications and variations without departing from the spirit of this application, and it is intended that the appended embodiments include these modifications and variations without departing from this application.
Claims
1. A compact, lightweight compressor heater integrated module, characterized in that, The compressor heater integrated module includes: compressor; There is one and only one controller, which is located at one end of the compressor. The controller includes a first connection terminal and a second connection terminal, and the first connection terminal is electrically connected to the compressor. The heater includes a metal tube, a heating unit, and a cover plate. The heating unit is electrically connected to the second connection terminal. The heating unit tube is used to heat the liquid in the metal tube. The metal tube is covered by the cover plate on the side of the controller away from the compressor.
2. The small-volume, low-weight compressor heater integrated module according to claim 1, characterized in that: The metal tube includes a first drain tube, a first heating tube, a second heating tube, and a second drain tube arranged in series. The first heating tube is provided with a first terminal, and the second heating tube is provided with a second terminal. The first terminal and the second terminal extend toward the controller and are plugged into the controller.
3. The small-volume, low-weight compressor heater integrated module according to claim 2, characterized in that: The first heating tube and the second heating tube are connected by a connecting plate. The first heating tube, the second heating tube, and the connecting plate are configured to be connected in a U-shape. The first terminal and the second terminal extend to the connecting plate.
4. The small-volume, low-weight compressor heater integrated module according to claim 2, characterized in that: The first heating tube and the second heating tube are provided with a spiral flow guiding structure extending along the extension direction of the first heating tube and the second heating tube.
5. The small-volume, low-weight compressor heater integrated module according to claim 2, characterized in that: The first drainage tube passes through the cover plate and is inserted into the first heating tube. A first sealing ring is provided between the first drainage tube and the cover plate, and a second sealing ring is provided between the first drainage tube and the first heating tube. The second drainage tube passes through the cover plate and is inserted into the second heating tube. A third sealing ring is provided between the second drainage tube and the cover plate, and a fourth sealing ring is provided between the second drainage tube and the second heating tube.
6. The small-volume, low-weight compressor heater integrated module according to claim 2, characterized in that: The first heating tube has a first mounting slot for mounting a sensor at the connection point with the first drain tube; the second heating tube has a second mounting slot for mounting a sensor at the connection point with the second drain tube, and the first mounting slot and the second mounting slot are opened towards the controller.
7. The small-volume, low-weight compressor heater integrated module according to claim 2, characterized in that: The height of the first drainage tube is higher than the height of the second drainage tube.
8. The small-volume, low-weight compressor heater integrated module according to claim 2, characterized in that: A support plate is provided between the first heating tube and the second heating tube.
9. The small-volume, low-weight compressor heater integrated module according to claim 2, characterized in that: A partition is provided between the first heating tube and the second heating tube.
10. The small-volume, low-weight compressor heater integrated module according to claim 2, characterized in that: The first heating tube and the second heating tube are inclinedly arranged in the cover plate.