A liquid heater for a vehicle using an integrated electric heating rod

Abstract

This utility model relates to a vehicle liquid heater employing an integrated electric heating rod, characterized by: the main housing cavity being divided into upper and lower chambers, the upper chamber being an electrical chamber and the lower chamber being a heat exchange chamber; the heat exchange chamber being composed of front and rear chambers, with the front wall of the rear chamber serving as the mounting surface for the heating rod rear cover; a U-shaped water channel is provided within the front chamber; the heating rod assembly consists of a heating rod rear cover, two heating rod bodies, and a front fixing component for the heating rod; the rear ends of the two heating rod bodies are inserted into and welded to two insertion holes on the heating rod rear cover; the heating rod assembly is inserted from the rear chamber into the front chamber, the heating rod rear cover is sealed and fixedly connected to the heating rod rear cover mounting surface, and the two heating rod bodies extend into the two parallel vertical water channels of the U-shaped water channel, with the front ends of the two heating rod bodies pressed against the inner wall of the top of the main housing via the front fixing component. This heater simplifies the structure, reduces costs, and optimizes the sealing.

Description

Technical Field

[0001] This utility model belongs to the technical field of automotive liquid heaters, specifically relating to an automotive liquid heater that uses an integrated heating rod. Background Technology

[0002] Electric heating rods are key structural components in automotive liquid heaters used for heating liquids. Currently, automotive liquid heaters on the market that use single-head heating rods as heating elements generally have the following defects: 1. The large number of parts results in a complex structure and a cumbersome assembly process; 2. High manufacturing costs: High component costs hinder market promotion; 3. The water circuit sealing structure mainly relies on sealing rings. The sealing points are scattered and numerous, resulting in poor sealing reliability. After long-term use, liquid leakage is prone to occur due to sealing ring aging, assembly errors, etc., posing a safety hazard. 4. Insufficient electrical connection stability: Electrical connections rely on processes such as terminal blocks, TG soldering, and reflow soldering, which not only increases the cost of components but may also affect the stability of electrical performance due to welding quality issues. Utility Model Content

[0003] This invention addresses the shortcomings of existing technologies by proposing a vehicle liquid heater that utilizes an integrated electric heating rod, which simplifies the structure, reduces costs, optimizes sealing, lowers leakage risks, and improves electrical connection reliability.

[0004] The above-mentioned objective of this utility model is achieved through the following technical solution: A vehicle liquid heater employing an integrated electric heating rod includes a main housing, a top cover, a heating rod assembly, a rear cover, a water inlet pipe, a water outlet pipe, a control board assembly, a low-voltage connector assembly, and a high-voltage connector assembly; characterized in that: The main shell is a one-piece cast structure. The inner cavity of the main shell is divided into upper and lower chambers. The upper chamber is the electrical chamber, and the lower chamber is the heat exchange chamber. The heat exchange chamber consists of a front chamber and a rear chamber. The front wall of the rear chamber is the mounting surface for the heating rod rear cover. A U-shaped water channel is provided in the front chamber. The front ends of the two parallel vertical water channels of the U-shaped water channel extend to the top of the main shell, and the rear ends of the two parallel vertical water channels extend to the mounting surface for the heating rod rear cover. A sealing groove is provided on the mounting surface for the heating rod rear cover. Two clearance grooves communicating with the electrical chamber are provided on the top surface of the rear chamber. The inlet pipe and outlet pipe are respectively connected to the front ends of the two parallel vertical water channels. The heating rod assembly consists of a heating rod rear cover, two heating rod bodies with leads, and a heating rod front fixing member; the heating rod rear cover is provided with insertion holes that mate with the rear ends of the two heating rod bodies, and the rear ends of the two heating rod bodies are inserted into and welded to the two insertion holes on the heating rod rear cover; the heating rod front fixing member is fitted on the top of the two heating rod bodies. The heating rod assembly is inserted from the rear chamber of the heat exchange chamber into the front chamber of the heat exchange chamber. The rear cover of the heating rod and the mounting surface of the rear cover of the heating rod form a sealed contact through a sealing ring installed in the sealing groove and are fixedly connected by screws. The two heating rod bodies extend into the two parallel vertical channels of the U-shaped water channel respectively. The front ends of the two heating rod bodies contact the inner wall of the top of the main shell or the side wall of the vertical water channel through the front fixing member of the heating rod. The top cover is sealed to the upper end of the main housing by a rubber sealing ring and fixedly connected by screws; the rear cover is sealed and fixed to the rear end of the main housing by rear cover sealant. The control board assembly is supported and fixed in the electrical cavity; the high-voltage connector assembly and the low-voltage connector assembly are fixed on the side wall of the main housing and electrically connected to the control board assembly; the two lead terminals of the heating rod assembly pass through the two clearance slots of the main housing and are electrically connected to the control board assembly.

[0005] Furthermore, a high-voltage wiring harness assembly interface is provided on the front side wall of the main housing corresponding to the position of the electrical chamber, and a low-voltage wiring harness assembly interface is provided on the rear side wall of the main housing corresponding to the position of the electrical chamber; the high-voltage connector assembly and the low-voltage connector assembly are respectively fixed to the high-voltage wiring harness assembly interface and the low-voltage wiring harness assembly interface by screws.

[0006] Furthermore, the lead end of the high-voltage connector assembly is connected to the control board assembly via a bolt and nut structure; the low-voltage connector assembly is connected to the control board assembly via connectors.

[0007] Furthermore, the control board assembly integrates IGBTs, and a heat dissipation platform is provided on the main housing below the IGBTs on the control board assembly. The IGBT mounting plate is fixedly connected to the main housing with screws, so that the lower end of the IGBT is in close contact with the front of the heat dissipation platform through an insulating gasket; and crisscrossing heat dissipation fins are provided on the back of the heat dissipation platform.

[0008] Furthermore, an inlet pipe interface and an outlet pipe interface are provided at the top of the main shell. The inlet pipe interface and the outlet pipe interface are respectively offset and connected to the two parallel vertical water channels of the U-shaped water channel. The inlet pipe and the outlet pipe are sealed to the inlet pipe interface and the outlet pipe interface through the tube sheet sealing ring, respectively, and are fixedly connected by screws, so that the front chamber of the heat exchange chamber forms a closed fluid cavity.

[0009] Moreover, the water inlet pipe and water outlet pipe are integrally formed with the main shell.

[0010] The advantages and positive effects of this utility model are as follows: 1. The heating rod assembly in this vehicle liquid heater adopts a welded integrated structure, and the main housing adopts an integral casting structure, eliminating redundant components such as heating rod terminal blocks and high voltage input terminal blocks, reducing TG welding and reflow soldering processes, reducing the number of parts by more than 30%, reducing weight, and significantly reducing manufacturing costs.

[0011] 2. This vehicle liquid heater replaces the traditional sealing ring seal between the heating rod and the rear cover with laser welding, reducing the number of sealing points and lowering the risk of leakage by more than 50%; the electrical connection process is simplified, reducing the potential for welding failures and improving reliability.

[0012] 3. The electrical chamber of this vehicle liquid heater is physically isolated from the water circuit, and the metal housing improves EMC performance; it integrates overvoltage, overcurrent, and overtemperature protection functions, and the liquid temperature sensor monitors in real time to ensure safe use and enhance safety.

[0013] 4. The heating rod assembly and main housing of this vehicle liquid heater adopt an integrated structural design to reduce assembly steps, making it suitable for mass production and improving production efficiency. Attached Figure Description

[0014] Figure 1 This is an exploded perspective view of the vehicle liquid heater of this utility model (taking the inlet and outlet water pipes and the main housing as separate structures as an example). Figure 2 This is an assembly diagram of the heating rod assembly of the automotive liquid heater of this utility model; Figure 3 This is an exploded view of the heating rod assembly of the automotive liquid heater of this utility model; Figure 4 This is a three-dimensional structural diagram of the main housing of the vehicle liquid heater of this utility model. Figure 1 ; Figure 5 This is a three-dimensional structural diagram of the main housing of the vehicle liquid heater of this utility model. Figure 2 ; Figure 6 This is an overall assembly diagram of the vehicle liquid heater of this utility model; Figure 7 This is a water circuit diagram showing that the main shell of this utility model is connected to the inlet pipe and the outlet pipe separately. Figure 8 This is a water circuit diagram showing that the main shell, inlet pipe, and outlet pipe of this utility model are integrally molded. Detailed Implementation

[0015] 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.

[0016] Please see the following: A vehicle liquid heater using an integrated electric heating rod. Figures 1-8 This includes components such as the top cover 2, rubber sealing ring 3, IGBT mounting plate 5, control board assembly 6, breather valve 7, low-voltage connector assembly 8, rear cover 9, rear cover sealant 10, heating rod assembly 11, rear cover sealing ring 12, main housing 13, grounding bolt 14, tube sheet sealing ring 15, water inlet pipe 16, water outlet pipe 19, insulating gasket 17, and high-voltage connector assembly 18. The main improvements of this vehicle liquid heater include the following aspects: Heating rod assembly: The heating rod assembly uses an integrated electric heating rod; please refer to [link / reference]. Figure 2 and Figure 3 The device comprises a heating rod rear cover 11-1, a heating rod body 11-2 with leads, and a heating rod front fixing member 11-3. The heating rod rear cover is made of stamped stainless steel and has insertion holes for the rear ends of the two heating rod bodies. The rear ends of the two heating rod bodies are inserted into the two insertion holes on the heating rod rear cover and fixed to the heating rod rear cover by stainless steel laser welding. Compared with the traditional connection between the heating rod and the rear cover via a sealing ring, this reduces the risk of leakage. The heating rod front fixing member 11-3 is fitted onto the top of the heating rod and can contact the inner wall of the front end of the main housing or the side wall of the vertical water channel described below, providing shock absorption and protection.

[0017] The front fixing part 11-3 of the heating rod is not limited to the rubber sheath. Any structure with a similar principle, such as stainless steel bracket or plastic bracket, is within the scope of protection of this utility model.

[0018] The heating rod body structure with lead wires allows the terminals at one end of the lead wires to be connected to the control board assembly 6, saving the traditional heater terminal block structure and eliminating the need for TG soldering and reflow soldering processes. The structure is simple, energy-saving and efficient.

[0019] Main shell: The main shell 13 is manufactured using a one-piece casting process and is a nearly square shell. Please refer to [reference needed]. Figure 4 and Figure 5The main housing is divided into upper and lower chambers. The upper chamber is the electrical chamber, and the lower chamber is the heat exchange chamber. The heat exchange chamber consists of a front chamber and a rear chamber, with the front wall of the rear chamber serving as the mounting surface for the heating rod rear cover. A U-shaped water channel is provided in the front chamber. The front ends of the two parallel vertical channels of the U-shaped water channel extend to the top of the main housing, and the rear ends extend to the mounting surface for the heating rod rear cover. A sealing groove is provided on the mounting surface 13-4 for installing the rear cover sealing ring 12. The heating rod assembly 11 is inserted from the rear chamber into the front chamber of the heat exchange chamber. The heating rod rear cover is in sealed contact with the mounting surface and is fixed with screws, ensuring complete sealing and isolation between the front and rear chambers of the heat exchange chamber after the heating rod assembly is installed. The two heating rod bodies extend into the two parallel vertical channels of the U-shaped water channel. The front ends of the two heating rods are pressed into contact with the inner wall of the top of the main housing through the front fixing parts of the heating rods.

[0020] Two clearance slots, labeled 13-1 and 13-2 respectively, are provided on the top surface of the rear chamber to communicate with the electrical chamber, allowing the two lead terminals of the heating rod to pass through.

[0021] The aforementioned inlet and outlet pipes can be connected to the main casing using a separate sealed connection structure, see [link / reference]. Figure 7 Alternatively, a one-piece casting structure can be used; see [link / reference]. Figure 8 In the case of a split structure: An inlet pipe interface and an outlet pipe interface are provided at the top of the main shell. These interfaces are offset and connected to two parallel vertical water channels of the U-shaped water channel. The inlet and outlet pipe interfaces are sealed to each other by tube sheet sealing rings 15 and fixed with screws, forming a closed fluid cavity in the front chamber of the heat exchange chamber.

[0022] In terms of electrical connection and installation, a high-voltage wiring harness assembly interface is provided on the front side wall of the main housing, corresponding to the location of the electrical chamber, and a low-voltage wiring harness assembly interface is provided on the rear side wall of the main housing, corresponding to the location of the electrical chamber. Both the high-voltage connector assembly 18 and the low-voltage connector assembly 8 are installed together with corresponding interfaces on the main housing 13 using screws. A breather valve 7 is installed on one side of the main housing 13, and a grounding bolt 14 is installed on the other side of the main housing. The top cover 2 is sealed to the upper end of the main housing by a rubber sealing ring 3 and fixedly connected by hexagonal socket head cap screws 1. The rear cover 9 is sealed to the rear end of the main housing 13 by rear cover sealant 10, achieving isolation between the interior of the main housing and the outside environment.

[0023] The control board assembly (PCBA) 6 is supported and fixed within the electrical cavity. The lead ends of the high-voltage connector assembly 18 are connected to the control board assembly (PCBA) 6 via bolts and nuts. The low-voltage connector assembly 8 is connected to the control board assembly (PCBA) 6 via connectors. The lead terminals of the heating rod assembly 11 pass through the clearance slots 13-1 and 13-2 of the main housing and are connected to the control board assembly (PCBA) 6 via bolts and nuts, thereby enabling the PCBA to precisely control the heating element.

[0024] In terms of power supply and system control, the high-voltage connector assembly 18 is connected to the vehicle's high-voltage power supply system to provide the required power to the heater; the low-voltage connector assembly 8 is connected to the vehicle's low-voltage system, and the vehicle end uses a 12V low-voltage circuit to control the 390-925V high-voltage system, thereby achieving comprehensive control of the heater.

[0025] In terms of heat dissipation and safety, a heat dissipation platform is provided on the main housing below the IGBT mounting positions on the control board assembly (PCBA). The IGBT mounting plate 5 is fixedly connected to the main housing by screws 4, ensuring that the lower end of the IGBT is in close contact with the front of the heat dissipation platform through an insulating gasket 17, which provides electrical isolation between the two. Further, crisscrossing heat dissipation fins 13-3 are provided on the back of the heat dissipation platform to achieve better heat dissipation.

[0026] In terms of safety protection measures, in addition to overpressure and overcurrent protection, this vehicle liquid heater also features overtemperature protection. Unlike traditional inlet and outlet temperature sensors that are connected to the PCBA separately via connectors, the liquid temperature sensor is directly soldered onto the control board assembly (PCBA) 6. Its temperature-sensing component is mounted on the inlet and outlet sides of the main housing 13 using thermally conductive silicone grease, enabling real-time acquisition of the inlet and outlet liquid temperatures and transmission to the control board assembly (PCBA) 6, thus achieving comprehensive temperature monitoring and protection for the heater.

[0027] In addition, in this embodiment, the main housing, top cover, and bottom cover of the heater are all made of metal, which effectively solves the electromagnetic compatibility (EMC) problem of electronic components and ensures the normal operation of electronic equipment inside the vehicle.

[0028] 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 liquid heater employing an integrated electric heating rod, comprising a main housing, a top cover, a heating rod assembly, a rear cover, a water inlet pipe, a water outlet pipe, a control board assembly, a low-voltage connector assembly, and a high-voltage connector assembly; characterized in that: The main shell is a one-piece cast structure. The inner cavity of the main shell is divided into upper and lower chambers. The upper chamber is the electrical chamber and the lower chamber is the heat exchange chamber. The heat exchange chamber is composed of a front chamber and a rear chamber. The front wall of the rear chamber is the mounting surface of the heating rod rear cover. A U-shaped water channel is provided in the front chamber. The front ends of the two parallel vertical water channels of the U-shaped water channel extend to the top of the main shell, and the rear ends of the two parallel vertical water channels of the U-shaped water channel extend to the mounting surface of the heating rod rear cover. A sealing groove is provided on the mounting surface of the heating rod rear cover. Two clearance grooves communicating with the electrical chamber are provided on the top surface of the rear chamber. The water inlet pipe and the water outlet pipe are respectively connected to the front ends of the two parallel vertical water channels. The heating rod assembly consists of a heating rod rear cover, two heating rod bodies with leads, and a heating rod front fixing member; the heating rod rear cover is provided with insertion holes that mate with the rear ends of the two heating rod bodies, and the rear ends of the two heating rod bodies are inserted into and welded to the two insertion holes on the heating rod rear cover; the heating rod front fixing member is fitted on the top of the two heating rod bodies. The heating rod assembly is inserted from the rear chamber of the heat exchange chamber into the front chamber of the heat exchange chamber. The rear cover of the heating rod and the mounting surface of the rear cover of the heating rod form a sealed contact through the sealing ring installed in the sealing groove and are fixedly connected by screws. The two heating rod bodies extend into the two parallel vertical channels of the U-shaped water channel respectively. The front ends of the two heating rod bodies contact the top inner wall of the main shell or the side wall of the vertical water channel through the front fixing member of the heating rod. The top cover is sealed to the upper end of the main housing by a rubber sealing ring and fixedly connected by screws; the rear cover is sealed and fixed to the rear end of the main housing by rear cover sealant. The control board assembly is supported and fixed in the electrical cavity; the high-voltage connector assembly and the low-voltage connector assembly are fixed on the side wall of the main housing and electrically connected to the control board assembly; the two lead terminals of the heating rod assembly pass through the two clearance slots of the main housing and are electrically connected to the control board assembly.

2. The liquid heater for vehicle using the integrated electric heating rod according to claim 1, characterized in that: A high-voltage wiring harness assembly interface is provided on the front side wall of the main housing, corresponding to the position of the electrical chamber, and a low-voltage wiring harness assembly interface is provided on the rear side wall of the main housing, corresponding to the position of the electrical chamber; the high-voltage connector assembly and the low-voltage connector assembly are respectively fixed to the high-voltage wiring harness assembly interface and the low-voltage wiring harness assembly interface by screws.

3. The liquid heater for vehicle using the integrated electric heating rod according to claim 1, characterized in that: The lead end of the high-voltage connector assembly is connected to the control board assembly via a bolt and nut structure; the low-voltage connector assembly is connected to the control board assembly via connectors.

4. The liquid heater for vehicle using the integrated electric heating rod according to claim 1, characterized in that: The control board assembly integrates IGBTs. A heat dissipation platform is provided on the main housing below the IGBTs on the control board assembly. The IGBT mounting plate is fixedly connected to the main housing with screws, so that the lower end of the IGBT is in close contact with the front of the heat dissipation platform through an insulating gasket. A crisscrossing heat dissipation fin is provided on the back of the heat dissipation platform.

5. The liquid heater for vehicle using the integrated electric heating rod according to claim 1, characterized in that: The water inlet pipe interface and the water outlet pipe interface are arranged in offset communication with the two parallel vertical water channels of the U-shaped water channel respectively.

6. The liquid heater for vehicle using the integrated electric heating rod according to claim 1, characterized in that: The water inlet pipe and the water outlet pipe are integrally formed with the main shell.

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