A PTC heater structure for new energy vehicles

Abstract

This utility model discloses a PTC heater structure for new energy vehicles. It includes several strip-shaped heating cores and heat dissipation strips bonded to their heat dissipation surfaces with adhesive. The bonding surfaces of the heat dissipation strips and / or heating cores have textured surfaces, and the adhesive fills the recessed spaces within these textured surfaces. Each heating core contains an electrode strip, and each electrode strip has a conductor connected to its end. The conductor is a right-angled bend structure consisting of two sides, one side being a U-shape and the other a straight section. The inner cavity formed by the U-shape clamps and fixes the end of the electrode strip, and the straight section is fixedly conductively connected to a busbar of corresponding polarity. The advantages are: it effectively improves the bonding strength between the conductor and the heating core, not only improving heat dissipation efficiency but also better resisting shear forces, thereby enhancing the overall structural stability of the heater, reducing abnormal grounding resistance caused by peeling, and improving the safety and reliability of the product under complex operating conditions.

Description

Technical Field ,

[0009]

[0001] The utility model relates to a PTC heater device for new energy vehicles, in particular to a PTC heater structure for new energy vehicles. Background Technique

[0002] In the prior art, a PTC heater usually consists of multiple heating cores and a heat dissipation component. The heating core and the heat dissipation strip are bonded by an insulating adhesive to achieve structural fixation and electrical isolation. However, the commonly used heat dissipation strips at present mostly adopt smooth aluminum alloy materials without surface treatment, resulting in that the adhesive is difficult to be fully embedded into the material surface, and it is difficult to form a good physical locking structure, thus causing insufficient bonding strength at the bonding interface. At the same time, in the existing connection method, the electrode strips mostly adopt point-to-point connection, lacking a unified current guiding mechanism.

[0003] During the actual use process, if the vehicle is vibrated or impacted, the bonding layer is prone to interface peeling, affecting the overall structural stability of the PTC heater. If the peeling area affects the grounding path of the heater shell, it may cause the grounding resistance to increase or even fail. When the system has an insulation failure, if the metal shell of the heater is charged and the grounding is poor, there will be an electric shock risk; an excessive grounding resistance will cause the leakage current to not be imported into the ground in time, making the insulation monitoring system of the vehicle unable to accurately judge the electrical fault, thus delaying the fault cut-off and posing a serious hidden danger of inducing a fire. Summary of the Invention

[0004] The technical problem to be solved by the utility model is to provide a PTC heater structure for new energy vehicles with reliable conductivity, firm bonding and efficient heat dissipation.

[0005] To solve the above technical problem, the PTC heater structure for new energy vehicles of the utility model includes several strip-shaped heating cores and heat dissipation strips bonded to their heat dissipation surfaces by an adhesive. The bonding surfaces of the heat dissipation strips and / or the heating cores are provided with concave and convex patterns, and the adhesive is filled in the concave spaces of the concave and convex patterns.

[0006] Each heat dissipation strip includes a frame with a "day" - shaped longitudinal section. Two upper and lower placement cavities are formed inside the frame, and heat dissipation fins extending longitudinally and in a corrugated shape are embedded in the placement cavities.

[0007] Electrode strips are arranged in the heating core. The end of each electrode strip is connected with a conducting row. The conducting row is a right - angled bending structure composed of two sides. One side is a U - shaped structure, and the other side is a straight section. The inner cavity formed by the U - shaped structure is clamped and fixed at the end of the electrode strip, and the straight section is fixedly conductively connected with the busbar of its corresponding polarity.

[0008] The frame is made of aluminum alloy material.

[0009] The adhesive is made of an insulating material.

[0010] The depth of the raised and recessed texture ranges from 0.1 to 0.15 mm.

[0011] The textured surface of the heat sink is a directional pattern formed by a wire drawing method.

[0012] Advantages of this utility model: (1) The surface of the heat sink is textured, especially when it is made of aluminum alloy with brushed surface, which effectively improves the bonding strength between it and the heating core. Compared with the traditional smooth surface heat sink, by increasing the surface area at the bonding interface, more anchoring points are provided for the adhesive. After the adhesive penetrates into the groove of the texture, it forms a physical "claw" structure, which makes the heating core and the heat sink tightly bonded. This not only improves the heat dissipation efficiency, but also better resists shear force, thereby enhancing the stability of the overall structure of the heater, reducing the abnormal grounding resistance caused by peeling, and improving the safety and reliability of the product under complex working conditions. (2) The heat sink adopts a H-shaped frame structure with two cavities inside the frame and heat sinks are placed in the cavities. The heat sinks extend longitudinally and are corrugated. The structure is compact and facilitates heat conduction. The H-shaped frame can improve heat dissipation efficiency without increasing volume, effectively avoid local overheating of PTC chip, and improve the overall thermal management performance of heater. (3) The conductor adopts a right-angle bending structure and has a U-shaped structure design. The inner cavity formed by the U-shaped structure is clamped and fixed at the end of the electrode strip to ensure the stability of the conductive connection and the accuracy of the positioning, and avoid the problem of loose contact caused by installation error or thermal expansion and contraction. (4) Multiple conductors are connected in a unified manner through the busbar set on the outside, realizing the centralized current diversion of multiple electrical terminals. The current path is clear and controllable, which not only simplifies the internal wiring structure, but also improves the overall conductivity, reduces the risk of heating or burning caused by local contact resistance, improves the level of modular integration, and facilitates manufacturing and maintenance. (5) The heat sink and the heating core are bonded together with an insulating adhesive. This ensures electrical insulation and makes the connection structure stable, avoiding electrical short circuits or bonding failures during long-term use, and improving the service life and environmental adaptability of the heater. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the heat sink in the PTC heater structure for new energy vehicles of this utility model; Figure 2 This is an exploded structural diagram of the heat dissipation strip in the PTC heater structure for new energy vehicles of this utility model; Figure 3 This is a schematic diagram of the heating element in the PTC heater structure for new energy vehicles of this utility model; Figure 4 This is a structural schematic diagram (front view) of the PTC heater structure for new energy vehicles of the present utility model; Figure 5 This is a partial enlarged view of the end of the electrode strip in the PTC heater structure for new energy vehicles of the present utility model; Figure 6 This is a structural schematic diagram (bottom view) of the PTC heater structure for new energy vehicles of the present utility model. Detailed implementation manners

[0014] The following further details the PTC heater structure for new energy vehicles of the present utility model in conjunction with the accompanying drawings and specific implementation manners. Embodiment

[0015] The PTC heater structure for new energy vehicles includes a PTC heater structure 1. The PTC heater structure 1 includes a plurality of strip-shaped heating cores 2. Heat dissipation strips 3 are bonded to both sides of each heating core 2. The heat dissipation strips 3 are bonded to the heating cores 2 through an adhesive made of insulating material; the bonding surfaces of the heat dissipation strips 3 and / or the heating cores 2 are provided with concave and convex patterns, and the concave and convex patterns on the surface are directional patterns made by a wire drawing method, and the depth range of the concave and convex patterns is 0.1 - 0.15 mm; electrode strips 4 are arranged in the heating cores 2. Leads 5 are connected to the ends of the electrode strips 4. A plurality of leads 5 are electrically connected through a bus bar 6 located outside thereof to form a unified current path. The lead 5 is a right-angle bending structure composed of two sides, one side is a U-shaped structure, and the other side is a straight section. The inner cavity formed by the U-shaped structure is clamped and fixed at the end of the electrode strip 4, and the straight section is fixedly and conductively connected to the bus bar 6 of its corresponding polarity; the heat dissipation strip 3 includes a frame 7 with a daily-shaped longitudinal section and heat dissipation fins 8 arranged in the frame 7. The frame 7 is made of aluminum alloy material. Two upper and lower placement cavities are formed in the frame 7, and longitudinally extending and corrugated heat dissipation fins 8 are embedded in the placement cavities; a side plate extending along the arrangement direction of the heating cores 2 is arranged on the side of the PTC heater structure 1, and square frames for cooperation and limiting are arranged at the upper and lower ends of the side plate.

Claims

1. A new energy vehicle PTC heater structure, comprising a plurality of strip-shaped heating cores (2) and a heat dissipation strip (3) bonded to the heat dissipation surface thereof by an adhesive, characterized in that: The bonding surface of the heat dissipation strip (3) and / or the heating core (2) is provided with concave and convex纹路, and the adhesive is filled in the concave space of the concave and convex纹路; an electrode strip (4) is arranged in the heating core (2), and each end of the electrode strip (4) is connected with a lead-out row (5). The lead-out row (5) is a right-angle bending structure composed of two sides, one side is a U-shaped structure, and the other side is a straight section. The inner cavity formed by the U-shaped structure is clamped and fixed at the end of the electrode strip (4), and the straight section is fixedly and conductively connected to the bus bar (6) of its corresponding polarity.

2. The PTC heater structure for new energy vehicles according to claim 1, characterized in that: Each heat dissipation strip (3) includes a frame (7) with an "8" - shaped longitudinal section. Two upper and lower placement cavities are formed inside the frame (7), and a longitudinally extending and corrugated heat dissipation fin (8) is embedded in the placement cavity.

3. The PTC heater structure for new energy vehicles according to claim 2, characterized in that: The frame (7) is made of aluminum alloy material.

4. The PTC heater structure for new energy vehicles according to claim 1, characterized in that: The adhesive is made of insulating material.

5. The PTC heater structure for new energy vehicles according to claim 1, characterized in that: The depth range of the concave and convex纹路 is 0.1 - 0.15 mm.

6. The PTC heater structure for new energy vehicles according to claim 1 or 5, characterized in that: The concave and convex纹路 on the surface of the heat dissipation strip (3) are directional纹路 formed by the wire drawing method.

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