A gasket for mounting IGBTs in a vehicle water heater and an IGBT puncture-proof mounting structure.

Abstract

This utility model discloses an IGBT mounting gasket, comprising an upper and lower layer of thermally conductive silicone pads and a ceramic sheet located between the thermally conductive silicone pads. The thermally conductive silicone pads are attached to the upper and lower surfaces of the ceramic sheet, and the thermally conductive silicone pads are recessed around the perimeter of the ceramic sheet to form a gripping area for robotic arm grasping. The IGBT puncture-proof mounting structure for automotive water heaters includes a PTC heater, which includes a control box with a mounting slot. A gasket is inserted into the mounting slot, and several IGBTs are evenly arranged laterally on the outer surface of the gasket. The advantages are: traditional single-layer thermally conductive silicone pads are easily punctured by sharp impurities in the control box. Therefore, replacing the single-layer thermally conductive silicone pad with a ceramic sheet prevents sharp impurities from puncturing it. Furthermore, the 0.35mm thick thermally conductive silicone pads are attached to the upper and lower surfaces of the ceramic sheet, ensuring that the ceramic sheet can withstand product vibration tests and the bumpy conditions of vehicle use without cracking.

Description

Technical Field

[0001] This utility model relates to the application of PTC water heating in new energy vehicles, and in particular to an IGBT mounting gasket and an IGBT puncture-proof mounting structure for a vehicle water heating heater. Background Technology

[0002] Water-based PTC heaters are gaining increasing attention as a core component of air conditioning and battery thermal management systems in new energy vehicles. Compared to traditional air heaters, they offer higher heating efficiency, better comfort, and more flexible vehicle placement, leading to their widespread adoption by major OEMs. However, current water-based heaters on the market often use a single layer of thermally conductive silicone sheet to ensure insulation between the IGBT and the housing. The main problem is that this single-layer silicone sheet, typically 0.5mm to 1mm thick, can puncture the sheet if sharp impurities are present on the IGBT mounting surface of the control box, causing poor insulation between the control box and the assembly, resulting in product failure. If these products are not identified and reach the customer, there is a risk of customer complaints or even vehicle-wide rejection.

[0003] The production process requires strict control over foreign objects, as it is easy for foreign objects on the control box to puncture the thermally conductive silicone sheet, leading to substandard product insulation performance. Since the tooling process for the thermally conductive silicone sheet is relatively late in the production chain, if insulation failure occurs due to a foreign object puncture, rework is more difficult, and the product is more likely to be scrapped. Summary of the Invention

[0004] The technical problem to be solved by this utility model is to provide an IGBT mounting gasket and an IGBT puncture-proof mounting structure for a vehicle water heater that prevents sharp impurities from piercing the single-layer thermally conductive silicone sheet of the control box, has higher heat conduction efficiency, and is easy to install by a robotic arm on an automated production line.

[0005] To solve the above-mentioned technical problems, the IGBT mounting gasket of this utility model includes a gasket, which includes upper and lower thermally conductive silicone pads and a ceramic sheet located between the thermally conductive silicone pads. The thermally conductive silicone pads are attached to the upper and lower surfaces of the ceramic sheet, and the thermally conductive silicone pads are recessed inward around the perimeter of the ceramic sheet to form a gripping area for a robotic arm to grasp.

[0006] The thickness of the ceramic sheet ranges from 0.585 mm to 0.685 mm.

[0007] The thickness of the thermally conductive silicone pad ranges from 0.35 to 0.40 mm.

[0008] The edge of the thermally conductive silicone pad is recessed by 0.95mm to 1.05mm from the perimeter of the ceramic sheet.

[0009] The IGBT puncture-proof mounting structure for a vehicle water heater includes a PTC heater. The PTC heater includes a control box with a mounting slot. The gasket is inserted into the mounting slot, and several IGBTs are evenly arranged laterally on the outer surface of the gasket.

[0010] Advantages of this utility model: (1) Traditional single-layer thermal conductive silicone sheet is easily punctured by sharp impurities in the control box. Therefore, the single-layer thermal conductive silicone sheet is replaced with a ceramic sheet so that sharp impurities cannot puncture it. Furthermore, a 0.35mm thick thermal conductive silicone pad is attached to the upper and lower surfaces of the ceramic sheet to ensure that the ceramic sheet can pass the product vibration test and the bumpy working conditions of the whole vehicle without breaking. (2) The thickness of the single-layer thermal conductive silicone pad is less than that of the thermal conductive silicone sheet. The thinner the thickness, the better the thermal conductivity. Therefore, the thermal conductivity of the thermal conductive silicone sheet is ≥3W (m*k)@25℃, while the thermal conductivity of the ceramic sheet is ≥21W (m*k)@25℃, which can dissipate heat from the IGBT faster. (3) The thermal conductive silicone pad is made of red glass fiber substrate. The material is relatively soft and requires manual installation by production line staff. Deviations are prone to occur during installation. By shrinking the thermal conductive silicone pad 1.0mm inward around the ceramic sheet, it is easier for the robotic arm of the automated production line to grasp it. Attached Figure Description

[0011] Figure 1 This is a structural diagram of the IGBT mounting gasket of this utility model; Figure 2 This is an assembly drawing of the IGBT mounting gasket and the IGBT puncture-proof mounting structure for the vehicle water heater of this utility model. Detailed Implementation

[0012] The following description, in conjunction with the accompanying drawings and specific embodiments, provides a more detailed explanation of the IGBT mounting gasket and IGBT puncture-resistant mounting structure for the vehicle water heater of this utility model. Example

[0013] The IGBT mounting pad includes a pad comprising upper and lower thermally conductive silicone pads 2 and a ceramic sheet 1 located between the thermally conductive silicone pads 2. The thermally conductive silicone pads 2 are attached to the upper and lower surfaces of the ceramic sheet 1, and the thermally conductive silicone pads 2 are recessed inward around the perimeter of the ceramic sheet 1 to form a gripping area for robotic arm grasping. The thickness of the ceramic sheet 1 ranges from 0.585mm to 0.685mm, preferably 0.635mm; the thickness of the thermally conductive silicone pads ranges from 0.35mm to 0.40mm, preferably 0.35mm; the edge of the thermally conductive silicone pads is recessed inward from the perimeter of the ceramic sheet 1 by 0.95mm to 1.05mm, preferably 1mm. The IGBT puncture-proof mounting structure includes a PTC heater, which includes a control box 4 with a mounting slot. A pad 3 is inserted into the mounting slot, and several IGBTs 5 are evenly arranged laterally on the outer surface of the pad 3. The pad is aligned with the mounting slot of the control box and installed in place. Four IGBTs are installed in fixed positions in sequence to complete the installation.

Claims

1. A spacer for IGBT mounting, characterized by: Includes a pad (3), which includes upper and lower thermally conductive silicone pads (2) and a ceramic sheet (1) located between the thermally conductive silicone pads (2). The thermally conductive silicone pads (2) are attached to the upper and lower surfaces of the ceramic sheet (1). The thermally conductive silicone pads (2) are recessed around the ceramic sheet (1) to form a gripping area for the robotic arm to grasp.

2. The spacer for IGBT mounting according to claim 1, characterized by: The thickness of the ceramic sheet (1) ranges from 0.585 mm to 0.685 mm.

3. The spacer for IGBT mounting according to claim 1, characterized by: The thickness of the thermally conductive silicone pad (2) ranges from 0.35 to 0.40 mm.

4. The spacer for IGBT mounting according to claim 1, characterized by: The edge of the thermally conductive silicone pad (2) is recessed by 0.95mm to 1.05mm from the perimeter of the ceramic sheet (1).

5. An IGBT puncture-proof mounting structure for a water heater for a vehicle, characterized by: The device includes a PTC heater, which includes a control box (4) with a mounting slot, and a gasket (3) as described in any one of claims 1-4 is inserted into the mounting slot. A plurality of IGBTs (5) are arranged laterally and evenly on the outer surface of the gasket (3).

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