A reinforced waterproof PTC heater structure

Abstract

The utility model discloses a kind of PTC heater structures of reinforced waterproof.It includes heating core assembly and controller body, heating core assembly and controller body are fixedly connected by support, outer sealing cavity is formed between support and the tail portion of heating core assembly, and outer sealing cavity is sealed using filling sealant;Heating core assembly includes electrode, controller body includes controller shell, electrode is inserted into controller shell, inner sealing cavity is formed between heating core assembly and controller shell, and inner sealing cavity is sealed using filling sealant.The advantage is: heating core tail portion is formed double seal by silica gel gluing and filling sealant, controller shell is sealed using filling sealant inside and outside, base and shell are sealed by sealing glue and interference clasp cooperation, so that heating appliance has multilayer waterproof structure, can satisfy the waterproof requirement under long-term durable use.

Description

Technical Field

[0001] This utility model designs a reinforced waterproof PTC heater structure for use in new energy vehicles. Background Technology

[0002] With the rapid development of the new energy vehicle industry, battery heating, in-vehicle air conditioning, and other systems all require independent heaters. In traditional gasoline vehicles, heating typically utilizes engine coolant or exhaust waste heat, resulting in complex systems, low efficiency, and slow heating rates, which are insufficient to meet the needs of new energy vehicles. PTC (Positive Temperature Coefficient) material is a semiconductor heating element whose resistivity increases sharply near the Curie point with increasing temperature. Heaters made with PTC offer advantages such as fast start-up, high thermal efficiency, good temperature control, safety without open flame, and long service life, and are therefore widely used in the heating systems of new energy vehicles, making it an ideal electric heating element.

[0003] However, existing PTC heaters have shortcomings in waterproofing. To reduce costs, some air conditioning manufacturers have eliminated the hot and cold air dampers in the air conditioning unit, causing the condenser and PTC heater to share the same air duct. During summer air conditioning use, condensate on the condenser surface is blown onto the PTC heater surface by the airflow, thus placing higher demands on its waterproofing performance. Traditional PTC heaters often use single-layer or limited sealing measures, only meeting short-term IPX7 protection standards. Under long-term humid and hot environments or after durable aging, they are prone to water ingress, decreased insulation performance, and even failure. Summary of the Invention

[0004] The technical problem to be solved by this utility model is to provide a PTC heater structure that can improve sealing and enhance waterproofing.

[0005] To solve the above-mentioned technical problems, the present invention provides a reinforced waterproof PTC heater structure including a heating core assembly and a controller body. The heating core assembly and the controller body are fixedly connected by a bracket, and an outer sealing cavity is formed between the bracket and the tail of the heating core assembly. The outer sealing cavity is sealed with potting compound. The heating core assembly includes electrodes, and the controller body includes a controller housing. The electrodes extend into the controller housing, and an inner sealing cavity is formed between the heating core assembly and the controller housing. The inner sealing cavity is sealed with potting compound.

[0006] The controller body also includes a PCB board, a control board, and a base connected to the controller housing; the base and the edge of the controller housing are fixed together by sealant and interference fit.

[0007] The PCB board is electrically connected to the electrodes and control board and fixed inside the controller housing; the PCB board is soldered to the electrodes and control board.

[0008] The heating core assembly includes an aluminum tube, a heating element inserted into the aluminum tube, and a ceramic insulating layer covering the outside of the electrode. The ceramic insulating layer is made of wedge-shaped alumina material and is covered with an insulating film on the outside.

[0009] The insulating film has two and a half layers.

[0010] The aluminum tube is provided with plastic caps at both ends to prevent the electrode ends from contacting the aluminum tube.

[0011] The tail of the heating element assembly is coated with silicone and sealed with potting compound.

[0012] Advantages of this utility model: (1) The tail of the heating core is sealed by silicone coating and potting compound. The controller housing is sealed with potting compound inside and out. The base and the housing are sealed by sealant and interference snap fastener, so that the heater has a multi-layer waterproof structure and can meet the waterproof requirements under long-term durable use. (2) The PCB board is connected to the electrodes and control board by soldering and fixed in the controller housing, which can effectively reduce stress concentration, avoid poor soldering and breakage caused by vibration or thermal expansion and contraction, and improve the overall reliability and service life of the connection. (3) A wedge-shaped alumina ceramic insulating layer is provided on the outside of the electrode of the heating core, and multiple insulating films are wrapped on the outside. At the same time, plastic end caps are provided at both ends of the aluminum tube to form multiple insulation protections, avoid contact between the electrode and the metal tube, and improve the insulation strength and working safety. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the heating core assembly in the reinforced waterproof PTC heater structure of this utility model; Figure 2 This is a front view of the heating core assembly in the reinforced waterproof PTC heater structure of this utility model; Figure 3 This is an exploded view of the structure of the waterproof PTC heater of this utility model; Figure 4 This is a bottom view of the structure of the waterproof PTC heater of this utility model. Figure 5 This is a top view of the structure of the waterproof PTC heater of this utility model; Figure 6 This is a perspective view of the structure of the waterproof PTC heater of this utility model; Figure 7This is a front view of the structure of the waterproof PTC heater of this utility model; Figure 8 This is a cross-sectional view of the structure of the waterproof PTC heater of this utility model. Detailed Implementation

[0014] The structure of the enhanced waterproof PTC heater of this utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments. Example

[0015] The reinforced waterproof PTC heater structure includes a heating core assembly 1 and a controller body. The heating core assembly 1 and the controller body are fixedly connected by a bracket 11. The heating core assembly includes an aluminum tube 3, a heating element 4 inserted into the aluminum tube, and a ceramic insulating layer 5 covering the outside of the electrode 2. The ceramic insulating layer 5 is made of wedge-shaped alumina material and is covered with two layers of semi-insulating film on the outside. Plastic caps 6 are provided at both ends of the aluminum tube to prevent the end of the electrode 2 from contacting the aluminum tube 3. The tail of the heating core assembly 1 is coated with silicone and sealed with potting compound. An outer sealing cavity 9 is formed between the bracket 11 and the tail of the heating core assembly 1, and the outer sealing cavity 9 is sealed with potting compound. The heating core assembly 1 includes electrodes. 2. The controller body includes a controller housing 7, with the electrode 2 extending into the controller housing 7. An inner sealed cavity 10 is formed between the heating core assembly 1 and the controller housing 7, and the inner sealed cavity 10 is sealed with potting compound. The controller body also includes a PCB board, a control board, and a base 8 connected to the controller housing 7. The base 8 is fixed to the edge of the controller housing 7 with sealant and interference fit buckles 12, which can make the assembly achieve IP67 waterproof rating. The PCB board is electrically connected to the electrode 2 and the control board and fixed inside the controller housing 7. The PCB board is soldered to the electrode 2 and the control board to minimize the stress on the control board and fix it to the control housing.

Claims

1. A reinforced waterproof PTC heater structure, comprising a heating core assembly (1) and a controller body, characterized in that: The heating core assembly (1) and the controller body are fixedly connected by a bracket (11). An outer sealing cavity (9) is formed between the bracket (11) and the tail of the heating core assembly (1). The outer sealing cavity (9) is sealed with potting compound. The heating core assembly (1) includes an electrode (2). The controller body includes a controller housing (7). The electrode (2) extends into the controller housing (7). An inner sealing cavity (10) is formed between the heating core assembly (1) and the controller housing (7). The inner sealing cavity (10) is sealed with potting compound.

2. The reinforced waterproof PTC heater structure according to claim 1, characterized in that: The controller body also includes a PCB board, a control board, and a base (8) connected to the controller housing (7); the base (8) and the edge of the controller housing (7) are fixed together by sealant and interference clips (12).

3. The reinforced waterproof PTC heater structure according to claim 2, characterized in that: The PCB board is electrically connected to the electrode (2) and the control board and fixed inside the controller housing (7); the PCB board is soldered to the electrode (2) and the control board.

4. The reinforced waterproof PTC heater structure according to claim 1, characterized in that: The heating core assembly includes an aluminum tube (3), a heating element (4) inserted into the aluminum tube, and a ceramic insulating layer (5) covering the outside of the electrode (2). The ceramic insulating layer (5) is a wedge-shaped alumina material and is covered with an insulating film on the outside.

5. The reinforced waterproof PTC heater structure according to claim 4, characterized in that: The insulating film is covered with two and a half layers.

6. The reinforced waterproof PTC heater structure according to claim 4, characterized in that: The aluminum tube is provided with plastic caps (6) at both ends to prevent the end of the electrode (2) from contacting the aluminum tube (3).

7. The reinforced waterproof PTC heater structure according to claim 1, characterized in that: The tail of the heating core assembly (1) is coated with silicone and sealed with potting compound.

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