A liquid heater for new energy vehicles

Abstract

The utility model relates to a liquid heater for new energy automobile, its characterized in that: liquid heater includes integrative aluminium base, is equipped with a cavity for cooling liquid flow in aluminium base, and the both sides of cavity are connected with water inlet and water outlet respectively, and the both sides of aluminium base are equipped with water chamber sealing cover plate matched with cavity. In implementation, integrative aluminium base structure is compact, light, and the scope of application is wider, and the cavity is equipped with the serpentine channel, makes cooling liquid to be able to flow fully in chamber, and carries out sufficient heat exchange with aluminium base, improves heating efficiency, and aluminium base and the sealing effect of water chamber sealing cover plate on both sides are good, is not easy to produce fatigue damage in the temperature cyclic variation process, significantly reduces the risk of leakage, improves the security and service life of heater, and reduces the cost.

Description

Technical Field

[0001] This utility model relates to the field of liquid heating technology in the thermal management system of new energy vehicles, specifically a liquid heater for new energy vehicles, and more particularly to a liquid heater without a controller for new energy vehicles. Background Technology

[0002] Against the backdrop of the rapid development of the new energy vehicle industry, the performance of the thermal management system has a crucial impact on the vehicle's range, ride comfort, and battery life. As a core component of the thermal management system, the liquid heater plays a vital role in functions such as heating the vehicle interior and maintaining battery temperature. Currently, a typical structure among the widely used PTC ceramic heaters in the industry consists of a heat dissipation chamber formed by a combination of metal and plastic components. The metal component houses the heating element, while the plastic component, with water pipe connections, surrounds the heat exchange structure of the metal component, forming a coolant circulation channel.

[0003] However, this structure is monopolized by foreign manufacturers through patent EP2797382 A1, posing a serious patent infringement risk to domestic enterprises during production and application, severely restricting the development of related industries in the domestic new energy vehicle sector. Furthermore, this existing structure suffers from numerous technical defects: the metal groove (i.e., heating rib) for placing the heating pack needs to extend into the circulation chamber; since the outer casing is made of plastic, the heating rib must protrude from the metal surface, with a wall thickness of only 1.5-4mm to ensure heat exchange efficiency. During mold production, the bottom of the heating rib groove is far from the injection port, making it highly susceptible to die-casting defects and the generation of micropores. Simultaneously, the PTC component inside the heating rib is pressed in with a pressure of 1000-2000N via a wedge-shaped component, keeping the bottom of the groove under constant stress. Under the repeated circulation of coolant at low and high temperatures, these micropores gradually enlarge, eventually leading to leakage and potentially causing serious safety incidents such as heater short circuits and damage to vehicle fuses.

[0004] Furthermore, the existing structure is composed of metal and plastic parts, resulting in a large number of components, complex assembly processes, and low production efficiency. Moreover, the sealing performance of the joints between the plastic and metal parts is difficult to guarantee over the long term, failing to meet the development requirements of new energy vehicles for high reliability, high integration, and lightweight heaters. Therefore, developing a liquid heater that can circumvent existing patents, has a more rational structure, and superior performance has become an urgent problem for the industry. Summary of the Invention

[0005] The purpose of this utility model is to provide an improved liquid heater for new energy vehicles. Through structural improvements, it achieves the characteristics of reasonable structural layout, simple assembly process, and good sealing performance.

[0006] To achieve the above objectives, the technical solution of this utility model is: a liquid heater for new energy vehicles, characterized in that: the liquid heater includes an integrally formed aluminum base, the aluminum base is provided with a cavity for coolant flow, an inlet and an outlet are respectively connected to both sides of the cavity, and a water chamber sealing cover plate that cooperates with the cavity is provided on both sides of the aluminum base.

[0007] Preferably, the cavity is provided with a serpentine channel, and a sealing ring is provided between the water chamber sealing cover and the cavity.

[0008] Furthermore, a sealing groove is provided on one side of the water chamber sealing cover to cooperate with the sealing ring. The sealing groove is a rectangular sealing groove, and the water chamber sealing cover is fixedly connected to the aluminum base through a connector.

[0009] Furthermore, the aluminum base has a raised semi-circular connecting part at the bend of the serpentine channel, and the semi-circular connecting part has an aluminum base connecting hole.

[0010] Furthermore, the water chamber sealing cover is provided with evenly distributed cover plate connection holes around its perimeter. The cover plate connection holes are divided into upper and lower end cover plate connection holes and middle cover plate connection holes. The position of the middle cover plate connection hole corresponds to the position of the aluminum base connection hole. The water chamber sealing cover is fixedly connected to the aluminum base by the connectors set in the cover plate connection holes.

[0011] Furthermore, the sealing grooves are evenly distributed around the water chamber sealing cover plate, and a concave semi-circular sealing groove is formed at the semi-circular connection to match it.

[0012] Furthermore, the front panel of the aluminum base is provided with a water inlet, and the bottom of the cavity is provided with a matching circular water inlet chamber; the sealing cover of one side water chamber is provided with a water outlet, and the top of the cavity is provided with a matching trumpet-shaped water outlet chamber. The circular water inlet chamber and the trumpet-shaped water outlet chamber are diagonally arranged inside the aluminum base.

[0013] Furthermore, both the aluminum base and the water chamber sealing cover are made of aluminum alloy. The aluminum base is a one-piece molded structure, and the sealing ring is made of fluororubber.

[0014] Compared with the prior art, the technical solution of this utility model not only improves the overall technical solution, but also includes many detailed improvements. Specifically, it has the following beneficial effects: 1. The improved solution of this utility model includes an integrally formed aluminum base, a cavity for coolant flow inside the aluminum base, an inlet and an outlet connected to the two sides of the cavity respectively, and a water chamber sealing cover plate that matches the cavity on both sides of the aluminum base. The above structure can avoid the risk of leakage during use, is not prone to fatigue damage during temperature cycling, improves safety, and at the same time simplifies the processing technology and improves production efficiency. 2. In the technical solution of this utility model, a sealing groove is provided on one side of the water chamber sealing cover plate to cooperate with the sealing ring. The sealing groove is a rectangular sealing groove. The water chamber sealing cover plate is fixedly connected to the aluminum base through the connector, so that the sealing surface is subjected to uniform force, the sealing performance is good, the safety and reliability of the heater are improved, and the service life is extended. 3. In the structure of this utility model, the cavity is provided with a serpentine channel, and the aluminum base is an integrally formed structure, which is conducive to the transfer and diffusion of heat; the sealed cavity and the cavity design allow the coolant to flow fully in the cavity and exchange heat fully with the aluminum base, thereby improving the heating efficiency. 4. This utility model has a compact structure and reasonable layout, which meets the design requirements of lightweighting, while reducing production costs and facilitating promotion and utilization. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the dispersed structure of this utility model.

[0016] Figure 2 This is a cross-sectional view of one embodiment of the present invention.

[0017] Figure 3 This is a schematic diagram of the aluminum base of this utility model.

[0018] Figure label: 1. Aluminum base; 2. Sealing ring; 3. Water chamber sealing cover; 4. Connecting parts; 5. Cavity. 11 Inlet, 12 Outlet, 13 Semi-circular connecting part, 14 Circular inlet cavity, 15 Trumpet-shaped outlet cavity; 31 Sealing groove. Detailed Implementation

[0019] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0020] This utility model provides a liquid heater for new energy vehicles, see details below. Figure 1 The difference between this and the existing technology is that the liquid heater includes an integrally formed aluminum base 1. The integrally formed structure is conducive to heat conduction and is more compact. The aluminum base is provided with a cavity 5 for the flow of coolant. The two sides of the cavity are respectively connected to an inlet 11 and an outlet 12. The two sides of the aluminum base are respectively provided with water chamber sealing covers 3 that cooperate with the cavity to ensure the sealing effect and the integrity of the structure.

[0021] In practice, the integrated aluminum base structure is compact, lightweight, and has a wider range of applications. The cavity 5 is equipped with a serpentine channel, which allows the coolant to flow fully in the cavity and exchange heat fully with the aluminum base, thus improving heating efficiency. At the same time, the aluminum base and the water chamber sealing plates on both sides have a good sealing effect, which makes it less prone to fatigue damage during temperature cycling, significantly reducing the risk of leakage, improving the safety and service life of the heater, and reducing costs.

[0022] Example 1 In this embodiment, a liquid heater for new energy vehicles is described, including an integrally formed aluminum base 1. The integrally formed structure is conducive to heat conduction and is more compact. The aluminum base is provided with a cavity 5 for coolant flow. The two sides of the cavity are respectively connected to an inlet 11 and an outlet 12. The two sides of the aluminum base are respectively provided with water chamber sealing covers 3 that cooperate with the cavity to ensure the sealing effect and the integrity of the structure.

[0023] Preferably, the cavity is provided with an S-shaped or serpentine channel, and a sealing ring 2 is provided between the water chamber sealing cover and the cavity, so that the cavity of the aluminum base forms a sealed cavity for liquid circulation, ensuring the effectiveness of the seal. One side of the water chamber sealing cover is provided with a sealing groove 31 that mates with the sealing ring. The sealing groove is a rectangular sealing groove, and the water chamber sealing cover is fixedly connected to the aluminum base through a connector 4.

[0024] Furthermore, the aluminum base has a raised semi-circular connecting part 13 at the bend of the serpentine channel. The semi-circular connecting part is located on the side of the aluminum base and has aluminum base connecting holes for connecting and fixing the water chamber sealing cover. The water chamber sealing cover has evenly distributed cover plate connecting holes around its perimeter. The cover plate connecting holes are divided into upper and lower end cover plate connecting holes and middle cover plate connecting holes. The position of the middle cover plate connecting hole corresponds to the position of the aluminum base connecting hole. The water chamber sealing cover is fixedly connected to the aluminum base by the connector 4 set in the cover plate connecting hole.

[0025] The sealing grooves are evenly distributed around the water chamber sealing cover plate, and a concave semi-circular sealing groove is formed at the semi-circular connection to ensure effective sealing and extend service life.

[0026] Furthermore, the front panel of the aluminum base is provided with a water inlet, and the bottom of the cavity is provided with a matching circular water inlet chamber 14; the sealing cover of one side water chamber is provided with a water outlet, and the top of the cavity is provided with a matching trumpet-shaped water outlet chamber 15. The circular water inlet chamber and the trumpet-shaped water outlet chamber are diagonally arranged in the aluminum base, which facilitates the rapid and smooth inlet and outlet of water, and achieves an effective liquid circulation effect.

[0027] Both the aluminum base and the water chamber sealing cover are made of aluminum alloy. The aluminum base is a one-piece molded structure with a compact and reasonable overall structure, making it more compact, lightweight, and easy to install and transport. The sealing ring is made of fluororubber, which improves the sealing effect.

[0028] Example 2 This embodiment describes a liquid heater for new energy vehicles, including an integrally formed aluminum base. The integrally formed structure is conducive to heat conduction and is more compact. The aluminum base has a cavity for coolant flow. The two sides of the cavity are respectively connected to an inlet and an outlet. The two sides of the aluminum base are respectively provided with water chamber sealing covers that cooperate with the cavity to ensure the sealing effect and the integrity of the structure.

[0029] The aluminum base 1 is integrally formed from ADC12 aluminum alloy using a die-casting process. It has an internal cavity for coolant flow, designed as a meandering channel structure to increase the contact area between the coolant and the aluminum base. An inlet 11 is located on the left side of the aluminum base 1, and an outlet 12 is located on the right side, both communicating with the internal cavity. The tank structure on the aluminum base 1 for housing the PTC heating element is an integral structure with the upper and lower shells of the circulation chamber, formed in one piece during the die-casting process. This structure has uniform wall thickness and no splicing or welding marks.

[0030] The water chamber sealing cover 3 is made of the same aluminum alloy material as the aluminum base 1. A sealing groove 31 is formed on its surface. The sealing groove 31 has a rectangular or wedge-shaped cross-section, a depth of 2mm, and a width matching the diameter of the sealing ring 2. The sealing ring 2 is made of fluororubber, possessing good high and low temperature resistance and chemical corrosion resistance. Its diameter is 3mm, and its length matches the circumference of the sealing groove 31.

[0031] The assembly process is as follows: First, place the sealing ring 2 into the sealing groove 31 of the water chamber sealing cover plate 3, and use a special tool to press the sealing ring 2 firmly, ensuring that it is completely embedded in the sealing groove 31 without wrinkles. Then, align the two water chamber sealing covers 3 with the sealing rings 2 assembled on them with the openings on both sides of the aluminum base 1, so that the sealing groove 31 fits tightly with the edge of the aluminum base 1. Finally, use eight M5×16 socket head cap screws evenly distributed along the edge of the water chamber sealing cover plate 3 for tightening. The tightening torque of each screw is controlled at 8-10 N·m to ensure that the sealing surface is subjected to uniform force.

[0032] In use, the PTC heating pack is installed in the heating pack placement slot of the aluminum base 1. When the heater is working, the heat generated by the PTC heating pack is transferred to the aluminum base 1. At the same time, the coolant enters the sealed chamber of the aluminum base 1 from the inlet 11, exchanges heat with the aluminum base 1 in the chamber, absorbs heat and rises in temperature, and then flows out from the outlet 12 to heat the vehicle interior or keep the battery system warm.

[0033] This utility model has the following significant beneficial effects: Mitigating Patent Risks: This utility model adopts an all-metal combination structure of aluminum base and sealing cover, replacing the combination of metal and plastic parts in the prior art. It is fundamentally different from the structure protected by patent EP2797382 A1, which can effectively avoid the risk of patent infringement and provide new technology options for domestic enterprises.

[0034] Reduced risk of leakage: The structure on which the heating pack is placed on the aluminum base is directly connected to the upper and lower shells of the circulation chamber. It is integrally die-cast and the molding process is continuous. This avoids the problems of air entrapment and poor die-casting caused by broken die-casting of heating ribs in the prior art, and fundamentally eliminates the generation of micro-pores. At the same time, the structure has no weak parts that are subjected to long-term stress, and is not prone to fatigue damage during temperature cycling. This significantly reduces the risk of leakage and improves the safety and service life of the heater.

[0035] Improved production efficiency: The integrated die-cast aluminum base reduces the number and types of parts, simplifying production and assembly processes; the screw-fastened water chamber sealing cover is easy to operate, facilitating automated production, improving production efficiency and reducing production costs.

[0036] Enhanced sealing performance: The sealing structure, which uses a special sealing ring and sealing groove, combined with evenly distributed screws for fastening, ensures that the sealing surface is subjected to uniform force, maintains good sealing performance for a long time, and effectively prevents coolant leakage.

[0037] Optimized heat exchange efficiency: Aluminum has excellent thermal conductivity, and the integrated structure is conducive to heat transfer and diffusion; the sealed chamber design allows the coolant to flow fully within the chamber and exchange heat fully with the aluminum base, thus improving heating efficiency.

[0038] Adapting to development needs: Its compact structure and light weight align with the lightweight development trend of new energy vehicles; at the same time, its high reliability and long lifespan can meet the stringent requirements of new energy vehicles for thermal management systems, and it has broad application prospects.

[0039] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention. It should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the concept of the present invention, and all such modifications or substitutions should be considered within the protection scope of the present invention.

Claims

1. A liquid heater for a new energy vehicle, characterized in that: The liquid heater includes an integrally formed aluminum base with a cavity for coolant flow inside. An inlet and an outlet are connected to the two sides of the cavity, respectively. Water chamber sealing covers that mate with the cavity are provided on both sides of the aluminum base.

2. The liquid heater for a new energy vehicle according to claim 1, characterized in that: The cavity has a serpentine channel, and a sealing ring is provided between the water chamber sealing cover and the cavity.

3. The liquid heater for new energy vehicles according to claim 2, characterized in that: The water chamber sealing cover has a sealing groove on one side that matches the sealing ring. The sealing groove is rectangular. The water chamber sealing cover is fixedly connected to the aluminum base through a connector.

4. The liquid heater for new energy vehicles according to claim 2, characterized in that: The aluminum base has a raised semi-circular connecting part at the bend of the serpentine channel, and the semi-circular connecting part has an aluminum base connecting hole.

5. The liquid heater for new energy vehicles according to claim 4, characterized in that: The water chamber sealing cover is provided with evenly distributed cover plate connection holes around its perimeter. The cover plate connection holes are divided into upper and lower end cover plate connection holes and middle cover plate connection holes. The position of the middle cover plate connection hole corresponds to the position of the aluminum base connection hole. The water chamber sealing cover is fixedly connected to the aluminum base by the connectors set in the cover plate connection holes.

6. The liquid heater for a new energy vehicle according to claim 5, characterized in that: The sealing grooves are evenly distributed around the water chamber sealing cover plate, and a concave semi-circular sealing groove is formed at the semi-circular connection to match it.

7. The liquid heater for new energy vehicles according to claim 1, characterized in that: The front panel of the aluminum base has a water inlet, and the bottom of the cavity has a matching circular water inlet cavity; the sealing cover of one side water chamber has a water outlet, and the top of the cavity has a matching trumpet-shaped water outlet cavity. The circular water inlet cavity and the trumpet-shaped water outlet cavity are diagonally arranged inside the aluminum base.

8. The liquid heater for new energy vehicles according to claim 1, characterized in that: Both the aluminum base and the water chamber sealing cover are made of aluminum alloy. The aluminum base is a one-piece molded structure, and the sealing ring is made of fluororubber.

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