An immersion heater structure integrated with a compressor

Abstract

The utility model relates to the technical field of heating structure, concretely relates to a kind of immersed heater structure integrated with compressor, including shell, the shell has medium heat exchange cavity, wherein heating core is equipped, the heating core includes electric heating tube, the electric heating tube outside side integrally formed with heat exchange layer, the heat exchange layer includes opposite first heat exchange surface and second heat exchange surface;The heating core separates the medium heat exchange cavity into two chambers, and the first heat exchange surface and second heat exchange surface are located in one of chamber respectively.The utility model is applicable to the heater integrated with compressor, with compact structure, and heat exchange efficiency is high.

Description

Technical Field

[0001] This utility model relates to the field of heating structure technology, specifically to an immersion heater structure integrated with a compressor. Background Technology

[0002] In systems such as heat pumps, air conditioners, and thermal management systems for new energy vehicles, auxiliary heating of the externally circulating medium (such as water, refrigerant, or coolant) is often required. Immersion electric heaters are widely used in such applications due to their direct contact with the medium and high heating efficiency. To improve space utilization, existing technologies integrate the heater with the compressor, resulting in a more compact overall structure.

[0003] For example, Chinese patent CN223045514U, a utility model, discloses a heater and an automobile. The heater includes a control box and a heating module disposed on one side of the control box. The heating module includes a heating core and a housing. The housing is fitted onto the heating core through an opening and fixed to the outer wall of the control box. A heating channel is formed between the inner wall of the housing and the outer wall of the heating core, and the heating channel is independent of the inner cavity of the control box. Furthermore, one side wall of the housing has a first inlet / outlet communicating with one end of the heating channel, and the other side wall has a second inlet / outlet communicating with the other end of the heating channel. This utility model has a relatively compact structure, and the heating core is integrally formed on the outer wall of the control box, eliminating gaps between the heating core and the control box and preventing the possibility of heated fluid flowing into the control box. However, the fit between the heating core and the housing is not suitable for heaters integrated with compressors, and the heat exchange effect of its heating channel is poor. Utility Model Content

[0004] To address the problems existing in the prior art, this utility model proposes an immersion heater structure that is adapted to be integrated with a compressor. It has a compact structure, optimizes the medium flow channel, and avoids dead zones.

[0005] To achieve the above-mentioned technical effects, this utility model proposes: An immersion heater structure integrated with a compressor includes a housing having a medium heat exchange chamber therein, wherein a heating core is provided, the heating core including an electric heating tube, the outer surface of which is integrally formed with a heat exchange layer, the heat exchange layer including a first heat exchange surface and a second heat exchange surface opposite to each other; the heating core divides the medium heat exchange chamber into two chambers, the first heat exchange surface and the second heat exchange surface being located in one of the chambers respectively.

[0006] The heat exchange layer is integrally formed on the outer surface of the electric heating tube, resulting in low contact thermal resistance and high heat transfer efficiency between the electric heating tube and the heat exchange layer, while maintaining a compact overall design. The heating core divides the medium heat exchange chamber into two compartments. In actual operation, the medium is divided into two streams that enter the compartments containing the first and second heat exchange surfaces respectively, improving heat exchange efficiency and uniformity.

[0007] The heat exchange layer has partition plates on its opposite sides, and the partition plates are attached to the side walls of the medium heat exchange cavity; the partition plates form side flow channels.

[0008] The first heat exchange surface is provided with a plurality of finned plates and a plurality of U-shaped fins, and the plurality of finned plates and the plurality of U-shaped fins form a plurality of S-shaped flow channels.

[0009] The finned plates are arranged parallel to each other and at equal intervals; a bend baffle is provided at the bend of the S-shaped flow channel, and the bend baffle is arranged parallel to the finned plates; the S-shaped flow channel has a plurality of longitudinal flow channels, and the longitudinal flow channels are staggered with the S-shaped flow channel.

[0010] In one embodiment of this utility model, the second heat exchange surface is provided with a plurality of finned plates and a plurality of U-shaped fins, and the plurality of finned plates and the plurality of U-shaped fins form a plurality of S-shaped flow channels; the S-shaped flow channels on the second heat exchange surface are arranged oppositely to the S-shaped flow channels on the first heat exchange surface.

[0011] In one embodiment of this utility model, the second heat exchange surface is provided with a plurality of wavy fins, and the plurality of wavy fins form a plurality of wavy flow channels; the wavy fins are arranged parallel to each other and at equal intervals.

[0012] The second heat exchange surface is provided with a plurality of rectifier plates, and the plurality of rectifier plates form a plurality of rectifier channels; the rectifier plates are arranged parallel to each other and at equal intervals.

[0013] The second heat exchange surface is provided with a plurality of transverse flow channels, which are staggered with the wavy flow channels.

[0014] The outer casing is provided with an inlet and an outlet, which are respectively located on opposite sides of the outer casing; the positions of the inlet and outlet correspond to the S-shaped flow channel; the outer casing is provided with an electrical side cavity. The electrical side cavity is formed on the outer surface of the outer casing outside the medium heat exchange chamber. After the outer casing is connected to the compressor, the electrical side cavity is sealed between the compressor and the outer casing. This structure allows the overall volume of the heater to be reduced and the compactness to be improved after integrating the compressor with the heater.

[0015] The electric heating tube has several U-shaped bends; the heating core is fixed to the medium heat exchange chamber by a flange; a sealing ring is provided between the flange and the outer shell; the end of the electric heating tube is fixedly connected to the flange by a ceramic bead; the end of the electric heating tube is connected to a terminal block and fitted with a silicone cap.

[0016] The beneficial effects of this utility model are: 1. The heating core divides the medium heat exchange chamber into two chambers, improving the efficiency and uniformity of medium heat exchange; 2. The medium flow channels on the surface of the heating core are optimized to form S-shaped flow channels, side flow channels, and wavy flow channels to avoid dead zones; 3. The heating core is connected to the outer shell through a flange, which facilitates assembly and maintenance. Attached Figure Description

[0017] Figure 1 This is an exploded view of the present invention in Embodiment 1.

[0018] Figure 2 This is a schematic diagram of the overall structure of the present invention in Embodiment 1.

[0019] Figure 3 This is a schematic diagram of the structure of the first heat exchange surface in Example 1.

[0020] Figure 4 This is a side view of the heating core in Example 1.

[0021] Figure 5 This is a cross-sectional view of the present invention in Embodiment 1.

[0022] Figure 6 This is a schematic diagram of the structure of the second heat exchange surface in Example 2.

[0023] Figure 7 This is a side view of the heating core in Example 2.

[0024] Icon labels: 100. Outer shell; 200. Heating element; 300. Flange; 400. Ceramic bead; 500. Terminal block; 600. Silicone cap; 700. Cover; 101. Medium heat exchange chamber; 102. Water inlet; 103. Water outlet; 104. Electrical side chamber; 201. Electric heating element; 202. Heat exchange layer; 203. First heat exchange surface; 204. Second heat exchange surface; 205. Partition plate; 206. Side flow channel; 207. Finned plate; 208. U-shaped fin; 209. S-shaped flow channel; 210. Bending baffle; 211. Longitudinal flow channel; 212. Wavy fin; 213. Wavy flow channel; 214. Straightening plate; 215. Straightening flow channel; 216. Transverse flow channel; 217. U-shaped bend; 301. Sealing ring. Detailed Implementation

[0025] This utility model relates to an immersion heater structure integrated with a compressor, mainly used in vehicle heat pump systems, air conditioning systems or other fluid heating equipment. By directly integrating the heater into the compressor housing, a compact design, efficient heat exchange and energy-saving operation are achieved.

[0026] The following specific embodiments illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification.

[0027] Example 1 As one embodiment of this utility model, this embodiment proposes an immersion heater structure integrated with a compressor, as shown in the attached drawing. Figures 1 to 5 The device includes a housing 100 with a medium heat exchange chamber 101, in which a heating core 200 is provided. The heating core 200 includes an electric heating tube 201, and a heat exchange layer 202 is integrally formed on the outer surface of the electric heating tube 201. The heat exchange layer 202 includes a first heat exchange surface 203 and a second heat exchange surface 204 opposite to each other. The heating core 200 divides the medium heat exchange chamber 101 into two chambers, with the first heat exchange surface 203 and the second heat exchange surface 204 located in one of the chambers respectively. The heating core 200 is formed by integrally casting an aluminum alloy heat exchange layer 202 from the electric heating tube 201, and has good thermal conductivity.

[0028] The heat exchange layer 202 has opposing first heat exchange surfaces 203 and second heat exchange surfaces 204, while the heating core 200, as a whole, divides the medium heat exchange cavity 101 into two independent chambers, with the first and second heat exchange surfaces 204 located in one of the chambers respectively. This design ensures that the medium flowing into the medium heat exchange cavity 101 is divided into two streams, which exchange heat with the two heat exchange surfaces separately and sequentially, guaranteeing that all fluids participate in effective heat exchange. This design greatly improves the efficiency and uniformity of heat exchange. The overall width of the heat exchange layer 202 corresponds to the width of the medium heat exchange cavity 101 to ensure that the heating core 200 divides the medium heat exchange cavity 101 into two chambers. All four corners of the heat exchange layer 202 are rounded.

[0029] The medium heat exchange cavity 101 is a flat rectangular cavity with rounded corners at its bottom to avoid dead zones. The two rounded corners at the bottom of the heat exchange layer 202 correspond to the two rounded corners at the bottom of the medium heat exchange cavity 101. After the heating core 200 and the outer shell 100 are installed, the bottom of the heat exchange layer 202 abuts against the bottom of the medium heat exchange cavity 101.

[0030] In this embodiment, the heating core 200 is fixed to the medium heat exchange chamber 101 via a flange 300, and a sealing ring 301 is provided between the flange 300 and the outer shell 100. The flange 300 is made of stainless steel and is connected to the outer shell 100 by bolts, facilitating installation and maintenance. The flange 300 fixing method, in conjunction with the sealing ring 301, not only provides robust mechanical support to withstand pressure fluctuations within the chamber but also achieves effective chamber sealing. The open end of the outer shell 100 is sealed with a cap 700.

[0031] The electric heating element 201 consists of two sets of parallel electric heating elements 201. Each set of electric heating elements 201 is a stainless steel sheathed resistance heating element. Each set of electric heating elements 201 has three U-shaped bends 217 to improve the uniformity of heating in the heating core 200. Both ends of the electric heating element 201 are fixedly connected to the flange 300 via ceramic beads 400, and connected to the external control circuit via a terminal block 500. A silicone cap 600 is provided between the terminal block 500 and the electric heating element 201.

[0032] The outer casing 100 is made of high-strength aluminum alloy. An inlet 102 is located on the lower left side of the outer casing 100, and an outlet 103 is located on the upper right side. Both the inlet 102 and outlet 103 are connected to external pipes to ensure a tight seal. An electrical side cavity 104 is located on the side of the outer casing 100, opposite to the medium heat exchange cavity 101. This cavity houses electrical connection components such as terminals, temperature sensors, and control circuits, isolating the electrical and fluid areas and improving safety.

[0033] In this embodiment, partition plates 205 are respectively provided on opposite sides of the heat exchange layer 202. The partition plates 205 are attached to the sidewalls of the medium heat exchange cavity 101, forming side flow channels 206. The thickness of the partition plates 205 is less than the thickness of the heating core 200 where the first heat exchange surface 203 or the second heat exchange surface 204 is located, resulting in a larger volume of the medium heat exchange cavity 101 where the side flow channels 206 are located. The partition plates 205 ensure that the first and second chambers are completely isolated, forcing the fluid to flow only from one end of the heat exchange layer 202 to the other end, preventing leakage from the side, reducing bypass losses, and improving the uniformity of medium heat exchange. The side flow channels 206 formed between the partition plates 205 and the sidewalls provide a clear flow path with low resistance for the fluid, helping to guide the fluid to be evenly distributed across the entire heat exchange surface and preventing flow dead zones from forming in the corners of the chambers.

[0034] In this embodiment, the first heat exchange surface 203 is provided with a plurality of finned plates 207 and a plurality of U-shaped fins 208, which together form a plurality of S-shaped flow channels 209. The finned plates 207 and U-shaped fins 208 significantly increase the surface area of ​​the first heat exchange surface 203, making the area in contact with the fluid much larger than that of a flat surface. The finned plates 207 are arranged parallel to each other and at equal intervals. The finned plates 207 and U-shaped fins 208 together form a plurality of S-shaped flow channels 209, which allow the fluid to change direction multiple times during flow, prolonging the residence time and improving the heat exchange effect. A bend baffle 210 is provided at the bend of the S-shaped flow channel 209, and the bend baffle 210 is arranged parallel to the fins. The bend baffle 210 is located at the bend of the S-shaped flow channel 209 to divide the fin plates 207 on both sides of the U-shaped fin 208. At the same time, the bend baffle 210 abuts against the inner wall of the medium heat exchange chamber 101, so that the medium can flow along the S-shaped flow channel 209.

[0035] The bend baffle 210 is used to guide the fluid to a smooth turn. Without this baffle, a large vortex dead zone would form at the U-bend, resulting in poor heat exchange and significant local pressure loss. The introduction of the bend baffle 210 divides a large vortex zone into two ordered smaller channels, enabling the fluid to efficiently complete a 180° turn.

[0036] The S-shaped flow channel 209 has several longitudinal flow channels 211, which are staggered with the S-shaped flow channels 209. The longitudinal flow channels 211 are arranged between the finned plates 207 to balance the medium pressure between the S-shaped flow channels 209, and at the same time increase the contact area between the medium and the heating core 200, thereby improving the heat exchange effect. A single S-shaped flow channel 209 may have a high medium pressure; with the introduction of the longitudinal flow channels 211, the fluid will be automatically distributed when the flow rate increases.

[0037] In this embodiment, the second heat exchange surface 204 is provided with a finned plate 207, a U-shaped fin 208 and an S-shaped flow channel 209, and the layout of the S-shaped flow channel 209 is the same as that of the S-shaped flow channel 209 of the first heat exchange surface 203, but the direction of the flow channel 209 is opposite.

[0038] In this embodiment, when the heater structure is working, the medium enters the medium heat exchange chamber 101 through the inlet 102, flows through the heating core 200, and is then output through the outlet 103. During this process, the heat exchange medium entering through the inlet 102 is first divided into two streams by the partition plate 205 facing the inlet 102, and then enters the chambers containing the first heat exchange surface 203 and the second heat exchange surface 204, respectively. The medium fluid flows through the S-shaped flow channels 209 of the first heat exchange surface 203 and the second heat exchange surface 204, and after being fully heated, it converges at the outlet 103 for output.

[0039] Example 2 As one embodiment of this utility model, this embodiment provides an immersion heater structure integrated with a compressor. (Continuing with reference to the appendix...) Figures 1 to 3 , combined Figures 5 to 7 The device includes a housing 100, which has a medium heat exchange chamber 101, in which a heating core 200 is provided. The heating core 200 includes an electric heating tube 201, and a heat exchange layer 202 is integrally formed on the outer side of the electric heating tube 201. The heat exchange layer 202 includes a first heat exchange surface 203 and a second heat exchange surface 204 opposite to each other. The heating core 200 divides the medium heat exchange chamber 101 into two chambers, and the first heat exchange surface 203 and the second heat exchange surface 204 are respectively located in one of the chambers.

[0040] The outer casing 100 is provided with an inlet 102 and an outlet 103, which are respectively located on opposite sides of the outer casing 100. The inlet 102 is located on the lower left side of the outer casing 100, and the outlet 103 is located on the upper right side of the outer casing 100. The positions of the inlet 102 and the outlet 103 correspond to the S-shaped flow channel 209. The outer casing 100 is provided with an electrical side cavity 104. The electric heating tube 201 has several U-shaped bends 217. The heating core 200 is fixed to the medium heat exchange cavity 101 through a flange 300. A sealing ring 301 is provided between the flange 300 and the outer casing 100. The end of the electric heating tube 201 is fixedly connected to the flange 300 through a ceramic bead 400. The end of the electric heating tube 201 is connected to a terminal block 500 and fitted with a silicone cap 600.

[0041] The heat exchange layer 202 has partition plates 205 on both opposite sides, and the partition plates 205 are attached to the sidewalls of the medium heat exchange cavity 101; the partition plates 205 form side flow channels 206. The first heat exchange surface 203 is provided with a plurality of finned plates 207 and a plurality of U-shaped fins 208, and the plurality of finned plates 207 and the plurality of U-shaped fins 208 form a plurality of S-shaped flow channels 209. The finned plates 207 are arranged parallel to each other and at equal intervals; the bends of the S-shaped flow channels 209 are provided with bend baffles 210, and the bend baffles 210 are arranged parallel to the finned plates 207; the first heat exchange surface 203 is provided with a plurality of longitudinal flow channels 211, and the longitudinal flow channels 211 are staggered with the S-shaped flow channels 209.

[0042] In this embodiment, the second heat exchange surface 204 is provided with a plurality of corrugated fins 212, which form a plurality of corrugated flow channels 213. The height difference between the crests and troughs of the corrugated fins 212 is 8-12 mm, and the corrugated fins 212 are arranged parallel to each other and at equal intervals, with a spacing of approximately 6 mm. The corrugated flow channels 213 increase the heat exchange area and promote fluid mixing, enabling heat to diffuse more quickly and evenly in the medium, thus shortening the time from system startup to reaching the preset medium temperature.

[0043] The second heat exchange surface 204 is provided with a plurality of rectifier plates 214, which form a plurality of rectifier channels 215. The rectifier plates 214 are arranged parallel to each other and at equal intervals. In this embodiment, the rectifier plates 214 are positioned opposite the inlet 102 on the second heat exchange surface 204, and the rectifier channels 215 are parallel to the water inlet direction. Specifically, this embodiment includes four layers of rectifier plates 214. The upper two layers of rectifier plates 214 each consist of two sections of rectifier plates 214, and the lower two layers of rectifier plates 214 each consist of four sections of rectifier plates 214, forming four rectifier channels 215. The rectifier plates 214 are used to stabilize the flow field of the medium entering through the inlet 102 and reduce turbulence fluctuations.

[0044] The second heat exchange surface 204 is provided with several transverse flow channels 216, which are staggered with the corrugated flow channels 213. The transverse flow channels 216 are positioned between the corrugated fins 212, allowing the fluid to flow laterally between the corrugated flow channels 213, balancing the medium pressure between each corrugated flow channel 213, and promoting fluid mixing and temperature homogenization. Simultaneously, the transverse flow channels 216 increase the contact area between the medium and the heating core 200, improving the heat exchange effect. Through sufficient mixing via the transverse flow channels 216, the medium temperature at the outlet of the second heat exchange surface 204 is highly uniform across the cross-section, essentially eliminating localized overcooling or overheating hotspots.

[0045] In this embodiment, when the heater structure is working, the medium enters the medium heat exchange chamber 101 through the inlet 102, flows through the heating core 200, and is then output through the outlet 103. During this process, the heat exchange medium entering through the inlet 102 is first divided into two streams by the partition plate 205 facing the inlet 102, and then enters the chambers containing the first heat exchange surface 203 and the second heat exchange surface 204, respectively. The medium entering the chamber containing the first heat exchange surface 203 flows along the S-shaped flow channel 209 across the surface of the first heat exchange surface 203, is fully heated by the heating core 200, and then collects at the outlet 103 for output. The medium entering the chamber containing the second heat exchange surface 204 first passes through the rectifier flow channel 215, then passes through the wavy flow channel 213 for full heating, and finally collects at the outlet 103 for output.

[0046] This invention divides the medium heat exchange chamber into two independent chambers using a heating core and incorporates various flow channel designs, such as S-shaped, longitudinal, wavy, and transverse flow channels, to achieve efficient, compact, and reliable immersion heating. The above embodiment improves thermal performance, safety, and maintainability through flange fixing, electrical isolation, and innovative flow channels. When integrated with a compressor, this structure reduces system complexity and energy loss.

Claims

1. An immersion heater structure integrated with a compressor, comprising a housing having a medium heat exchange chamber therein, wherein a heating core is disposed, characterized in that, The heating core includes an electric heating tube, and a heat exchange layer is integrally formed on the outer side of the electric heating tube. The heat exchange layer includes a first heat exchange surface and a second heat exchange surface opposite to each other. The heating core divides the medium heat exchange cavity into two chambers, and the first heat exchange surface and the second heat exchange surface are respectively located in one of the chambers.

2. The immersion heater structure integrated with a compressor according to claim 1, characterized in that, The heat exchange layer has partition plates on its opposite sides, and the partition plates are attached to the side walls of the medium heat exchange cavity; the partition plates form side flow channels.

3. The immersion heater structure integrated with a compressor according to claim 2, characterized in that, The first heat exchange surface is provided with a plurality of finned plates and a plurality of U-shaped fins, and the plurality of finned plates and the plurality of U-shaped fins form a plurality of S-shaped flow channels.

4. The immersion heater structure integrated with a compressor according to claim 3, characterized in that, The finned plates are arranged parallel to each other and at equal intervals; a bend baffle is provided at the bend of the S-shaped flow channel, and the bend baffle is arranged parallel to the finned plates; the S-shaped flow channel has a plurality of longitudinal flow channels, and the longitudinal flow channels are staggered with the S-shaped flow channel.

5. The immersion heater structure integrated with a compressor according to claim 4, characterized in that, The second heat exchange surface is provided with a plurality of finned plates and a plurality of U-shaped fins, and the plurality of finned plates and the plurality of U-shaped fins form a plurality of S-shaped flow channels; the S-shaped flow channels on the second heat exchange surface are arranged oppositely to the S-shaped flow channels on the first heat exchange surface.

6. The immersion heater structure integrated with a compressor according to claim 4, characterized in that, The second heat exchange surface is provided with a plurality of wavy fins, and the plurality of wavy fins form a plurality of wavy flow channels; the wavy fins are arranged parallel to each other and at equal intervals.

7. The immersion heater structure integrated with a compressor according to claim 6, characterized in that, The second heat exchange surface is provided with a plurality of rectifier plates, and the plurality of rectifier plates form a plurality of rectifier channels; the rectifier plates are arranged parallel to each other and at equal intervals.

8. The immersion heater structure integrated with a compressor according to claim 6, characterized in that, The second heat exchange surface is provided with a plurality of transverse flow channels, which are staggered with the wavy flow channels.

9. An immersion heater structure integrated with a compressor according to any one of claims 3 to 8, characterized in that, The outer casing is provided with an inlet and an outlet, which are respectively located on opposite sides of the outer casing; the positions of the inlet and outlet correspond to the S-shaped flow channel; the outer casing is provided with an electrical side cavity.

10. The immersion heater structure integrated with a compressor according to claim 9, characterized in that, The electric heating tube has several U-shaped bends; the heating core is fixed to the medium heat exchange chamber by a flange; a sealing ring is provided between the flange and the outer shell; the end of the electric heating tube is fixedly connected to the flange by a ceramic bead; the end of the electric heating tube is connected to a terminal block and fitted with a silicone cap.

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