A new energy vehicle wind heating PTC heater structure

Abstract

The utility model discloses a new energy automobile wind is warm with PTC heater structure. It includes the frame of fixed frame of the periphery of heating core, and heating core includes the upper electrode and lower electrode of the same side, and the upper electrode is connected with the upper busbar, and the lower electrode is connected with the lower busbar, and the upper busbar and lower busbar are staggered a distance behind and ahead in the length direction of heating core, one side fixedly connected with controller assembly of frame, the rear side of the shell of controller assembly is covered on the upper busbar and lower busbar, and the lead -out section of upper busbar and lower busbar goes into the shell front side inner chamber of controller assembly and is connected with the controller in it. Advantage is: the upper busbar and lower busbar are staggered a distance behind and ahead along the length direction of heating core, and the electrical creepage distance between two is fundamentally enlarged, and the arc breakdown risk under the high -voltage operation can be reduced significantly.

Description

Technical Field

[0001] This utility model relates to the application field of PTC heaters for air heating in new energy vehicles, and in particular to a structure of a PTC heater for air heating in new energy vehicles. Background Technology

[0002] New energy vehicle heating systems commonly use PTC (Positive Temperature Coefficient) ceramic elements as the heat source, electrically heating the air for cabin heating. Existing PTC heaters mostly employ a single-layer busbar structure with limited electrical spacing between the upper and lower electrodes, making them susceptible to arcing and breakdown under high-voltage conditions. Furthermore, the installation of PTC heating elements generally relies on adhesive bonding or simple press-fitting, resulting in insufficient positioning reliability. Under vehicle vibration, this can lead to displacement, poor contact, or localized overheating. In addition, the electrical connection structure between the controller and the heating element is relatively simple, lacking independent limiting measures for the electrode heads, posing a short-circuit hazard. Summary of the Invention

[0003] The technical problem to be solved by this utility model is to provide a PTC heater structure for new energy vehicle air heating that is safer in structure, more reliable in positioning, and easier to install.

[0004] To solve the above-mentioned technical problems, the PTC heater structure for new energy vehicle air heating of this utility model includes a heating core and a frame fixed to the outer periphery of the heating core. The heating core includes an upper electrode and a lower electrode located on the same side. The upper electrode is connected to an upper busbar, and the lower electrode is connected to a lower busbar. The upper busbar and the lower busbar are offset by a distance in the length direction of the heating core. A controller assembly is fixedly connected to one side of the frame. The rear side of the housing of the controller assembly covers the upper busbar and the lower busbar. The lead-out sections of the upper busbar and the lower busbar extend into the inner cavity of the front side of the housing of the controller assembly and are connected to the controller located therein.

[0005] The housing and frame of the controller assembly are connected by screws.

[0006] The controller assembly is equipped with a partition plate for separating and limiting the positions of the electrode heads.

[0007] The inner side of the frame is provided with a limiting groove along the circumference of the heating core for positioning and fixing the heating core.

[0008] The front end of the heating element is fitted with a cap, and the front side of the frame is provided with a snap-fit ​​groove for engaging with the cap.

[0009] The upper and lower busbars are offset by a distance of 3-6 mm along the length of the heating core.

[0010] The frame is made of plastic.

[0011] Advantages of this utility model: 1. By offsetting the upper and lower busbars along the length of the heating core by a certain distance, the electrical creepage distance between them is significantly increased, which can significantly reduce the risk of arc breakdown under high voltage operation. Compared with the traditional planar busbar method, this structure can better meet the insulation safety requirements of new energy vehicles on high voltage platforms and improve the overall electrical reliability of the heater. 2. A limiting groove is set along the circumferential direction on the inner side of the frame, so that the heating core can be limited at multiple points and clamped in the circumferential direction during installation, effectively preventing loosening, displacement or falling off due to vehicle vibration. This structure does not require additional fasteners, improves assembly efficiency, and at the same time ensures that the relative position between the heating core and the busbar and electrode head is accurate and stable, improving heat dissipation and thermal efficiency. 3. A partition plate is added inside the controller assembly to independently separate and limit each electrode head, avoiding the risk of shaking, contact or short circuit of different electrode terminals under high voltage. Attached Figure Description

[0012] Figure 1 This is an exploded view of the structure of the PTC heater for new energy vehicle ventilation according to this utility model; Figure 2 This is a schematic diagram of the heating element in the PTC heater for new energy vehicle heating system of this utility model; Figure 3 This is a schematic diagram of the controller assembly in the PTC heater for new energy vehicles. Detailed Implementation

[0013] The structure of the PTC heater for new energy vehicle heating according to this utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments. Example

[0014] This utility model discloses a PTC heater for new energy vehicle heating, comprising a heating core 1 and a plastic frame 2 fixed around the heating core 1. The heating core 1 includes an upper electrode 3 and a lower electrode 4 on the same side. The upper electrode 3 is connected to an upper busbar 5, and the lower electrode 4 is connected to a lower busbar 6. The upper busbar 5 and the lower busbar 6 are offset from each other along the length of the heating core 1 by a distance ranging from 3 to 6 mm. A controller assembly 7 is fixedly connected to one side of the frame 2. The rear of the housing of the controller assembly 7 covers the upper busbar 5 and the lower busbar 6. The leads of the upper busbar 5 and the lower busbar 6 extend into the front cavity of the housing of the controller assembly 7 and connect to the controller located therein. A cap is installed at the front end of the heating core 1. The cap is made of PPS material, has a temperature resistance of 230 degrees Celsius, and high insulation performance. Its function is to support the busbars and isolate the positive and negative electrodes. The front side of the frame 2 is provided with... A snap-fit ​​groove 11 is provided for engaging with the end cap, which engages with the end cap to limit the forward movement of the heating element 1. A controller assembly 7 is installed on one side of the frame 2 and is electrically connected to the upper busbar 5 and the lower busbar 6. A partition plate 8 is installed in the controller assembly 7 to separate and limit the movement of each electrode head. A screw 9 is provided at the bottom of the controller assembly 7 for fixing to the frame 2. The upper electrode 3 and the lower electrode 4 are made of H65 material to ensure current carrying capacity. A heat sink made of aluminum material with good thermal conductivity is installed in the heating element 1. The fins adopt a corrugated structure to increase the contact area with the air and quickly transfer the heat generated by the heater. The heating element 1 generates heat after being powered on. This utility model is installed in the air conditioning box of a new energy vehicle and removes the heat generated by the PTC heater by blowing air. The number of heating elements and different heat outputs can be determined according to the power requirements.

Claims

1. A PTC heater structure for air heating in new energy vehicles, characterized in that: The device includes a heating core (1) and a frame (2) fixed to the outer periphery of the heating core (1). The heating core (1) includes an upper electrode (3) and a lower electrode (4) located on the same side. The upper electrode (3) is connected to an upper busbar (5), and the lower electrode (4) is connected to a lower busbar (6). The upper busbar (5) and the lower busbar (6) are offset by a distance in the length direction of the heating core (1). A controller assembly (7) is fixedly connected to one side of the frame (2). The rear side of the housing of the controller assembly (7) covers the upper busbar (5) and the lower busbar (6). The lead-out sections of the upper busbar (5) and the lower busbar (6) extend into the inner cavity of the front side of the housing of the controller assembly (7) and are connected to the controller located therein.

2. The PTC heater structure for new energy vehicle air heating according to claim 1, characterized in that: The housing of the controller assembly (7) is connected to the frame (2) by screws (9).

3. The PTC heater structure for new energy vehicle air heating according to claim 1, characterized in that: The controller assembly (7) is equipped with a partition plate (8) for separating and limiting the electrode heads.

4. The PTC heater structure for new energy vehicle air heating according to claim 1, characterized in that: The inner side of the frame (2) is provided with a limiting groove along the circumference of the heating core (1) for positioning and fixing the heating core (1).

5. The PTC heater structure for new energy vehicle air heating according to claim 1, characterized in that: The front end of the heating element (1) is equipped with a cap (10), and the front side of the frame (2) is provided with a snap-fit ​​groove (11) for engaging with the cap (10).

6. The PTC heater structure for new energy vehicle air heating according to claim 1, characterized in that: The distance between the upper busbar (5) and the lower busbar (6) in the longitudinal direction of the heating core (1) is 3-6 mm.

7. The PTC heater structure for new energy vehicle air heating according to claim 1, characterized in that: The frame (2) is made of plastic.

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