A PTC air heating device for vehicle with double-layer bus electrode structure

Abstract

The application relates to a PTC air heating heater for vehicles with a double-layer current collecting electrode structure, which comprises a mounting frame, a plurality of heating elements are arranged in the mounting frame, a positive electrode pin and a negative electrode pin are arranged on each heating element, a mounting shell is arranged on the mounting frame, a current collecting support is arranged in the mounting shell, a first electrode layer and a second electrode layer are arranged on the current collecting support, a first current collecting sheet electrically connected with the plurality of positive electrode pins is arranged in the first electrode layer, a positive electrode electrically connected with the first current collecting sheet through a connecting piece is arranged on the current collecting support, a second current collecting sheet electrically connected with the plurality of negative electrode pins is arranged in the second electrode layer, and a negative electrode is arranged on the second current collecting sheet. The application has the effect of improving the applicability of the PTC heating heater.

Description

Technical Field

[0001] This application relates to the field of PTC air heater technology, and in particular to a vehicle PTC air heater with a double-layer busbar electrode structure. Background Technology

[0002] A PTC heater is a type of heater based on semiconductor materials. When a PTC heater is powered on, the resistance of the PTC material increases with temperature, so a large amount of heat is generated when the current passes through the PTC material, which in turn raises the temperature of the PTC material and the surrounding environment. At present, PTC heaters are often used in new energy electric vehicles for battery thermal management and air conditioning heating.

[0003] Existing PTC heaters typically include a positive electrode plate, a negative electrode plate, and multiple PTC heating elements electrically connected to the positive and negative electrode plates. These components work together to convert electrical energy into heat energy and output it. However, due to the limited installation space in new energy vehicles and the electrical clearance and creepage distance safety standards that on-board high-voltage components must meet, existing PTC heaters generally use a single-layer busbar electrode structure to connect and collect current for each PTC heating element.

[0004] However, the traditional single-layer bus electrode structure, while meeting the electrical clearance requirements, makes it difficult to connect more components in series within the limited electrode space. This limits the performance improvement and functional expansion of the heater, reducing the applicability of the PCT heater and presenting significant shortcomings. Utility Model Content

[0005] To improve the applicability of PTC heaters, this application provides a vehicle PTC air heater with a double-layer bus electrode structure.

[0006] This application provides a vehicle PTC air heater with a double-layer busbar electrode structure, which adopts the following technical solution: A vehicle PTC air heater with a dual-layer busbar structure includes a mounting frame, inside which are arranged multiple heating elements, each of which has a positive electrode pin and a negative electrode pin. A mounting shell is provided on the mounting frame, and a busbar support is provided inside the mounting shell. A first electrode layer and a second electrode layer are provided on the busbar support. A positive electrode is provided in the first electrode layer, and a first busbar and a second busbar are provided in the second electrode layer. The input end of the first busbar is electrically connected to the positive electrode via a connector, and its output end is electrically connected to multiple positive electrode pins. The second busbar is electrically connected to multiple negative electrode pins and has a negative electrode.

[0007] By adopting the above technical solution, when the PTC heater is running, the power supply current flows into the positive electrode in the first electrode layer, and then flows into the first busbar in the second electrode layer through the connector. The first busbar transmits the current to multiple heating elements, causing their energized temperature to rise and achieve the heating effect. Subsequently, the current flows through the negative pin of the heating element to the second busbar, and the current flows along the second busbar into the negative electrode, and finally flows back to the negative terminal of the power supply, thus forming a double-layer busbar electrode structure. Compared with the traditional single-layer busbar electrode structure, the double-layer busbar electrode structure of this application can reasonably connect more heating elements and supporting components in series or in parallel on the two-layer electrode structure without taking up additional installation space of the heater, thus expanding the effective arrangement area of ​​the electrodes and improving the applicability of the PTC heater.

[0008] Optionally, multiple sets of heating elements are provided within the mounting frame, and the number of the second busbars corresponds one-to-one with the number of sets of heating elements.

[0009] By adopting the above technical solution, when it is necessary to adjust the heating demand of a certain area of ​​heating elements, the working state of a specific group of heating elements can be adjusted by individually controlling the current on and off of the corresponding second busbar. This achieves zoned adjustment of heating elements, improves the defect of all heating elements being turned on and off at the same time under the traditional single-layer busbar structure, and meets the energy-saving and consumption-reducing needs of new energy vehicles.

[0010] Optionally, the height of the first electrode layer and the second electrode layer is greater than 10 mm.

[0011] By adopting the above technical solution, setting the layer height of the busbar bracket to be greater than 10mm, sufficient interlayer space can be constructed in the double-layer busbar electrode structure to ensure that there is enough space between the double-layer busbar plates for electrical connection and heat dissipation.

[0012] Optionally, the distance between the first electrode layer and the second electrode layer on the width of the busbar support is greater than 6 mm.

[0013] By adopting the above technical solution, the distance between the first electrode layer and the second electrode layer is greater than 6mm, which ensures electrical clearance and reduces the possibility of safety hazards caused by electrical short circuits and breakdowns.

[0014] Optionally, the connector is a current fuse, which is mounted on the mounting frame.

[0015] By adopting the above technical solution, when the circuit current exceeds the rated value due to a sudden fault in the heater, the current fuse responds quickly and directly cuts off the current path between the positive electrode and the first busbar, preventing excessive current from continuously flowing through the heating element and electrode structure, thereby avoiding electrode burnout and heating element explosion caused by overcurrent, and achieving the protection effect of double-layer busbar electrode.

[0016] Optionally, the busbar support is provided with a positioning groove for inserting the positive electrode, the first busbar and the second busbar, and the positive electrode, the first busbar and the second busbar are fixed to the busbar support by welding.

[0017] By adopting the above technical solution, the positioning groove limits the installation position of the positive electrode, the first busbar, and the second busbar on the busbar bracket, avoiding positional deviations caused by component offset during assembly, ensuring the positional accuracy of the double-layer busbar structure during connection, reducing electrical connection problems caused by manual assembly errors, and the welding fixing method can effectively prevent component loosening caused by continuous vibration during vehicle operation, ensuring that the current transmission path is always stable and reliable.

[0018] Optionally, the mounting housing has an installation groove for mounting the busbar bracket. Each side of the mounting groove has an elastic locking block. The busbar bracket has a locking groove that engages with the elastic locking block, and the elastic locking block engages inside the locking groove.

[0019] By adopting the above technical solution, when installing the busbar bracket, the mounting groove can pre-position the installation position of the busbar bracket, guiding the busbar bracket to be quickly embedded. When the busbar bracket is embedded in the mounting groove, the elastic block is inserted into the slot and locked into the slot by its own elasticity. In this way, the busbar bracket is fixed inside the mounting shell, which facilitates the subsequent wiring of the double-layer busbar electrode structure on the busbar bracket.

[0020] In summary, this application includes at least one of the following beneficial technical effects: 1. This application sets up a double-layer busbar electrode structure consisting of a first electrode layer and a second electrode layer. Compared with the traditional single-layer busbar electrode structure, the double-layer busbar electrode structure of this application can reasonably connect more heating elements and supporting components in series or in parallel on the two electrode layers without taking up additional installation space of the heater. This expands the effective arrangement area of ​​the electrodes and thus improves the applicability of the PTC heater. 2. This application sets up a second busbar that corresponds one-to-one with multiple heating elements. When it is necessary to adjust the heating demand of a certain area of ​​heating elements, the current on and off of the corresponding second busbar can be controlled individually to regulate the working state of a specific group of heating elements. This achieves zoned adjustment of heating elements, improves the defect of all heating elements being turned on and off at the same time in the traditional single-layer busbar structure, and meets the energy-saving and consumption-reducing needs of new energy vehicles. 3. This application uses a current fuse as a connector. When the circuit current exceeds the rated value due to a sudden fault in the heater, the current fuse responds quickly and directly cuts off the current path between the positive electrode and the first busbar, preventing excessive current from continuously flowing through the heating element and electrode structure. This avoids electrode burnout and heating element explosion caused by overcurrent, thus achieving the protection effect of the double-layer busbar electrode. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of this application.

[0022] Figure 2 This is a schematic diagram of the mounting shell structure in an embodiment of this application.

[0023] Figure 3 This is a schematic diagram of the double-layer bus electrode structure on the bus support in the embodiments of this application.

[0024] Figure 4 This is a schematic diagram of the structure of the busbar support in the embodiments of this application. Explanation of reference numerals in the attached drawings: 1. Mounting frame; 2. Mounting shell; 21. Mounting slot; 22. Elastic retaining block; 3. Heating element; 31. Positive pin; 32. Negative pin; 4. Heat dissipation fins; 5. Busbar bracket; 51. Slot; 52. First electrode layer; 521. Positive electrode; 53. Second electrode layer; 531. First busbar; 532. Second busbar; 533. Negative electrode; 54. Connector; 55. Positioning slot. Detailed Implementation

[0025] The following is in conjunction with the appendix Figure 1-4 This application will be described in further detail.

[0026] This application discloses a vehicle PTC air heater with a double-layer busbar electrode structure.

[0027] Reference Figure 1 and Figure 2 A vehicle PTC air heater with a double-layer busbar electrode structure includes a mounting frame 1 and a mounting shell 2. The mounting frame 1 is provided with a plurality of heating elements 3. In this embodiment, the number of heating elements 3 is six. The specific composition and principle of the heating elements 3 are existing technologies and will not be described in detail in this embodiment. A plurality of heat dissipation fins 4 for auxiliary heat dissipation are provided between two adjacent heating elements 3. The plurality of heat dissipation fins 4 are distributed along the length direction of the heating elements 3.

[0028] Reference Figure 1 and Figure 2The mounting housing 2 is provided with a busbar bracket 5 for mounting a double-layer busbar electrode structure. In this embodiment, the busbar bracket 5 is made of PA66 material. The mounting housing 2 is provided with a mounting groove 21 for mounting the busbar bracket 5. The inner sidewalls of the mounting groove 21 on both sides are integrally formed with elastic locking blocks 22. The busbar bracket 5 is provided with a locking groove 51 that engages with the elastic locking blocks 22. The elastic locking blocks 22 are engaged inside the locking groove 51.

[0029] When installing the busbar bracket 5, the worker inserts the busbar bracket 5 into the mounting groove 21. At this time, the elastic block 22 is inserted into the slot 51 and is locked into the slot 51 by its own elasticity. This fixes the busbar bracket 5 inside the mounting shell 2, which facilitates the subsequent wiring of the double-layer busbar electrode structure on the busbar bracket 5.

[0030] Reference Figure 1 and Figure 3 Each heating element 3 extends into the mounting housing 2 and is equipped with a positive electrode pin 31 and a negative electrode pin 32. The busbar bracket 5 is provided with a first electrode layer 52 and a second electrode layer 53 along its thickness direction. A positive electrode 521 electrically connected to the power supply is welded and fixed in the first electrode layer 52. A first busbar 531 and a second busbar 532 are welded and fixed in the second electrode layer 53. A connector 54 electrically connected to the positive electrode 521 is installed on the outer surface of the mounting frame 1. The input end of the first busbar 531 is electrically connected to the positive electrode 521 through the connector 54, and the output end is electrically connected to six positive electrode pins 31. The second busbar 532 is electrically connected to six negative electrode pins 32. A negative electrode 533 electrically connected to the power supply is installed on each second busbar 532.

[0031] Reference Figure 3 and Figure 4 The busbar bracket 5 has a positioning groove 55 for inserting the positive electrode 521, the first busbar 531 and the second busbar 532. The positioning groove 55 limits the installation position of the positive electrode 521, the first busbar 531 and the second busbar 532 on the busbar bracket 5, ensuring the positional accuracy of the double-layer busbar structure during connection.

[0032] When the PTC heater is running, the power supply current flows into the positive electrode 521 in the first electrode layer 52, and then flows into the first busbar 531 in the second electrode layer 53 through the connector 54. The first busbar 531 transmits the current to multiple heating elements 3, causing their energized temperature to rise and achieve the heating effect. Then, the current flows through the negative pin 32 of the heating element 3 to the second busbar 532, and the current flows along the second busbar 532 into the negative electrode 533, and finally flows back to the negative terminal of the power supply. This forms a double-layer busbar electrode structure. Compared with the traditional single-layer busbar electrode structure, the double-layer busbar electrode structure of this application can reasonably connect more heating elements 3 and supporting components in series or parallel on the two electrode layers without taking up additional installation space of the heater, thus expanding the effective arrangement area of ​​the electrodes and improving the applicability of the PTC heater.

[0033] Reference Figure 3 and Figure 4 The connector 54 is a current fuse. The current fuse is connected in series with the positive electrode 521 through a wire. The working principle of the current fuse is existing technology and will not be described in detail in this embodiment. When the heater causes the circuit current to exceed the rated value due to a sudden failure, the current fuse responds quickly and directly cuts off the current path between the positive electrode 521 and the first busbar 531, preventing the excessive current from continuously flowing through the heating element 3 and the electrode structure, thereby avoiding electrode burnout and heating element 3 explosion caused by overcurrent, and achieving the protection effect of the double-layer busbar electrode.

[0034] Reference Figure 3 and Figure 4 In this embodiment, the six heating elements 3 are divided into two groups, left and right, and each group includes three heating elements 3. The number of second busbars 532 corresponds one-to-one with the number of groups of heating elements 3. When it is necessary to adjust the heating demand of a certain area of ​​heating elements 3, the working state of a specific group of heating elements 3 can be adjusted by individually controlling the current on and off of the corresponding second busbar 532. This achieves the zoned adjustment of heating elements 3, which improves the defect of all heating elements 3 being turned on and off at the same time in the traditional single-layer busbar structure, and meets the energy-saving and consumption-reducing requirements of new energy vehicles.

[0035] Reference Figure 3 and Figure 4 The height of the first electrode layer 52 and the second electrode layer 53 is greater than 10mm. The height of the first electrode layer 52 and the second electrode layer 53 is greater than 10mm. The height of the first electrode layer 52 and the second electrode layer 53 is greater than 6mm in width of the busbar bracket 5. The 6mm spacing ensures electrical clearance and reduces the possibility of electrical short circuits and breakdowns causing safety hazards.

[0036] The implementation principle of a vehicle PTC heater with a double-layer busbar electrode structure in this application embodiment is as follows: When the PTC heater is running, the power supply current flows into the positive electrode 521, and then flows into the first busbar 531 in the first electrode layer 52 through the connector 54. The first busbar 531 transmits the current to multiple heating elements 3, causing their energized temperature to rise and achieve the heating effect. Then, the current flows through the negative electrode pin 32 of the heating element 3 to the second busbar 532, and the current flows along the second busbar 532 into the negative electrode 533, and finally flows back to the negative electrode of the power supply, thus forming a double-layer busbar electrode structure. Compared with the traditional single-layer busbar electrode structure, the double-layer busbar electrode structure of this application can reasonably connect more heating elements 3 and supporting components in series or parallel on the two electrode layers without occupying additional overall installation space of the heater, thus expanding the effective arrangement area of ​​the electrodes and improving the applicability of the PTC heater.

[0037] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A vehicle PTC air heater with a double-layer busbar structure, comprising a mounting frame (1), wherein a plurality of heating elements (3) are disposed inside the mounting frame (1), and each heating element (3) is provided with a positive electrode pin (31) and a negative electrode pin (32), characterized in that, The mounting frame (1) is provided with a mounting shell (2), and a busbar bracket (5) is provided inside the mounting shell (2). The busbar bracket (5) is provided with a first electrode layer (52) and a second electrode layer (53). A positive electrode (521) is provided in the first electrode layer (52), and a first busbar (531) and a second busbar (532) are provided in the second electrode layer (53). The input end of the first busbar (531) is electrically connected to the positive electrode (521) through a connector (54), and the output end is electrically connected to multiple positive pins (31). The second busbar (532) is electrically connected to multiple negative pins (32), and a negative electrode (533) is provided on the second busbar (532).

2. The vehicle PTC air heater with a double-layer busbar electrode structure according to claim 1, characterized in that, The heating element (3) is provided in multiple sets within the mounting frame (1), and the number of the second busbar (532) corresponds one-to-one with the number of sets of the heating element (3).

3. A vehicle PTC air heater with a double-layer busbar electrode structure according to claim 1, characterized in that, The height of the first electrode layer (52) and the second electrode layer (53) is greater than 10 mm.

4. A vehicle PTC air heater with a double-layer busbar electrode structure according to claim 1, characterized in that, The distance between the first electrode layer (52) and the second electrode layer (53) on the width of the busbar bracket (5) is greater than 6 mm.

5. A vehicle PTC air heater with a double-layer busbar electrode structure according to claim 1, characterized in that, The connector (54) is a current fuse, which is mounted on the mounting frame (1).

6. A vehicle PTC air heater with a double-layer busbar electrode structure according to claim 1, characterized in that, The busbar support (5) has a positioning groove (55) for inserting the positive electrode (521), the first busbar (531) and the second busbar (532). The positive electrode (521), the first busbar (531) and the second busbar (532) are fixed on the busbar support (5) by welding.

7. A vehicle PTC air heater with a double-layer busbar electrode structure according to claim 1, characterized in that, The mounting housing (2) has an installation groove (21) for mounting the busbar bracket (5). There are elastic locking blocks (22) on both sides of the mounting groove (21). The busbar bracket (5) has a locking groove (51) that engages with the elastic locking blocks (22). The elastic locking blocks (22) engage inside the locking groove (51).

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