Compact L-shaped thick-film heater for one vehicle

Abstract

A compact L-shaped thick-film heater for a vehicle, characterized in that the thick-film heater comprises: a metal housing (100) having an overall L-shape rotated counterclockwise by 90° and comprising a horizontal extension (111) and a vertical extension (112) connected to a rear end of the horizontal extension (111), wherein a heating chamber (H) and a control chamber (I) located above the heating chamber (H) are provided in the horizontal extension (111), wherein a liquid inlet (1114) and a liquid outlet (1115) connected to the heating chamber (H) are provided on the horizontal extension (111), and wherein an intermediate chamber (G) is provided in the vertical extension (112); a heating plate arrangement (200) arranged in the horizontal direction in the heating chamber (H) to heat the liquid flowing through the heating chamber (H). heating;a printed circuit board assembly (PCBA) (300) arranged horizontally in the control chamber (I); and a busbar assembly (400) arranged in the intermediate chamber (G) and electrically connected to the heating plate assembly (200) and the printed circuit board assembly (300), the busbar assembly (400) comprising a capacitor (430) and an inductor (440) which extend from the printed circuit board assembly (300) into the busbar assembly (400) and are arranged extending horizontally in the intermediate chamber (G).

Description

Technical area

[0001] The present invention relates to the technical field of vehicle heaters, in particular to a compact L-shaped thick film heater for a vehicle. State of the art

[0002] New energy vehicles are becoming increasingly common, requiring a water heater for a high-voltage battery pack to enable normal operation at low temperatures. Currently, the main technical approaches for such heaters include PTC ceramic heaters and thick-film heating plates. PTC ceramic heaters were developed earlier and have a larger market share. Thick-film heating plates represent a newer technology and have a smaller market share.

[0003] A PTC ceramic heater typically has an L-shaped structure, while a thick-film heater is usually plate-shaped due to the shape of the heating plate. Furthermore, in conventional thick-film heater designs, capacitors, inductors, and other high-density components are often integrated into a printed circuit board (PCBA), resulting in a large PCB volume. Therefore, for the same power output, the thick-film heater has a smaller overall volume but a larger projection area, making it non-interchangeable with the PTC ceramic heater, which requires improvement. Disclosure of the invention

[0004] The object of the invention is to overcome the above-described disadvantage of the prior art and to provide a compact L-shaped thick-film heater for a vehicle, which is consistent with the PTC ceramic heater in terms of its overall structure and provides a wider product selection for the entire vehicle. Furthermore, the capacitors and inductors are relocated from the printed circuit board assembly to the busbar assembly, effectively reducing the height of the corresponding horizontal extension of the metal housing, thereby not only better achieving structural consistency with the PTC ceramic heater, but also reducing material consumption and lowering costs.

[0005] To achieve the above object, the present invention provides a compact L-shaped thick film heater for a vehicle, comprising: a metal housing having an overall L-shape rotated 90° counterclockwise and comprising a horizontal extension and a vertical extension connected to a rear end of the horizontal extension, wherein a heating chamber and a control chamber located above the heating chamber are provided in the horizontal extension, wherein a liquid inlet and a liquid outlet connected to the heating chamber are provided on the horizontal extension, and wherein an intermediate chamber is provided in the vertical extension; a heating plate assembly arranged in the horizontal direction in the heating chamber for heating the liquid flowing through the heating chamber; a printed circuit board assembly (PCBA) arranged in the horizontal direction in the control chamber; and a busbar assembly arranged in the intermediate chamber and electrically connected to the heater plate assembly and the printed circuit board assembly, respectively, wherein the busbar assembly comprises a capacitor and an inductor laid from the printed circuit board assembly into the busbar assembly and arranged in the intermediate chamber extending in the horizontal direction.

[0006] It is further provided that the thick film heater further comprises a first connector and a second connector which are arranged on a front wall of the vertical extension and are electrically connected to the busbar arrangement in the intermediate chamber.

[0007] It is further provided that a first pin projecting into the intermediate chamber is provided on the first connector and a first socket corresponding to the first pin is provided on the busbar arrangement, wherein the first pin and the first socket are connected to one another by soldering or fusion welding or resistance welding.

[0008] It is further provided that a second pin projecting into the intermediate chamber is provided on the second connector and a second socket corresponding to the second pin is provided on the busbar arrangement, wherein the second pin and the second socket are connected to one another by soldering or fusion welding or resistance welding.

[0009] It is further provided that a high-voltage line electrically connected to the capacitor, the inductor and the first connector, a low-voltage line electrically connected to the second connector and a load line are provided on the busbar arrangement.

[0010] It is further provided that a high-voltage connection hole, a low-voltage connection hole and a load connection hole are provided on the printed circuit board assembly, wherein the high-voltage line is electrically connected to the high-voltage connection hole, the low-voltage line is electrically connected to the low-voltage connection hole, and the load line is electrically connected to the load connection hole by press-fit pins or welding.

[0011] Furthermore, it is provided that a load connection is provided on the heating plate arrangement corresponding to at least one side of the horizontal rear end of the heating plate arrangement, the connecting line of which is electrically connected to the load line by press-in pins or welding.

[0012] It is further provided that the metal housing comprises a housing body and a lower cover, wherein a first recess is provided upwardly in the housing body corresponding to a lower wall of the horizontal extension of the housing body, and wherein a communication groove in communication with the liquid inlet and the liquid outlet is provided at a bottom of the first recess.

[0013] The heating plate assembly is firmly connected to a lower wall of the first recess by screws to close the opening of the communication groove to form a flow channel.

[0014] On the lower wall of the first recess there is also a socket into which the load connection can be inserted and which is in communication with the intermediate chamber.

[0015] The lower lid is arranged in such a way that it tightly closes the opening of the first recess.

[0016] It is further provided that the metal housing further comprises a top cover and a rear cover.

[0017] A second recess is provided downwards in the housing body, corresponding to an upper wall of the horizontal extension of the housing body. The printed circuit board assembly is mounted in the second recess. The upper cover is arranged to tightly close the opening of the second recess.

[0018] A third recess is provided forward in the housing body, corresponding to a rear wall of the vertical extension of the housing body. A communication channel is provided between the third recess and the second recess for communication therebetween. The busbar assembly is mounted in the third recess. The rear cover is arranged to tightly close the opening of the third recess.

[0019] Compared to the prior art, the invention has the following advantages: 1. The structure of the entire circuit is formed with leads (injection-molded copper bars) and connected by welding, so that the connection by jumper and pins is avoided, the requirement for installation space is reduced, the reliability and durability of the product are increased, and a reasonable and compact overall structure of the product is achieved. 2. Its overall structure is consistent with that of the PTC ceramic heater and provides a wider product selection for the entire vehicle. 3. The capacitors and inductors are relocated from the PCB assembly to the busbar assembly, effectively reducing the height of the corresponding horizontal extension of the metal housing, thereby not only better achieving structural compatibility with the PTC ceramic heater, but also reducing material consumption and cost. Short description of the characters

[0020] Fig. 1 is a schematic perspective view of the structure of a compact L-shaped thick film heater for a vehicle; Fig. 2 is a schematic sectional view of the structure of the thick film heater in the vertical direction; Fig. 3 is a schematic view of the internal structure of the thick film heater after removal of the metal casing; Fig. Figure 4 is a schematic enlarged view of the structure at location A of Fig. 3; Fig. Figure 5 is a schematic enlarged view of the structure at location B of Fig. 3; Fig. 6 is a schematic view of the structure for fitting the components of the thick film heater; Fig. Figure 7 is a schematic enlarged view of the structure at location C of Fig. 6; Fig. Figure 8 is a schematic enlarged view of the structure at location D of Fig. 6; Fig. Figure 9 is a schematic enlarged view of the structure at location E of Fig. 6; Fig. 10 is a schematic view of the electrical connection in the thick film heater; Fig. 11 is a first schematic exploded view of the metal housing; and Fig. 12 is a second schematic exploded view of the metal housing. List of reference symbols:

[0021] 100. Metal casing; 110. Case body; 111. Horizontal extension; 1111. First recess; 1112. Communication groove; 1113. Bushing; 1114. Liquid inlet; 1115. Liquid outlet; 1116. Second recess; 112. Vertical extension; 1121. Third recess; 1222. Communication channel; 120. Bottom cover; 130. Top cover; 140. Rear cover; H. Heating chamber; I. Control chamber; G. Intermediate chamber; 200. Heater plate assembly; 210. Load terminal; 211. Lead wire; 300. PCB assembly; 310. Positioning hole; 400. Busbar assembly; 410. Vertical plate; 411. Recess; 420. Horizontal plate; 421. Positioning support; 430. Capacitor; 440. Inductor; 450. First socket; 460. Second socket; 470. High-voltage line; 480. Low-voltage line; 490. Load line; 491. Third socket; 500. First connector; 510. First pin; 600. Second connector; 610. Second pin. Detailed embodiments

[0022] A detailed embodiment of the present invention will be described in more detail below in conjunction with the drawings. However, it should be understood that the scope of the invention is not intended to be limited by the detailed embodiment.

[0023] According to the invention, a compact L-shaped thick film heater for a vehicle as in Fig. 1 and Fig. 2, comprising a metal housing 100, a heating plate assembly 200, a printed circuit board assembly 300, and a busbar assembly 400. The metal housing 100 has an overall L-shape rotated 90° counterclockwise and comprises a horizontal extension 111 and a vertical extension 112 connected to a rear end of the horizontal extension 111. A heating chamber H and a control chamber I located above the heating chamber H are provided in the horizontal extension 111. A liquid inlet 1114 and a liquid outlet 1115, which are connected to the heating chamber H, are provided on the horizontal extension 111. An intermediate chamber G is provided in the vertical extension 112. The heating plate assembly 200 is arranged in the heating chamber H extending in the horizontal direction to heat the liquid flowing in through the liquid inlet 1114 and flowing out through the liquid outlet 1115.The printed circuit board assembly 300 is arranged in the control chamber I, extending in the horizontal direction. The busbar arrangement 400 is arranged in the intermediate chamber G and is electrically connected to the heating plate assembly 200 and the printed circuit board assembly 300, respectively. The busbar arrangement comprises a capacitor 430 and an inductor 440, which are routed from the printed circuit board assembly 300 into the busbar arrangement. The capacitor 430 and the inductor 440 are arranged in the intermediate chamber G, extending in the horizontal direction. According to the invention, the capacitor 430 and the inductor 440, which have a large height, are routed from the printed circuit board assembly 300 into the busbar arrangement 400, so that the height of the printed circuit board assembly 300 and thus the height of the horizontal extension 111 of the metal housing 100 is effectively reduced.In this way, not only can the structural conformity of the thick-film heater according to the invention with a conventional PTC ceramic heater be achieved, but also the material consumption of the metal housing 100 is reduced and thus the production costs are reduced.

[0024] As in Fig. 2, Fig. 3 and Fig. 12, the metal housing 100 in this embodiment includes a housing body 110, a lower cover 120, an upper cover 130, and a rear cover 140. A first recess 1111 is provided upwardly in the housing body 110, corresponding to a lower wall of the horizontal extension 111 of the housing body. A communication groove 1112 is provided on a lower wall of the first recess 1111, which corresponds to a central part of the first recess, and communicates with the liquid inlet 1114 and the liquid outlet 1115. The heater plate assembly 200 is firmly connected to the lower wall of the first recess 1111 by screws, and closes the opening of the communication groove 1112 to form a flow channel for liquid flow in cooperation with the communication groove 1112.In this way, since the heating layer of the heating plate assembly 200 is located on the upper surface, the heating plate assembly 200 can heat the liquid flowing along the flow channel. The lower lid 120 is arranged at the opening of the first recess 1111 so as to cooperatively form the heating chamber H. A load terminal 210 is provided on the heating plate assembly 200 corresponding to at least one side of the rear end of the heating plate assembly. The load terminal 210 is bent at a right angle to the plate and is electrically connected to a heating circuit in the heating plate assembly 200. In this embodiment, two heating circuits are provided in the heating plate assembly 200, and therefore, a load terminal 210 is provided on the heating plate assembly 200 corresponding to each of the two sides of the rear end of the heating plate assembly.Accordingly, a socket 1113 is further provided on the lower wall of the first recess 1111, into which the load terminal 210 can be inserted and which communicates with the intermediate chamber. In this way, the load terminal 210 of the heating plate assembly 200 can protrude through the socket 1113 into the intermediate chamber G to establish an electrical connection with the busbar assembly 400.

[0025] As in Fig. 2 and Fig. 11, in the approach described above, a second recess 1116 is provided downwardly in the housing body 110 corresponding to an upper wall of the horizontal extension 111 of the housing body. The printed circuit board assembly 300 is mounted in the second recess 1116. The upper cover 130 is arranged to firmly close the opening of the second recess 1116 to cooperate therewith to form the control chamber I. Corresponding to a rear wall of the vertical extension 112 of the housing body, a third recess 1121 is provided forwardly in the housing body 110. Between the third recess 1121 and the second recess 1116, a communication channel 1122 is provided for communication therebetween. The busbar assembly 400 is mounted in the third recess. The rear cover 140 is arranged to firmly close the opening of the first recess 1111 to cooperate therewith to form the intermediate chamber G.

[0026] As in Fig. 3, Fig. 6, Fig. 7 and Fig. 8, in the exemplary embodiment, the thick-film heater further comprises a first connector 500 and a second connector 600. The first connector 500 and the second connector 600 are arranged on the front wall of the vertical extension 112 of the metal housing 100. The first connector 500 and the second connector 600 are plug-in connectors. A first pin 510 protruding into the intermediate chamber G is provided on the first connector 500, and a first socket 450 matching the first pin 510 is provided on the busbar assembly 400. The first pin 510 and the first socket 450 are welded together, for example, by soldering, fusion welding, or resistance welding, to establish an electrical connection. A second pin 610 projecting into the intermediate chamber G is provided on the second connector 600, and a second socket 460 matching the second pin 610 is provided on the busbar arrangement 400.The second pin 610 and the second socket 460 are welded together, for example, by soldering or fusion welding or resistance welding, to establish an electrical connection.

[0027] As in Fig. 6 and Fig. As shown in Figure 10, in this embodiment, a high-voltage line 470, a low-voltage line 480, and a load line 490 are provided on the busbar assembly 400. A first end of the high-voltage line 470 is electrically connected to the capacitor 430, the inductor 440, and the first connector 500, so that the first connector 500 is used for high-voltage input. A first end of the low-voltage line 480 is electrically connected to the second connector 600. In particular, an auxiliary circuit board is provided on the busbar assembly 400 and is electrically connected to the second connector 600, so that the second connector 600 is used for communication with a control unit of the vehicle.

[0028] As in Fig. 10, in this embodiment, the busbar assembly 400 is electrically connected to the printed circuit board assembly 300 by a second end of the high-voltage line 470, a second end of the low-voltage line 480, and a first end of the load line 490 to establish the connection between the busbar assembly 400 and the printed circuit board assembly 300. In particular, the second end of the high-voltage line 470, the second end of the low-voltage line 480, and the first end of the load line 490 can be simply welded, e.g., by soldering, fusion welding, or resistance welding, onto the printed circuit board assembly 300 to establish the electrical connection between the busbar assembly and the printed circuit board assembly 300. A high-voltage connection hole, a low-voltage connection hole, and a load connection hole can also be provided on the printed circuit board assembly 300. The second end of the high-voltage line 470, orThe second end of the low-voltage line 480 and the first end of the load line 490 are inserted into the high-voltage connection hole, the low-voltage connection hole, and the load connection hole, respectively, to achieve connections by press-fit pins. The busbar assembly 400 and the printed circuit board assembly 300 are connected to each other with leads (injection-molded copper bars), thus avoiding the need for jumper and pin connections, reducing the space required, increasing the reliability and durability of the product, and achieving a reasonable and compact overall product structure.

[0029] As in Fig. 10, in this embodiment, the busbar assembly 400 is electrically connected to the connecting line 211 of the load terminal 210 of the heater plate assembly 200 by the second end of the load line 490 to establish the connection between the busbar assembly 400 and the heater plate assembly 200. At the same time, the signal connection between the printed circuit board assembly 300 and the heater plate assembly 200 is achieved through the load line 490 to enable the control of the heating of the heater plate assembly 200 by the printed circuit board assembly 300. In particular, the load line 490 and the connecting line 211 of the load terminal 210 can be easily welded together, for example, by soldering, fusion welding, or resistance welding. It is also possible that, as in Fig. As shown in Figure 9, the load line 490 is provided with a third socket 491 at its second end, so that the connecting line 211 of the load terminal 210 is simply inserted into the third socket 491 of the load line 490 to establish a connection by press-fit pins. The busbar assembly 400 and the heater plate assembly 200 are connected to each other with leads (injection-molded copper bars), thus avoiding the connection by jumpers and pins, reducing the required installation space, increasing the reliability and durability of the product, and achieving a reasonable and compact overall product structure.

[0030] Preferably as in Fig. 3, in this embodiment, the busbar assembly 400 is formed as a whole in an inverted T-shape or a mirrored L-shape with respect to the vertical direction, so that the busbar assembly 400 includes a vertical plate 410 and a horizontal plate 420. The first connector 500 and the second connector 600 are connected to the front surface of the vertical plate 410 of the busbar assembly 400. The capacitor 430 and the inductor 440 are connected to the rear surface of the vertical plate 410 of the busbar assembly 400. A front part of the horizontal plate 420 of the busbar assembly 400 protrudes through the communication channel 1122 into the control chamber I. A positioning support 421 is provided on a surface in the front part of the horizontal plate 420.The printed circuit board assembly 300 lies on the horizontal plate 420 and is provided with a positioning hole 310 (. Fig. 4). This ensures the fit between the printed circuit board assembly 300 and the busbar assembly. A notch 411 extending upward from a lower end is provided on the busbar assembly 400 corresponding to one side of the vertical plate 410 of the busbar assembly. The load terminal 210 of the heater plate assembly 200 projects through the socket 1113 into the intermediate chamber G and is received in the notch 411 of the vertical plate 410 ( Fig. 5). This ensures the fit between the heater plate assembly 200 and the busbar assembly 400.

[0031] Compared to the prior art, the invention has the following advantages: 1. The structure of the entire circuit is formed with leads (injection-molded copper bars) and connected by welding, so that the connection by jumper and pins is avoided, the requirement for installation space is reduced, the reliability and durability of the product are increased, and a reasonable and compact overall structure of the product is achieved. 2. Its overall structure is consistent with that of the PTC ceramic heater and provides a wider product selection for the entire vehicle. 3. The capacitors and inductors are relocated from the PCB assembly to the busbar assembly, effectively reducing the height of the corresponding horizontal extension of the metal housing, thereby not only better achieving structural compatibility with the PTC ceramic heater, but also reducing material consumption and cost.

[0032] Only the embodiments of the invention have been disclosed above, but the invention is not intended to be limited thereto. All modifications conceivable by a person skilled in the art are intended to be included within the scope of the invention.

Claims

[1] Compact L-shaped thick film heater for a vehicle, characterized by that the thick film heater includes: a metal housing having an overall L-shape rotated 90° counterclockwise and comprising a horizontal extension and a vertical extension connected to a rear end of the horizontal extension, wherein a heating chamber and a control chamber located above the heating chamber are provided in the horizontal extension, wherein a liquid inlet and a liquid outlet connected to the heating chamber are provided on the horizontal extension, and wherein an intermediate chamber is provided in the vertical extension; a heating plate assembly arranged in the horizontal direction in the heating chamber for heating the liquid flowing through the heating chamber; a printed circuit board assembly (PCBA) arranged in the horizontal direction in the control chamber; and a busbar assembly arranged in the intermediate chamber and electrically connected to the heater plate assembly and the printed circuit board assembly, respectively, wherein the busbar assembly comprises a capacitor and an inductor laid from the printed circuit board assembly into the busbar assembly and arranged in the intermediate chamber extending in the horizontal direction. [2] Compact L-shaped thick film heater for a vehicle according to claim 1, characterized by that the thick film heater further comprises a first connector and a second connector arranged on a front wall of the vertical extension and electrically connected to the busbar arrangement in the intermediate chamber. [3] Compact L-shaped thick film heater for a vehicle according to claim 2, characterized bythat a first pin projecting into the intermediate chamber is provided on the first connector and a first socket matching the first pin is provided on the busbar arrangement, wherein the first pin and the first socket are connected to one another by soldering or fusion welding or resistance welding. [4] Compact L-shaped thick film heater for a vehicle according to claim 2, characterized by that a second pin projecting into the intermediate chamber is provided on the second connector and a second socket matching the second pin is provided on the busbar arrangement, wherein the second pin and the second socket are connected to one another by soldering or fusion welding or resistance welding. [5] Compact L-shaped thick film heater for a vehicle according to claim 2, characterized bythat a high-voltage line electrically connected to the capacitor, the inductor and the first connector, a low-voltage line electrically connected to the second connector and a load line are provided on the busbar arrangement. [6] Compact L-shaped thick film heater for a vehicle according to claim 5, characterized by that a high-voltage connection hole, a low-voltage connection hole and a load connection hole are provided on the printed circuit board assembly, wherein the high-voltage line is electrically connected to the high-voltage connection hole, the low-voltage line is electrically connected to the low-voltage connection hole, and the load line is electrically connected to the load connection hole by press-fit pins or welding. [7] Compact L-shaped thick film heater for a vehicle according to claim 5, characterized bythat a load connection is provided on the heating plate arrangement corresponding to at least one side of the horizontal rear end of the heating plate arrangement, the connecting line of which is electrically connected to the load line by press-in pins or welding. [8] Compact L-shaped thick film heater for a vehicle according to claim 7, characterized by that the metal housing comprises a housing body and a lower cover, wherein a first recess is provided upwardly in the housing body corresponding to a lower wall of the horizontal extension of the housing body, and wherein a communication groove in communication with the liquid inlet and the liquid outlet is provided at a bottom of the first recess; wherein the heating plate assembly is fixedly connected to a bottom wall of the first recess by screws to close the opening of the communication groove to form a flow channel; wherein a socket is further provided on the lower wall of the first recess into which the load terminal can be inserted and which is in communication with the intermediate chamber; and wherein the lower lid is arranged to tightly close the opening of the first recess. [9] Compact L-shaped thick film heater for a vehicle according to claim 8, characterized by that the metal housing further comprises a top cover and a rear cover; wherein a second recess is provided downwardly in the housing body corresponding to an upper wall of the horizontal extension of the housing body, wherein the circuit board assembly is mounted in the second recess, and wherein the upper cover is arranged to firmly close the opening of the second recess to form the control chamber in cooperation therewith; wherein a third recess is provided forwardly in the housing body corresponding to a rear wall of the vertical extension of the housing body, wherein a communication channel is provided between the third recess and the second recess for communication therebetween, wherein the busbar assembly is mounted in the third recess, and wherein the rear cover is arranged to firmly close the opening of the third recess to form the intermediate chamber in cooperation therewith.

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