Heater assembly for electric vehicle

Abstract

The present invention provides a heater assembly for an electric vehicle, the heater assembly comprising: a bracket installed in an air conditioning case and having at least two slots formed on one surface thereof to allow a heater to be coupled thereto, the two slots extending in the longitudinal direction; and the heater coupled to the slots to heat air flowing inside the air conditioning case, wherein the heater includes: insertion electrode parts electrically connected to a heat generation part and formed at opposite ends of the heater, respectively; and at least two electrode tabs connecting the insertion electrode parts and an external wire, and wherein each of the electrode tabs has one end connected to the insertion electrode parts and the other end connected to the wire and includes a step part formed between the one end and the other end and bent at a predetermined angle to generate a step between the one end and the other end of the electrode tab.

Description

Heater assembly for electric vehicles

[0001] The present invention relates to a heater assembly for an electric vehicle that can be used in an electric vehicle to save energy.

[0002] Unlike internal combustion engine vehicles, which use the heat generated by the internal combustion engine to heat the vehicle's interior, electric vehicles do not have a separate heat source. Therefore, electric vehicles require a heat source to heat their interiors.

[0003] Currently commercialized electric vehicles primarily utilize PTC (Positive Temperature Coefficient) heaters. For example, Patent Publication No. 10-2019-0056468 (May 27, 2019) discloses a PTC heater for electric vehicles. While PTC heaters have the advantage of a relatively simple production process and easy heating, they suffer from high power consumption.

[0004] For example, when operating a PTC heater in sub-zero outdoor temperatures during winter, it is known that up to 40% of an electric vehicle's battery is used for heating. This significantly reduces the driving range of electric vehicles on a single charge in winter.

[0005] For battery-powered electric vehicles, energy efficiency is crucial, extending the driving range on a single charge. From this perspective, low-energy efficiency heating devices, such as PTC heaters, have significant room for improvement.

[0006] Other methods have also been proposed, such as using heat pumps or heating the coolant discharged from the fuel cell stack of a fuel cell vehicle. A heat pump is a heating and cooling device that uses the exothermic or condensation heat of a refrigerant to transfer a low-temperature heat source to a high-temperature one, or vice versa. Its design allows for both cooling and heating.

[0007] Heat pumps have advantages in energy efficiency compared to PTC heaters, but there are still problems that need to be improved, such as the problem of reduced heating capacity due to the reduced density of the refrigerant when the outside temperature is very low, which reduces the amount of refrigerant flowing into the compressor (i.e., the amount of low-temperature, low-pressure gaseous refrigerant flowing in), and the problem of frost formation due to condensate freezing in the outdoor heat exchanger in sub-zero weather.

[0008] Therefore, there is a growing demand for heater technology for electric vehicles that is energy efficient and does not cause problems such as condensate freezing.

[0009] The first object of the present invention is to provide a heater assembly for an electric vehicle that can improve energy efficiency compared to conventional heaters for electric vehicles and has no problems such as insufficient heating capacity or freezing of condensate.

[0010] A second object of the present invention is to provide a heater assembly for an electric vehicle that can minimize battery consumption of the electric vehicle even in cold weather.

[0011] The third object of the present invention is to provide a heater assembly for an electric vehicle that can minimize volume and has a compact structure, making it easy to install, maintain, and repair in an electric vehicle.

[0012] In order to achieve the object of the present invention, the present invention discloses a heater assembly for an electric vehicle, comprising: a bracket installed in an air conditioning case and having at least two slots formed on one side extending in the longitudinal direction so that a heater is coupled; and a heater coupled to the slots to heat air flowing inside the air conditioning case, wherein the heater comprises: an inlet electrode portion electrically connected to a heat generating portion and formed at each end of the heater; and at least two electrode tabs connecting the inlet electrode portion and an external wire, wherein one end of the electrode tab is connected to the inlet electrode portion, the other end is connected to the wire, and a step portion is formed between the one end and the other end to create a step between the one end and the other end of the electrode tab by bending at a predetermined angle.

[0013] At least two of the above-mentioned lead electrode parts are formed at each of one end and the other end of the heater, and a ground electrode part is further formed between the lead electrode parts of each of the one end and the other end.

[0014] The above heater includes at least two electrical connectors arranged in parallel at the top and bottom and electrically connected to the above-described electrode parts, and the electrical connectors are formed to be connected by the heating part.

[0015] The electrical connection part includes a first electrical connection part extending in a first direction, which is the longitudinal direction of the heater; and a second electrical connection part consisting of a first part extending in a second direction intersecting the first direction and a second part extending in the first direction.

[0016] The slot is provided with an elastic fixing member that presses one side of the heater when the heater is coupled to the slot so that the other side of the heater is fixed in close contact with the other side wall of the slot.

[0017] The above bracket is installed in the slot, the heater is detachably mounted, and further includes a heater mounting / detaching unit that closes and fixes both ends of the heater when the heater is mounted.

[0018] The above heater attachment / detachment unit includes a base that surrounds and secures the lower part of the heater; and a lever that is rotatably connected to both ends of the base to pressurize the heater to be fixed to or detached from the base.

[0019] The above bracket is installed between the heaters coupled to the slot or on both sides of the heater to support the heater from one side or both sides, and further includes a plate spring guide that guides the flow of air flowing around the heaters.

[0020] The above-mentioned plate spring guide is configured such that at least two of them are detachably connected to the surface of the above-mentioned bracket.

[0021] The above bracket further includes a composite functional member formed with a connecting slot connecting between the slots, which is in close contact with the side of the heater to support the heater from the side and guide the flow of air flowing around the heaters.

[0022] The effects of the present invention obtained through the above-described solution are as follows.

[0023] First, the present invention can be installed in an air conditioning case that can be applied to an air conditioning duct, headrest, interior trim, etc. of an electric vehicle, and can significantly improve energy efficiency compared to a conventional electric vehicle heater, and at the same time, can implement a heater assembly for an electric vehicle that does not cause problems such as insufficient heating capacity or freezing of condensate.

[0024] Second, by implementing a heater assembly by combining at least two heaters in a slot-formed bracket and applying an electrode tab with excellent safety to the heater, the increase in the volume of the heater can be minimized and the heater can be manufactured as a compact structure, thereby minimizing battery consumption of an electric vehicle even in cold weather and exhibiting excellent heating efficiency.

[0025] Third, a heater assembly having a simple structure in which a heater is combined into a slot of a bracket can be constructed to implement a heater having a lightweight and compact structure, and can provide ease of installation, maintenance, and repair in an electric vehicle.

[0026] Figure 1 is a conceptual diagram showing a heater assembly for an electric vehicle according to a first embodiment of the present invention installed in an air conditioning case.

[0027] Fig. 2 is a conceptual diagram showing a plan view of the electric vehicle heater of Fig. 1.

[0028] Fig. 3 is a conceptual diagram showing the appearance of a heater and a groove formed in a bracket of a heater assembly for an electric vehicle of Fig. 1.

[0029] Fig. 4 is a conceptual diagram showing the appearance of a heating part, an electrical connection part, an inlet electrode part, and an electrode tab of a heater of a heater assembly for an electric vehicle of Fig. 1.

[0030] FIG. 5 is a conceptual diagram showing an elastic fixing member formed in a slot of a bracket in a heater assembly for an electric vehicle according to a second embodiment of the present invention.

[0031] FIG. 6 is a conceptual diagram showing a heater attachment / detachment unit installed in a slot of a bracket in a heater assembly for an electric vehicle according to a third embodiment of the present invention.

[0032] Fig. 7 is a conceptual diagram showing a wire management section formed on one side of a bracket in a heater assembly for an electric vehicle according to a fourth embodiment of the present invention.

[0033] FIG. 8 is a conceptual diagram showing a shape in which a plate spring guide is formed on a bracket surface between heaters in a heater assembly for an electric vehicle according to a fifth embodiment of the present invention.

[0034] FIG. 9 is a conceptual diagram showing a heater assembly for an electric vehicle according to a sixth embodiment of the present invention, in which a connecting slot and a composite function member are formed on a bracket surface between heaters.

[0035] Hereinafter, a heater assembly for an electric vehicle related to the present invention will be described in more detail with reference to the drawings.

[0036] In describing the embodiments disclosed in this specification, if it is determined that a detailed description of a related known technology may obscure the gist of the embodiments disclosed in this specification, the detailed description is omitted.

[0037] The attached drawings are only intended to facilitate understanding of the embodiments disclosed in this specification, and the technical ideas disclosed in this specification are not limited by the attached drawings, and should be understood to include all modifications, equivalents, or substitutes included in the spirit and technical scope of the present invention.

[0038] In the following description, singular expressions include plural expressions unless the context clearly indicates otherwise.

[0039] In this application, terms such as “include” or “have” are intended to specify the presence of a feature, number, step, operation, component, part or combination thereof described in the specification, but should be understood not to exclude in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts or combinations thereof.

[0040] Figure 1 is a conceptual diagram showing a heater assembly for an electric vehicle according to a first embodiment of the present invention installed in an air conditioning case.

[0041] Fig. 2 is a conceptual diagram showing a plan view of the electric vehicle heater of Fig. 1.

[0042] Fig. 3 is a conceptual diagram showing the appearance of a heater and a groove formed in a bracket of a heater assembly for an electric vehicle of Fig. 1.

[0043] Fig. 4 is a conceptual diagram showing the appearance of a heating part, an electrical connection part, an inlet electrode part, and an electrode tab of a heater of a heater assembly for an electric vehicle of Fig. 1.

[0044] Referring to FIGS. 1 to 4, a heater assembly (100) for an electric vehicle according to the present invention includes a heater (110) and a bracket (120).

[0045] The heater (110) is coupled to the slot (121) of the bracket (120) to heat the air flowing inside the air conditioning case (AC).

[0046] A heater (110) includes, for example, a substrate (not shown), an insulating layer (not shown) sequentially laminated on one surface of the substrate, an electrical connection part (114), a heating part (113), and a protective layer (not shown), and includes an inlet electrode part (115) and an electrode tab (116) connected to the electrical connection part (114).

[0047] The substrate can be made of various materials, such as stainless steel, ceramic, aluminum, and glass. If the substrate thickness is less than 0.5 mm, the thickness has a greater effect than the substrate material, and the substrate may exhibit a tendency to warp.

[0048] The insulating layer covers one side of the substrate. The term "one side of the substrate" refers to the upper surface of the substrate. If the substrate is formed of a conductive material such as stainless steel, current supplied to the electrical connection (114), which will be described later, can flow to the substrate. Therefore, if the insulating layer is positioned between the electrical connection (114) and the substrate, current flow to the substrate can be prevented.

[0049] An insulating layer laminated on one side of a substrate has a shape corresponding to the substrate. For example, even if the insulating layer is flat and flat, if a protrusion is formed on the substrate, the insulating layer can be partially deformed to have a shape corresponding to the protrusion of the substrate.

[0050] The electrical connection part (114) is a type of electrode and is placed on one side of the insulating layer. Here, the one side of the insulating layer may be the upper surface of the insulating layer. Two electrical connection parts (114) may be formed at each end of each heating part (113) described later.

[0051] The electrical connector (114) is electrically connected to the battery via external conductive wires, such as wires, and receives power from the battery. The battery here may include not only the main battery that provides driving power to the electric vehicle, but also an auxiliary battery. The power supplied from the battery is transmitted to the heating element (113) via the electrical connector (114).

[0052] A heating element (113) is formed on one surface of the insulating layer together with an electrical connection element (114). An electrical connection element (114) is connected to each end of the heating element (113). The heating element (113) has the property of generating heat by variation of electrical resistance when power is supplied through the electrical connection element (114).

[0053] The heating element (113) is composed of a conductive material containing paste, glass frit, and organic binder.

[0054] The paste contains ruthenium oxide (RuO2), palladium (Pd), CNT, and silver (Ag). Ruthenium oxide (RuO2), palladium (Pd), CNT, and silver (Ag) may each be contained in an amount of 4 to 50 wt% based on the entire conductive material.

[0055] Glass frit can be made of thermocrystalline powdered glass with strong adhesive strength, excellent mechanical strength, and excellent chemical durability. The glass frit can be contained in an amount of 5 to 35 wt% based on the total conductive material.

[0056] The organic binder is used to improve bonding strength. The organic binder may be present in an amount of 10 to 35 wt% based on the total conductive material.

[0057] When a conductive material having the above composition is printed on an insulating layer with a thickness of 0.1 to 0.3 mm using a screen printing technique, a planar heating pattern (not shown) can be formed. If the patterns of these heating elements (113) are formed in parallel, for example, even if a short circuit occurs in one pattern, the other patterns can maintain their function.

[0058] The heating element (113) that forms this type of surface heating pattern has a shorter heating time, a uniform temperature distribution, and a semi-permanent lifespan compared to a conventional heating wire method such as nichrome wire.

[0059] The protective layer covers the heating element (113) and the electrical connection element (114) to protect them from external stimuli. The protective layer can be adhered to the insulating layer at the outer edge. The protective layer, like the insulating layer, has insulating properties.

[0060] In the heater assembly (100) for an electric vehicle according to the present invention, the maximum power consumption of each heater (110) is approximately 120 W, and even if 10 heaters are installed in one electric vehicle, the maximum power consumption is only 1200 W. Considering that the PTC heater currently used in electric vehicles consumes 5 to 7 kW of power, the heater assembly for an electric vehicle provided by the present invention can significantly reduce battery consumption and has the advantage of being able to supply power even using a small auxiliary battery.

[0061] The lead electrode portion (115) is electrically connected to the heating portion (113) and is formed at each end of the heater (110).

[0062] Specifically, as illustrated in FIG. 4, at least two of the above-described lead electrode parts (115) are formed at each of one end and the other end of the heater (110), and a ground electrode part (115a) may be further formed between the lead electrode parts (115) at each of the one end and the other end. In this way, since at least two lead electrode parts (115) are formed at each of one end and the other end of the heater (110), the degree of freedom of the electrode direction and wire connection structure according to the arrangement position of the heater (110) within the air conditioning case (AC) can be increased, and thus, by diversifying the arrangement number or arrangement structure of the heaters (110) in the bracket (120), an electric vehicle heater assembly (100) with superior performance can be conveniently manufactured.

[0063] In addition, the heater (110) includes at least two electrical connection parts (114) arranged parallel to each other at the top and bottom and electrically connected to the lead electrode parts (115), and the electrical connection parts (114) may be formed to be connected by the heating part (113). This arrangement structure of the electrical connection parts (114) and the heating part (113) maximizes the space utilization of the heating parts (113) arranged between the electrical connection parts (114), thereby implementing a heater (110) with excellent heating efficiency.

[0064] Here, the electrical connection part (114) may include a first electrical connection part (114a) and a second electrical connection part (114b).

[0065] The first electrical connection portion (114a) may be formed as a rod structure extending in the first direction, which is the longitudinal direction of the heater (110).

[0066] The second electrical connection portion (114b) may be formed of a first part (114ba) extending in a second direction intersecting the first direction and a second part (114bb) extending in the first direction. That is, the second electrical connection portion (114b) may be formed in an overall “ㄱ” shape by the first part (114ba) extending in the second direction and the second part (114bb) extending in the first direction.

[0067] Accordingly, a heater (110) having a stable structure can be configured by conveniently arranging the first electrical connection part (114a) extending in the first direction on the lower side and the second electrical connection part (114b) having an “ㄱ” shape on the upper side, and arranging the heating part (113) between them.

[0068] In this way, the heater composed of the first electrical connection part (114a) and the second electrical connection part (114b) generates a counter current when power is supplied so that the heating part (113) arranged between the electrical connection parts (113a, 113b) is heated from the center, thereby making the heated part of the heater (110) concentric and preventing the heated part from being biased.

[0069] The electrode tab (116) connects the above-mentioned lead electrode part (115) and an external wire. Here, the wire refers to the wire connected to the battery described above.

[0070] The electrode tab (116) has one end connected to the lead-in electrode portion (115), and the other end connected to the wire. At this time, the electrode tab (116) is bent at a certain angle between the one end and the other end, thereby forming a step portion (116a) that creates a step between the one end and the other end of the electrode tab (116).

[0071] The electrode tab (116) formed with such a step portion (116a) is composed of a first tab portion (116b) including one end connected to the lead-in electrode portion (115) and a second tab portion (116c) including the other end connected to the wire.

[0072] Accordingly, the step portion (116a) may be formed in the form of an inclined surface connecting, for example, the first tab portion (116b) and the second tab portion (116c), and at this time, the angle between the first tab portion (116b) and the inclined surface, or the angle (θ) between the second tab portion (116c) and the inclined surface may be formed as an angle between 130 degrees and 140 degrees.

[0073] This step portion (116a) provides a space between the heater (110) and the electrode tab (116) so that an insulating layer can be interposed when the electrode tab (116) is brought into close contact with the heater (110) for connection with the lead-in electrode portion (115).

[0074] That is, when the step portion (116a) does not exist while the first tab portion (116b) is in close contact with the lead-in electrode portion (115), the heater (110) having a plate structure has a high possibility of direct contact between a part of the second tab portion (116c) and other components of the heater (110), i.e., the electrical connection portion (114) or the heating portion (113). At this time, if direct contact occurs between a part of the second tab portion (116c) and the electrical connection portion (114) or the heating portion (113), a sudden change in electrical resistance may occur, which may cause a short circuit of the heater (110).

[0075] However, in the case of the electrode tab (116) provided with the step portion (116a), a gap is created between the second tab portion (116c) and the heater (110), and an insulating layer may be interposed in this gap, so that direct contact between a part of the second tab portion (116c) and the electrical connection portion (114) or the heating portion (113) is fundamentally blocked, thereby minimizing the possibility of a short circuit of the heater (110) and improving safety.

[0076] In addition, since the electrode tab (116) prevents direct contact with other parts of the heater (110) by the step portion (116a) when connected to the lead-in electrode portion (115), there is an advantage in that the design freedom for the connection structure or connection direction of the electrode tab (116) to the heater (110) is improved, thereby enabling the production of a heater assembly with excellent space utilization and energy efficiency.

[0077] The bracket (120) is installed within the air conditioning case (AC), and at least two slots (121) extending longitudinally are formed on one side to allow the heater (110) to be coupled thereto. That is, the bracket (120) secures the heater (110) through the slots (121) formed on one side, thereby forming a heater assembly.

[0078] Here, a groove (121a) for fixing the heater can be formed in the slot (121) to achieve a stable fixing state of the heater (110) and to increase the contact area with the air flowing around the heater (110) to improve heater efficiency.

[0079] The groove (121a) for fixing the heater is formed on the inner surface of the slot (121) and can be applied in various forms depending on the position of the slot (121).

[0080] For example, the grooves (121a) for fixing the heater may be formed in two to five pairs of grooves (121a) at regular intervals in one slot (121), may be formed in corresponding positions in two slots (121), and may be formed in alternating positions in two slots (121).

[0081] In addition, the groove (121a) for fixing the heater may be formed in various shapes such as a semicircle (121aa), a trapezoid (121ab), and an oval (not shown).

[0082] In addition, the groove (121a) for fixing the heater may be made of a high-elasticity resin selected from the group consisting of a copolymer resin including rubber or polypropylene, an ethylene-vinylacetate copolymer resin, a copolymer resin including polymethyl methacrylate, methyl methacrylate, and butyl acrylate, or a high-heat-resistant resin including a resin selected from the group consisting of polyethylene, polypropylene, polyethylene / α-olefin, ethylene-α-olefin copolymer, ethylene-vinylacetate copolymer, and ethylene-propylene-diene copolymer, depending on the case.

[0083] At this time, the groove (121a) for fixing the heater is formed alternately on the inner surface of the slot (121) by forming one or more of the high-elasticity resin and the high-heat-resistant resin, thereby further improving the fixing force of the heater (110) and the durability and structural stability of the heater assembly (100).

[0084] FIG. 5 is a conceptual diagram showing an elastic fixing member formed in a slot of a bracket in a heater assembly for an electric vehicle according to a second embodiment of the present invention.

[0085] Referring to Fig. 5, the heater assembly (200) for an electric vehicle is provided with an elastic fixing member (221a) in a slot (221) of a bracket (220). That is, when the heater (210) is coupled to the slot (221), an elastic fixing member (221a) is formed in the slot (221) of the bracket (220) to pressurize one side of the heater (210) so that the other side of the heater (210) is fixed in close contact with the other side wall of the slot (221).

[0086] The above elastic fixing part (221a) may be formed, for example, as a pure elastic fixing part (221a), or a certain empty space is formed on the inner wall of the slot (221), and a separate elastic member (221b) (ex, spring) is placed in this empty space and combined with the elastic fixing part (221a), so that the elastic fixing part (221a) moves left and right by the elastic member (221b) to pressurize or release one side of the heater (210).

[0087] Here, the end (221aa) of the elastic fixing member (221a) may be formed as a smooth curved surface or inclined surface, etc., so that a smooth insertion process can be achieved when the heater (210) is inserted into the slot (221). The end (221aa) of the elastic fixing member (221a) may be formed as a structure selected from the group consisting of, for example, an inclined surface (221ab), a diamond shape (221ac), and a semicircle (221ad), as shown in FIG. 5.

[0088] In addition, the material of the elastic fixing part (221a) may be made of a high-elasticity resin or high-heat-resistant resin that is the same as the material of the groove (121a) formed in the slot (121) of the heater assembly (200) for an electric vehicle of the first embodiment.

[0089] FIG. 6 is a conceptual diagram showing a heater attachment / detachment unit installed in a slot of a bracket in a heater assembly for an electric vehicle according to a third embodiment of the present invention.

[0090] Referring to Fig. 6, the heater assembly (300) for an electric vehicle has a heater attachment / detachment unit (330) installed in a slot (321) of a bracket (320). The heater attachment / detachment unit (330) has a structure in which the heater (310) is detachably mounted, and when the heater (310) is mounted, it closes both ends of the heater (310) and fixes them.

[0091] Accordingly, the bracket (320) in which the heater attachment / detachment unit (330) is installed is easier to assemble the heater (310) than the heater assembly of the embodiment in which the heater (310) is simply inserted into the slot (321) and fixed, and the heater (310) can be more stably fixed when mounted on the bracket (320), so that the durability and stability of the heater assembly (300) can be greatly improved.

[0092] Here, the heater detachable unit (330) may be configured to include a base (331) and a lever (332).

[0093] The base (331) surrounds and secures the lower part of the heater (310). The base (331) may be manufactured in a shape corresponding to the shape of the slot (321), and may have a width size slightly smaller than the slot (321) and may be configured to be inserted into the slot (321).

[0094] In addition, a lever coupling portion (331a) for coupling with the lever (332) is formed at both ends of the base (331). A pin insertion hole (not shown) is formed on the side of the lever coupling portion (331a) so that a coupling pin (333) is inserted when coupling with the lever (332).

[0095] The lever (332) is rotatably connected to both ends of the base (331) to pressurize the heater (310) so as to be fixed to or separated from the base (331). Here, a pin insertion hole (not shown) is formed at the lower side of the lever (332) so as to overlap with the pin insertion hole of the lever coupling portion (331a), and the coupling pin (333) is inserted to achieve connection between the base (331) and the lever (332).

[0096] Fig. 7 is a conceptual diagram showing a wire management section formed on one side of a bracket in a heater assembly for an electric vehicle according to a fourth embodiment of the present invention.

[0097] Referring to Fig. 7, a heater assembly (400) for an electric vehicle has a heater (410) installed in a slot (421) of a bracket (420). At this time, the heater (410) has wires (417) connected to electrode tabs (416) on both sides extending through the lower end of the bracket (420). The wires (417) extending through the lower end of the bracket (420) are organized into a single bundle by a wire organizing portion (430) provided on one side of the bracket (420) and all extend to one side of the bracket (420).

[0098] Here, the wire management unit (430) includes a body (431), a hook (432), and a fixing pin (433).

[0099] The body (431) is connected to one end of the bracket (420) on one side and has a hook (432) formed on the other side to secure it as a bundle through the wires (417).

[0100] The hook (432) is formed to extend in the other direction of the body (431) and has a constant thickness so as to surround the bundle of wires (417) on the outer periphery.

[0101] The fixed pin (433) is formed near the end of the hook (432) and extends in the inner direction of the hook (432). The fixed pin (433) closes the bundle of wires (417) whose outer circumference is surrounded by the hook (432) on the inner side of the hook (432) so that the bundle is fixed in close contact with the inner circumference of the hook (432). Accordingly, the fixed pin (433) is rotatably connected to the end of the hook (432), and at the same time, it can be configured to implement a fixed state or an unfixed state for the bundle of wires (417) by elasticity.

[0102] The above-mentioned wire management unit (430) organizes the wires (417) extending through the lower end of the bracket (420) into a single bundle and extends to one side of the bracket (420), thereby increasing the space utilization of the electric vehicle heater assembly (400) within the air conditioning case (AC) and improving the design freedom of the electric vehicle heater. In addition, the above-mentioned wire management unit (430) can reduce the resistance of air flowing around the electric vehicle heater assembly (400), thereby improving energy efficiency.

[0103] FIG. 8 is a conceptual diagram showing a shape in which a plate spring guide is formed on a bracket surface between heaters in a heater assembly for an electric vehicle according to a fifth embodiment of the present invention.

[0104] Referring to Fig. 8, a heater assembly (500) for an electric vehicle has a heater (510) mounted in a slot (521) of a bracket (520). In addition, a plate spring guide (530) is installed on the surface of the bracket (520) between the heaters (510).

[0105] The plate spring guide (530) includes a connecting body (531) and a guide body (532).

[0106] The connecting body (531) is joined to the surface of the bracket (520) in close contact, and a guide body (532) is formed on one side in the form of an inclined surface having a certain angle.

[0107] The guide body (532) first adheres to the side of the heater (510) mounted in the slot (521) and serves to fix the heater (510) from the side. In addition, the guide body (532) guides the direction of movement of air flowing around the heater (510) and can implement various functions depending on the structure of the air conditioning case (AC).

[0108] Figure 8 (a) shows a state in which a plate spring guide (530) is installed on the surface of a bracket (520) near a connection part (CP) of an air conditioning case (AC) to induce a rapid air flow around the connection part (CP), thereby reducing the pressure at the connection part (CP) and minimizing external leakage of heated air.

[0109] Specifically, when a plate spring guide (530) is installed on the surface of a bracket (520) near a connection portion (CP) on one side of an air conditioning case (AC), air injected by a blower fan (not shown) from the other side of the air conditioning case (AC) is guided slightly upward by the guide body (532) of the plate spring guide (530) and its flow velocity increases. Accordingly, a relatively low pressure is generated in the connection portion (CP) where the air flow velocity is higher than in other parts of the air conditioning case (AC) due to the Venturi effect, and by this low pressure, external leakage of air from the connection portion (CP) of the air conditioning case (AC) can be minimized.

[0110] FIG. 8 (b) shows a state in which a plate spring guide (530) is installed on one side and the other side of the air conditioning case (AC), respectively, to improve the overall air flow velocity inside the air conditioning case (AC). That is, the heater assembly (500) for an electric vehicle installed inside the air conditioning case (AC) has a plate spring guide (530) installed on one side and the other side of the bracket (520) to guide the direction of air flow, thereby increasing the overall air flow velocity inside the air conditioning case (AC). Accordingly, while maintaining the driving mode of the blower fan supplying air to the air conditioning case (AC) weak, a high air flow velocity can be generated inside the air conditioning case (AC), thereby saving energy for driving the heater for an electric vehicle.

[0111] Here, when the flow rate of air supplied to the air conditioning case (AC) becomes excessively fast, the guide body (532) of the plate spring guide (530) is elastically deformed downward so that the guiding function of the air flowing inside the air conditioning case (AC) is naturally reduced, thereby preventing a decrease in temperature due to excessively fast flow rate inside the air conditioning case (AC) or a decrease in the durability of the electric vehicle heater itself due to vibration and shaking.

[0112] In Fig. 8 (c), when the upper part of the air conditioning case (AC) is an open structure, the heater assembly (500) for an electric vehicle has two plate spring guides (530) arranged on a bracket (520) at a position corresponding to the opening (OP) of the air conditioning case (AC). At this time, the two plate spring guides (530) are arranged so that the inclined surfaces formed by the respective guide bodies (532) face each other, so that the air flowing into the air conditioning case (AC) can be guided to efficiently flow into both sides of the air conditioning case (AC) without escaping through the opening (OP).

[0113] Meanwhile, the material forming the above-described plate spring guide (530) may be formed of a heat sink material such as aluminum, for example. The plate spring guide (530) formed of a heat sink material in this way can guide air flowing around the heater (510) while simultaneously performing a heat sink function, thereby contributing to energy savings for driving the heater for an electric vehicle.

[0114] In addition, the plate spring guide (530) may be detachably provided on the surface of the bracket (520). Here, the means for mounting the plate spring guide (530) on the surface of the bracket (520) is not particularly limited, and for example, a coupling structure selected from the group consisting of a coupling structure using a protrusion and a groove, a coupling structure using a bolt and a nut, and a coupling structure using an adhesive film may be adopted.

[0115] FIG. 9 is a conceptual diagram showing a heater assembly for an electric vehicle according to a sixth embodiment of the present invention, in which a connecting slot and a composite function member are formed on a bracket surface between heaters.

[0116] Referring to Fig. 9, a heater assembly (600) for an electric vehicle has a heater (610) mounted in a slot (621) of a bracket (620). In addition, a connecting slot (622) is formed between the slots (621) of the bracket (620), and a composite function member (630) is installed in the connecting slot (622).

[0117] The composite functional member (630) includes a first body (631) and a second body (632).

[0118] The first body (631) is inserted into and fixed in the connecting slot (622) of the bracket (620), and the second body (632) is formed at the top by extending in a direction intersecting the extension direction of the first body (631).

[0119] The second body (632) is formed to partially cover the surface of the bracket (620) between the heaters (610), and its side is in close contact with the side of the heater (610) to support and fix the heater (610) from the side. In addition, the second body (632) guides the direction of movement of air flowing between the heaters (610).

[0120] FIG. 9 (a) shows a state in which a composite functional member (630) installed in a connecting slot (622) of a bracket (620) is formed to form a constant step (SP) on the surface of the bracket (620). Accordingly, the step (SP) generated on the surface of the bracket (620) by the composite functional member (630) (a) generates a vortex in the air flowing between the heaters (610), thereby increasing the residence time of the air introduced into the air conditioning case (AC), i.e., the time for which the air is heated by the heater (610), thereby improving the energy efficiency of the heater (610).

[0121] Fig. 9 (b) shows a composite functional member (630) installed in a connecting slot (622) of a bracket (620) forming a protruding surface (PS) with a smooth curve on the surface of the bracket (620). The protruding surface (PS) formed by the composite functional member (630) (b) performs a function similar to that of the step (SP), and has an advantage of forming a weaker vortex compared to the step (SP) to increase the residence time of air introduced into the air conditioning case (AC) while simultaneously maintaining an appropriate flow rate within the air conditioning case (AC).

[0122] FIG. 9 (c) shows a composite functional member (630) installed in a connecting slot (622) of a bracket (620) forming a constant guide surface on the surface of the bracket (620) through a second body (632) to guide the direction of movement of air flowing between the heaters (610).

[0123] That is, the composite function member (630) of FIG. 9 (c) is implemented to perform a function similar to the plate spring guide (530) of the fifth embodiment described above, and can perform a function such as suppressing the phenomenon of air heated by the heater (610) leaking to the outside by generating a high flow rate at the connection part of the air conditioning case (AC).

[0124] The above composite function member (630) can implement a convenient attachment / detachment structure for the bracket (620) by inserting the first body (631) into the connection slot (622) or separating it from the connection slot (622).

[0125] Meanwhile, the material forming the composite functional member (630) may be formed of a heat sink material such as aluminum, for example. In this way, the composite functional member (630) formed of a heat sink material can guide air flowing around the heater (610) while simultaneously performing a heat sink function, thereby contributing to energy savings for driving a heater for an electric vehicle.

[0126]

[0127] The heater assembly for an electric vehicle according to the present invention is described in more detail through the following examples, but the configuration of the heater assembly for an electric vehicle is not limited thereto.

[0128]

[0129] [Example]

[0130] An insulating film was formed on a substrate, and a heating element composed of a paste containing ruthenium oxide, palladium, and silver, a glass frit, and a conductive material containing an organic binder was formed on the insulating film. Thereafter, three heaters were manufactured by forming a protective layer covering the heating element. The size of these heaters was a rectangular plate shape with a long side of 60 mm and a short side of 20 mm, and the heaters were manufactured with a thickness of 2 mm.

[0131] An electrical connection part is connected to the heating part of each heater, and the electrical connection part is formed to be connected to the lead-in electrode part formed at both ends of the heater, respectively. In addition, an electrode tab is welded and joined to the lead-in electrode part, and a wire connected to an external battery is connected to the electrode tab. Here, the electrode tab has a center part that is bent to form a certain inclined plane, and a step part is formed where the inclined plane forms a 135 degree angle with the extended surface of the end of the electrode tab. An insulating film is interposed in the space between the step part and the heater.

[0132] The bracket is a rectangular plate with a long side of 60 mm and a short side of 50 mm, and is manufactured with a thickness of 6 mm. On the surface of the bracket, three slots, each 2.4 mm wide and 3 mm deep, extend in the long side direction and are formed at equal intervals (15 mm) on the center and both sides of the short side direction of the bracket.

[0133] On the inner surface of the slot, semicircular heater fixing grooves made of a resin composition including a copolymer resin containing polypropylene and an ethylene-vinyl acetate copolymer resin were formed on both sides of the inner surface, protruding by about 0.2 mm. Here, the diameter of the heater fixing grooves was 0.3 mm, and a groove group of four heater fixing grooves arranged at 0.3 mm intervals was formed on each of the three slot ends.

[0134] In addition, a connecting slot having a width of 2.4 mm and a depth of 3 mm was formed at the longitudinal center between the three slots. In addition, a composite functional member made of aluminum and having a first body and a second body having a smooth protruding surface on the upper end of the first body was joined to the connecting slot. The first body of the composite functional member was formed to have a thickness of 2 mm, the second body was formed to have a thickness of 1.5 mm, and the second body had a horizontal width of 15 mm and a vertical length of 13 mm.

[0135] By additionally assembling the three heaters to the bracket in which the composite functional member was assembled, a heater assembly for an electric vehicle with a power consumption of 110.0 W to 125.0 W was manufactured.

[0136]

[0137] [Experimental Example 1]

[0138] An air conditioning housing with an open structure at both ends was additionally manufactured to surround the manufactured electric vehicle heater assembly, and was additionally assembled to the electric vehicle heater assembly. A blower fan was placed and operated at one open end of the air conditioning housing, and the temperature at the other open end of the air conditioning housing was measured at the heater surface, 5 cm from the end of the heater, and 10 cm from the end of the heater, respectively, according to the amount of power used. The resulting data is shown in Tables 1 to 10 below.

[0139]

[0140] [Table 1]

[0141]

[0142] <Heater surface temperature for 68W power>

[0143]

[0144] [Table 2]

[0145]

[0146] <Heater surface temperature for 98W power>

[0147]

[0148] [Table 3]

[0149]

[0150] <Heater surface temperature for 120W power>

[0151]

[0152] [Table 4]

[0153]

[0154] <20m 3△T> at 5 cm from the end of the heater by power at / h flow rate

[0155]

[0156] [Table 5]

[0157]

[0158] <22.3m 3 △T> at 5 cm from the end of the heater by power at / h flow rate

[0159]

[0160] [Table 6]

[0161]

[0162] <25.3m 3 △T> at 5 cm from the end of the heater by power at / h flow rate

[0163]

[0164] [Table 7]

[0165]

[0166] <20m 3 △T> at 10 cm from the end of the heater by power at / h flow rate

[0167]

[0168] [Table 8]

[0169]

[0170] <22.3m 3 △T> at 10 cm from the end of the heater by power at / h flow rate

[0171]

[0172] [Table 9]

[0173]

[0174] <25.3m 3 △T> at 10 cm from the end of the heater by power at / h flow rate

[0175]

[0176] [Table 10]

[0177]

[0178] <△T at 5cm and 10cm from the heater end by flow rate and power>

[0179]

[0180] As can be seen from the results in Tables 1 to 10 above, in the case of an electric vehicle using the heater assembly for an electric vehicle according to the present invention as an auxiliary heater, it can be seen that the effect of increasing the indoor temperature equivalent to that of using the PTC heater can be achieved even when using a significantly smaller amount of power (120 W) compared to the amount of power (1000 W to 2000 W) that can be used to increase the indoor temperature by operating the PTC heater, which is the main heater.

[0181]

[0182] The foregoing description is merely exemplary, and various modifications may be made by those skilled in the art to which the present invention pertains without departing from the scope and technical spirit of the described embodiments. The foregoing embodiments may be implemented individually or in any combination.

[0183] 100: Heater assembly for electric vehicles

[0184] 110: Heater

[0185] 120: Bracket

[0186] 121: Slot

[0187]

[0188] The present invention can improve energy efficiency by minimizing battery consumption of an electric vehicle, and can be implemented as a heater assembly for an electric vehicle that is easy to install, maintain, and repair in an electric vehicle.

Claims

1. A bracket installed within an air conditioning case and having at least two slots formed on one side extending longitudinally to allow a heater to be coupled thereto; and A heater coupled to the slot to heat the air flowing inside the air conditioning case; Including, The above heater, An inlet electrode portion electrically connected to the heating portion and formed at each end of the heater; and At least two electrode tabs connecting the above-mentioned inlet electrode part and an external wire; Includes, The electrode tab has one end connected to the lead-in electrode portion, the other end connected to the wire, and a step portion formed by bending at a certain angle between the one end and the other end to create a step between the one end and the other end of the electrode tab. Heater assembly for electric vehicles.

2. In paragraph 1, At least two of the above lead electrode parts are formed at each of one end and the other end of the heater, and a ground electrode part is further formed between the lead electrode parts of each of the one end and the other end. Heater assembly for electric vehicles.

3. In paragraph 1, The heater includes at least two electrical connectors arranged in parallel at the top and bottom and electrically connected to the inlet electrode parts, and the electrical connectors are formed to be connected by the heating part. Heater assembly for electric vehicles.

4. In paragraph 3, The above electrical connection part is, A first electrical connection extending in a first direction, which is the longitudinal direction of the heater; and A second electrical connection part comprising a first part extending in a second direction intersecting the first direction and a second part extending in the first direction; including, Heater assembly for electric vehicles.

5. In paragraph 1, The slot is provided with an elastic fixing member that presses one side of the heater when the heater is coupled to the slot so that the other side of the heater is fixed in close contact with the other side wall of the slot. Heater assembly for electric vehicles.

6. In paragraph 1, The bracket is installed in the slot, the heater is detachably mounted, and further includes a heater mounting / detaching unit that fixes both ends of the heater while finishing them when mounting the heater. Heater assembly for electric vehicles.

7. In paragraph 6, The above heater detachable unit is, A base that surrounds and secures the lower part of the heater; and A lever rotatably connected to both ends of the base to pressurize the heater so as to be fixed to or separated from the base; including, Heater assembly for electric vehicles.

8. In paragraph 1, The bracket is installed between the heaters coupled to the slot or on both sides of the heater to support the heater from one side or both sides, and further includes a plate spring guide that guides the flow of air flowing around the heaters. Heater assembly for electric vehicles.

9. In paragraph 8, The above-mentioned plate spring guide is formed such that at least two of them are detachably connected to the surface of the above-mentioned bracket. Heater assembly for electric vehicles.

10. In paragraph 1, The above bracket further includes a composite functional member formed with a connecting slot connecting between the slots, which is in close contact with the side of the heater to support the heater from the side and guide the flow of air flowing around the heaters. Heater assembly for electric vehicles.

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