Coolant heater

Abstract

The present invention relates to a coolant heater disposed in a vehicle to preheat coolant to an appropriate temperature before the coolant is supplied to each component, the coolant heater being characterized by comprising: a housing of which one side is open; a heating plate disposed inside the housing and having a cooling flow path formed therein; and a cover disposed on one side of the housing and coupled to the housing, wherein an outer surface of the heating plate corresponds to an open shape of the housing, and a side surface of the heating plate is welded to an inner surface in contact with the housing to form a welded portion.

Description

Coolant heater

[0001] The present invention relates to a coolant heater, and more particularly, to a coolant heater disposed in a vehicle to preheat coolant to an appropriate temperature before being supplied to each component.

[0002]

[0003] A coolant heater is a device that heats the engine coolant even when the engine is not running, facilitating engine starting and providing interior heating. Coolant heaters are useful in cold winter weather, pre-warming the vehicle's engine and interior to improve fuel efficiency and reduce engine wear. They also reduce incomplete combustion in cold engines, reducing exhaust emissions. Furthermore, coolant heaters are installed not only in engines but also in electric vehicles. Coolant heaters in electric vehicles are used for thermal management and interior heating of the electric vehicle battery.

[0004] A coolant heater generally has a structure similar to a radiator, and is composed of a heater core that radiates heat to the interior, an electric resistor, an electric heater that generates heat by the flow of current to heat the coolant, a circulation pump that circulates the coolant, and a temperature sensor that monitors the coolant to maintain a constant temperature, etc. are included inside or connected externally.

[0005] A typical water heater requires numerous components for assembly, including a cooling channel that cools the heating element and the IGBT (Insulated Gate Bipolar Transistor). Joining each component requires numerous considerations, including bolt holes for gasket and bolt joints, gasket grooves, insulation, and creepage distances. Furthermore, the necessary materials for joining are required. As the number of components in a water heater increases, the sealing performance becomes more challenging.

[0006] In addition, since the shape of the bolt fastening part, etc. is required on the heating plate, there is a disadvantage in that the area of ​​the heating element placed on the upper side is reduced.

[0007]

[0008] Accordingly, the present embodiment has been devised to solve the above-mentioned problems, and proposes a highly efficient cooling water heater by increasing the internal airtightness of the cooling water heater and expanding the area of ​​the heating element placed on the heating plate.

[0009]

[0010] The present invention comprises a housing having one open side, a heating plate disposed inside the housing and having a cooling channel formed therein, and a cover disposed on an upper side of the housing and coupled with the housing, wherein an outer surface of the heating plate corresponds to the open shape of the housing, and a side surface of the heating plate is welded to an inner surface in contact with the housing to form a welded portion.

[0011] In addition, the heating plate is characterized in that four sides are in contact with the inner surface of the housing and are joined by friction stir welding along the lines of contact with each other.

[0012] In addition, the width of the welded portion is characterized by being formed to be 6 mm to 12 mm.

[0013] In addition, it includes a sealant disposed between the housing and the cover, and includes a step formed by cutting the inner side of the upper surface of the housing including the welded portion, and is characterized in that the sealant is disposed including the step and the processed surface.

[0014] In addition, the housing includes a sealant disposed between the housing and the cover, and the upper surface of the housing including the welded portion includes two steps formed by cutting, and the sealant is characterized in that it is disposed including the two steps and the processed surface.

[0015] In addition, it includes a sealant disposed between the housing and the cover, and includes a step formed by cutting the outer surface of the upper surface of the housing, and is characterized in that the sealant is disposed including the step and the processed surface.

[0016] In addition, it includes a sealant disposed between the housing and the cover, and includes two steps formed by cutting the inner side of the upper surface of the housing including the welded portion and the outer side of the upper surface of the housing, and is characterized in that the sealant is disposed including the two steps and the processed surface.

[0017] Additionally, the cover includes a curved portion corresponding to the step so that the sealant is in close contact with the cover and the housing.

[0018] In addition, it is characterized in that the height difference between the upper surface of the housing and the processing surface is 3 mm or less.

[0019] In addition, the heating plate includes a heating element disposed on an upper surface, the heating element includes a lower insulating layer disposed on an upper surface of the heating plate, a heating wire and an electrode disposed on an upper surface of the lower insulating layer, a bus bar connected to the electrode, an upper insulating layer disposed on an upper side of the lower insulating layer and disposed such that the heating wire and the electrode are buried, and a moisture-proof insulating layer disposed on an upper side of the upper insulating layer, and the lower insulating layer and the upper insulating layer are characterized in that they are disposed by a spray coating method.

[0020] In addition, the lower insulating layer is formed of alumina oxide (Al₂O₃) material and is characterized by having a thickness of 200 um to 350 um.

[0021] In addition, the upper insulating layer is characterized in that it is arranged so that the heating wire and the electrode are buried, and is formed thicker than the thickness of the heating wire and the electrode.

[0022] In addition, the heating plate has a cooling channel formed at the bottom, and includes a heat dissipation member disposed inside the heating plate to improve heat exchange efficiency between the heating element and the cooling channel.

[0023] In addition, the housing is characterized by being divided into an independent upper space and a lower space based on the center.

[0024] In addition, the upper space is characterized in that the heating plate and the heating element are arranged, and the lower space is characterized in that a control device for controlling the temperature of heat generated from the heating element and the heat dissipation time is arranged.

[0025]

[0026] The present invention has the advantage of improving airtightness by integrating the housing and the heating plate through welding.

[0027] In addition, there is an advantage in that the sealing material is placed to include the step by forming a step on the upper surface of the housing, thereby improving the sealing quality and reducing the size of the housing.

[0028] In addition, there is an advantage in that the heating element is placed on the upper surface of the heating plate through a coating method, thereby maximizing the contact area between the heating element and the heating plate.

[0029]

[0030] Figure 1 is a perspective view of the present invention.

[0031] Figure 2 is a plan view of the housing and heating plate with the cover removed.

[0032] Figure 3 is a vertical cross-sectional view of the present invention.

[0033] Figure 4 is an enlarged view of Figure 3.

[0034] Figure 5 is a first embodiment of the present invention.

[0035] Figure 6 is a second embodiment of the present invention.

[0036] Figure 7 is a third embodiment of the present invention.

[0037] Figure 8 is a fourth embodiment of the present invention.

[0038] Figure 9 is a diagram of the internal configuration of the present invention.

[0039]

[0040] The present invention is susceptible to various modifications and embodiments. Specific embodiments are illustrated in the drawings and described in detail. However, this is not intended to limit the invention to specific embodiments, but rather to encompass all modifications falling within the spirit and technical scope of the present invention.

[0041] Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention belongs.

[0042] Terms defined in commonly used dictionaries should be interpreted to have a meaning consistent with their meaning in the context of the relevant technology, and should not be interpreted in an idealized or overly formal sense unless expressly defined in this application.

[0043] Hereinafter, a cooling water heater according to an embodiment of the present invention will be described in detail with reference to the attached drawings.

[0044] Fig. 1 is a perspective view of the present invention. Referring to Fig. 1, the coolant heater includes a housing (200) having an internal space formed therein, and a cover (100) disposed on the upper surface of the housing (200).

[0045] A plurality of housing connecting portions (203) are formed on the outer surface of the housing (200), and a cover connecting portion (101) corresponding to the housing connecting portions (203) is formed on the outer surface of the cover (100). The cover (100) is placed on the upper surface of the housing (200), and the housing connecting portions (203) and the cover connecting portion (101) are bolt-connected.

[0046] A housing (200) has a heating plate with a cooling channel formed therein. A cooling water inlet (201) is formed on one side of the housing (200) through which cooling water is introduced or discharged. Cooling water is supplied to the heating plate through the cooling water inlet (201), passes through the cooling channel formed in the heating plate, and is then discharged to the outside.

[0047] A plurality of components, including a heating plate, are arranged within the internal space. A connector (202) is arranged on one side of the housing (200) so as to be electrically connected to the components arranged within the internal space. A heating element that generates heat is arranged within the housing (200). The heating element receives electrical energy from the connector (202) and emits heat. The control unit controls the temperature of the heat generated from the heating element, the heat emission time, etc.

[0048] The appearance of the housing (200) and cover (100) illustrated is an example and may be modified as needed. For example, the location of the coolant inlet (201) may be changed, and the method of joining the housing (200) and cover (100) may be changed.

[0049] Fig. 2 is a plan view of a housing and a heating plate with the cover removed. Referring to Fig. 2, a heating plate (300) is placed within the internal space formed by the housing (200) and the cover. The heating plate (300) is placed within the housing (200), and the side of the heating plate (300) that comes into contact with the housing (200) is welded and joined. The position is fixed and integrated by welding.

[0050] The housing (200) has an open shape on one side, and the outer surface of the heating plate (300) corresponds to the open portion of the housing (200). The four side surfaces of the heating plate (300) are in contact with the inner surface of the housing (200), and are welded along the line of contact to form a welding line (B). In this embodiment, friction stir welding (FSW) is described as an example among various welding methods. Friction stir welding generates heat by rotating a non-consumable tool at high speed and mutual friction between the tool and the materials to be joined. The material is softened and stirred by the generated frictional heat, and welding is performed. That is, the housing (200) and the heating plate (300) are stirred and integrated by friction stir welding. The width of the friction stir welding is formed to be 6 mm to 12 mm.

[0051] The joining of the housing (200) and the heating plate (300) is not limited to friction stir welding, and various welding methods can be applied.

[0052] The present invention adopts a welding method, thereby reducing the number of bolts, nuts, and other connecting parts used when connecting a conventional housing (200) and a heating plate (300). This provides the advantage of improved bondability and airtightness. Furthermore, it has the advantage of reducing the space required to fasten connecting parts such as bolts and nuts.

[0053] A heating element arrangement area (C) is formed recessed on the upper surface of the heating plate (300). The heating element receives electric energy and heats the heating plate (300). Conventional heating elements are formed in multiple configurations, and multiple connecting parts are arranged to be combined with the housing (200). However, the arrangement of connecting parts on the upper surface of the heating plate (300) has the disadvantage that the contact area between the heating plate (300) and the heating element is reduced.

[0054] The present invention increases the contact area with the heating plate (300) by arranging the heating element through a coating method. This increased contact area has the advantage of improving heat exchange efficiency. A detailed description of the arrangement of the heating element will be provided later.

[0055] Fig. 3 is a vertical cross-sectional view of the present invention. It is a portion AA' of Fig. 2. Referring to Fig. 3, the cooling water heater is composed of a housing (200) having an internal space formed therein, a cover (100) disposed on the upper surface of the housing (200), and a heating plate (300) disposed in the internal space.

[0056] The housing (200) and the cover (100) are connected through a housing connecting portion and a cover connecting portion formed on the outer surface. A sealant (10) is placed between the upper surface of the housing (200) and the lower surface of the cover (100) to seal the internal space.

[0057] The inner surface of the housing (200) and the outer surface of the heating plate (300) are in contact with each other, and a welded portion (210) is formed by welding. The heating plate (300) has a cooling path (310) formed therein through which fluid flows. A control device is placed in the space formed on the lower side of the heating plate (300).

[0058] The heating plate (300) and the cover (100) are spaced apart from each other, and a heating element (not shown) is placed in the space formed by the space. The heating element (not shown) is placed on the upper surface of the heating plate (300) and emits heat.

[0059] Fig. 4 is an enlarged view of Fig. 3. Referring to Fig. 4, a cover (100) is placed on one side of a housing (200). The cover (100) is formed so that its center is convex upward, and its edge is placed and joined to the housing (200) so as to be in contact with it. A heating plate (300) is placed inside the housing (200). The heating plate (300) is welded to fix its position.

[0060] The present invention has a feature in that a step (221) is formed by cutting and processing a welded portion where a housing (200) and a heating plate (300) are welded. The sealant (10) is arranged to include the processed surface (220) and the step (221), and the housing (200) and the cover (100) are arranged. There is no limitation on the processing method of the welded portion (210).

[0061] At this time, the cover (100) includes a curved portion (110) corresponding to the position of the step (221) and the depth of the step (221). The sealant has the advantage of being in close contact with the cover (100) and the housing (200) by the step (221) and the curved portion (110), thereby improving the sealing power of the internal space. In addition, there is the advantage of being able to manufacture the housing in a smaller size by improving the sealing power through the step processing.

[0062] Fig. 5 illustrates a first embodiment of the present invention. Referring to Fig. 5, a heating plate (300) is placed inside a housing (200), and a welded portion (210) is formed by welding the portion where the housing (200) and the heating plate (300) come into contact. A cover (100) is placed on one side of the housing (200), and a sealant (10) is placed between the housing (200) and the cover (100).

[0063] The first embodiment includes a sealant disposed between the housing and the cover, and includes a step formed by cutting the inner side of the upper surface of the housing including the welded portion, and is characterized in that the sealant is disposed to include a step (221) and a machined surface (220). The welded portion (210) has a step-down shape in which the inner side is cut to form the step (221). The height difference between the upper surface of the housing and the machined surface is formed to be 3 mm or less.

[0064] The cover (100) is arranged on one side of the housing (200) and includes a curved portion (110) corresponding to a step (221). A sealant arranged between the housing (200) and the cover (100) is deformed in shape by the step (221) and the curved portion (110). Specifically, the sealant is arranged to include the step (221) and the processing surface (220), and is bent by the step (221) and the curved portion (110). The sealant is arranged in close contact with the cover (100) and the housing (200) by the bending, thereby providing improved airtightness.

[0065] Fig. 6 is a second embodiment of the present invention. Referring to Fig. 6, a heating plate (300) is placed inside a housing (200), and a welded portion (210) is formed by welding the portion where the housing (200) and the heating plate (300) come into contact. A cover (100) is placed on one side of the housing (200), and a sealant (10) is placed between the housing (200) and the cover (100).

[0066] The second embodiment includes a sealant disposed between the housing and the cover.

[0067] The upper surface center of the housing including the above welding portion includes two steps formed by cutting, and the sealant is characterized in that it is arranged including the two steps and the machined surface. The upper surface center of the housing (200) is cut to have a concave groove shape. The height difference between the upper surface of the housing and the machined surface is formed to be 3 mm or less.

[0068] The cover (100) is placed on one side of the housing (200) and includes a curved portion (110) corresponding to a step (221). The sealant placed between the housing (200) and the cover (100) is shaped by the step (221) and the curved portion (110). Specifically, the sealant applied to the second embodiment is placed across two steps (221) and the processing surface (220). The second embodiment has the advantage of improved airtightness due to the sealant being folded multiple times.

[0069] Fig. 7 illustrates a third embodiment of the present invention. Referring to Fig. 7, a heating plate (300) is placed inside a housing (200), and a welded portion (210) is formed by welding the portion where the housing (200) and the heating plate (300) come into contact. A cover (100) is placed on one side of the housing (200), and a sealant (10) is placed between the housing (200) and the cover (100).

[0070] A third embodiment includes a sealant disposed between the housing and the cover, and includes a step formed by cutting the outer surface of the upper surface of the housing, and is characterized in that the sealant is disposed to include a step (221) and a machined surface (220). The upper surface of the housing (200) has a step-up shape in which the outer surface is cut to form the step (221). The height of the welded portion (210) is fixed, and the outer surface of the housing (200) is cut to lower it. The height difference between the upper surface of the housing and the machined surface is formed to be 3 mm or less.

[0071] The cover (100) is arranged on one side of the housing (200) and includes a curved portion (110) corresponding to a step (221). A sealant arranged between the housing (200) and the cover (100) is deformed in shape by the step (221) and the curved portion (110). Specifically, the sealant is arranged to include the step (221) and the processing surface (220), and is bent by the step (221) and the curved portion (110). The sealant is arranged in close contact with the cover (100) and the housing (200) by the bending, thereby providing improved airtightness.

[0072] Fig. 8 is a fourth embodiment of the present invention. Referring to Fig. 8, a heating plate (300) is placed inside a housing (200), and a welded portion (210) is formed by welding the portion where the housing (200) and the heating plate (300) come into contact. A cover (100) is placed on one side of the housing (200), and a sealant is placed between the housing (200) and the cover (100).

[0073] A fourth embodiment includes a sealant disposed between the housing and the cover, and includes two steps formed by cutting the inner side of the upper surface of the housing including the welded portion and the outer side of the upper surface of the housing, and is characterized in that the sealant is disposed to include a step (221) and a machined surface (220). The inner side and the outer side of the housing (200) are cut so that the step (221) has a convex groove shape. The height difference between the upper surface of the housing and the machined surface is formed to be 3 mm or less.

[0074] The cover (100) is arranged on one side of the housing (200) and includes a curved portion (110) corresponding to a step (221). A sealant arranged between the housing (200) and the cover (100) is deformed in shape by the step (221) and the curved portion (110). Specifically, the sealant is arranged to include the step (221) and the processing surface (220), and is bent by the step (221) and the curved portion (110). The sealant is arranged in close contact with the cover (100) and the housing (200) by the bending, thereby providing improved airtightness.

[0075] Fig. 9 is a diagram of the internal configuration of the present invention. Referring to Fig. 9, the cooling water heater has a heating element (400) region formed in a recessed shape on the upper surface of the heating plate (300) so that a heating element (400) is disposed therein, and the heating element (400) includes a lower insulating layer (410) disposed on the upper surface of the heating plate (300), a heating wire (420) and an electrode (430) disposed on the upper surface of the lower insulating layer, a bus bar (440) connected to the electrode (430), an upper insulating layer (450) disposed on the upper side of the lower insulating layer (410) and disposed so that the heating wire (420) and the electrode (430) are buried therein, and a moisture-proof insulating layer (460) disposed on the upper side of the upper insulating layer (450).

[0076] The interior of the housing (200) is divided into an upper space and a lower space based on the center. The upper and lower spaces are independent spaces. However, they can be modified to be connected as needed.

[0077] The upper space of the housing (200) is where a heating plate (300) and a heating element (400) are placed. The lower space of the housing (200) is the control side (20) where a control device is placed.

[0078] A heating plate (300) is placed inside a housing (200). The end where the housing (200) and the heating plate (300) come into contact is welded to form a welded portion (210). A cooling channel (310) is formed on the lower side of the heating plate (300), and the interior of the heating plate (300) is filled with a heat dissipation member. The heating plate (300) improves the heat exchange efficiency between the cooling water of the cooling channel (310) and the heating wire (420) of the heating element (400) by the heat dissipation member.

[0079] A groove is formed on the upper surface of the heating plate (300) in which a heating element (400) is placed. Conventional heating elements (400) have been placed in such a way that each component is joined to the upper surface of the heating plate (300). In this case, there is a disadvantage in that the area of ​​the heating element (400) in contact with the heating plate (300) is reduced because the necessary accessories for joining are required.

[0080] The present invention has the advantage of maximizing the contact area with the heating plate (300) by adopting a spray coating method. The contact area between the heating plate (300) and the heating element (400) is larger than before, so there is the advantage of increased heat exchange efficiency. The lower insulating layer (410) is formed on the upper surface of the heating plate (300) by a spray coating method. The lower insulating layer (410) is formed of an AL2O3 (alumina oxide) material and is formed to a thickness of 200 μm to 350 μm.

[0081] A heating wire (420) is arranged on the upper surface of the lower insulating layer (410). An electrode (430) is arranged at an end of the heating wire (420). The electrode (430) is arranged on the upper surface of the lower insulating layer (410) by a printing method. A printing method utilizing a screen may be adopted. A bus bar (440) is connected to the electrode (430) by being in contact with it. The heating wire (420), the electrode (430), and the bus bar (440) are electrically connected. The current supplied through the bus bar (440) is supplied to the heating wire (420), thereby generating heat.

[0082] The upper insulating layer (450) is formed on the upper surface of the lower insulating layer (410). The upper insulating layer (450) is formed thicker than the thickness of the heating wire (420) and the electrode (430) so that the heating wire (420) and the electrode (430) are not exposed to the outside.

[0083] The moisture-proof insulating layer (460) is placed on the upper surface of the upper insulating layer (450). The upper surface of the moisture-proof insulating layer (460) corresponds to or is formed lower than the upper surface of the heating plate (300).

[0084] The supplied electrical energy is converted into thermal energy in the heating wire (420). The generated heat is transferred to the heating plate (300) positioned below the electrode (430). The fluid flowing in the cooling channel (310) receives the heat and is heated to a constant temperature.

[0085] The present invention is not limited to one embodiment, and the scope of application is diverse, and it goes without saying that various modifications can be implemented without departing from the gist of the present invention as claimed in the claims.

[0086]

[0087] [Explanation of symbols]

[0088] 10: Sealant 20: Control side

[0089] 100: Cover

[0090] 101: Cover joint

[0091] 110: Bend

[0092] 200: Housing

[0093] 201: Coolant inlet 202: Connector

[0094] 203: Joint

[0095] 210: Welding

[0096] 220: Processing surface

[0097] 221: Step

[0098] 300: Heating plate

[0099] 310: Cooling oil

[0100] 400: Heating element

[0101] 410: Lower insulation layer 420: Heating wire

[0102] 430: Electrode 440: Busbar

[0103] 450: Upper insulation layer 460: Moisture-proof insulation layer

[0104] B: Welding line

[0105] C: Heating element placement area

Claims

1. Housing with one side open, A heating plate disposed inside the housing and having a cooling channel formed therein, and A cover disposed on one side of the housing and coupled with the housing, A cooling water heater characterized in that the outer surface of the heating plate corresponds to the open shape of the housing, and the side surface of the heating plate is welded to the inner surface that contacts the housing to form a welded portion.

2. In paragraph 1, A cooling water heater characterized in that the above heating plate has four sides that are in contact with the inner surface of the housing and are joined by friction stir welding along the lines of contact with each other.

3. In paragraph 1, A cooling water heater characterized in that the width of the above welded portion is formed to be 6 mm to 12 mm.

4. In paragraph 1, Including a sealant disposed between the housing and the cover, The inner surface of the upper surface of the housing including the above welding part includes a step formed by cutting, A cooling water heater characterized in that the sealing agent is arranged including the step and the processing surface.

5. In paragraph 1, Including a sealant disposed between the housing and the cover, The upper surface center of the housing including the above welding part includes two steps formed by cutting, A cooling water heater characterized in that the sealing agent is arranged including two of the steps and the processing surface.

6. In paragraph 1, Including a sealant disposed between the housing and the cover, The upper surface of the housing includes a step formed by cutting the outer surface, A cooling water heater characterized in that the sealing agent is arranged including the step and the processing surface.

7. In paragraph 1, Including a sealant disposed between the housing and the cover, The upper surface inner side of the housing including the above welding part and the upper surface outer side of the housing include two steps formed by cutting, A cooling water heater characterized in that the sealing agent is arranged including two of the steps and the processing surface.

8. In any one of paragraphs 4 to 7, A coolant heater in which the cover includes a curved portion corresponding to the step so that the sealant is in close contact with the cover and the housing.

9. In any one of paragraphs 4 to 7, A coolant heater characterized in that the height difference between the upper surface of the housing and the processing surface is 3 mm or less.

10. In paragraph 1, The above heating plate includes a heating element disposed on the upper surface, The above heating element A lower insulating layer disposed on the upper surface of the above heating plate, Heating wires and electrodes arranged on the upper surface of the above lower insulation, A bus bar connected to the above electrode, An upper insulating layer arranged on the upper side of the lower insulating layer and arranged so that the heating wire and the electrode are buried, and Including a moisture-proof insulating layer placed on the upper side of the upper insulating layer, A cooling water heater characterized in that the lower insulating layer and the upper insulating layer are arranged by spray coating.

11. In paragraph 10, A cooling water heater characterized in that the lower insulating layer is formed of alumina oxide (Al₂O₃) material and has a thickness of 200 um to 350 um.

12. In paragraph 10, A cooling water heater characterized in that the upper insulating layer is arranged so that the heating wire and the electrode are buried, and is formed thicker than the thickness of the heating wire and the electrode.

13. In paragraph 10, The above heating plate has a cooling channel formed at the bottom, A cooling water heater including a heat dissipation member disposed inside the heating plate to improve heat exchange efficiency between the heating element and the cooling passage.

14. In paragraph 10, A coolant heater characterized in that the housing is divided into an upper space and a lower space independent of each other based on the center.

15. In paragraph 14, A cooling water heater characterized in that the upper space has the heating plate and the heating element disposed therein, and the lower space has a control device disposed therein for controlling the temperature of heat generated from the heating element and the heat dissipation time.

Images