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CN-122029388-A - Vehicle heating device

CN122029388ACN 122029388 ACN122029388 ACN 122029388ACN-122029388-A

Abstract

A method for manufacturing a heating device (1) for a vehicle, the heating device (1) being adapted to heat a liquid flowing therethrough. The method comprises the steps of a) arranging at least one tubular electric heater (3) inside a mould (200) leaving two end sections (31 a,31 b) of the tubular electric heater (3) outside the mould (200), b) injecting metal into the mould (200) to embed the at least one tubular electric heater (3) in the metal, step b) in particular the die casting step, wherein in step b) the at least one tubular electric heater (3) is locked in place by at least one fastening element (91, 92,93, 94) traversing the mould (200) at the clamping face of the two half-moulds (201, 202) of the mould (200) to lock the at least one tubular electric heater (3) and at least a part (2, 94) of the at least one fastening element (91, 92,93, 94) in place by pressure exerted on the at least one fastening element (91, 92,93, 94) by in particular the two half-moulds (201, 202) during injection of the metal into the mould (200).

Inventors

  • M. BENVENUTO
  • R caulo
  • A. Daytos
  • F. Zopas

Assignees

  • I.R.C.A.共同股份公司工业铠装及类似电阻

Dates

Publication Date
20260512
Application Date
20241014
Priority Date
20231012

Claims (15)

  1. 1. A method for manufacturing a heating device (1) of a vehicle, the heating device (1) being adapted to heat a liquid flowing therethrough; the method comprises the following steps: a) -arranging at least one tubular electric heater (3, 103a,103b,103 c) inside the mould (200), leaving two end sections (31 a,31 b) of said at least one tubular electric heater (3, 103a,103b,103 c) outside the mould (200); b) Injecting a metal into the mould (200) to embed the at least one tubular electric heater (3, 103a,103b,103 c) in the metal, step b) being in particular a die casting step; Wherein in step b) the at least one tubular electric heater (3, 103a,103b,103 c) is locked in place by at least one fastening element (91, 92,93, 94) positioned at the clamping face of the two half-moulds (201, 202) of the mould (200) to lock the at least one tubular electric heater (3, 103a,103b,103 c) in place during the injection of metal into the mould (200) by the pressure exerted by the two half-moulds (201, 202) on the at least one fastening element (91, 92,93, 94), obtaining a metal body (2) embedding at least part of the at least one tubular electric heater (3, 103a,103b,103 c) and the at least one fastening element (91, 92,93, 94); Wherein the at least one fastening element (91, 92,93, 94) comprises two ends (91 a,91b,92a,92b,93a,93b,94a,94 b) extending outwardly on opposite sides of the mould (200) with respect to a forming surface (201 c,202 c) of the mould (200); And wherein the at least one tubular electric heater (3, 103a,103b,103 c) comprises a serpentine or U-shaped heating section (32), and the at least one fastening element (91, 92,93, 94) is arranged transversely to a straight section of the heating section (32).
  2. 2. Method according to claim 1, wherein the at least one fastening element (91, 92,93, 94) is fastened, in particular integrally fastened, to the at least one tubular electric heater (3, 103a,103b,103 c), preferably before performing step a).
  3. 3. A method according to claim 1 or 2, wherein the at least one fastening element (91, 92,93, 94) is arranged in contact with the heating section (32) of the at least one tubular electric heater (3, 103a,103b,103 c).
  4. 4. Method according to any of the preceding claims, wherein at least one pair of mutually fastened fastening elements (91, 93) is provided, the tubular electric heater (3) being arranged therebetween, in particular being clamped, preferably wherein each pair of fastening elements (91, 93;92, 94) comprises a portion in contact with each other and a portion in contact with the tubular electric heater (3), in particular with the heating section (32), preferably wherein at least two pairs of fastening elements (91, 93;92, 94) are provided.
  5. 5. Method according to claim 4, wherein the portions in contact with each other and the portions in contact with the tubular electric heater (3), in particular the portions in contact with the straight sections of the heating section (32), are alternately arranged.
  6. 6. Method according to claim 4 or 5, wherein each pair of fastening elements (91, 93;92, 94) is arranged parallel to each other, wherein the portions in contact with each other are overlapping and adjacent flat portions, and wherein the portions in contact with the tubular electric heater (3) are overlapping curved portions, the profile of which is intended to enclose a respective portion of a straight section of the heating section (32).
  7. 7. The method according to any of the preceding claims, wherein the two ends (91 a,91b,92a,92b,93a,93b,94a,94 b) of each fastening element (91, 92,93, 94) are in contact with a non-forming surface (201 a,201b,202a,202 b) of the mold (200) during metal injection.
  8. 8. The method according to any of the preceding claims, wherein the at least one fastening element (91, 92,93, 94) is a bracket.
  9. 9. Method according to claim 8, wherein at least one pair of mutually fastened brackets (91, 92,93, 94) is provided, between which the at least one tubular electric heater (3, 103a,103b,103 c) is arranged, in particular clamped, preferably wherein at least two pairs of brackets (91, 92,93, 94) are provided.
  10. 10. Method according to any one of the preceding claims, wherein the metal body (2) is manufactured with at least one face (21) adapted to define a flow path of the liquid to be heated, and wherein a step is provided in which a first cover plate (6) is fastened to the metal body (2) such that the first cover plate defines the flow path with a first side (61) thereof, preferably wherein the first cover plate (6) defines with a second side (62) thereof opposite to the first side (61) a portion of a compartment (80) adapted to house an electronic board (8).
  11. 11. Method according to claim 10, wherein an electronic board (8) is arranged on the second side (62) of the first cover plate (6), in particular wherein after arranging the electronic board (8) at least one second cover plate (9) is fastened to the first cover plate (6) to form a compartment (80) accommodating the electronic board (8).
  12. 12. A method according to any one of the preceding claims, wherein the metal is injected at a pressure of greater than 100 bar, preferably between 300 and 700 bar.
  13. 13. A method according to any one of the preceding claims, wherein a plurality of said tubular electric heaters (3, 103a,103b,103 c) are provided.
  14. 14. A heating device (1) for a vehicle, adapted to heat a liquid flowing therethrough, made by a method according to any one of the preceding claims, comprising a metal body (2), the metal body (2) having embedded therein at least one tubular electric heater (3, 103a,103b,103 c) and the at least one fastening element (91, 92,93, 94), the tubular electric heater having two end sections (31 a,31 b) located outside the metal body (2), wherein the metal body (2) completely covers a heating section (32) of the at least one tubular electric heater (3, 103a,103b,103 c); and wherein the heating section (32) of the at least one tubular electric heater (3, 103a,103b,103 c) is serpentine or U-shaped, and the at least one fastening element (91, 92,93, 94) is arranged transversely to a straight section of the heating section (32).
  15. 15. Vehicle provided with at least one heating device (1) according to claim 14, in particular wherein the heating device (1) is adapted to heat a cooling liquid of a vehicle battery or to heat a liquid for heating passenger compartment air.

Description

Vehicle heating device Technical Field The present invention is in the field of vehicle heating devices, preferably but not necessarily for electric or hybrid vehicles, in particular for heating battery cooling fluid at low outdoor temperatures to maintain a constant desired operating temperature, or for heating fluid for heating air in a passenger compartment in an exchanger. In particular, the invention relates to a method for manufacturing a vehicle heating device, a vehicle heating device and a vehicle equipped with such a device. Background Batteries are critical to the operation of electric or hybrid vehicles. The battery must provide the vehicle with the energy required for quick, reliable operation. Most cells are high voltage hybrid lithium ion cells and nickel metal cells. The battery used must operate within a defined temperature range. In fact, at operating temperatures exceeding +40 ℃, the service life begins to shorten, while below-10 ℃, performance and power decline. Further, the temperature difference between the individual battery cells must not exceed a certain value. Exceeding the limit temperature may lead to accelerated aging and, correspondingly, premature battery failure. The goal of vehicle manufacturers is to equalize battery life to vehicle life. Thus, the aging process can only be delayed by optimizing the temperature management. The battery cell generally includes a battery cell, a cooling plate, and an auxiliary electric heating device. The cooling plate is installed in the battery cell stack, and a cooling liquid (e.g., a mixture of water and ethylene glycol) flows therethrough. To ensure higher performance and maximum service life of the battery, the temperature of the associated coolant should be between about 15 ℃ and 30 ℃. When the temperature is too high, the liquid is cooled, for example, by a low-temperature radiator. Conversely, if the temperature is too low, the coolant is heated by the auxiliary electric heating means. The latter thus ensures adequate control of the battery temperature when the outdoor temperature is low. To perform this heating, the battery is integrated into the secondary loop. The loop ensures that the desired operating temperature is maintained between 15 ℃ and 30 ℃. Such electric heating devices generally comprise at least one electric heating unit or electric heater for generating heat and transferring the generated heat to a heat transfer medium (i.e. the aforementioned liquid) through a body made of metallic material in contact with the electric heating unit. Such a liquid may be, for example, water, ethylene glycol, a mixture of water and ethylene glycol, or other suitable heat transfer liquid. The liquid flows along a flow path that includes at least one channel disposed on one face of the metal body, and the channel is closed by a cover plate secured to the metal body. The at least one channel communicates at both ends thereof directly with the inlet section and the outlet section of the heating device, respectively. The heating device must be compact and is generally shaped substantially as a rectangular hexahedron. The diameters of the inlet and outlet are determined by the cross section of the hydraulic circuit conduit. The electric heating unit is connected to an electronic control unit which allows to control the thermal power of the heating unit. The electronic control unit comprises an electronic board accommodated in a compartment of the heating device. The electric heating unit comprises a heating element, in particular a tubular heater embedded in the thickness of the metal body. To manufacture a metal body embedded in an electric heater, molten metal is injected into a mold in which a tubular electric heater is disposed. During the injection of the metal, the tubular electric heater must be supported in the mould. Thus, pins in direct contact with the metal casing (or sheath) of the tubular electric heater are used to hold the heater in place within the mold during metal injection. Disadvantageously, the pins that are removed at the end of the molding leave undesirable marks. Specifically, the pins leave uncovered areas of the tubular electric heater uncovered in certain areas of the metal body, i.e., the electric heater is uncovered by the metal from which the metal body is made. Such bare areas may be disadvantageous in that the liquid may directly contact the surface of the tubular electric heater and these areas may allow liquid to penetrate through the interface between the metal body and the tubular heater, even though the liquid may flow into the compartment housing the electronic board, for example through undesired pores present in the metal body. In practice, the metal body of the heating device may have manufacturing defects, which are disadvantageous. In particular, the metal body may have an undesirable porosity. Thus, even without the trace left by the aforementioned pins, the liquid may disadvantageously penetrate