Welding process of PTC heater

Abstract

The invention provides a PTC heater welding process which comprises the following steps: S1, mounting an electrical module in a plastic shell, and pre-fixing a plastic cover plate on the plastic shell through a bolt structure; s2, the pre-fixed plastic shell is placed in welding equipment, parts needing to be welded are located on a welding base, and parts not needing to be welded are located in a containing basket; and S3, the welding equipment is started for welding, the ultrasonic welding head moves downwards, meanwhile, the welding base synchronously moves inwards to the position under the ultrasonic welding head, the welding time is controlled to be 1-2 S, and welding operation of the PTC heater is completed.

Description

Technical Field

[0001] The invention belongs to the technical field of PTC heater production and relates to a welding process of a PTC heater. Background Art

[0002] PTC heater, also known as PTC heating tube, is composed of PTC ceramic heating element and aluminum tube. This type of PTC heater has the characteristics of low thermal resistance and high heat exchange efficiency. It is an automatic constant temperature, energy-saving electric heating equipment, widely used in various household appliances. The existing production process of PTC heaters basically uses glue filling or silicone strips to limit the sealing points required and then use screws to lock and fix. Silicone filling has pores, glue leakage, and silicone rings are also affected by temperature resistance and aging and cannot effectively meet the waterproof requirements; at the same time, the use of glue, strips, screws and other fixings also increases the cost of materials and accessories. Therefore, it is very necessary to design a welding process for PTC heaters. Summary of the invention

[0003] The purpose of the present invention is to solve the above problems in the prior art and to propose a welding process for a PTC heater.

[0004] The object of the present invention can be achieved by the following technical solution: A welding process of a PTC heater comprises the following steps: S1. Install the electrical module into the plastic housing, and then pre-fix the plastic cover to the plastic housing through a latch structure; S2, placing the pre-fixed plastic shell in the welding equipment, with the parts to be welded being located at the welding seat, and the parts not to be welded being located in the placement basket; S3, start the welding equipment to perform welding, and move the ultrasonic welding head downward. At the same time, the welding seat moves inward synchronously to the bottom of the ultrasonic welding head. The welding time is controlled within 1-2S, and the welding operation of the PTC heater is completed.

[0005] The electrical module includes a thermostat, a fuse, and a current fuse.

[0006] The plastic cover plate is provided with a welding protrusion protruding downward.

[0007] The plastic cover plate and the welding flange are made of the same plastic material and are integrally formed by injection molding.

[0008] The welding equipment includes an L-shaped machine base, a guide rail is horizontally installed at the lower part of the L-shaped machine base, a sliding seat is slidably connected to the guide rail, a U-shaped table is connected to the sliding seat, a guide sleeve is installed on the U-shaped table, a guide column is vertically slidably connected inside the guide sleeve, a welding seat for placing a PTC heater is connected to the guide column, an adjusting screw is vertically threadedly connected to the U-shaped platform, the adjusting screw and the welding seat are rotatably connected, a fastening nut is also threadedly connected to the adjusting screw, a shell is installed on the upper part of the L-shaped machine base, an ultrasonic welding head that can be raised and lowered is provided on the shell, and the ultrasonic welding head can cooperate with the welding seat.

[0009] The ultrasonic welding head is provided with an avoidance hole.

[0010] The U-shaped platform is also connected with a placement basket.

[0011] The lower part of the L-shaped machine base is connected to an auxiliary base, and the auxiliary base is rotatably connected to a V-shaped regulating swing arm through a mounting shaft, a guide wheel is installed at one end of the V-shaped regulating swing arm, and an L-shaped groove is opened at the other end of the V-shaped regulating swing arm, and a cross bar is installed on the U-shaped platform, the cross bar is rotatably connected to one end of the guide shaft, and the other end of the guide shaft is located in the L-shaped groove, and a torsion spring is also provided on the mounting shaft, one end of the torsion spring is against the V-shaped regulating swing arm, and the other end of the torsion spring is against the auxiliary seat; a guide column two is also vertically installed at the lower part of the L-shaped machine base, a guide sleeve two is slidably connected to the guide column two, and a lifting beam that can be lifted up and down is connected to the guide sleeve two, the lifting beam is connected to the upper end of the L-shaped pressing rod, and the lower end of the L-shaped pressing rod is against the guide wheel.

[0012] A supporting member matching with the torsion spring is also installed on the other end of the V-shaped regulating swing arm.

[0013] A power motor is installed in the shell, the output shaft end of the power motor is fixedly connected to one end of the rotating arm, the other end of the rotating arm is rotatably connected to one end of the connecting rod arm, the other end of the connecting rod arm is rotatably connected to the upper part of the reciprocating seat, both sides of the lower part of the reciprocating seat are rotatably connected to one end of the active rod arm, the other end of the active rod arm is rotatably connected to the connecting head, the connecting head is also rotatably connected to one end of the upper driven rod arm and one end of the lower driven rod arm at the same time, the other end of the upper driven rod arm is rotatably connected to the shell, the other end of the lower driven rod arm is rotatably connected to the connecting ear of the lifting beam, a guide block is also installed on the shell, an intermediate rod arm is vertically slidably installed on the guide block, the upper end of the intermediate rod arm is connected to the middle of the lower part of the reciprocating seat, the lower end of the intermediate rod arm passes through the lifting beam and is detachably connected through a connecting tube and an ultrasonic welding head.

[0014] Compared with the prior art, the welding process of the PTC heater has the following advantages: The process adopted in the present invention has the advantages of simple operation, less parts and components, a waterproof grade that can reach IP67, and good waterproof sealing performance; at the same time, the welding is reliable and safe. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic diagram of the product of the present invention; Figure 2 It is a schematic diagram of the dismantled part of the product of the present invention; Figure 3 is a schematic diagram of the device in the present invention; Figure 4 It is a schematic diagram of the dismantling part of the equipment in the present invention. Figure 1 ; Figure 5 It is a schematic diagram of the dismantling part of the equipment in the present invention. Figure 2 ; Figure 6 It is a schematic diagram of the dismantling part of the equipment in the present invention. Figure 3 ; Figure 7 It is a schematic diagram of the dismantling part of the equipment in the present invention. Figure 4 ; In the figure, 1, L-shaped machine base; 2, V-shaped regulating swing arm; 201, L-shaped groove; 3, guide wheel; 4, L-shaped pressing rod; 5, lifting beam; 6, shell; 7, guide sleeve 2; 8, intermediate lever arm; 9, guide column 2; 10, connecting tube; 11, ultrasonic welding head; 1101, avoidance hole; 12, U-shaped table; 13, welding seat; 14, placing basket; 15, guide column 1; 16, sliding seat; 17, guide rail; 18, guide sleeve 1; 19, cross bar; 20, guide shaft; 21, PTC heater; 2101, plastic housing; 2102, electrical module; 2103, plastic cover; 2103X, welding flange; 22, torsion spring; 23, mounting shaft; 24, auxiliary seat; 25, adjusting screw; 26, abutment; 27, fastening nut; 28, reciprocating seat; 29, connecting rod arm; 30, rotating arm; 31, power motor; 32, active rod arm; 33, upper driven rod arm; 34, lower driven rod arm; 35, connector; 36, guide block. DETAILED DESCRIPTION

[0016] The following are specific embodiments of the present invention and the accompanying drawings to further describe the technical solution of the present invention, but the present invention is not limited to these embodiments.

[0017] like Figure 1-Figure 7 The welding process of the PTC heater 21 includes the following steps: S1, installing the electrical module 2102 into the plastic housing 2101, and then pre-fixing the plastic cover 2103 to the plastic housing 2101 through a latch structure; S2, placing the pre-fixed plastic shell 2101 in the welding equipment, with the parts to be welded being located at the welding seat 13, and the parts not to be welded being located in the placement basket 14; S3. Start the welding equipment to perform welding. The ultrasonic welding head 11 moves downward. At the same time, the welding seat 13 moves inward synchronously to the bottom of the ultrasonic welding head 11. The welding time is controlled within 1-2S, and the welding operation of the PTC heater 21 is completed. In this embodiment, the welding time is 1S. The plastic cover 2103 has a welding convex edge 2103X protruding downward. With this structure, the welding convex edge 2103X is melted, and the plastic cover 2103 and the plastic shell 2101 are reliably connected together to form an integral structure, thereby achieving a better sealing effect.

[0018] The electrical module 2102 includes a thermostat, a fuse, and a current fuse, which are existing products.

[0019] The plastic cover 2103 and the welding flange 2103X are made of the same plastic material by injection molding. In this embodiment, the plastic shell 2101 and the plastic cover 2103 are also made of the same plastic material.

[0020] The welding equipment includes an L-shaped machine base 1, a guide rail 17 is horizontally installed at the lower part of the L-shaped machine base 1, a slide seat 16 is slidably connected to the guide rail 17, and a U-shaped table 12 is connected to the slide seat 16. Specifically, the U-shaped table 12 is also connected to a placement basket 14; a guide sleeve 18 is installed on the U-shaped table 12, and a guide column 15 is vertically slidably connected in the guide sleeve 18, and a welding seat 13 for placing a PTC heater 21 is connected to the guide column 15, and an adjusting screw 25 is vertically threadedly connected to the U-shaped table 12, and the adjusting screw 25 and the welding The seat 13 is rotatably connected, and a fastening nut 27 is threadedly connected to the adjusting screw 25. With the cooperation of the adjusting screw 25 and the fastening nut 27, the height position of the welding seat 13 can be adjusted; a shell 6 is installed on the upper part of the L-shaped machine base 1, and an ultrasonic welding head 11 that can be raised and lowered is provided on the shell 6, and the ultrasonic welding head 11 can cooperate with the welding seat 13. In this embodiment, the ultrasonic welding head 11 is downwardly cooperated with the welding seat 13 to complete the welding operation. This adopts the existing technology.

[0021] The ultrasonic welding head 11 is provided with an avoidance hole 1101. With this structure, damage to the electrical module can be avoided during the welding operation.

[0022] An auxiliary seat 24 is connected to the lower part of the L-shaped machine base 1, and a V-shaped regulating swing arm 2 is rotatably connected to the auxiliary seat 24 through a mounting shaft 23. A guide wheel 3 is installed at one end of the V-shaped regulating swing arm 2, and an L-shaped groove 201 is opened at the other end of the V-shaped regulating swing arm 2. A cross bar 19 is installed on the U-shaped platform 12, and the cross bar 19 is rotatably connected to one end of the guide shaft 20, and the other end of the guide shaft 20 is located in the L-shaped groove 201. A torsion spring 22 is also provided on the mounting shaft 23, and one end of the torsion spring 22 abuts against the V-shaped regulating swing arm 2. Specifically: a supporting member 26 matching the torsion spring 22 is also installed on the other end of the V-shaped regulating swing arm 2; the other end of the torsion spring 22 abuts against the auxiliary seat 24; a guide column 29 is also vertically installed at the lower part of the L-shaped machine base 1, and the guide column A guide sleeve 29 is slidably connected to a lifting beam 5 which can be lifted up and down. The lifting beam 5 is connected to the upper end of an L-shaped pressing rod 4, and the lower end of the L-shaped pressing rod 4 is against the guide wheel 3. With this structure, when the lifting beam 5 moves downward, the L-shaped pressing rod 4 is driven to move downward, and the L-shaped pressing rod 4 presses the guide wheel 3, so that the V-shaped regulating swing arm 2 swings accordingly. With the cooperation of the guide shaft 20 and the L-shaped groove 201, the slide seat 16 can move inward along the guide rail 17, and then the U-shaped table 12 moves inward, and finally the welding seat 13 is located directly below the ultrasonic welding head 11. When loading and unloading, the welding seat 13 is located outside, so that the PTC heater 21 can be conveniently taken in and placed.

[0023] A power motor 31 is installed in the housing 6. The output shaft end of the power motor 31 is fixedly connected to one end of the rotating arm 30. The other end of the rotating arm 30 is rotatably connected to one end of the connecting rod arm 29. The other end of the connecting rod arm 29 is rotatably connected to the upper part of the reciprocating seat 28. Both sides of the lower part of the reciprocating seat 28 are rotatably connected to one end of the active lever arm 32. The other end of the active lever arm 32 is rotatably connected to the connecting head 35. The connecting head 35 is also rotatably connected to one end of the upper driven lever arm 33 and one end of the lower driven lever arm 34 at the same time. The other end of the upper driven lever arm 33 is rotatably connected to the housing 6, and the other end of the lower driven lever arm 34 is rotatably connected to the housing 6. The connecting ear of the lifting beam 5 is rotatably connected, and a guide block 36 is also installed on the shell 6. An intermediate lever arm 8 is vertically slidably installed on the guide block 36. The upper end of the intermediate lever arm 8 is connected to the middle of the lower part of the reciprocating seat 28, and the lower end of the intermediate lever arm 8 passes through the lifting beam 5 and is detachably connected to the ultrasonic welding head 11 through the connecting tube 10. With this structure, the power motor 31 can drive the lifting beam 5 to move downward quickly first, and then the welding seat 13 is located directly below the ultrasonic welding head 11; then the reciprocating seat 28 is used to drive the ultrasonic welding head 11 to move slowly downward, and then the welding operation is completed.

[0024] The above components are all common standard parts or components known to those skilled in the art, and their structures and principles can be known to those skilled in the art through technical manuals or conventional experimental methods.

[0025] The specific embodiments described herein are merely examples of the spirit of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in similar ways, but they will not deviate from the spirit of the present invention or exceed the scope defined by the appended claims.

Claims

1. A welding process for a PTC heater, characterized in that: The steps include: S1, installing the electrical module (2102) into the plastic housing (2101), and then pre-fixing the plastic cover (2103) to the plastic housing (2101) via a latch structure; S2, placing the pre-fixed plastic shell (2101) in a welding device, with the parts to be welded being located at the welding seat (13), and the parts not to be welded being located in a placement basket (14); S3, starting the welding equipment to perform welding, the ultrasonic welding head (11) moves downward, and at the same time, the welding seat (13) moves inward to the bottom of the ultrasonic welding head (11), and the welding time is controlled within 1-2 seconds, thus completing the welding operation of the PTC heater (21).

2. A welding process for a PTC heater according to claim 1, characterized in that: The electrical module (2102) includes a thermostat, a fuse, and a current fuse.

3. A welding process for a PTC heater according to claim 1, characterized in that: The plastic cover plate (2103) is provided with a welding protrusion (2103X) protruding downward.

4. A welding process for a PTC heater according to claim 3, characterized in that: The plastic cover plate (2103) and the welding flange (2103X) are made of the same plastic material and are integrally formed by injection molding.

5. The welding process of a PTC heater according to claim 1, characterized in that: The welding device comprises an L-shaped machine base (1), a guide rail (17) being horizontally mounted on the lower part of the L-shaped machine base (1), a slide seat (16) being slidably connected to the guide rail (17), a U-shaped platform (12) being connected to the slide seat (16), a guide sleeve (18) being mounted on the U-shaped platform (12), a guide column (15) being vertically slidably connected inside the guide sleeve (18), a welding seat (13) for placing a PTC heater (21) being connected to the guide column (15), an adjusting screw (25) being vertically threadedly connected to the U-shaped platform (12), the adjusting screw (25) and the welding seat (13) being rotatably connected, a fastening nut (27) being threadedly connected to the adjusting screw (25), a shell (6) being mounted on the upper part of the L-shaped machine base (1), an ultrasonic welding head (11) being capable of being raised and lowered is provided on the shell (6), and the ultrasonic welding head (11) can cooperate with the welding seat (13).

6. A welding process for a PTC heater according to claim 5, characterized in that: The ultrasonic welding head (11) is provided with an avoidance hole (1101).

7. The welding process of a PTC heater according to claim 5, characterized in that: The U-shaped platform (12) is also connected to a placement basket (14).

8. The welding process of a PTC heater according to claim 5, characterized in that: The lower part of the L-shaped machine base (1) is connected to an auxiliary base (24), and a V-shaped regulating swing arm (2) is rotatably connected to the auxiliary base (24) via a mounting shaft (23). A guide wheel (3) is mounted on one end of the V-shaped regulating swing arm (2), and an L-shaped groove (201) is formed at the other end of the V-shaped regulating swing arm (2). A cross bar (19) is mounted on the U-shaped platform (12), and the cross bar (19) is rotatably connected to one end of a guide shaft (20), and the other end of the guide shaft (20) is located in the L-shaped groove (201). The mounting shaft (23) is provided to the U-shaped platform (12). The L-shaped machine base (1) further comprises a torsion spring (22), one end of which is in contact with the V-shaped regulating swing arm (2), and the other end of which is in contact with the auxiliary seat (24); a guide column (9) is vertically mounted at the lower part of the L-shaped machine base (1), a guide sleeve (7) is slidably connected to the guide column (9), a lifting beam (5) capable of being lifted up and down is connected to the guide sleeve (7), the lifting beam (5) is connected to the upper end of the L-shaped pressing rod (4), and the lower end of the L-shaped pressing rod (4) is in contact with the guide wheel (3).

9. A welding process for a PTC heater according to claim 8, characterized in that: A supporting member (26) matching with the torsion spring (22) is also installed on the other end of the V-shaped regulating swing arm (2).

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