T-type ptc heater

Abstract

The application discloses a T-shaped PTC heater which is composed of a T-shaped shell, a PTC element, electrode sheets and insulating paper. The T-shaped shell comprises at least one metal tube. The cross section of the metal tube is rectangular. The metal tube comprises two heat-conducting surfaces which are opposite to the heat-emitting surface of the PTC element. The outer surface of the heat-conducting surface is provided with an array of protrusions or concave surfaces. The surfaces are spaced apart to form separation parts. After the tube pressing process, the stress distribution of the heat-conducting surface is uniform, and the heat-conducting surface is tightly combined with the heat-emitting surface of the PTC element. Compared with the prior art, the PTC core can be easily inserted into the metal tube, the stress distribution of the heat-conducting surface is uniform during the tube pressing process of the metal tube, the heat-conducting surface is tightly combined with the heat-emitting surface of the PTC element, the consistency of the product power is ensured, the PTC core is stably fixed in the metal tube, the safety hidden danger caused by the damage of the insulating paper is avoided, and the yield of the product is improved.

Description

Technical Field

[0001] This invention relates to a PTC heater, and more particularly to a T-type PTC heater. Background Technology

[0002] Currently, PTC heaters are widely used in the PTC heater industry. With the widespread application of PTC heaters, more and more fields have higher and stricter requirements for the use of PTC. PTC heaters also come in various shapes and sizes, and their applications in the market are becoming more diversified.

[0003] Popular PTC heaters on the market include ventilated PTC heaters, contact PTC heaters, and liquid PTC heaters. They not only meet users' temperature requirements but also allow for easy adjustment. Even after burning dry, the PTC heater's heating element remains undamaged, exhibiting consistent heating stability. It will not glow red or ignite when powered on, consumes no oxygen, and will not exhibit the surface "red-hot" phenomenon seen in electric heating tube heaters under any application conditions, thus avoiding safety hazards such as burns and fires. PTC heaters offer advantages such as constant temperature heating, no open flame (no red-hot glow), high heat conversion rate, minimal impact from power supply voltage, and long service life.

[0004] Liquid PTC heaters on the market all have certain drawbacks. Currently, liquid PTC heaters require a pressing process during assembly. To ensure the smooth implementation of this process, flat molds are mainly used, and the cross-section of the aluminum tube in the liquid PTC heater is correspondingly set to rectangular. However, in the technical solution disclosed in patent number 202221945986.6, entitled "A Heater with Embedded PTC Heating Components," due to the manufacturing process of the aluminum tube itself, the surface of the aluminum tube is not perfectly flat. This leads to uneven stress on the aluminum tube during the pressing process after inserting the PTC core (insulating paper, electrode sheet, PTC element), causing the PTC core to loosen within the aluminum tube. This results in inconsistent product power. The performance is poor, failing to meet customer power requirements. To address this, current methods require adding one or two additional gaskets to the electrode plates on both sides of the PTC core for matching and pressing. During assembly, the PTC core is first inserted into the aluminum tube, and then the gaskets are inserted on both sides. Since the PTC core is wrapped with insulating paper, inserting the gaskets can easily tear the insulating paper, exposing the electrode plates and causing the aluminum tube to become electrified during operation. This leads to numerous hidden dangers, such as wasting labor costs and electricity during product manufacturing, wasting product repair time, significantly increasing product scrap rates, and reducing production efficiency. This not only contradicts our original intention of energy conservation and environmental protection but also causes considerable inconvenience to frontline production workers. Summary of the Invention

[0005] The purpose of this invention is to provide a T-type PTC heater. The technical problem to be solved is that the heat-conducting surface of the metal tube is subjected to uniform force during the tube pressing process, so that the heat-conducting surface is in close contact with the heating surface of the PTC element, and the power of the product is consistent.

[0006] To solve the above problems, the present invention adopts the following technical solution: a T-type PTC heater, comprising a T-type shell, a PTC element, electrode plates, and insulating paper. The T-type shell includes at least one metal tube with a rectangular cross-section, including two heat-conducting surfaces opposite to the heating surface of the PTC element. The outer surface of the heat-conducting surfaces is provided with an array of raised or recessed surfaces, with spacing between the surfaces forming partitions. When the surface is raised, the partition is a recessed groove; when the surface is recessed, the partition is raised, ensuring uniform stress distribution on the heat-conducting surfaces after the tube pressing process, so that the heat-conducting surfaces are tightly fitted to the heating surface of the PTC element.

[0007] Furthermore, the surface is provided with at least three.

[0008] Furthermore, the shape of the surface is polygonal, circular, or elliptical.

[0009] Furthermore, the PTC element array is arranged between the electrode sheets.

[0010] Furthermore, the surface is raised.

[0011] Furthermore, the heating surface of each PTC element is opposite to at least one surface position.

[0012] Furthermore, all of the surfaces are disposed on the same plane.

[0013] Compared with the prior art, this invention provides an array of raised or recessed surfaces on the outer surface of the heat-conducting surface, ensuring that the PTC core can easily penetrate into the metal tube. This results in uniform stress distribution on the heat-conducting surface during the pressing process of the metal tube, achieving a tight fit between the heat-conducting surface and the heating surface of the PTC element, ensuring consistent product power, and also ensuring that the PTC core is firmly fixed in the metal tube, preventing safety hazards caused by damage to the insulating paper, and improving product yield. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of the present invention.

[0015] Figure 2 This is an assembly diagram of the present invention.

[0016] Figure 3 This is a schematic diagram of the internal structure of the present invention.

[0017] Figure 4 This is a schematic diagram of the surface structure of the present invention. Figure 1 .

[0018] Figure 5 This is a schematic diagram of the surface structure of the present invention. Figure 2 .

[0019] Figure 6 This is a schematic diagram of the surface structure of the present invention. Figure 3 . Detailed Implementation

[0020] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0021] like Figures 1 to 3 As shown, this invention discloses a T-type PTC heater, comprising a T-shaped outer shell 1, a PTC element 2, electrode plates 3, and insulating paper 4. The PTC core is composed of the PTC element 2, electrode plates 3, and insulating paper 4. The T-shaped outer shell 1 includes two metal tubes 11, which are symmetrically fixed to a flange 15. The cross-section of each metal tube 11 is rectangular, and it includes two heat-conducting surfaces 12 opposite to the heating surface of the PTC element 2. The outer surface of each heat-conducting surface 12 has an array of protruding or recessed surfaces 13, with spaces between the surfaces 13. The spacer 14 is formed with a gap. When the surface 13 is raised, the spacer 14 is a recessed groove; when the surface 13 is recessed, the spacer 14 is raised. This ensures that the stress distribution of the heat-conducting surface 12 of the metal tube 11 is uniform after the tube pressing process, so that the heat-conducting surface 12 and the heating surface of the PTC element 2 are closely attached, ensuring the consistency of product power. At the same time, since there is no need to set a pad, the problem of setting a pad outside the insulating paper 4 to prevent uneven contact between the PTC core and the heat-conducting surface 12 is solved, and the pad scratches the insulating paper 4 during assembly is avoided.

[0022] The electrode sheet 3 is placed outside the heating surface of the PTC element 2, and the insulating paper 4 is wrapped around the electrode sheet 3 to insulate the PTC core as a whole from the metal tube 11. The electrode sheet 3 is provided with electrode wires, which are led out to the outside of the metal tube 11.

[0023] The shape of surface 12 can be set to a polygon, a circle or an ellipse, where the polygon is a rectangle, a regular polygon or an irregular polygon.

[0024] like Figure 1 As shown, surface 12 is a raised rectangle and partition 14 is a groove. This structure is suitable for use when the width of the heat-conducting surface 12 is greater than its length. There are at least three surfaces 12 to form a three-grid structure. Of course, there can also be nine surfaces 12 to form a nine-grid structure, arranged in a three-row, three-column array. This can further make the stress distribution of the heat-conducting surface 12 more uniform after the tube pressing process.

[0025] Of course, other methods can also be used, such as Figure 4 As shown, when the surface 12 is a concave circle, the partition 14 is a protrusion. This structure is also suitable for use when the width of the heat-conducting surface 12 is greater than its length. The surface 12 is arranged in an array of multiple rows and columns.

[0026] like Figure 5 As shown, when surface 12 is a raised rectangular strip, the partition 14 is a groove. This surface extends along the length of the metal tube 11 and is arranged in an array along the width of the heat-conducting surface 12 of the metal tube 11, i.e., one row and multiple columns. Of course, it can also extend along the width of the heat-conducting surface 12 of the metal tube 11 and be arranged in an array along the length of the metal tube 11 (e.g., Figure 6 As shown in the figure, it is a multi-row, one-column layout.

[0027] In this invention, the PTC elements 2 are arranged in an array between the electrode plates 3. When there are an even number of PTC elements 2, they are distributed in a row and column manner, such as two rows and two columns. When there are an odd number of PTC elements 2, they can be arranged vertically or horizontally.

[0028] The PTC element 2 can be configured such that the heating surface of each PTC element 2 is opposite to at least one surface 13. This ensures that after the tube pressing process, the heating surface of the PTC element 2 is in close contact with the heat-conducting surface 12 of the metal tube, further improving the consistency of product power. Of course, the surface 13 can also be configured according to the number of PTC elements 2, such as having at least two surfaces 13 corresponding to the heating surface of one PTC element 2.

[0029] In this invention, all surfaces 13 are disposed on the same surface so that the surfaces 13 and the pressure plate used in the tube pressing process are in uniform contact, thereby ensuring uniform force distribution.

[0030] This invention ensures that the PTC core can be easily inserted into the metal tube without the need for gaskets on both sides of the PTC core, and that the PTC core can be pressed tightly after tube pressing. This solves the problem of uneven stress on the surface of the metal tube, and also solves the problems of air gaps that are not conducive to heat conduction and can easily tear the insulation paper when using side gaskets in the prior art, resulting in poor power consistency and insulation failure.

Claims

1. A T-type PTC heater, characterized in that: Composed of a T-shaped shell (1), a PTC element (2), an electrode sheet (3), and insulating paper (4), the T-shaped shell (1) includes at least one metal tube (11), the cross-section of the metal tube (11) is rectangular, and includes two heat-conducting surfaces (12) opposite to the heating surface of the PTC element (2). On the outer surface of the heat-conducting surface (12), there are arrayed protrusions or depressions (13), and there are gaps between the surfaces (13) to form partitions (14). When the surface (13) is protruding, the partition (14) is a recessed groove; when the surface (13) is recessed, the partition (14) is protruding, so as to ensure that the stress distribution of the heat-conducting surface (12) of the metal tube (11) is uniform after the tube pressing process, so that the heat-conducting surface (12) and the heating surface of the PTC element (2) are closely attached.

2. The T-type PTC heater according to claim 1, characterized in that: The surface (13) has at least three.

3. The T-type PTC heater according to claim 2, characterized in that: The surface (13) is polygonal, circular or elliptical in shape.

4. The T-type PTC heater according to any one of claims 1-3, characterized in that: The PTC elements (2) are arranged in an array between the electrode plates (3).

5. The T-type PTC heater according to claim 4, characterized in that: The surface (13) is raised.

6. The T-type PTC heater according to claim 5, characterized in that: The heating surface of each PTC element (2) is positioned opposite at least one surface (13).

7. The T-type PTC heater according to claim 6, characterized in that: All surfaces (13) are located on the same plane.

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