A welding process for PTC heater

Abstract

The application provides a welding process of a PTC heater, which comprises the following steps: S1, installing an electrical module into a plastic shell, and then pre-fixing a plastic cover plate to the plastic shell through a bolt structure; S2, placing the pre-fixed plastic shell into a welding device, wherein components that need to be welded are located at a welding seat, and components that do not need to be welded are located in a placing basket; S3, starting the welding device to perform welding, moving an ultrasonic welding head downward, and simultaneously, moving the welding seat inward to be directly below the ultrasonic welding head, and the welding time is controlled to be 1-2 seconds, so that the welding work of the PTC heater is completed.

Description

Technical Field

[0001] This invention belongs to the field of PTC heater manufacturing technology and relates to a welding process for PTC heaters. Background Technology

[0002] PTC heaters, also known as PTC heating elements, consist of a PTC ceramic heating element and an aluminum tube. These PTC heating elements feature low thermal resistance and high heat exchange efficiency, making them automatic temperature-controlled, energy-saving electric heating devices widely used in various household appliances. Current PTC heater manufacturing processes primarily use potting compound filling or silicone sealant strips to define sealing points before screwing. However, silicone filling suffers from air bubbles and leakage, and silicone rings are susceptible to temperature aging, failing to effectively meet waterproofing requirements. Furthermore, the use of glue, sealant strips, and screws increases material costs. Therefore, designing a welding process for PTC heaters is essential. Summary of the Invention

[0003] The purpose of this invention is to address the aforementioned problems in existing technologies by proposing a welding process for PTC heaters.

[0004] The objective of this invention can be achieved through the following technical solution: a welding process for a PTC heater, comprising the following steps:

[0005] S1. Install the electrical module into the plastic housing, and then pre-fix the plastic cover to the plastic housing using a pin structure;

[0006] S2. Place the pre-fixed plastic shell into the welding equipment. The parts to be welded are located at the welding seat, and the parts not to be welded are located in the placement basket.

[0007] S3. Start the welding equipment to perform welding. Move the ultrasonic welding head downwards, and at the same time, move the welding seat inwards to directly below the ultrasonic welding head. Control the welding time to 1-2 seconds to complete the welding operation of the PTC heater.

[0008] The electrical module includes a thermostat, a fuse, and an overcurrent fuse.

[0009] The plastic cover plate has a downward-protruding welded flange.

[0010] The plastic cover and the welded flange are injection molded from the same plastic material.

[0011] The welding equipment includes an L-shaped base, a guide rail horizontally mounted on the lower part of the L-shaped base, a slide block slidably connected to the guide rail, a U-shaped platform connected to the slide block, a guide sleeve mounted on the U-shaped platform, a guide post vertically slidably connected inside the guide sleeve, a welding seat for placing a PTC heater connected to the guide post, an adjusting screw vertically threadedly connected to the U-shaped platform, the adjusting screw and the welding seat rotatably connected, a fastening nut threadedly connected to the adjusting screw, a housing mounted on the upper part of the L-shaped base, an ultrasonic welding head that can move up and down on the housing, and the ultrasonic welding head can cooperate with the welding seat.

[0012] The ultrasonic welding head has clearance holes.

[0013] The U-shaped platform is also connected to a basket.

[0014] The lower part of the L-shaped base is connected to an auxiliary seat. A V-shaped control arm is rotatably connected to the auxiliary seat via a mounting shaft. A guide wheel is installed at one end of the V-shaped control arm, and an L-shaped groove is opened at the other end of the V-shaped control arm. A crossbar is installed on the U-shaped platform. The crossbar 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. A torsion spring is also installed on the mounting shaft. One end of the torsion spring abuts against the V-shaped control arm, and the other end of the torsion spring abuts against the auxiliary seat. A second guide post is also vertically installed at the lower part of the L-shaped base. A second guide sleeve is slidably connected to the second guide post. A lifting beam that can move up and down is connected to the second guide sleeve. 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 abuts against the guide wheel.

[0015] The other end of the V-shaped control arm is also equipped with a stopper that cooperates with the torsion spring.

[0016] A power motor is installed inside the housing. The output shaft 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 driving rod arm. The other end of the driving rod arm is rotatably connected to the connector. The connector is also rotatably connected to one end of the upper driven rod arm and one end of the lower driven rod arm. The other end of the upper driven rod arm is rotatably connected to the housing. 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 housing. A middle rod arm is vertically slidably installed on the guide block. The upper end of the middle rod arm is connected to the middle of the lower part of the reciprocating seat. The lower end of the middle rod arm passes through the lifting beam and is detachably connected to the ultrasonic welding head through the connecting cylinder.

[0017] Compared with existing technologies, the welding process of this PTC heater has the following advantages:

[0018] The process used in this invention is simple to operate, requires fewer parts, and can achieve an IP67 waterproof rating, providing good waterproof sealing performance; at the same time, the welding is reliable and safe. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the product in this invention;

[0020] Figure 2 This is a schematic diagram of the product with the part removed in this invention;

[0021] Figure 3 This is a schematic diagram of the device in this invention;

[0022] Figure 4 This is a schematic diagram of the disassembly section of the device in this invention. Figure 1 ;

[0023] Figure 5 This is a schematic diagram of the disassembly section of the device in this invention. Figure 2 ;

[0024] Figure 6 This is a schematic diagram of the disassembly section of the device in this invention. Figure 3 ;

[0025] Figure 7 This is a schematic diagram of the disassembly section of the device in this invention. Figure 4 ;

[0026] In the diagram: 1. L-shaped base; 2. V-shaped control arm; 201. L-shaped groove; 3. Guide wheel; 4. L-shaped pressing rod; 5. Lifting beam; 6. Housing; 7. Guide sleeve two; 8. Intermediate rod arm; 9. Guide post two; 10. Connecting cylinder; 11. Ultrasonic welding head; 1101. Clearance hole; 12. U-shaped platform; 13. Welding seat; 14. Placement basket; 15. Guide post one; 16. Slide seat; 17. Guide rail; 18. Guide sleeve one; 19. Crossbar; 20. Guide shaft; 21. PTC heater; 2101, plastic housing; 2102, electrical module; 2103, plastic cover plate; 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, driving rod arm; 33, upper driven rod arm; 34, lower driven rod arm; 35, connector; 36, guide block. Detailed Implementation

[0027] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0028] like Figures 1-7 The welding process for this PTC heater 21 includes the following steps:

[0029] S1. Install the electrical module 2102 into the plastic housing 2101, and then pre-fix the plastic cover plate 2103 to the plastic housing 2101 through the pin structure.

[0030] S2. Place the pre-fixed plastic shell 2101 into the welding equipment. The parts to be welded are located at the welding seat 13, and the parts not to be welded are located in the placement basket 14.

[0031] S3. Start the welding equipment to perform welding. Move the ultrasonic welding head 11 downwards, and at the same time, move the welding seat 13 inwards to directly below the ultrasonic welding head 11. Control the welding time to 1-2 seconds, thus completing the welding operation of the PTC heater 21. In this embodiment, the welding time is 1 second. The plastic cover plate 2103 has a downwardly protruding welding flange 2103X. By adopting this structure, the welding flange 2103X is melted, reliably connecting the plastic cover plate 2103 and the plastic shell 2101 together to form an integral structure, thereby achieving a better sealing effect.

[0032] Electrical module 2102 includes a thermostat, fuse, and current fuse, which are existing products.

[0033] The plastic cover plate 2103 and the welding flange 2103X are injection molded from the same plastic material. In this embodiment, the plastic shell 2101 and the plastic cover plate 2103 are also made of the same plastic material.

[0034] The welding equipment includes an L-shaped base 1, with a guide rail 17 horizontally mounted on the lower part of the L-shaped base 1. A slide block 16 is slidably connected to the guide rail 17, and a U-shaped platform 12 is connected to the slide block 16. Specifically, a placement basket 14 is also connected to the U-shaped platform 12; a guide sleeve 18 is installed on the U-shaped platform 12, and a guide post 15 is vertically slidably connected inside the guide sleeve 18. A welding seat 13 for placing a PTC heater 21 is connected to the guide post 15; an adjusting screw 25 is vertically threaded onto the U-shaped platform 12, and the adjusting screw 25 and the welding seat 13 are connected to the guide post 15. The base 13 is rotatably connected, and a fastening nut 27 is threaded onto the adjusting screw 25. With the cooperation of the adjusting screw 25 and the fastening nut 27, the height of the welding base 13 can be adjusted. A housing 6 is installed on the upper part of the L-shaped base 1. An ultrasonic welding head 11 that can be raised and lowered is provided on the housing 6. The ultrasonic welding head 11 can cooperate with the welding base 13. In this embodiment, the welding operation is completed by the ultrasonic welding head 11 cooperating with the welding base 13 downward. This is a prior art technique.

[0035] The ultrasonic welding head 11 has a clearance hole 1101. This structure can prevent damage to the electrical module during welding operations.

[0036] An auxiliary seat 24 is connected to the lower part of the L-shaped base 1. A V-shaped control arm 2 is rotatably connected to the auxiliary seat 24 via a mounting shaft 23. A guide wheel 3 is mounted on one end of the V-shaped control arm 2, and an L-shaped groove 201 is opened on the other end of the V-shaped control arm 2. A crossbar 19 is mounted on the U-shaped platform 12. The crossbar 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 mounted on the mounting shaft 23. One end of the torsion spring 22 abuts against the V-shaped control arm 2. Specifically, a stop piece 26 that cooperates with the torsion spring 22 is also mounted on the other end of the V-shaped control arm 2; the other end of the torsion spring 22 abuts against the auxiliary seat 24; a guide post 9 is also vertically mounted on the lower part of the L-shaped base 1. A guide sleeve 7 is slidably connected to the second 9, and a lifting beam 5 that can move 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 abuts against the guide wheel 3. With this structure, when the lifting beam 5 moves downward, it drives the L-shaped pressing rod 4 to move downward. The L-shaped pressing rod 4 presses the guide wheel 3, causing the V-shaped control arm 2 to swing accordingly. With the cooperation of the guide shaft 20 and the L-shaped groove 201, the slide 16 can move inward along the guide rail 17, thereby causing the U-shaped platform 12 to move inward, and finally placing the welding seat 13 directly below the ultrasonic welding head 11. When loading and unloading, the welding seat 13 is located on the outside, which makes it convenient to pick up and put down the PTC heater 21.

[0037] A power motor 31 is installed inside the housing 6. The output shaft 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 driving rod arm 32. The other end of the driving rod arm 32 is rotatably connected to the connector 35. The connector 35 is also rotatably connected to one end of the upper driven rod arm 33 and one end of the lower driven rod arm 34. The other end of the upper driven rod arm 33 is rotatably connected to the housing 6, and the other end of the lower driven rod arm 34 is rotatably connected to... The lifting beam 5 is rotatably connected to the connecting lug. A guide block 36 is also installed on the housing 6. A middle rod arm 8 is vertically slidably installed on the guide block 36. The upper end of the middle rod arm 8 is connected to the middle of the lower part of the reciprocating seat 28. The lower end of the middle rod arm 8 passes through the lifting beam 5 and is detachably connected to the ultrasonic welding head 11 through the connecting cylinder 10. With this structure, the lifting beam 5 can be driven to move downward quickly by the power motor 31, so that the welding seat 13 is located directly below the ultrasonic welding head 11. Then, the reciprocating seat 28 drives the ultrasonic welding head 11 to move downward slowly, thereby completing the welding operation.

[0038] All of the above components are general standard parts or components known to those skilled in the art. Their structure and principles can be learned by those skilled in the art through technical manuals or conventional experimental methods.

[0039] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A welding process for a PTC heater, characterized in that, Includes the following steps: S1. Install the electrical module (2102) into the plastic housing (2101), and then pre-fix the plastic cover plate (2103) to the plastic housing (2101) through the pin structure; S2. Place the pre-fixed plastic shell (2101) into the welding equipment. The parts to be welded are located at the welding seat (13), and the parts not to be welded are located in the placement basket (14). S3. Start the welding equipment to perform welding. Move the ultrasonic welding head (11) downwards. At the same time, the welding seat (13) moves inwards to the direct underside of the ultrasonic welding head (11). The welding time is controlled within 1-2 seconds, thus completing the welding operation of the PTC heater (21). The welding equipment includes an L-shaped base (1), with a guide rail (17) horizontally mounted on the lower part of the L-shaped base (1). A slide block (16) is slidably connected to the guide rail (17), and a U-shaped platform (12) is connected to the slide block (16). A guide sleeve (18) is mounted on the U-shaped platform (12), and a guide post (15) is vertically slidably connected inside the guide sleeve (18). A welding seat (13) for placing a PTC heater (21) is connected to the guide post (15). An adjusting screw (25) is vertically threaded onto the platform (12). The adjusting screw (25) and the welding seat (13) are rotatably connected. A fastening nut (27) is also threaded onto the adjusting screw (25). A housing (6) is installed on the upper part of the L-shaped base (1). An ultrasonic welding head (11) that can move up and down is provided on the housing (6), and the ultrasonic welding head (11) can cooperate with the welding seat (13). An auxiliary seat is connected to the lower part of the L-shaped base (1). (24) A V-shaped control arm (2) is rotatably connected to the auxiliary seat (24) via the mounting shaft (23). A guide wheel (3) is installed at one end of the V-shaped control arm (2), and an L-shaped groove (201) is opened at the other end of the V-shaped control arm (2). A crossbar (19) is installed on the U-shaped platform (12). One end of the crossbar (19) is rotatably connected to the guide shaft (20), and the other end of the guide shaft (20) is located in the L-shaped groove (201). The mounting shaft (23) also has a torsion bar. Spring (22), one end of torsion spring (22) abuts against V-shaped control arm (2), and the other end of torsion spring (22) abuts against auxiliary seat (24); guide column two (9) is also vertically installed on the lower part of L-shaped base (1), guide sleeve two (7) is slidably connected on guide column two (9), and lifting beam (5) that can be raised and lowered is connected on guide sleeve two (7). Lifting beam (5) is connected to the upper end of L-shaped pressing rod (4), and the lower end of L-shaped pressing rod (4) abuts against guide wheel (3).

2. The 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. The welding process for a PTC heater according to claim 1, characterized in that, The plastic cover plate (2103) has a downwardly protruding welded flange (2103X).

4. The welding process for a PTC heater according to claim 3, characterized in that, The plastic cover plate (2103) and the welding flange (2103X) are injection molded from the same plastic material.

5. The welding process for a PTC heater according to claim 1, characterized in that, The ultrasonic welding head (11) has a clearance hole (1101).

6. The welding process for a PTC heater according to claim 1, characterized in that, A placement basket (14) is also connected to the U-shaped platform (12).

7. The welding process for a PTC heater according to claim 1, characterized in that, The other end of the V-shaped control arm (2) is also equipped with a stop (26) that cooperates with the torsion spring (22).

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