Manufacturing method of heating device and heating device

Abstract

The invention relates to the technical field of electric heating devices, and discloses a manufacturing method of a heating device, which is characterized in that a heating core is processed in a preset shape, so that the heating core can be accurately matched with a to-be-heated piece, heat distribution is matched and reliable, a plurality of heating sub-pieces can be independently connected with electrodes, and multi-temperature-zone coordinated regulation is realized. And secondly, the insulating part and the bonding part which are processed in the same preset shape are used, so that the assembly error is eliminated, and the overall stability of the heating device is improved. Moreover, the metal electrode is connected to the heating core, then the metal electrode and the heating core are stacked in sequence to obtain a stacked piece, a bonding piece is softened and permeates into micropores of the heating core and the insulating piece through hot pressing, a compact heating blank is formed, the overall mechanical strength of the heating device is enhanced, and finally a power line is connected to the metal electrode, so that manufacturing of the heating device is completed. According to the manufacturing method of the heating device, the stability of the heating device and the matching performance of the heating device and the to-be-heated piece are greatly improved through the technical methods of customizing the assembly and laminating and hot pressing.

Description

Technical Field

[0001] This invention relates to the field of electric heating device technology, and in particular to a method for manufacturing a heating device and a heating device. Background Technology

[0002] As high-end equipment develops towards miniaturization, integration, and high precision, the heating requirements for heating elements are also increasing. In industrial equipment heating systems, electric heating tubes or electromagnetic heating are typically arranged below the workpiece to be heated. Electric heating tubes are relatively thick and difficult to bend, resulting in low wiring density and thus limited controllability of the temperature field in the heating zone. Electromagnetic heating is also limited by the large diameter of the induction coil wires, making bending difficult, resulting in low wiring density and interference between the wires, further hindering temperature field controllability. Therefore, there is an urgent need for a manufacturing method for a heating device that offers high heating stability, a stable temperature field, precise matching with the workpiece to be heated, and high integration. Summary of the Invention

[0003] The purpose of this invention is to provide a method for manufacturing a heating device with controllable temperature field.

[0004] To achieve this objective, the present invention adopts the following technical solution:

[0005] A method for manufacturing a heating device, the heating device comprising a heating core, an insulating component, and an adhesive component stacked together, wherein a metal electrode is connected to the heating core, and the insulating component is connected to the heating core via the adhesive component, the method comprising the following steps:

[0006] S10. Prepare the heating core, the insulating component, and the adhesive component with a preset shape, wherein the preset shape is one of annular, circular, U-shaped, or polygonal, and prepare a metal electrode;

[0007] S20. Connect the metal electrode to the heating element;

[0008] S30. The insulating component, the adhesive component, the heating core connected to the metal electrode, the adhesive component, and the insulating component are stacked in sequence to form a laminated component;

[0009] S40. The laminated part is hot-pressed to obtain a heated blank;

[0010] S50. Connect the power cord to the metal electrode on the heated blank to obtain a heating device;

[0011] Step S10 includes:

[0012] S101. Multiple heating components are prepared from conductive heating material, and the multiple heating components are spliced ​​together to form the heating core; wherein, if the preset shape is annular, the multiple heating components are all annular with increasing diameters, and the multiple heating components are arranged concentrically, or, the multiple heating components are all fan-shaped; if the preset shape is circular, the multiple heating components are all fan-shaped; if the preset shape is a square or polygonal, the multiple heating components are all spirally encircling;

[0013] The conductive heating material includes one or more of the following: carbon-containing materials, metal-containing materials, or conductive ceramic materials.

[0014] Preferably, step S10 further includes:

[0015] S102. The insulating material is processed into the insulating component having a preset shape;

[0016] S103. The adhesive material is processed into the adhesive component having a preset shape.

[0017] Preferably, the metal electrode and the heating core are connected by at least one of the following methods: bonding, welding, and interlocking mechanical fixation.

[0018] Preferably, in step S30, the laminate is fabricated using a tooling fixture, which has a positioning groove for aligning the insulating component, the adhesive component, and the heating core, and the laminate is placed in the positioning groove.

[0019] Preferably, after step S40 and before step S50, the following steps are further included:

[0020] S45: Trim or punch the heated blank.

[0021] Preferably, in step S40, the process of raising the temperature from room temperature to the hot pressing temperature during the hot pressing process adopts a gradient heating method, and the heating rate is 0.1-10℃ / min.

[0022] Preferably, a vacuum is drawn to a preset vacuum pressure before the room temperature reaches the hot-pressing temperature or after the room temperature reaches the hot-pressing temperature, and maintained under vacuum for a preset time.

[0023] Preferably, in step S50, after connecting the power cord to the metal electrode on the heated blank, the metal electrode and the power cord are insulated and encapsulated with an insulating material.

[0024] Preferably, in step S101, the conductive heating material is used to prepare multiple heating components by laser or mechanical processing.

[0025] The heating device is manufactured by the above-described method, wherein the power density of the heating device is 500-500000W per square meter and the thickness ranges from 0.2 to 10.0mm.

[0026] The beneficial effects of this invention are:

[0027] This invention proposes a method for manufacturing a heating device. The heating device includes a heating core, an insulating component, and an adhesive component stacked together. A metal electrode is connected to the heating core, and the insulating component is connected to the heating core via the adhesive component. In the manufacturing method, the heating core, the insulating component, and the adhesive component with a preset shape are first prepared. The preset shape is one of annular, circular, U-shaped, or polygonal. A metal electrode is also prepared. Then, the metal electrode is connected to the heating core. Next, the insulating component, the adhesive component, the heating core, the adhesive component, and the insulating component are stacked sequentially to form a laminated assembly. The laminated assembly is then hot-pressed to obtain a heating blank. Finally, a power line is connected to the metal electrode on the heating blank to obtain the heating device. In the preparation of the heating core with a preset shape, the process involves fabricating multiple heating components from conductive heating material. These components are then assembled to form the heating core. If the preset shape is annular, all heating components are annular with increasing diameters and concentrically arranged; alternatively, they may be fan-shaped. If the preset shape is circular, they are fan-shaped. If the preset shape is U-shaped or polygonal, they are spirally arranged. The conductive heating material includes one or more of carbon-containing, metallic, or conductive ceramic materials. First, by processing the heating core into the preset shape, it is ensured that the heating core can precisely match the object to be heated, ensuring a consistent and reliable heat distribution. In this manufacturing method, multiple heating components can be independently connected to electrodes, enabling coordinated control of multiple temperature zones. Second, using insulating and bonding components with the same preset shape eliminates assembly errors and improves the overall stability of the heating device. Furthermore, metal electrodes are connected to the heating core, and then stacked sequentially to form a laminate. Hot pressing is used to soften the adhesive, allowing it to penetrate into the micropores of the heating core and insulating components, forming a dense heating blank. This enhances the overall mechanical strength of the heating device. Finally, the power cord is connected to the metal electrodes, completing the manufacturing of the heating device. This heating device manufacturing method, through customized components and the stacked hot pressing technique, significantly improves the stability of the heating device and its compatibility with the workpiece to be heated.

[0028] On the other hand, the present invention also proposes a heating device, which is manufactured by the above-mentioned heating device manufacturing method and has high adaptability and high heating stability. Attached Figure Description

[0029] Figure 1This is a schematic flowchart of the manufacturing method of the heating device proposed in the embodiments of the present invention;

[0030] Figure 2 This is an exploded view of the heating device proposed in the embodiments of the present invention;

[0031] Figure 3 This is a schematic diagram of the structure of a heating device with a pre-defined rectangular shape in an embodiment of the present invention;

[0032] Figure 4 This is a structural schematic diagram of a heating device with a pre-defined rectangular shape, as shown in another perspective, in an embodiment of the present invention.

[0033] Figure 5 This is a schematic diagram of the structure of a heating device with a pre-defined annular rectangular shape in an embodiment of the present invention;

[0034] Figure 6 This is a structural schematic diagram of a heating device with a pre-defined annular rectangular shape, as shown in another perspective of an embodiment of the present invention.

[0035] Figure 7 This is a schematic diagram of the structure of a heating device with a pre-defined annular shape in an embodiment of the present invention;

[0036] Figure 8 This is a structural schematic diagram of a heating device with a pre-set circular shape, as shown in another perspective, in an embodiment of the present invention.

[0037] In the picture:

[0038] 1. Heating element; 2. Insulating component; 3. Adhesive component; 4. Metal electrode; 5. External terminal. Detailed Implementation

[0039] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0040] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0041] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0042] In the description of this embodiment, the terms "upper," "lower," "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. In addition, the terms "first" and "second" are used only for distinction in description and have no special meaning.

[0043] This embodiment discloses a method for manufacturing a heating device, referring to... Figure 2 The heating device includes a heating core 1, an insulating component 2, and an adhesive component 3 stacked together. A metal electrode 4 is connected to the heating core 1. The insulating component 2 is connected to the heating core 1 via the adhesive component 3. The heating core 1, insulating component 2, and adhesive component 3 are all layered structures, and the heating device as a whole has a plate-like structure. In some embodiments, there is one heating core 1, two insulating components 2, and at least two adhesive components 3. Adhesive components 3 are provided on both sides of the heating core 1, and the two insulating components 2 are respectively located on the side of the two adhesive components 3 away from the heating core 1. The manufacturing method of the heating device is described in reference [reference needed]. Figure 1 This includes the following steps:

[0044] S10. Prepare a heating core 1, an insulating component 2, and an adhesive component 3 with a preset shape, wherein the preset shape is one of annular, circular, square, or polygonal; prepare a metal electrode 4.

[0045] S20. Connect the metal electrode 4 to the heating core 1;

[0046] S30. The insulating component 2, the adhesive component 3, the heating core 1 connected to the metal electrode 4, the adhesive component 3 and the insulating component 2 are stacked in sequence to form a laminated component;

[0047] S40. The laminated parts are hot-pressed to obtain a heated blank.

[0048] S50. Connect the power cord to the metal electrode 4 on the heated blank to obtain the heating device.

[0049] Further, step S10 includes: S101, preparing multiple heating components from conductive heating material, and splicing the multiple heating components to form heating core 1; wherein, if the preset shape is annular, the multiple heating components are all annular with increasing diameters and are arranged concentrically, or, the multiple heating components are all fan-shaped; if the preset shape is circular, the multiple heating components are all fan-shaped; if the preset shape is a square or polygonal, the multiple heating components are all spirally encircling.

[0050] First, in step S10, the process includes preparing the heating core 1, the insulating component 2, and the adhesive component 3. This process is the preparation of the basic components. The metal electrode 4 is connected to the heating core 1. After the metal electrode 4 is connected to a power source, current can be directly introduced into the interior of the heating core 1. Because the material resistance of the heating core 1 impedes the current flow, electrical energy is converted into heat energy, and the entire heating core 1 is connected to the power source to generate heat, ensuring uniform heat distribution. In addition, the insulating component 2 provides electrical isolation and safety protection, while the adhesive component 3 acts as an intermediate layer, providing adhesion and eliminating assembly errors, thus improving the stability of the heating device. Furthermore, multiple adhesive components 3 can be provided; that is, multiple adhesive components 3 can be provided between the heating core 1 and the insulating component 2 to improve connection stability. When there are two adhesive components 3, the heating core 1 can be located between the two adhesive components 3. When the number of adhesive components 3 is greater than two, the number of adhesive components 3 provided on both sides of the heating core 1 can be the same or different. This heating device manufacturing method significantly improves the stability of the heating device and its compatibility with the heated component through customized components and layered hot pressing technology. Furthermore, this manufacturing method is easy to operate, low in cost, and applicable to most heating scenarios. Further, based on the specific preset shape of the heating core 1, heating components of different shapes are manufactured. Taking a pre-set circular shape as an example, the heating core 1 is disassembled into multiple concentric circular or fan-shaped heating components. High-density filling is achieved through these multiple heating components, increasing the number of heat sources per unit area several times, thus improving heating stability. Moreover, multiple heating components can be independently connected to electrodes, enabling multi-temperature zone coordinated control, actively offsetting thermal field distortion, and improving the uniformity of heating temperature differences. The conductive heating material includes one or more of carbon-containing, metal-containing, or conductive ceramic materials, possessing excellent cutability and supporting the processing of complex curved surface microstructures. It is understandable that the heating elements are specifically formed by the folding of heating wires. For example, when the heating element is ring-shaped, the conductive heating material is processed into one or more heating wires, and the folded-back heating wires form a ring shape. When the heating element is fan-shaped, the conductive heating material is processed into one or more heating wires, and the folded-back heating wires form a fan-shaped ring. Similarly, when the preset shape is circular, multiple heating elements are fan-shaped structures, with the conductive heating material processed into one or more heating wires, and the folded-back heating wires form a fan shape. When the preset shape is a U-shape or polygon, the heating element is spirally coiled, with the conductive heating material processed into one or more heating wires, and the heating wires spirally coiled. In more embodiments, the heating elements can also be processed into other shapes, which will not be listed here. For example, regardless of the specific structure of the preset shape, the shapes of multiple heating elements can be all different or partially different, as long as multiple heating elements can be spliced ​​together to form a heating core 1 with the preset shape.

[0051] Each heating element is connected to two or more metal electrodes 4, ensuring that each heating element can heat independently. Therefore, zoned heating can be achieved according to the heating requirements of the workpiece, enabling multi-temperature zone coordinated control and adapting to various heating conditions. For example, when the preset shape is annular, if multiple heating elements are all annular with increasing diameters and are concentrically arranged, the multiple annular heating elements are spliced ​​together to form an annular heating core 1, which can be applied to conditions where the heating requirements of the middle and edge areas of the workpiece are different; when multiple heating elements are fan-shaped, the multiple fan-shaped elements are spliced ​​together to form an annular heating core 1, which can be applied to conditions where the heating requirements of different local areas of the workpiece are different. The same applies when the preset shape is circular, U-shaped, or polygonal.

[0052] Furthermore, when the preset shape is annular, whether the heating element is annular or fan-shaped, the thickness of the multiple heating elements can vary, or the thickness of different segments within each heating element can differ, or the thickness and width of different segments can differ. Since the heating element is formed by the folding of heating wires, the difference in wire thickness is reflected in the wire's shape. Thicker heating wires produce less heating power and are suitable for locations requiring low-temperature heating, while thinner heating wires, due to their smaller diameter, can be more easily bent and installed in confined spaces, making them suitable for bending areas. The same principle applies when the preset shape is circular, U-shaped, or polygonal. In more embodiments, during the folding process, the heating wire can also generate a multi-path branch structure. For example, the heating wire can physically split at the folding node or non-node to form two or more branches, thereby creating two or more parallel current paths to achieve localized temperature control.

[0053] In other embodiments, the heating device may also include multiple sub-heating structures, each of which includes a heating core 1, an insulating component 2, and an adhesive component 3 stacked together. The heating core 1, the insulating component 2, and the adhesive component 3 in each sub-heating structure are all fan-shaped, and thus each sub-heating structure as a whole presents a fan-shaped structure. Multiple sub-heating structures are spliced ​​together to form a complete heating device.

[0054] Furthermore, step S10 also includes:

[0055] S102. The insulating material is processed into an insulating component 2 with a preset shape;

[0056] S103, Process the adhesive material into an adhesive part 3 with a preset shape.

[0057] In this process, the conductive heating material is processed separately to prepare the heating core 1, allowing for targeted control of the resistance distribution. For example, local impedance can be adjusted through laser etching to achieve controllable temperature field. Based on the target heating area of ​​the heating device and power requirements, the resistance value of the conductive heating material can be calculated to determine the material thickness and effective heating area, ensuring heating efficiency. Specifically, laser or mechanical processing can be used to process the conductive heating material into multiple heating components. These components are then assembled to form the heating core 1. Insulating and bonding materials are mechanically processed to obtain insulating component 2 and bonding component 3, respectively. The conductive heating material can be one or more of carbon-containing, metallic, or conductive ceramic materials, with a sheet resistance ranging from 0.00001 to 10000 Ω / □ and a thickness ranging from 0.01 to 5 mm. The insulating material can be a high-temperature resistant insulating material, such as silicone, polyimide, or mica composite sheet. When polyimide film is used as the insulating material, its thickness ranges from 0.02 to 2 mm. When mica composite sheet is used, its insulation strength is greater than 10 kV / mm, and its thickness ranges from 0.02 to 4.0 mm. Specifically, the mica composite sheet is a composite structure of mica paper and glass fiber cloth. The bonding material is made of one or more of epoxy resin, polyimide, silicone, bismaleimide resin, cyanate ester resin, and phenolic resin, combined with one or more of pre-oxidized carbon fiber, glass fiber, aramid fiber, alumina fiber, quartz fiber, boron nitride fiber, silicon carbide fiber, silicon nitride fiber, basalt fiber, and polyimide fiber. The bonding material has a temperature resistance range greater than 120℃ and a thickness range of 0.02 to 2 mm. Additionally, it should be explained that although the heating element 1, the insulating element 2, and the adhesive element 3 are all of a preset shape, the dimensions of the insulating element 2 and the adhesive element 3 are slightly larger than or equal to the dimensions of the heating element 1, ensuring that the insulating element 2 and the adhesive element 3 completely cover the heating element 1.

[0058] Furthermore, in step S101, multiple heating components are prepared from the conductive heating material, and these components are spliced ​​together to form the heating core 1. Multiple external ends 5 are machined onto the heating core 1. The number of external ends 5 is related to the number of electrodes in each heating component; specifically, two or more external ends 5 are machined onto each heating component. It is understood that the heating core 1 is specifically used for heating, and the two external ends 5 provide mounting and connection positions for the metal electrodes 4. The external ends 5 may protrude from the laminated component, or be recessed within the laminated component, or be flush with the outer peripheral sidewall of the laminated component. In this embodiment, the external ends 5 protrude from the laminated component. The dimensional tolerance of the heating core 1 is ±0.03 mm, and the length of each of the two external ends 5 ranges from 10-30 mm, and the width ranges from 2-5 mm.

[0059] Then, in step S20, the metal electrode 4 is connected to the heating core 1, and the metal electrode 4 is correspondingly disposed on the two external ends 5. The metal electrode 4 is connected to the heating core 1 by at least one of the following methods: bonding, welding, and interlocking mechanical fixation. The metal electrode 4 is specifically disposed on the external ends 5 to facilitate connection with an external power cord. In this embodiment, the metal electrode 4 is a short energizing segment, connected to the two ends of the heating component in each heating core 1. After being energized, the metal electrode 4 supplies power to the heating core 1, and the heating core 1 emits heat. In other embodiments, the metal electrode 4 may be connected to the upper surface of the heating core 1, or to the lower surface of the heating core 1 (not shown in the figure), or partially connected to the upper surface of the heating core 1 and partially connected to the lower surface of the heating core 1 (not shown in the figure). In other embodiments, a heat spreader may be provided on the heating core 1. This heat spreader is laid on the upper and lower surfaces of the adhesive or insulating layer on the outer side of the heating core 1 to form an all-around heat-conducting layer. When the heating core 1 generates heat, the heat spreader utilizes its high thermal conductivity to laterally disperse the concentrated heat generated by the heating core 1, ensuring uniform heat distribution and preventing localized burn-out. Furthermore, the heat spreader may specifically be one or more of copper, aluminum, and carbon.

[0060] In this embodiment, the two terminals of the metal electrode 4 are respectively disposed on two external terminals 5 for easy connection to an external power cord. The metal electrode 4 is polished and is made of one or more of the following materials: copper, aluminum, titanium, gold, silver, tin, nickel, and chromium. The metal electrode 4 is connected to the heating core 1, and its thickness ranges from 0.01 to 3 mm. The terminals of the metal electrode 4 are attached to the external terminals 5, and the contact area between them is greater than 5 mm². When the metal electrode 4 is connected to the heating core 1 by welding, ultrasonic welding or brazing can be used. When the metal electrode 4 is connected to the heating core 1 by adhesive bonding, conductive adhesive can be used. When the metal electrode 4 is connected to the heating core 1 by a mechanical fastening method, rivets or multi-claw fasteners can be used.

[0061] Further, in step S30, a laminated component is fabricated using a tooling fixture. The tooling fixture is provided with a positioning groove for aligning the insulating component 2, the adhesive component 3, and the heating core 1. The laminated component is placed within the positioning groove. Specifically, the tooling fixture has a recessed positioning groove. Before forming the laminated component, the insulating component 2, the adhesive component 3, the heating core 1 connected to the metal electrode 4, and the adhesive component 2 are placed sequentially within the positioning groove. Under the action of the positioning groove, the axes of the insulating component 2, the adhesive component 3, and the heating core 1 connected to the metal electrode 4 are completely aligned, ensuring that the insulating component 2, the adhesive component 3, and the heating core 1 connected to the metal electrode 4 can be aligned, thus ensuring the stability of the laminated component and, consequently, the stability of the heating device. The positioning groove has two clearance grooves at its edges, which are connected to the interior of the positioning groove. Each clearance groove corresponds to one of the two external ends 5 on the heating core 1. When the laminated assembly is placed in the positioning groove, the heating core 1, adhesive component 3, and insulating component 2 are stacked within the positioning groove, while the two external ends 5 on the heating core 1 are located within the clearance grooves. The clearance grooves prevent interference between the external ends 5 and the tooling fixture, ensuring that the laminated assembly can be smoothly placed in the positioning groove for alignment. The diameter tolerance of the positioning hole is ±0.01mm, and the center distance tolerance is ±0.02mm.

[0062] During steps S30 and S40, the insulating component 2, the adhesive component 3, the heating core 1, the adhesive component 3, and the insulating component 2 are stacked sequentially to form a laminated assembly. The laminated assembly has a stacked design to ensure electrical isolation and structural stability. Then, it is formed by hot pressing, including one or more of hot pressing machines, hot press tanks, and vacuum bag hot pressing. During the hot pressing process, the adhesive component 3 inside the laminated assembly softens and penetrates into the micropores of the heating core 1 and the insulating component 2 to form a dense and seamless heating blank, which strengthens the overall mechanical strength. In addition, the insulating components 2 on both sides form an overall seal, which enhances the moisture resistance and corrosion resistance.

[0063] In step S40, the laminated parts are hot-pressed to obtain a heated blank. During the hot-pressing process, a gradient heating method is used to raise the temperature from room temperature to the hot-pressing temperature at a rate of 0.1-10°C / min. This gradient heating method reduces energy consumption and prevents internal defects such as cracks in the heated blank, thereby improving the overall quality of the heating device. Further, before or after reaching the hot-pressing temperature from room temperature, a vacuum is drawn to a preset vacuum pressure and maintained under vacuum for a preset time. In this embodiment, after reaching the hot-pressing temperature from room temperature, a vacuum is drawn to a preset vacuum pressure and maintained under vacuum for a preset time, which is 20-60 minutes. Specifically, after reaching the hot-pressing temperature from room temperature, a vacuum is drawn to a preset vacuum pressure for a preset time of 20-60 minutes, and this preset time can be adjusted according to the different bonding parts 3. After hot pressing, restore normal pressure and then cool down to below 80℃ at a rate of 1-20℃ / min before removing the heated blank. It should also be noted that the specific parameters of hot pressing are related to the specific material used in the bonded part 3 to ensure its high adhesion. For example, if the bonded part 3 is mainly made of epoxy resin, the hot pressing temperature is 150-180℃, the pressure is 0.3-5MPa, the total time is 1-30h, and the absolute vacuum pressure is 0.05-101kPa; if the bonded part 3 is mainly made of polyimide, the hot pressing temperature is 200-380℃, the pressure is 0.3-15MPa, the total time is 2-18h, and the absolute vacuum pressure is 0.05-101kPa; if the bonded part 3 is mainly made of silicone, the hot pressing temperature is 120-300℃, the pressure is 0.2-2MPa, the total time is 1-5h, and the absolute vacuum pressure is 0.05-101kPa.

[0064] After step S40 and before step S50, step S45 is also included: trimming or punching the heated blank. Since the heated blank obtained after hot pressing the laminated part will have overflow edges, it needs to be trimmed or punched. The dimensional tolerance of the trimmed heated blank is ±0.05mm.

[0065] Finally, in step S50, after connecting the power cord to the metal electrode 4 on the heated blank, the exposed metal electrode 4 is insulated and encapsulated with insulating material to prevent short circuits and ensure the safety and stability of the heating device. Specifically, high-temperature insulating resin or plastic can be wrapped or coated at the connection between the power cord and the metal electrode 4, so that the high-temperature insulating resin or plastic tightly wraps the connection part, completing the manufacturing of the heating device. The metal electrode 4 and the power cord are connected via terminals. Specifically, one end of the terminal is fixed to the metal electrode 4 by riveting, welding, or crimping, and the other end of the terminal is connected to the internal battery core of the power cord by crimping or welding, thus achieving the connection between the metal electrode 4 and the power cord. The terminals are made of pure copper or copper alloy, with a cross-sectional area greater than 0.5 mm² at both ends, and the contact resistance when the terminal is connected to the internal battery core of the power cord is no greater than 0.1 Ω. After the heating device is manufactured, the power density is 500-500000W per square meter, and the thickness ranges from 0.2-10.0 mm.

[0066] On the other hand, this embodiment also proposes a heating device, manufactured by the above-described method, which is adaptable to various components to be heated, exhibiting high adaptability and high heating stability. (Refer to...) Figures 3 to 8 The preset shape is square, spiral, or ring. In more embodiments, the preset shape can also be one of rectangle, circle, or polygon.

[0067] Taking a rectangular shape as an example, the manufacturing process of the heating device is explained:

[0068] S1. The conductive heating material is a nano-silver composite film with a thickness of 0.02mm and a sheet resistance of 7Ω / □, which is cut into a rectangle with a size of 37×37cm as the heating core 1, while leaving two external ends 5 with a length of 15mm and a width of 3mm.

[0069] S2. The insulating material is a polyimide film with a thickness of 0.05mm and an insulation strength greater than 100kV / mm. Two rectangles with a size of 37×37cm are cut out as insulating parts 2.

[0070] S3. The bonding material is a phenolic resin and glass fiber composite with a thickness of 0.1mm and a temperature resistance greater than 200℃. Ten rectangles with a size of 37×37cm are cut out as bonding parts 3.

[0071] S4. The metal electrode 4 is a copper electrode with a thickness of 0.05mm, a width of 15mm, and a length of 40mm. It is bonded to the heating core 1 with conductive adhesive. At the same time, the two terminals of the metal electrode 4 are connected to the two external terminals 5 respectively.

[0072] S5. On the tooling fixture, the insulating part 2, the adhesive part 3, the heating core 1 with metal electrode 4, the adhesive part 3, and the insulating part 2 are stacked in sequence to form a laminated part;

[0073] S6. The laminated parts are hot-pressed at a temperature of 180℃, a pressure of 0.3MPa, a time of 12h, and a vacuum absolute pressure of 10kPa. The hot pressing is completed to form a heated blank.

[0074] S7. Trim the heated blank into a rectangle of 37×37cm;

[0075] S8. Connect the power cord to the metal electrode 4 on the heated blank, and encapsulate the metal electrode 4 with insulating material.

[0076] When the preset shape is a ring-shaped rectangle, only the specific dimensions of the heating core 1, insulating component 2, and adhesive component 3 are changed. For example, the heating core 1, insulating component 2, and adhesive component 3 can all be cut into ring-shaped rectangles with an outer diameter of 35×35cm and an inner diameter of 18×18cm. All other process parameters remain unchanged, and the manufacturing process will not be described in detail here. When the preset shape is a circular ring, the heating core 1, insulating component 2, and adhesive component 3 can all be cut into a circular ring with an outer diameter of 90cm and an inner diameter of 36cm. All other process parameters remain unchanged, and the manufacturing process will not be described in detail here.

[0077] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A method for manufacturing a heating device, characterized in that, The heating device includes a heating core (1), an insulating component (2), and an adhesive component (3) stacked together. A metal electrode (4) is connected to the heating core (1). The insulating component (2) is connected to the heating core (1) through the adhesive component (3). The manufacturing method of the heating device includes the following steps: S10. Prepare the heating core (1), the insulating component (2) and the adhesive component (3) with a preset shape, wherein the preset shape is one of annular, circular, square or polygonal, and prepare the metal electrode (4). S20. Connect the metal electrode (4) to the heating core (1); S30. The insulating component (2), the adhesive component (3), the heating core (1) connected to the metal electrode (4), the adhesive component (3) and the insulating component (2) are stacked in sequence to form a laminated component; S40. The laminated part is hot-pressed to obtain a heated blank; S50. Connect the power cord to the metal electrode (4) on the heated blank to obtain a heating device; Step S10 includes: S101. Multiple heating components are prepared from conductive heating material, and the multiple heating components are spliced ​​together to form the heating core (1); wherein, if the preset shape is annular, the multiple heating components are all annular with increasing diameters, and the multiple heating components are arranged concentrically, or, the multiple heating components are all fan-shaped; if the preset shape is circular, the multiple heating components are all fan-shaped; if the preset shape is a square or polygonal, the multiple heating components are all spirally encircled. The conductive heating material includes one or more of the following: carbon-containing materials, metal-containing materials, or conductive ceramic materials.

2. The method for manufacturing the heating device according to claim 1, characterized in that, Step S10 further includes: S102. The insulating material is processed into the insulating component (2) having a preset shape; S103. The adhesive material is processed into the adhesive component (3) having a preset shape.

3. The method for manufacturing the heating device according to claim 1, characterized in that, The metal electrode (4) and the heating core (1) are connected by at least one of the following methods: bonding, welding and interlocking mechanical fixation.

4. The method for manufacturing the heating device according to claim 1, characterized in that, In step S30, the laminated component is fabricated using a tooling fixture. The tooling fixture is provided with a positioning groove for aligning the insulating component (2), the adhesive component (3), and the heating core (1). The laminated component is placed in the positioning groove.

5. The method for manufacturing the heating device according to claim 1, characterized in that, After step S40 and before step S50, the following steps are also included: S45: Trim or punch the heated blank.

6. The method for manufacturing the heating device according to claim 1, characterized in that, In step S40, during the hot pressing process, the process of raising the temperature from room temperature to the hot pressing temperature adopts a gradient heating method, and the heating rate is 0.1-10℃ / min.

7. The method for manufacturing the heating device according to claim 6, characterized in that, Before or after the room temperature reaches the hot-pressing temperature, a vacuum is drawn to a preset vacuum pressure and maintained under vacuum for a preset time.

8. The method for manufacturing the heating device according to claim 1, characterized in that, In step S50, after connecting the power line to the metal electrode (4) on the heated blank, the metal electrode (4) and the power line are insulated and encapsulated with insulating material.

9. The method for manufacturing the heating device according to claim 1, characterized in that, In step S101, multiple heating components are prepared from the conductive heating material using laser or mechanical processing techniques.

10. A heating device, characterized in that, The heating device is manufactured by the method of any one of claims 1-9, wherein the power density of the heating device is 500-500000W per square meter and the thickness is 0.2-10.0mm.

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