Integrated connection structure of PTC controller and film heater

Abstract

This invention discloses an integrated connection structure for a PTC controller and a membrane heater, including a control box, a bottom shell, a limiting cover plate, and a PCB board disposed within the bottom shell. The control box contains high-voltage connectors and low-voltage connectors leading out high-voltage and low-voltage wire harnesses. The limiting cover plate is fixed inside the control box and is used for regional isolation and guiding of the high-voltage and low-voltage wire harnesses. The PCB board is provided with a terminal block, which has copper terminals corresponding to the high-voltage wire harnesses. The structure also includes an elastic spring plate and a wire harness snap-fit ​​structure disposed between the limiting cover plate and the PCB board. When the control box and the bottom shell are fastened together, the wire harness snap-fit ​​structure, under the elastic force of the elastic spring plate, abuts the end of the high-voltage wire harness against the corresponding copper terminal to achieve electrical conduction. This invention effectively solves the problems of messy wire harness arrangement, easy misassembly, and easy short circuit in a confined space, and simplifies the assembly process.

Description

Technical Field

[0001] This invention relates to the field of membrane heater technology, specifically to an integrated connection structure of a PTC controller and a membrane heater. Background Technology

[0002] Currently, the air conditioning and battery thermal management systems of new energy vehicles typically consist of refrigeration and heating systems. The heating system mainly comprises an air-cooled PTC heater and a water-cooled film heater. In existing integrated solutions for air-cooled PTC controllers and water-cooled film heaters, the connections between high-voltage connectors, low-voltage connectors, and the PCB board are usually achieved by directly soldering high-voltage wire harnesses or by securing terminals to the PCB board with screws.

[0003] The existing connection method has the following shortcomings: First, due to the small internal space of the control box and the long length of the integrated 5 high-voltage wire harnesses and 1 low-voltage wire harness, the wire harnesses are arranged in a messy manner inside the control box, making the assembly process more difficult. Secondly, when multiple high-voltage harnesses are arranged in a space-constrained and messy manner, it is very easy for the harnesses to be installed incorrectly during assembly. Finally, the lack of limiting sleeves at the fixing points on the PCB board and the irregular arrangement of the fastening terminals can easily lead to mutual interference between components, and may even pose a safety hazard of short circuit. Summary of the Invention

[0004] The present invention addresses the problem that existing technical solutions are too simplistic by providing a solution that is significantly different from existing technologies. It mainly provides an integrated connection structure for a PTC controller and a membrane heater to solve the technical problems mentioned in the background.

[0005] The technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: An integrated connection structure for a PTC controller and a membrane heater includes a control box and a base shell. The control box is provided with a high-voltage connector and a low-voltage connector. The control box contains a high-voltage wiring harness and a low-voltage wiring harness respectively connected to the high-voltage connector and the low-voltage connector. The base shell contains a PCB board. The low-voltage wiring harness is connected to the PCB board via a first female connector. The structure also includes: A limiting cover plate is fixedly installed inside the control box. The limiting cover plate isolates and guides the high-voltage wire harness and the low-voltage wire harness respectively. A terminal block is disposed on the PCB board, and the terminal block has copper terminals that correspond one-to-one with the high-voltage wire harness; The elastic component includes an elastic spring plate disposed between the limiting cover and the PCB board, and a wire harness snap-fit ​​structure disposed at the free end of the elastic spring plate; The high-voltage wire harness ends are positioned on the wire harness snap-fit ​​structure. After the control box is fastened to the bottom shell, the wire harness snap-fit ​​structure, under the elastic force of the elastic spring plate, abuts the ends of the high-voltage wire harness against the corresponding copper terminal to achieve electrical conduction.

[0006] Furthermore, the high-voltage harness is provided with a copper lug at its end; The wire harness clip structure includes an insulated clip and a terminal clip located on one side of the clip. The terminal clip is used to clamp and fix the conductor connection of the copper lug, so that the electrical connection of the copper lug remains in contact with the clip.

[0007] Furthermore, the wire clamp is vertically provided with an insulating positioning post, the copper sheet terminal is provided with a positioning hole for the positioning post to pass through, the terminal base is provided with a countersunk hole, and the positioning post passes through the circular hole of the copper lug electrical connection part and the positioning hole and then inserts into the countersunk hole to position the wire clamp and the copper lug. The end of the positioning post is provided with a suction cup, which enhances the stability of the connection between the copper lug and the copper sheet terminal by adhering to the bottom wall of the countersunk hole.

[0008] Furthermore, the terminal block is provided with raised insulating partitions on both sides of each copper terminal; The terminal block with the copper sheet terminals is soldered onto the PCB board by reflow soldering.

[0009] Furthermore, the wire clamp is provided with a heat dissipation hole that penetrates its body.

[0010] Furthermore, the elastic spring plate has an elastic portion located between its two ends, and a reinforcing spring plate is provided between the free end of the connecting pressure buckle of the elastic spring plate and the elastic portion.

[0011] Furthermore, each side of the limiting cover is provided with at least one guide limiting groove for guiding and limiting the wire harness. The high-voltage wire harness and the low-voltage wire harness are guided and limited by the guide limiting grooves on both sides, thereby realizing the regional isolation and guiding and limiting of the high-voltage wire harness and the low-voltage wire harness.

[0012] Furthermore, the number of the guide limiting grooves is the same as the total number of high-voltage and low-voltage wire harnesses; The limiting cover plate is provided with a first line sequence mark corresponding to each of the multiple guide limiting grooves; The high-voltage connector and the low-voltage connector are provided with a second wire sequence mark that corresponds one-to-one with the high-voltage wire harness and the low-voltage wire harness, and the first wire sequence mark corresponds one-to-one with the second wire sequence mark.

[0013] Furthermore, one side of the limiting cover plate having a guide limiting groove corresponding to the high-voltage wire harness is fitted with the inner wall of the control box with a clearance, so that the guide limiting groove of the high-voltage wire harness fits with the inner wall of the control box to form a hole-like structure to prevent the high-voltage wire harness from detaching. The opening of the guide groove corresponding to the low-voltage wiring harness is oriented away from the low-voltage connector.

[0014] Furthermore, the limiting cover is T-shaped, the guide limiting groove corresponding to the low-voltage wiring harness is located in the narrow part of the limiting cover, and notches are formed on both sides of the narrow part of the limiting cover.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) Improve assembly efficiency and prevent wire harness misalignment: The limit cover is designed with multiple guide limit grooves and wire sequence markings to effectively isolate and position the high voltage wire harness and the low voltage wire harness. During assembly, the wire harness and the cover markings correspond one-to-one, avoiding the risk of wire harness misalignment and greatly reducing the difficulty of assembly operation inside the small control box. (2) Optimize assembly process and reduce production cost: The terminal block can be directly soldered onto the PCB board by reflow soldering. Relying on the snap-fit ​​action between the control box and the bottom shell, the elastic component can automatically apply pressure to complete the wire harness connection and conduction, eliminating the traditional wire welding or screw tightening process, making the production process simpler and reducing production cost. (3) Stable and reliable electrical connection: The combination design of the positioning column and the suction cup accurately positions the wire clamp and the copper lug, and enhances the physical connection stability when the copper lug and the copper plate terminal are in contact through the adsorption effect, ensuring the reliability of high voltage conduction. (4) Enhance insulation withstand voltage and avoid short circuit interference: The insulating partition and wire clamps on the terminal block isolate adjacent copper lugs, so that multiple high voltage wires are arranged neatly and do not interfere with each other when they are tightened, thus avoiding the risk of short circuit. At the same time, this isolation increases the insulation withstand voltage of the device, thereby reducing the difficulty of hardware wiring design on the PCB board and facilitating the optimization of the internal layout of the product.

[0016] The present invention will be explained in detail below with reference to the accompanying drawings and specific embodiments. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the control box and bottom shell of the present invention; Figure 2 This is a schematic diagram of the integrated connection structure of the present invention; Figure 3 This is a schematic diagram of the internal structure of the control box of the present invention; Figure 4 This is a schematic diagram showing the connection between the PCB board and the high-voltage and low-voltage wire harnesses of the present invention. Figure 5 This is a schematic diagram of the structure of the limiting cover and the elastic component of the present invention; Figure 6 This is a schematic diagram of the structure of the elastic component of the present invention; Figure 7 This is a schematic diagram of the terminal block structure of the present invention; Figure 8 This is a schematic diagram of the structure of the copper sheet terminal of the present invention; Figure 9 This is a schematic diagram of the second line sequence marking on the high-voltage connector and low-voltage connector of the present invention.

[0018] Reference numerals: 1. Control box; 2. Bottom shell; 3. High-voltage connector; 4. Low-voltage connector; 5. High-voltage wiring harness; 6. Low-voltage wiring harness; 7. PCB board; 8. First female / female connector; 9. Limiting cover plate; 10. Terminal block; 11. Copper sheet terminal; 12. Elastic component; 13. Copper lug; 14. Positioning post; 15. Positioning hole; 16. Countersunk hole; 17. Suction cup; 18. Insulating partition; 19. Heat dissipation hole; 20. Reinforcing spring plate; 21. Guide limiting groove; 22. First wiring sequence mark; 23. Second wiring sequence mark; 24. Interlocking wiring harness; 25. Second female / female connector; 26. First internal thread post; 27. Second internal thread post; 28. Limiting post; 29. ​​Reinforcing rib plate; 30. Positioning clip; 31. Membrane heating plate; 1201. Elastic spring plate; 1202. Wire clamp; 1203. Terminal clip. Detailed Implementation

[0019] To facilitate understanding of the present invention, a more comprehensive description of the present invention will be given below with reference to the accompanying drawings, which illustrate several embodiments of the present invention. However, the present invention can be implemented in different forms and is not limited to the embodiments described in the text. Rather, these embodiments are provided to make the disclosure of the present invention more thorough and complete.

[0020] It should be noted that when an element is said to be fixed to another element, it can be directly on the other element or there may be an intermediate element. When an element is said to be connected to another element, it can be directly connected to the other element or there may be an intermediate element at the same time. The terms vertical, horizontal, left, right and similar expressions used in this article are for illustrative purposes only.

[0021] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly associated with one of ordinary skill in the art to which this invention pertains. The terminology used herein in the specification of this invention is for the purpose of describing particular embodiments and is not intended to limit the invention. The terminology used herein includes any and all combinations of one or more of the associated listed items.

[0022] Please refer to the appendix carefully. Figure 1-9 An integrated connection structure for a PTC controller and a membrane heater includes a control box 1 and a base shell 2. The control box 1 has a high-voltage connector 3 and a low-voltage connector 4. The control box 1 contains a high-voltage wiring harness 5 and a low-voltage wiring harness 6, which are respectively connected to the high-voltage connector 3 and the low-voltage connector 4. The base shell 2 contains a PCB board 7 and a membrane heating element 31. The low-voltage wiring harness 6 is connected to the PCB board 7 via a first female connector 8. The structure also includes: Limiting cover 9 is fixedly installed inside control box 1. Limiting cover 9 isolates and guides the high voltage harness 5 and low voltage harness 6 respectively. Terminal block 10 is disposed on PCB board 7. Terminal block 10 has copper sheet terminals 11 that correspond one-to-one with high voltage wire harness 5. The elastic component 12 includes an elastic spring plate 1201 disposed between the limiting cover plate 9 and the PCB board 7, and a wire harness snap-fit ​​structure disposed at the free end of the elastic spring plate 1201. The end of the high-voltage wire harness 5 is located on the wire harness buckle structure. After the control box 1 and the bottom shell 2 are fastened together, the wire harness buckle structure, under the elastic force of the elastic spring plate 1201, will press the end of the high-voltage wire harness 5 against the corresponding copper plate terminal 11 to achieve electrical conduction.

[0023] By using the limiting cover plate 9 to arrange and guide the high-voltage wire harness 5 and the low-voltage wire harness 6 in separate zones, it is possible to effectively avoid confusion between multiple wire harnesses during wire harness assembly due to the messy wire harnesses inside the control box 1, which would cause wire harness assembly errors.

[0024] The top fixed end of the elastic spring plate 1201 is connected to the limiting cover plate 9. Since the limiting cover plate 9 is fixed in the control box 1 by fasteners, when the control box 1 and the bottom shell 2 are fastened together, the multiple wire harness clamping structures at the lower end of the elastic spring plate 1201 respectively press and fix the copper lugs 13 at the ends of multiple high-voltage wire harnesses 5 onto multiple copper terminals 11 on the terminal block 10, realizing the electrical connection between the high-voltage wire harnesses 5 and the PCB board 7. Furthermore, under the elastic force of the elastic spring plate 1201, it can prevent the open circuit between the high-voltage wire harnesses 5 and the copper terminals 11 caused by soldering or screw fixing, which may result in solder joint breakage or screw loosening. In addition, the terminal block 10 with copper terminals 11 is soldered to the PCB board 7 by reflow soldering. Combined with the design of the elastic component 12, it can realize the rapid assembly and connection of the high-voltage wire harnesses 5 and the PCB board 7.

[0025] In this embodiment, the wire harness clip structure includes an insulated wire clip 1202 and a terminal clip 1203 disposed on one side of the wire clip 1202. The terminal clip 1203 is used to clamp and fix the conductor connection part of the copper lug 13, so that the electrical connection part of the copper lug 13 is kept in close contact with the wire clip 1202, and one end of the guide connection part is located behind the wire clip 1202 or in contact with the rear side of the wire clip 1202.

[0026] The terminal clip 1203 has two arc-shaped clamps. The axial ends of the clamps are not fixed. The two arc-shaped clamps form an open clamping area that conforms to the shape of the conductor connection part of the copper lug 13. By utilizing the elasticity of the clamps, the portion of the conductor connection part of the copper lug 13 exceeding 1 / 2 of its circumference is tightly clamped and held, thereby fixing the copper lug 13.

[0027] A further optimization of the above embodiment is that the wire clamp 1202 is vertically provided with an insulated positioning post 14, the end of which is tapered or chamfered to facilitate insertion into the countersunk hole 16. The copper terminal 11 is provided with a positioning hole 15 for the positioning post 14 to pass through, and the terminal block 10 is provided with a countersunk hole 16. After the positioning post 14 passes through the circular hole of the electrical connection part of the copper lug 13 and the positioning hole 15, it is inserted into the countersunk hole 16 to position the wire clamp 1202 and the copper lug 13.

[0028] The positioning post 14 serves two purposes: firstly, it further positions the insulating clip on the copper lug 13; secondly, it works in conjunction with the countersunk hole 16 on the terminal block 10 and the positioning hole 15 on the copper plate terminal 11 to radially position the copper lug 13, the terminal block 10, and the copper plate terminal 11. Through this design, combined with the elastic clamping force of the spring plate 1201, a stable connection is achieved between the copper lug 13, the wire clamp 1202, the copper plate terminal 11, and the terminal block 10. This ensures efficient assembly and connection of the high-voltage wiring harness 5 to the PCB board 7, while also meeting the stringent requirement that the high-voltage wiring harness 5 will not detach even during prolonged vehicle vibrations.

[0029] Furthermore, a suction cup 17 is provided at the end of the positioning post 14. The diameter of the suction cup 17 is smaller than the diameter of the positioning post 14. The suction cup 17 enhances the stability of the connection between the electrical connection part of the copper nose 13 and the copper plate terminal 11 by adsorbing with the bottom hole wall of the countersunk hole 16. Combined with the elastic spring plate 1201, it can effectively prevent the connection between the copper nose 13 and the copper plate terminal 11 from loosening due to vehicle bumps.

[0030] Furthermore, the design of the suction cup 17 reduces the stringent requirements on the elastic spring plate 1201. For example, after the control box 1 and the bottom shell 2 are assembled, the elastic spring plate 1201 is compressed, and the excessive elastic force applied to the wire clamp 1202 can prevent the copper lug 13 from separating from the copper terminal 11. However, it can also put excessive pressure on the PCB board 7. If a support structure is not added to the bottom of the PCB board 7, it may cause excessive deformation or even breakage of the PCB board 7, affecting its service life. On the other hand, if the elastic spring plate 1201 is compressed and the elastic force applied to the wire clamp 1202 is too small, when the vehicle is driving, especially on bumpy roads, the elastic force provided by the elastic spring plate 1201 may be insufficient to suppress the jumping of the wire clamp 1202, resulting in the copper lug 13 separating from the copper terminal 11 and short-circuiting. The suction force provided by the suction cups 17 at the bottom of the multiple positioning posts 14 can compensate for the insufficient elasticity of the elastic spring plate 1201 after compression, thereby relaxing the requirements for the parameters and performance of the elastic spring plate 1201 and ensuring a stable connection between the copper lug 13 and the copper terminal 11. Furthermore, when the performance of the elastic spring plate 1201 weakens due to temperature changes, the suction cups 17 remain attached to the bottom of the countersunk hole 16 under the elastic force of the elastic spring plate 1201. Therefore, the suction cups 17 can also compensate for the weakening of the elasticity of the elastic spring plate 1201 due to aging and temperature changes, thereby enhancing the connection stability between the copper lug 13 and the copper terminal 11.

[0031] In addition, the suction cup 17 also serves to buffer vibrations. The suction cup 17 can absorb the vibration of the PCB board 7 and suppress the shaking of the PCB board 7, thereby effectively preventing the fasteners fixing the PCB board 7 from loosening. Under the action of the elastic spring plate 1201, the suction cup 17 can also maintain its adsorption state with the hole wall for a long time.

[0032] A further optimization of the above embodiment is that the wire clamp 1202 is provided with a heat dissipation hole 19 that penetrates its body. When the copper lug 13 and the copper plate terminal 11 are energized for a long time and generate heat, the design of the heat dissipation hole 19 increases the heat exchange area between the wire clamp 1202 and the air, thereby enhancing the heat dissipation efficiency of the wire clamp 1202, delaying the aging of the wire clamp 1202, and preventing high temperature from being conducted to the elastic spring plate 1201 and affecting the performance of the elastic spring plate 1201.

[0033] Furthermore, the design of the heat dissipation hole 19 reduces the weight of the wire clamp 1202, which can reduce the inertial force on the wire clamp 1202 during vehicle bumps, thereby preventing the wire clamp 1202 from jumping due to the elasticity of the elastic spring plate 1201 during vehicle bumps, which could cause poor contact between the copper lug 13 and the copper plate terminal 11, and can also further prevent the positioning post 14 from breaking.

[0034] In this embodiment, a raised insulating partition 18 is provided on both sides of each copper sheet terminal 11 on the terminal block 10. The insulating partition 18 is used to prevent arc breakdown short circuit between adjacent copper lugs 13 and copper sheet terminals 11.

[0035] In this embodiment, the elastic spring plate 1201 has an elastic portion located between its two ends. This elastic portion typically has one or more bends, for example, such as... Figure 5 The spring plate 1201 is shaped like an "M" and its elastic part is designed to allow the free end of the spring plate 1201 to extend and contract in a direction perpendicular to the PCB board 7 and to apply sufficient elastic force.

[0036] Furthermore, a reinforcing spring plate 20 is provided between one end of the connecting wire buckle 1202 of the elastic spring plate 1201 and the elastic part. The function of the reinforcing spring plate 20 is to suppress the unsupported far side of the bottom free end of the elastic spring plate 1201 from tilting and jumping, so that the wire buckle 1202 is subjected to uniform force in the front and rear directions, and ensure that the copper coil and the copper sheet terminal 11 can be fully and tightly connected.

[0037] In this embodiment, at least one guide limiting groove 21 for guiding and limiting the wire harness is provided on both sides of the limiting cover plate 9. The high voltage wire harness 5 and the low voltage wire harness 6 are guided and limited by the guide limiting grooves 21 on both sides, so as to realize the regional isolation of the high voltage wire harness 5 and the low voltage wire harness 6.

[0038] In this embodiment, the number of guide limiting grooves 21 is the same as the total number of high-voltage wire harnesses 5 and low-voltage wire harnesses 6. The limiting cover plate 9 is provided with first thread sequence marks 22 corresponding one-to-one with the multiple guide limiting grooves 21. The high-voltage connector 3 and the low-voltage connector 4 are provided with second thread sequence marks 23 corresponding one-to-one with the high-voltage wire harnesses 5 and low-voltage wire harnesses 6. The first thread sequence marks 22 and the second thread sequence marks 23 correspond one-to-one, thereby effectively preventing wire harness confusion and assembly errors when assembling the wire harnesses with the PCB board 7.

[0039] A further optimization of the above embodiment is that the side of the limiting cover 9 with the guide limiting groove 21 corresponding to the high-voltage wire harness 5 is clearance-fitted with the inner wall of the control box 1, so that the guide limiting groove 21 of the high-voltage wire harness 5 and the inner wall of the control box 1 form a hole-like structure to prevent the high-voltage wire harness 5 from detaching. On the one hand, the edge design of the limiting cover 9 conforms to the design logic of the power interface on the PCB board 7 being close to the edge. On the other hand, it enables the side of the limiting cover 9 with the guide limiting groove 21 of the high-voltage wire harness 5 to form a hole-like structure with the inner wall of the control box 1 through clearance fit, preventing the high-voltage wire harness 5 from detaching from the guide limiting groove 21. The opening of the low-voltage wire harness 6 corresponding to the guide limiting groove 21 faces away from the low-voltage connector 4, preventing the low-voltage wire harness 6 from detaching from the low-voltage wire harness 6 guide limiting groove 21.

[0040] In this embodiment, two high-voltage connectors 3 are respectively located on two adjacent sides of the control box 1, and a low-voltage connector 4 is located on the same side as one of the high-voltage connectors 3.

[0041] In this embodiment, the limiting cover 9 is T-shaped, and the guide limiting groove 21 corresponding to the low-voltage wiring harness 6 is located in the narrow part of the limiting cover 9. Notches are formed on both sides of the narrow part of the limiting cover 9 to avoid the wiring harness or / and reduce weight. For example, if at least one side of the notch in the narrow part of the limiting cover 9 is located on the wiring harness arrangement path of the high-voltage connector 3 and / or the low-voltage connector 4, the size of the corresponding notch is adjusted accordingly to avoid the wiring harness arrangement path.

[0042] In this embodiment, the control box 1 is also equipped with an interlocking harness 24 for connecting the high-voltage connector 3. The interlocking harness 24 is connected to the PCB board 7 via a second female connector 25. The function of the interlocking harness 24 is to detect whether the harness on the high-voltage connector 3 is connected to the PCB board 7. The high-voltage harness 5 and the low-voltage harness 6 are passed through the corresponding guide grooves 21 on the limiting cover plate 9, and the low-voltage harness 6 and the interlocking harness 24 are connected to the PCB board 7. Then, the copper lug 13 and the wire clamp 1202 are assembled, thus assembling the control box 1 and the bottom shell 2.

[0043] During the actual assembly of the control box 1 and the base shell 2, auxiliary tools or high-precision assembly equipment can be used to complete the assembly of the control box 1 and the base shell 2, ensuring efficient and precise assembly between the control box 1 and the base shell 2, between the wire clamp 1202 and the adjacent insulating partition 18, and between the positioning post 14 and the countersunk hole 16 in actual production. Since this part is not the focus of this application, and the specific implementation method can be implemented by those skilled in the art by referring to existing assembly techniques, it will not be elaborated further here.

[0044] In this embodiment, the inner wall of the control box 1 is provided with a first internal threaded post 26, a second internal threaded post 27, and a limiting post 28. The fixed ends of the top of the limiting cover plate 9 and the elastic spring plate 1201 are provided with multiple holes corresponding to the positions of the first internal threaded post 26, the second internal threaded post 27, and the limiting post 28. The limiting post passes through the corresponding holes on the limiting cover plate 9 and the elastic spring plate 1201 to achieve the initial positioning of the limiting cover plate 9 and the elastic spring plate 1201. Then, the limiting cover plate 9 and the elastic spring plate 1201 are rotated around the limiting post 28 until the remaining holes on them are aligned with the first internal threaded post 26 and the second internal threaded post 27. Finally, the limiting cover plate 9 and the elastic spring plate 1201 are fixed to the first internal threaded post and the second internal threaded post with two screws.

[0045] In this embodiment, the holes on the limiting cover plate 9 are located on the wide portion, and the narrow portion of the limiting cover plate 9 is provided with a reinforcing rib plate 29 extending towards the wide portion to enhance the structural strength of the narrow portion of the limiting cover plate 9. The fixed end of the elastic spring plate 1201 is provided with a positioning clip 30 with a slot. The elastic spring plate 1201 is inserted into and abuts against the reinforcing rib plate through the slot of the positioning clip, thereby aligning the multiple holes on the elastic spring plate 1201 with the multiple holes on the limiting cover plate 9.

[0046] The guide and limiting groove 21 extends downward at 90° to enhance the guidance and limiting of the wire harness, while preventing the wire harness from being cut by friction with the thinner limiting cover plate 9.

[0047] The present invention has been described by way of example in conjunction with the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvement made by adopting the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution of the present invention to other occasions without modification, shall be within the protection scope of the present invention.

Claims

1. An integrated connection structure for a PTC controller and a membrane heater, comprising a control box (1) and a base shell (2), wherein the control box (1) is provided with a high-voltage connector (3) and a low-voltage connector (4), the control box (1) contains a high-voltage wiring harness (5) and a low-voltage wiring harness (6) respectively connected to the high-voltage connector (3) and the low-voltage connector (4), the base shell (2) contains a PCB board (7), and the low-voltage wiring harness (6) is connected to the PCB board (7) via a first female connector (8), characterized in that, Also includes: The limiting cover (9) is fixedly installed inside the control box (1). The limiting cover (9) respectively isolates and guides the high voltage wire harness (5) and the low voltage wire harness (6). Terminal block (10) is disposed on the PCB board (7), and the terminal block (10) has copper sheet terminals (11) corresponding one-to-one with the high voltage wire harness (5). The elastic component (12) includes an elastic spring plate (1201) disposed between the limiting cover plate (9) and the PCB board (7), and a wire harness snap-fit ​​structure disposed at the free end of the elastic spring plate (1201); The end of the high-voltage wire harness (5) is set on the wire harness buckle structure. After the control box (1) and the bottom shell (2) are fastened together, the wire harness buckle structure, under the elastic force of the elastic spring plate (1201), abuts the end of the high-voltage wire harness (5) against the corresponding copper plate terminal (11) to achieve electrical conduction.

2. The integrated connection structure of a PTC controller and a membrane heater according to claim 1, characterized in that, The high-voltage harness (5) is provided with a copper lug (13) at its end. The wire harness snap-fit ​​structure includes an insulated snap-fit ​​(1202) and a terminal snap (1203) provided on one side of the snap-fit ​​(1202). The terminal snap (1203) is used to clamp and fix the conductor connection part of the copper lug (13) so that the electrical connection part of the copper lug (13) is kept close to the snap-fit ​​(1202).

3. The integrated connection structure of a PTC controller and a membrane heater according to claim 2, characterized in that, The wire clamp (1202) is vertically provided with an insulated positioning post (14), the copper plate terminal (11) is provided with a positioning hole (15) for the positioning post (14) to pass through, and the terminal block (10) is provided with a countersunk hole (16). The positioning post (14) passes through the circular hole of the electrical connection part of the copper lug (13) and the positioning hole (15) and then inserts into the countersunk hole (16) to position the wire clamp (1202) and the copper lug (13). The end of the positioning post (14) is provided with a suction cup (17), which enhances the stability of the connection between the copper nose (13) and the copper plate terminal (11) by adsorbing with the bottom hole wall of the countersunk hole (16).

4. The integrated connection structure of a PTC controller and a membrane heater according to claim 1, characterized in that, The terminal block (10) has raised insulating partitions (18) on both sides of each copper sheet terminal (11). The terminal block (10) with the copper sheet terminal (11) is soldered onto the PCB board (7) by reflow soldering.

5. The integrated connection structure of a PTC controller and a membrane heater according to claim 2, characterized in that, The wire clamp (1202) has a heat dissipation hole (19) that penetrates its body.

6. The integrated connection structure of a PTC controller and a membrane heater according to claim 2, characterized in that, The elastic spring plate (1201) has an elastic part located between its two ends, and a reinforcing spring plate (20) is provided between the free end of the connecting wire buckle (1202) of the elastic spring plate (1201) and the elastic part.

7. The integrated connection structure of a PTC controller and a membrane heater according to claim 1, characterized in that, The limiting cover (9) is provided with at least one guide limiting groove (21) on both sides for guiding and limiting the wire harness. The high voltage wire harness (5) and the low voltage wire harness (6) are guided and limited by the guide limiting groove (21) on both sides, so as to realize the regional isolation and guiding and limiting of the high voltage wire harness (5) and the low voltage wire harness (6).

8. The integrated connection structure of a PTC controller and a membrane heater according to claim 7, characterized in that, The number of the guide limiting grooves (21) is the same as the total number of the high voltage wire harness (5) and the low voltage wire harness (6); The limiting cover plate (9) is provided with a first line sequence mark (22) corresponding one-to-one with the multiple guide limiting grooves (21); The high-voltage connector (3) and the low-voltage connector (4) are provided with second line sequence marks (23) that correspond one-to-one with the high-voltage wire harness (5) and the low-voltage wire harness (6), and the first line sequence mark (22) corresponds one-to-one with the second line sequence mark (23).

9. The integrated connection structure of a PTC controller and a membrane heater according to claim 7, characterized in that, The limiting cover plate (9) has a guide limiting groove (21) corresponding to the high voltage wire harness (5) on one side that is in clearance fit with the inner wall of the control box (1), so that the guide limiting groove (21) of the high voltage wire harness (5) and the inner wall of the control box (1) form a hole-like structure to prevent the high voltage wire harness (5) from detaching. The opening of the low-voltage harness (6) corresponding to the guide limiting groove (21) faces away from the low-voltage connector (4).

10. The integrated connection structure of a PTC controller and a membrane heater according to claim 7, characterized in that, The limiting cover (9) is T-shaped, and the guide limiting groove (21) corresponding to the low voltage wire harness (6) is located in the narrow part of the limiting cover (9). Notches are formed on both sides of the narrow part of the limiting cover (9).

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