A heating element for an electric heater

Abstract

The utility model discloses a heating body for electric heater relates to PTC heating body technical field, including one -sided two -pole PTC element, conducting wire and insulating seat body. One -sided two -pole PTC element has electrode face, and electrode face is equipped with the first electrode and second electrode of interval distribution, and two conducting wires are respectively through the electric connection of welding mode with the first electrode and second electrode. Insulating seat body 3 has the cavity of bottom closed, and one -sided two -pole PTC element of welding conducting wire is set up in the cavity with the direction of electrode face downward, and the first electrode is completely buried with second electrode in the cavity. The utility model discloses by adopting one -sided two -pole PTC, and two electrodes are located same electrode face, and electrode area reduces about two -thirds, and the use amount of silver is reduced greatly, and cost is saved, can simultaneously weld two conducting wires, and production efficiency improves one time, can ensure two welding spots when assembling and completely place in the cavity bottom of ceramic seat body, make all electrified components deep bury in insulating seat body, and the risk of breakdown is eliminated.

Description

Technical Field

[0001] This utility model relates to the field of PTC heating element technology, and in particular to a heating element for electric heaters. Background Technology

[0002] In the field of electric heaters, PTC heating elements are widely used in products such as electric mosquito repellents and liquid evaporators due to their self-regulating temperature characteristics. Traditional electric heaters typically use PTC ceramic heating elements with upper and lower electrodes, i.e., one electrode on top and one electrode on the bottom. The manufacturing process involves first welding wires to the upper and lower electrodes of the PTC, then filling the ceramic shell with adhesive, inserting the welded PTC into the shell, drying and curing it, and finally riveting the ceramic shell to the plastic bracket and metal ring to form the final product.

[0003] However, the above-mentioned traditional PTC ceramic heating elements with upper and lower electrodes have the following defects: (1) The electrode area is large, and the cost is high because the electrodes are usually made of expensive silver materials; (2) In the welding process, traditional upper and lower electrode PTCs need to weld one electrode first, rotate and then weld the other electrode, which takes a long time; (3) During assembly, one electrode of the PTC is on the top and the other electrode is on the bottom. In mass production, problems such as excessively high solder joints, warped wires, insufficient glue, or air gaps after the glue has cured are likely to occur. This may lead to exposed live parts or too close to the metal ring, causing high voltage breakdown risk. Utility Model Content

[0004] The purpose of this invention is to provide a heating element for an electric heater to solve the problems existing in the prior art, reduce costs, shorten labor hours and processes, and reduce product defect rate.

[0005] To achieve the above objectives, this utility model provides the following solution:

[0006] A heating element for an electric heater, comprising:

[0007] A single-sided bipolar PTC element has an electrode surface, on which a first electrode and a second electrode are provided at intervals.

[0008] Two conductive wires are electrically connected to the first electrode and the second electrode respectively by welding.

[0009] An insulating base with a closed cavity at the bottom;

[0010] The single-sided bipolar PTC element with the conductive wire welded to it is disposed in the cavity with the electrode face downward, and the first electrode and the second electrode are completely embedded in the cavity.

[0011] In one exemplary embodiment, the distance between the first electrode and the second electrode is greater than the standard safe distance between two electrodes.

[0012] In one exemplary embodiment, the first electrode and the second electrode have the same area.

[0013] In an exemplary embodiment, the areas of the first electrode and the second electrode are set according to actual needs.

[0014] In one exemplary embodiment, the welded conductive wire is bent and extended in a direction away from the electrode surface.

[0015] In one exemplary embodiment, the insulating base is a ceramic base or a plastic base, and the cavity is filled with encapsulating adhesive covering the electrode surface.

[0016] In one exemplary embodiment, the insulating base is a plastic base, the cavity size of the plastic base is smaller than that of a single-sided bipolar PTC element, and the plastic base tightly wraps the PTC element by ultrasonic welding.

[0017] In one exemplary embodiment, the device further includes a bipod having a first through hole, and the single-sided bipolar PTC element having a second through hole arranged parallel to the cavity. The bipod and the single-sided bipolar PTC element are riveted together by a metal ring passing through the first through hole and the second through hole.

[0018] In one exemplary embodiment, a breakdown-resistant isolation layer is formed between the cavity arranged side by side and the second through hole.

[0019] In one exemplary embodiment, the insulating base has an integrally formed fixing foot structure.

[0020] The present invention achieves the following technical advantages over the prior art:

[0021] 1. By using a single-sided bipolar PTC, the two electrodes are located on the same electrode surface, which greatly reduces the electrode area compared to traditional PTC, significantly reducing the amount of silver used and saving costs.

[0022] 2. Single-sided bipolar PTC can weld two wires simultaneously, which facilitates automated welding and doubles the production efficiency compared to traditional methods, making the process more efficient.

[0023] 3. By soldering both wires to both sides of the same electrode surface of the PTC, assembly ensures that both solder points face downwards and are completely placed at the bottom of the ceramic housing. This design deeply embeds all live components within the insulating housing, preventing them from being exposed and maintaining a sufficient safe distance from the metal ring. This completely eliminates the risk of breakdown and avoids many drawbacks of traditional processes, making the product safer and more reliable. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a schematic diagram of a single-sided bipolar PTC element disclosed in a specific embodiment of the present invention.

[0026] Figure 2 A schematic diagram of a single-sided bipolar PTC element with its conductive wires soldered on.

[0027] Figure 3 This is a schematic diagram of the structure of the insulating base disclosed in a specific embodiment of the present utility model;

[0028] Figure 4 This is a schematic diagram of the conductive wire structure in Example 1;

[0029] Figure 5 This is a schematic diagram of the assembly structure of the single-sided bipolar PTC element with the conductive wires welded on and the insulating base in Example 1;

[0030] Figure 6 This is a schematic diagram of the conductive wire structure in Example 2;

[0031] Figure 7 This is a schematic diagram of the structure of the insulating base disclosed in another specific embodiment of the present utility model;

[0032] Figure 8 This is a schematic diagram of the assembly structure of the single-sided bipolar PTC element with the conductive wires welded on and the insulating base in Example 2;

[0033] Figure 9 This is a schematic diagram of the bipod structure disclosed in a specific embodiment of the present utility model;

[0034] Figure 10 This is a schematic diagram of the structure of a metal ring disclosed in a specific embodiment of the present utility model;

[0035] Figure 11 This is a schematic diagram of the assembled heating element of an electric heater, as disclosed in a specific embodiment of the present invention.

[0036] Among them, 1. Single-sided bipolar PTC element; 11. Electrode surface; 12. First electrode; 13. Second electrode; 2. Conductive wire; 3. Insulating base; 31. Cavity; 32. Second through hole; 4. Two legs; 41. First through hole; 5. Metal ring. Detailed Implementation

[0037] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings. Those skilled in the art can easily understand other advantages and effects of the present utility model from the content disclosed in this specification. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present utility model.

[0038] The purpose of this invention is to provide a heating element for electric heaters to solve the problems existing in the prior art, reduce costs, shorten labor hours and processes, and reduce product defect rate.

[0039] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0040] Please refer to Figures 1 to 11 This embodiment provides a heating element for an electric heater, including a single-sided bipolar PTC element 1, a conductive wire 2, and an insulating base 3.

[0041] The single-sided bipolar PTC element 1 has an electrode surface 11, on which a first electrode 12 and a second electrode 13 are provided at intervals. The distance between the first electrode 12 and the second electrode 13 is greater than the safe distance between standard electrodes. The safe distance between standard electrodes needs to be greater than 2 mm. In this embodiment, the distance is set to 4 mm, which is much greater than the safe distance.

[0042] Please refer to Figure 1 PTC elements are typically cubic in structure, with the electrode surface 11 being rectangular. The first electrode 12 and the second electrode 13 disposed on it can also be rectangular, matching the width of one side of the electrode surface 11, and the areas of the first electrode 12 and the second electrode 13 are the same. Furthermore, the areas of the first electrode 12 and the second electrode 13 are set according to actual needs, such as both being one-third of the electrode surface 11.

[0043] Please refer to Figure 2 The two conductive wires 2 are electrically connected to the first electrode 12 and the second electrode 13 by welding, respectively.

[0044] Please refer to Figure 3 The insulating base 3 has a bottom-closed cavity 31. A single-sided bipolar PTC element 1 with a conductive wire 2 welded on is arranged in the cavity 31 with the electrode surface 11 facing downwards, and the first electrode 12 and the second electrode 13 are completely embedded in the cavity 31.

[0045] There are several ways to connect the single-sided bipolar PTC element 1 with the welded conductive wire 2 to the insulating base 3. Two of them are described in detail below.

[0046] Example 1

[0047] Please refer to Figure 4 and Figure 5 The insulating base 3 is a ceramic or plastic base, and the cavity 31 is filled with encapsulating adhesive covering the electrode surface 11. The soldered conductive wire 2 is bent and extended in a direction away from the electrode surface 11, and then the single-sided bipolar PTC element 1 with the soldered conductive wire 2 is placed into the cavity 31 of the insulating base 3 with the electrode surface 11 facing downward, so that the first electrode 12 and the second electrode 13 are located at the bottom of the cavity 31, and then placed in an oven for drying.

[0048] Example 2

[0049] Please refer to Figures 6 to 8 The insulating base 3 is a plastic base, and the cavity 31 of the plastic base is smaller than the single-sided bipolar PTC element 1 and extends laterally through the insulating base 3. The welded conductive wire 2 extends in its original direction without bending. The single-sided bipolar PTC element 1 with the welded conductive wire 2 is placed into the cavity 31 with the electrode surface 11 facing downward. Then, the single-sided bipolar PTC element 1 is welded into the cavity 31 using an ultrasonic welding device, and the plastic tightly wraps the single-sided bipolar PTC element 1, so that the heat of the single-sided bipolar PTC element 1 can be completely conducted to the insulating base 3, improving the heat conduction efficiency.

[0050] After the single-sided bipolar PTC element 1 with the welded conductive wire 2 is assembled with the insulating base 3, it can be riveted to the two legs 4 through the metal ring 5.

[0051] For details, please refer to Figures 9 to 11 The bipod 4 has a first through hole 41, and the single-sided bipolar PTC element 1 has a second through hole 32 arranged side by side with the cavity 31. The bipod 4 and the single-sided bipolar PTC element 1 are riveted together by a metal ring 5 passing through the first through hole 41 and the second through hole 32. In this way, a breakdown-proof isolation layer is formed between the cavity 31 and the second through hole 32 arranged side by side, which completely prevents the first electrode 12 and the second electrode 13 from contacting the metal ring 5, thus eliminating the problem of breakdown.

[0052] Alternatively, the insulating base 3 can also have an integrated fixed foot structure, which eliminates the need for the two legs 4, the metal ring 5, and the riveting assembly process.

[0053] This embodiment employs a single-sided bipolar PTC, which, on the one hand, places both electrodes on the same electrode surface 11, reducing the electrode area by approximately two-thirds compared to traditional PTCs, significantly reducing silver usage and saving costs. On the other hand, the single-sided bipolar PTC can simultaneously weld two wires, facilitating automated welding and doubling production efficiency compared to traditional methods, making the process more efficient. Furthermore, by welding both wires to both sides of the same electrode surface 11 of the PTC, assembly ensures that the two solder points face downwards and are completely placed at the bottom of the ceramic base cavity 31. This design deeply embeds all live components within the insulating base 3, preventing exposure and maintaining a sufficient safe distance from the metal ring 5, completely eliminating the risk of breakdown and avoiding many undesirable phenomena of traditional processes, resulting in a safer and more reliable product.

[0054] In the description of this utility model, it should be understood that the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are used only for the convenience of describing this utility model, and do not imply or require that the device or element referred to have a specific orientation or construction method, and therefore should not be construed as a limitation on this utility model. Furthermore, the terms "first," "second," and "third," etc., are only used to distinguish the objects of description and should not be construed as limiting importance or order, and the features defined by such terms may explicitly or implicitly include one or more of those features. Unless otherwise stated, "a plurality of" in the description of this utility model refers to two or more.

[0055] The terms "installation," "connection," and "joining" should be interpreted broadly, unless otherwise explicitly defined, to include, but are not limited to, fixed connections, detachable connections, or integrally formed connections; mechanical or electrical connections; direct connections or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art can understand their meaning based on the specific technical solution. The fixed connections involved in this utility model, unless otherwise stated, include both detachable fixed connections (such as bolt and screw connections) and non-detachable fixed connections (such as riveting and welding), and may also include integral structures achieved through an integral forming process (such as casting) (except where integral forming is clearly impossible).

[0056] Unless otherwise stated, the terms used in any of the technical solutions disclosed in this utility model to indicate positional relationships or shapes cover states or shapes that are similar to, close to, or adjacent to them.

[0057] Any component provided by this utility model can be assembled from multiple individual components, or it can be a single component manufactured by a one-piece molding process.

[0058] It should be noted that the structures, proportions, sizes, etc., depicted in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which this utility model can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and objectives that this utility model can produce, should still fall within the scope of the technical content disclosed in this utility model.

[0059] In the embodiments of this application, the same reference numerals are used to denote the same component or part.

[0060] Any adaptive changes made according to actual needs are within the protection scope of this utility model.

[0061] It should be noted that, for those skilled in the art, it is obvious that this utility model is not limited to the details of the above exemplary embodiments, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this utility model. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of this utility model is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this utility model. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A heating element for an electric heater, characterized in that, include: A single-sided bipolar PTC element (1) has an electrode surface (11) on which a first electrode (12) and a second electrode (13) are provided at intervals. Two conductive wires (2) are electrically connected to the first electrode (12) and the second electrode (13) respectively by welding. The insulating base (3) has a cavity (31) with a closed bottom. The single-sided bipolar PTC element (1) with the conductive wire (2) welded on it is disposed in the cavity (31) with the electrode surface (11) facing downward, and the first electrode (12) and the second electrode (13) are completely embedded in the cavity (31).

2. The heating element according to claim 1, characterized in that: The distance between the first electrode (12) and the second electrode (13) is greater than the safe distance between standard electrodes.

3. The heating element according to claim 1, characterized in that: The first electrode (12) and the second electrode (13) have the same area.

4. The heating element according to claim 3, characterized in that: The areas of the first electrode (12) and the second electrode (13) are set according to actual needs.

5. The heating element according to claim 1, characterized in that: After welding, the conductive wire (2) bends and extends in a direction away from the electrode surface (11).

6. The heating element according to claim 1, characterized in that: The insulating base (3) is a ceramic base or a plastic base, and the cavity (31) is filled with encapsulating adhesive covering the electrode surface (11).

7. The heating element according to claim 1, characterized in that: The insulating base (3) is a plastic base. The cavity (31) of the plastic base is smaller than the single-sided bipolar PTC element (1), and the plastic base tightly wraps the PTC element by ultrasonic welding.

8. The heating element according to claim 1, characterized in that: It also includes a bipod (4), the bipod (4) having a first through hole (41), the single-sided bipolar PTC element (1) having a second through hole (32) arranged side by side with the cavity (31), and the bipod (4) and the single-sided bipolar PTC element (1) being riveted together by a metal ring (5) passing through the first through hole (41) and the second through hole (32).

9. The heating element according to claim 8, characterized in that: A puncture-resistant isolation layer is formed between the cavity (31) arranged side by side and the second through hole (32).

10. The heating element according to claim 1, characterized in that: The insulating base (3) has an integrally formed fixed foot structure.

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