Electrode end cap of ceramic material and PTC heater structure

Abstract

The utility model discloses an electrode head of ceramic material and PTC heater structure. It includes the head body of adopting the ceramic material to make, and the head body is equipped with two front and rear through and be used for inserting electrode's electrode socket, the head body includes the exposed part, sets up the plug -in part of exposed part rear end and is located the limiting shoulder portion of transition position between plug -in part and exposed part, and the exposed part includes the mounting block of setting in the convex of limiting shoulder portion front surface, is equipped with the through slot of communication with electrode socket in mounting block, the PTC heater structure of electrode head includes PTC heater, and PTC heater includes PTC element and electrode, and the plug -in part of head body is inserted in the electrode installation side of PTC element, and the electrode is inserted in electrode socket in the slot mouth and is positioned by the head body. Advantage is: ceramic material has excellent high temperature resistance and non - combustibility, has improved the use security and reliability of heater significantly, realizes the accurate positioning and stable connection of head and PTC element.

Description

Technical Field

[0001] This utility model relates to the assembly structure of a PTC air heater for new energy vehicles, and in particular to a ceramic electrode end cap and PTC heater structure. Background Technology

[0002] In existing PTC heater core structures, the heating core typically consists of heating elements, electrode strips, an insulating film, an aluminum tube, and end caps. The end caps are primarily used to fix the electrodes, protect the contact ends, and provide electrical connections. In current technology, these end caps are mostly made of plastic materials such as PBT, PPS, and PA66. While this reduces processing costs, it still presents significant technical drawbacks.

[0003] On the one hand, plastic end caps are easily ignited when PTC element heads experience localized sparking or breakdown, posing a significant risk of combustion and potentially leading to spontaneous combustion of the entire heater system, resulting in serious safety hazards. On the other hand, plastic, as an organic polymer material, has low mechanical strength and is prone to deformation and breakage under long-term stress, temperature rise, or external impact, making it unsuitable for applications requiring high structural strength and thermal stability. Especially during long-term use, plastic end caps may develop cracks or breakage due to thermal aging and frictional wear, affecting the assembly firmness of the end caps and the reliability of electrode contact.

[0004] In addition, the existing head structure is poorly designed in terms of electrode positioning, which can easily lead to problems such as electrode misalignment, poor contact or low assembly efficiency, seriously affecting the overall performance and consistency of the heater. Summary of the Invention

[0005] The technical problem to be solved by this utility model is to provide a ceramic electrode head and PTC heater structure that has high stability, good protection performance, good insulation and convenient installation.

[0006] To solve the above-mentioned technical problems, the ceramic electrode end cap and PTC heater structure of this utility model includes an end cap body made of ceramic material. The end cap body has two electrode sockets that are through the front and rear for inserting electrodes. The end cap body includes an exposed part, a plug-in part located at the rear end of the exposed part, and a limiting shoulder located at the transition position between the plug-in part and the exposed part. The exposed part includes a protruding mounting block provided on the front surface of the limiting shoulder. The mounting block has a through groove communicating with the electrode socket.

[0007] The end of the plug-in part is provided with two slots, which are respectively located on the upper and lower surfaces of the plug-in part and are diagonally distributed.

[0008] The slot is provided with an outer guide slope in the electrode width direction and an inner guide slope in the electrode thickness direction.

[0009] The limiting shoulder has a ring-shaped stepped structure.

[0010] The surface of the plug-in part is provided with a circular limiting groove for fixing and engaging with components.

[0011] The end edge of the plug is connected to a beveled guide section.

[0012] A PTC heater structure with an electrode cap includes a PTC heater, which includes a PTC element and an electrode. The plug portion of the cap body is plugged into the electrode mounting side of the PTC element, and the electrode passes through a slot and is inserted into an electrode socket and positioned by the cap body.

[0013] Advantages of this utility model:

[0014] (1) The end cap is made of ceramic material instead of traditional plastic material. Traditional plastic material has relatively low strength and is prone to deformation or damage under external impact or long-term mechanical stress. It is not suitable for heating components with high structural strength requirements. Ceramic material has higher strength due to its dense molecular structure. It performs well in terms of pressure resistance, bending resistance and impact resistance, which can effectively improve the overall mechanical stability of the end cap. In addition, plastic material may crack or even break due to wear, thermal aging and other factors during long-term use. Ceramic material has higher wear resistance and thermal stability and can be used for a long time without damage. More importantly, in extreme working conditions such as PTC element failure or head sparking, traditional plastic end cap is at risk of being ignited. Ceramic material has excellent high temperature resistance and non-flammability, which significantly improves the safety and reliability of the heating element.

[0015] (2) By matching the structure between the limiting shoulder, the plug and the electrode socket, the end cap and the PTC element are accurately positioned and securely connected, effectively preventing loosening or falling off during operation;

[0016] (3) The end of the plug is provided with a slot for electrode insertion. The slots are respectively set on the upper and lower surfaces of the plug and are diagonally distributed to ensure better insulation performance.

[0017] (4) The groove is provided with an outer guide slope in the electrode width direction and an inner guide slope in the electrode thickness direction, which helps the electrode to be quickly aligned and smoothly inserted during the installation process, improves assembly efficiency and contact reliability, and further enhances the installation stability and conductivity of the end cap. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of the ceramic electrode head of this utility model;

[0019] Figure 2 This is a plan view of the ceramic electrode head of this utility model;

[0020] Figure 3 This is a cross-sectional view of the ceramic electrode head of this utility model;

[0021] Figure 4 This is a side view of the ceramic electrode head of this utility model;

[0022] Figure 5 This is a front view of the ceramic electrode head of this utility model;

[0023] Figure 6 This is a schematic diagram of the assembly of the ceramic electrode head of this utility model;

[0024] Figure 7 This is a top view of the ceramic electrode head of this utility model.

[0025] Figure 8 This is an assembly side view of the ceramic electrode head of this utility model;

[0026] Figure 9 This is the main view of the ceramic electrode head assembly of this utility model. Detailed Implementation

[0027] The ceramic electrode cap and PTC heater structure of this utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments. Example

[0028] The ceramic electrode end cap of this utility model includes an end cap body 1 made of ceramic material, which can be high-frequency ceramic. The end cap body 1 has two through-hole electrode sockets 6 for inserting electrodes. The end cap body 1 includes an exposed portion 2, a plug-in portion 3 located at the rear end of the exposed portion 2, and a limiting shoulder 4 located at the transition position between the plug-in portion 3 and the exposed portion 2. The exposed portion includes a protruding mounting block 5 located on the front surface of the limiting shoulder 4. The mounting block has a through groove communicating with the electrode socket 6. The end of the plug-in portion has two slots 7, which are respectively located on the upper and lower surfaces of the plug-in portion 3 and are diagonally distributed. The slots 7 have an outer guide slope 12 in the electrode width direction and an inner guide slope 13 in the electrode thickness direction. The limiting shoulder... 4 is an annular stepped structure. The surface of the insertion part 3 is provided with a circular limiting groove 11 for fixing with the parts. The end edge of the insertion part is connected with a beveled guide section 10 for improving the insertion alignment effect. The PTC heater structure of the electrode head is made of ceramic material. The PTC heater includes a PTC element 8 and an electrode 9. The insertion part 3 of the end cap body 1 is inserted into the electrode mounting side of the PTC element 8. The electrode passes through the groove and is inserted into the electrode socket and is positioned by the end cap body 1. The PTC heater structure of the electrode head includes a PTC heater. The PTC heater includes a PTC element 8 and an electrode 9. The insertion part 3 of the end cap body 1 is inserted into the electrode mounting side of the PTC element 8. The electrode passes through the groove and is inserted into the electrode socket and is positioned by the end cap body 1.

[0029] The heating core consists of an internal PTC heating element, ceramic sheet, electrode strip, adhesive, end cap, and polyimide insulating film. After the PTC heating element, electrode strip, polyimide insulating film, and other components are assembled, they are inserted into an aluminum tube and assembled with the end cap body, and then a pressing process is performed to form the core.

Claims

1. An electrode end cap made of ceramic material, characterized in that: The device includes a head body (1) made of ceramic material, which has two through-hole electrode sockets (6) for inserting electrodes. The head body (1) includes an exposed part (2), a plug-in part (3) located at the rear end of the exposed part, and a limiting shoulder (4) located at the transition position between the plug-in part (3) and the exposed part (2). The exposed part includes a protruding mounting block (5) provided on the front surface of the limiting shoulder (4). The mounting block has a through groove communicating with the electrode sockets (6).

2. The ceramic electrode end cap according to claim 1, characterized in that: The end of the plug part is provided with two slots (7), which are respectively located on the upper and lower surfaces of the plug part (3) and are diagonally distributed.

3. The ceramic electrode end cap according to claim 2, characterized in that: The slot (7) is provided with an outer guide slope (12) in the electrode width direction and an inner guide slope (13) in the electrode thickness direction.

4. The ceramic electrode end cap according to claim 1, characterized in that: The limiting shoulder (4) has a ring-shaped step structure.

5. The ceramic electrode end cap according to claim 1, characterized in that: The surface of the plug-in part (3) is provided with a circular limiting groove (11) for fixing with the component.

6. The ceramic electrode end cap according to claim 1, characterized in that: The end edge of the plug is connected to a beveled guide section (10).

7. A PTC heater structure with a ceramic electrode end cap according to any one of claims 1-6, characterized in that: The device includes a PTC heater, which includes a PTC element (8) and an electrode (9). The plug part (3) of the end cap body (1) is plugged into the electrode mounting side of the PTC element (8). The electrode passes through the slot and is inserted into the electrode socket and positioned by the end cap body (1).

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