Insulated ring-shaped PTC heater

Abstract

The utility model provides a kind of insulation type annular PTC heater, it includes outer circle heat dissipation strip, it includes outer circle corrugated fin and outer circle connecting plate, and its outer circle connecting plate is spaced apart and forms multiple single connecting plate;Inner circle heat dissipation strip, it includes inner circle corrugated fin and inner circle connecting plate;Multiple pipe bodies are bonded between the outer circle single connecting plate and inner circle connecting plate, and insulating layer is arranged in the inside of pipe body, and upper and lower electrode pieces and PTC heating element located in the middle of upper and lower electrode pieces are arranged in insulating layer.The utility model has the beneficial effect that: after the outside of PTC heating element and electrode piece is provided with insulating layer, the structure design of being loaded into pipe body realizes the insulation protection function of annular PTC heater;After straight strip type PTC heater is processed using prior art equipment, it can be easily bent into polygon by the deformation of corrugated fin and the wrinkle area of electrode piece, and the purpose of manufacturing approximate annular PTC heater using conventional straight strip type processing method is realized in general.

Description

Technical Field

[0001] This utility model belongs to the field of PTC heater technology, specifically relating to an insulating annular PTC heater. Background Technology

[0002] In the current field of heating equipment technology, PTC heaters have been widely used due to their unique constant-temperature heating characteristics, high safety, and good energy-saving effects. The annular PTC heater, as a special structural form of PTC heater, demonstrates unique application value in scenarios with special requirements for space utilization and heating uniformity, such as fan heaters and air purifiers.

[0003] However, while the insulation technology for straight-bar PTC heaters is relatively mature, annular PTC heaters are currently mostly electrified due to the complexity of their manufacturing process. The surface of the heat sink is electrified, affecting safety. Furthermore, electrified heaters are prone to aging in humid and dusty environments, severely impacting their lifespan.

[0004] Currently, most ring heaters are manufactured using a ring-curing process, which requires multiple specialized fixtures. Uneven pressure leads to poor curing and rapid product aging. Therefore, innovative solutions are urgently needed to overcome insulation and manufacturing process bottlenecks, and improve product performance and production efficiency. Utility Model Content

[0005] To solve the above problems, this utility model provides an insulated annular PTC heater comprising: The outer ring heat dissipation strip includes an outer ring corrugated heat dissipation fin and an outer ring connecting plate, wherein the outer ring connecting plate is spaced apart to form multiple individual outer connecting plates; The inner ring heat dissipation strip includes an inner ring corrugated heat dissipation fin and an inner ring connecting plate; Multiple tubes are bonded between the outer connecting plate and the inner ring connecting plate. An insulating layer is provided inside the tubes, and an upper electrode plate, a lower electrode plate, and a PTC heating element located between the upper and lower electrode plates are provided inside the insulating layer.

[0006] Furthermore, the inner ring connecting plate can also be spaced out to form multiple individual inner connecting plates. In order to prevent the inner connecting plate from generating compressive stress when bending, a certain length of the inner connecting plate is removed. This length must be less than the tooth pitch of the inner ring corrugated heat sink; otherwise, the inner ring corrugated heat sink will be cut off.

[0007] Furthermore, rivet ends are set at both ends of the upper and lower electrode plates. First, all the upper electrode plates are riveted together in pairs using cables, and the lower electrode plates are riveted together in pairs using cables. Then, PTC heating elements are set in the middle of the corresponding upper and lower electrode plate planes. Next, after setting an insulating layer around all the upper and lower electrode plates, they are inserted into individual tubes, ensuring that each PTC heating element is inside the tube. In order to ensure that the cables do not generate tension when bending, a certain length is reserved when riveting the two electrode plates together. The size of the reserved length is the difference between the arc length when folded into a ring and the corresponding chord length.

[0008] As an improvement, the electrode sheet is integral, with a rivet end at one end for connection to an external power supply line. A pleated area is provided between the two planes corresponding to the two PTC heating elements. These pleats can provide more deformation space during the final bending and stretching process, thereby reducing stress concentration during stretching and making the stretching more uniform and stable.

[0009] As an improvement, the pleated areas are all oriented towards the PTC heating element so that it can be smoothly installed into the tube body later.

[0010] As an improvement, the width of the folded area is narrower than the width of the plane, forming a gap area of ​​a certain distance after the upper and lower electrode plates are assembled. The gap area can prevent the upper and lower electrode plates from contacting each other during bending and deformation, thereby avoiding short circuits.

[0011] As an improvement, the plane corresponding to the electrode sheet and the PTC heating element (the dimension in the length direction is larger than the dimension of the PTC heating element, and the length direction is defined as the direction in which the PTC heating elements are arranged sequentially) is conducive to reducing the process requirements of PTC heating element arrangement and improving production efficiency, while ensuring that the heating element can be misaligned during arrangement so that both electrode surfaces of the PTC heating element can contact the plane of the upper and lower electrode sheets, thus ensuring the reliability of the electrical connection.

[0012] As an improvement, a relief groove is provided between the planes. The length of the relief groove is greater than the length of the folded area to ensure that when the folded area is bent and deformed, the compression deformation will touch the two edges corresponding to the length of the relief groove, so as to avoid short circuit.

[0013] As an improvement, the insulating layer can be wrapped to protect the electrode sheet and PTC heating element. This is suitable for applications where the dustproof and waterproof ratings of the finished PTC heater are not high.

[0014] Furthermore, if the requirements for dustproof and waterproof ratings of the finished PTC heater are relatively high, the insulation layer 4 needs to be made into a sleeve structure with one end open in advance, so that the electrode sheet and PTC heating element can be directly installed.

[0015] The beneficial effects of this utility model of PTC heater are as follows: The structural design of setting an insulating layer on the outside of the PTC heating element and electrode plate before installing it into the tube body realizes the insulation protection function of the ring-shaped PTC heater; After processing the straight strip PTC heater with existing technology and equipment, the corrugated heat sink and the wrinkled area of ​​the electrode plate can be easily bent into a polygon, thus achieving the overall goal of manufacturing an approximately ring-shaped PTC heater using conventional straight strip processing methods. Attached Figure Description

[0016] To more clearly illustrate the embodiments of this utility model, the accompanying drawings used in the description of 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.

[0017] Figure 1 A partial schematic diagram of an insulating annular PTC heater assembly. Figure 2 A schematic diagram of a straight bar type insulated annular PTC heater. Figure 3 This is a schematic diagram of an insulating annular PTC heater structure in Example 1. Figure 4 This is a schematic diagram of an insulating annular PTC heater structure in Example 2. Explanation of icon numbers: 1—Outer ring heat sink; 11—Outer ring corrugated heat sink; 12—Outer ring connecting plate; 12A—Outer connecting plate; 2—Inner ring heat sink; 21—Inner ring corrugated heat sink; 22—Inner ring connecting plate; 22A—Inner connecting plate; 3—tube body; 4—Insulation layer; 51—Upper electrode sheet; 51A—Rivet end of upper electrode sheet; 51B—Wrinkled area of ​​upper electrode sheet; 51C—Allowing groove of upper electrode sheet; 51D—Plane of upper electrode sheet; 52—Lower electrode sheet; 52A—Rivet end of lower electrode sheet; 52B—Wrinkled area of ​​lower electrode sheet; 52C—Relief groove of lower electrode sheet; 52D—Plane of lower electrode sheet; 53—Gap Zone 6—PTC heating element; 7—Cable; Detailed Implementation

[0018] Exemplary embodiments of this application will now be described in detail with reference to the accompanying drawings. The same reference numerals in the drawings denote elements that have the same or similar functions. Although various aspects of the embodiments are shown in the drawings, they are not necessarily drawn to scale unless specifically indicated otherwise.

[0019] It should be understood that the terms "inner", "outer", "front", "rear", "left", "right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model or simplifying the description, 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 this utility model.

[0020] The design will be further explained below with reference to the accompanying drawings in the structural specification.

[0021] like Figures 1-4 As shown, an insulated annular PTC heater includes: an outer ring heat sink 1, which includes an outer ring corrugated heat sink 11 and an outer ring connecting plate 12, the outer ring connecting plate 12 being spaced apart to form multiple individual outer connecting plates 12A; an inner ring heat sink 2, which includes an inner ring corrugated heat sink 21 and an inner ring connecting plate 22; multiple tubes 3 are bonded between the outer connecting plates 12A and the inner ring connecting plate 22, an insulating layer 4 is provided on the inner side of the tubes 3, and an upper electrode plate 51 and a lower electrode plate 52 and a PTC heating element 6 located between the upper electrode plate 51 and the lower electrode plate 52 are provided in the insulating layer 4.

[0022] Furthermore, the inner ring connecting plate 22 can also be spaced out to form multiple individual inner connecting plates 22A. In order to prevent the inner connecting plate 22A from generating compressive stress when bending, a certain length of the inner connecting plate 22A can be removed. This length must be less than the tooth pitch of the inner ring corrugated heat sink 21. Otherwise, the inner ring corrugated heat sink 21 will be cut off. Example

[0023] like Figure 3 At both ends of the upper electrode 51 and the lower electrode 52, there are riveting ends 51A and 52A respectively. First, all the upper electrode 51 are riveted together in pairs by cables 7, and the lower electrode 52 are riveted together in pairs by cables 7. Then, a PTC heating element 6 is set in the middle of the corresponding upper electrode 51 and lower electrode 52. Next, an insulating layer 4 is set around all the upper electrode 51 and lower electrode 52 and then inserted into each tube 3, ensuring that each PTC heating element 6 is in each tube 3. In order to ensure that the cables 7 do not generate tension when bending, a certain length is reserved when riveting the upper electrode 51 and lower electrode 52 in pairs. The reserved length is the difference between the arc length when folded into a ring and the corresponding chord length. When the insulating layer 4 is inserted into the tube 3, it can also create a certain fold between the two tubes to facilitate subsequent bending. Example

[0024] The difference between Embodiment 2 and Embodiment 1 is that the upper electrode plate 51 and the lower electrode plate 52 are integral.

[0025] In this embodiment, the upper electrode 51 and the lower electrode 52 are integrated. A riveting end is provided at one end of each electrode: the riveting end 51A and the riveting end 52A of the upper electrode 51 and lower electrode 52 are riveted to the cable 7 and then connected to the external power supply. Upper electrode pleated areas 51B and lower electrode pleated areas 52B are provided between the two upper electrode planes 51D and the two lower electrode planes 52D corresponding to the two PTC heating elements 6. These upper electrode pleated areas 51B and lower electrode pleated areas 52B can provide more deformation space during the final bending and stretching process, thereby reducing stress concentration during stretching and making the stretching more uniform and stable. To ensure that the upper electrode 51 and lower electrode 52 can be smoothly installed into the tube body 3, the upper electrode pleated areas 51B and lower electrode pleated areas 52B are both oriented towards the PTC heating element 6.

[0026] Furthermore, in order to prevent the upper electrode sheet 51 and the lower electrode sheet 52 from coming into contact during bending and deformation, thereby causing a short circuit, the width of the wrinkled area 51B of the upper electrode sheet and the wrinkled area 52B of the lower electrode sheet are narrower than the width of the plane 51D of the upper electrode sheet and the plane 52D of the lower electrode sheet. When the upper electrode sheet 51 and the lower electrode sheet 52 are assembled, a gap area 53 with a certain distance is formed.

[0027] Furthermore, if the product requires high current operation, and the upper electrode plate 51 and lower electrode plate 52 cannot form a gap area 53 after assembly, an insulating sheet can be placed between the upper electrode plate 51 and lower electrode plate 52 to prevent short circuit.

[0028] Furthermore, the dimensions of the upper electrode plate 51, the lower electrode plate 52, and the upper electrode plate plane 51D and the lower electrode plate plane 52D corresponding to the PTC heating element 6 in the length direction are larger than the dimensions of the PTC heating element 6. The length direction is defined as the direction in which the PTC heating elements 6 are arranged sequentially. This helps to reduce the process requirements for arranging the PTC heating elements 6 and improve production efficiency. For example, when arranging the PTC heating elements 6, a certain degree of misalignment can still ensure that both electrode surfaces of the PTC heating element 6 can contact the upper electrode plate plane 51D and the lower electrode plate plane 52D to ensure the reliability of the electrical connection.

[0029] Furthermore, an upper electrode relief groove 51C is provided between the upper electrode sheet planes 51D. The length of the upper electrode relief groove 51C is greater than the length of the lower electrode sheet wrinkled area 52B, so as to ensure that when the lower electrode sheet wrinkled area 52B is bent and deformed, it is squeezed and deformed upward and touches the two edges of the upper electrode sheet relief groove 51C in the length direction, causing a short circuit. Similarly, a lower electrode relief groove 52C is provided between the lower electrode plate planes 52D. The length of the lower electrode relief groove 52C is greater than the length of the upper electrode plate wrinkled area 51B, so as to ensure that when the upper electrode plate wrinkled area 51B is bent and deformed, it touches the two edges of the lower electrode plate relief groove 52C in the length direction, causing a short circuit.

[0030] Furthermore, the insulating layer 4 can be rolled up to protect the upper electrode sheet 51, the lower electrode sheet 52, and the PTC heating element 6. This is suitable for applications where the dustproof and waterproof ratings of the finished PTC heater are not high.

[0031] Furthermore, the insulating layer 4 can also be made into a sleeve structure with one end open in advance, so that the upper electrode plate 51, the lower electrode plate 52 and the PTC heating element 6 can be directly installed. This is suitable for use when the dustproof and waterproof rating of the finished PTC heater is relatively high.

[0032] The difference between the straight bar processing technology of the insulated annular PTC heater in Implementation 1 and the existing technology is that the individual PTC heating elements are connected together by cables 7. The rest is the same and will not be described in detail here.

[0033] The processing technology for an insulating annular PTC heater according to Embodiment 2 is as follows: First, use existing straight-bar PTC heater equipment for processing. The processing sequence is as follows: Step 1: Apply adhesive to PTC heating element 6; Step 2: Arrange the adhesive-coated PTC heating element 6 on the electrode sheet with wrinkled areas; Step 3: Install the insulating layer 4; Step 4: Insert the tube 3; Step 5: Curing in a straight line. Finally, after the performance is qualified, bend it into an approximately ring-shaped PTC heater.

[0034] The embodiments of this application have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles of the embodiments, their practical application, or improvements to the technology in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. An insulated annular PTC heater, characterized in that: The outer ring heat dissipation strip (1) includes an outer ring corrugated heat dissipation fin (11) and an outer ring connecting plate (12). The outer ring connecting plate (12) is spaced apart to form multiple outer connecting plates (12A). The inner ring heat dissipation strip (2) includes an inner ring corrugated heat dissipation fin (21) and an inner ring connecting plate (22). Multiple tubes (3) are bonded between the outer connecting plate (12A) and the inner ring connecting plate (22). An insulating layer (4) is provided inside the tube (3). An upper electrode plate (51) and a lower electrode plate (52) are provided inside the insulating layer (4). A PTC heating element (6) is provided between the upper electrode plate (51) and the lower electrode plate (52).

2. An insulating annular PTC heater according to claim 1, characterized in that: The inner ring connecting plate (22) is spaced apart to form multiple inner connecting plates (22A). In order to prevent the inner connecting plate (22A) from generating compressive stress when bending, a certain length of the inner connecting plate (22A) is removed. This length is less than the tooth pitch of the inner ring corrugated heat sink (21).

3. An insulated annular PTC heater according to claim 2, characterized in that: The upper electrode plate (51) and the lower electrode plate (52) are each provided with an upper electrode plate riveting end (51A) and a lower electrode plate riveting end (52A). Each upper electrode plate (51) and the lower electrode plate (52) are riveted to a cable (7) through the upper electrode plate riveting end (51A) and the lower electrode plate riveting end (52A).

4. An insulated annular PTC heater according to claim 2, characterized in that: The upper electrode plate (51) and the lower electrode plate (52) are integral. The upper electrode plate (51) and the lower electrode plate (52) are provided with upper electrode plate wrinkled area (51B) and lower electrode plate wrinkled area (52B) between the upper electrode plate (51D) and the lower electrode plate (52D) corresponding to the PTC heating element (6). The upper electrode plate wrinkled area (51B) and the lower electrode plate wrinkled area (52B) can provide more deformation space during bending and stretching, thereby reducing stress concentration during stretching.

5. An insulated annular PTC heater according to claim 4, characterized in that: Both the upper electrode plate wrinkle area (51B) and the lower electrode plate wrinkle area (52B) are positioned towards the PTC heating element (6) so that it can be smoothly installed into the tube body (3) later.

6. An insulated annular PTC heater according to claim 5, characterized in that: The width of the upper electrode plate wrinkled area (51B) and the lower electrode plate wrinkled area (52B) is narrower than the width of the upper electrode plate plane (51D) and the lower electrode plate plane (52D). When the upper electrode plate (51) and the lower electrode plate (52) are assembled, a gap area (53) of a certain distance is formed.

7. An insulated annular PTC heater according to claim 6, characterized in that: The dimensions of the upper electrode plate plane (51D) and the lower electrode plate plane (52D) in the length direction are larger than the dimensions of the PTC heating element (6), and the length direction is defined as the direction in which the PTC heating elements (6) are arranged in sequence.

8. An insulated annular PTC heater according to claim 7, characterized in that: An upper electrode relief groove (51C) and a lower electrode relief groove (52C) ​​are provided between the upper electrode plane (51D) and the lower electrode plane (52D). The length of the upper electrode relief groove (51C) and the lower electrode relief groove (52C) ​​is greater than the length of the upper electrode wrinkle area (51B) and the lower electrode wrinkle area (52B) to prevent the upper electrode wrinkle area (51B) and the lower electrode wrinkle area (52B) from being squeezed and deformed when bent, and touching the two edges of the corresponding upper electrode relief groove (51C) and lower electrode relief groove (52C) ​​in the length direction, causing a short circuit.

9. An insulating annular PTC heater according to any one of claims 1 to 8, characterized in that: The insulating layer (4) protects the upper electrode sheet (51), the lower electrode sheet (52) and the PTC heating element (6) by wrapping them in a roll.

10. An insulating annular PTC heater according to any one of claims 1 to 8, characterized in that: The insulating layer (4) is pre-made into a sleeve structure with one end open, and the upper electrode plate (51), lower electrode plate (52) and PTC heating element (6) are directly installed inside.

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