阅读说明：本技术 一种ptc发热器及制作工艺 (PTC heater and manufacturing process thereof ) 是由 王海涛 于 2019-10-08 设计创作，主要内容包括：本发明公开了一种PTC发热器及制作工艺,包括PTC发热层、导电金属片、电介质层、金属导热管；所述的PTC发热层由PTC陶瓷片组成；所述的金属导热管一端焊接密封,另一端敞口；所述的PTC发热层位于金属导热管内,PTC发热层的两侧贴合导电金属片；所述的电介质层包覆PTC发热层和导电金属片,导电金属片伸出电介质层的一侧,延伸到金属导热管敞口端外用于连接电源对PTC发热层供电发热；PTC发热层、导电金属片、电介质层组成发热芯,发热芯的一端与金属导热管的焊接密封端接触,另一端在金属导热管的敞口端处胶接密封；在金属导热管胶接密封端处外圈焊接有PTC发热器接口法兰。(The invention discloses a PTC heater and a manufacturing process thereof, comprising a PTC heating layer, a conductive metal sheet, a dielectric layer and a metal heat conducting pipe; the PTC heating layer consists of PTC ceramic plates; one end of the metal heat conduction pipe is welded and sealed, and the other end of the metal heat conduction pipe is open; the PTC heating layer is positioned in the metal heat conduction pipe, and two sides of the PTC heating layer are attached with the conductive metal sheets; the dielectric layer coats the PTC heating layer and the conductive metal sheet, and the conductive metal sheet extends out of one side of the dielectric layer and extends to the open end of the metal heat conduction pipe to be externally used for connecting a power supply to supply power to the PTC heating layer for heating; the PTC heating layer, the conductive metal sheet and the dielectric layer form a heating core, one end of the heating core is contacted with the welding sealing end of the metal heat conduction pipe, and the other end of the heating core is sealed at the open end of the metal heat conduction pipe in a gluing way; the outer ring of the cementing and sealing end of the metal heat conducting pipe is welded with a PTC heater interface flange.)

1. A PTC heater is characterized by comprising a PTC heating layer, a conductive metal sheet, a dielectric layer and a metal heat conduction pipe; the PTC heating layer consists of PTC ceramic plates; one end of the metal heat conduction pipe is welded and sealed, and the other end of the metal heat conduction pipe is open; the PTC heating layer is positioned in the metal heat conduction pipe, and two sides of the PTC heating layer are attached with the conductive metal sheets; the dielectric layer coats the PTC heating layer and the conductive metal sheet, and the conductive metal sheet extends out of one side of the dielectric layer and extends to the open end of the metal heat conduction pipe to be externally used for connecting a power supply to supply power to the PTC heating layer for heating; the PTC heating layer, the conductive metal sheet and the dielectric layer form a heating core, one end of the heating core is contacted with the welding sealing end of the metal heat conduction pipe, and the other end of the heating core is sealed at the opening end of the metal heat conduction pipe in a gluing manner.

2. A PTC heater according to claim 1, wherein the dielectric layer is a hard dielectric ceramic in the form of a pair of U-shaped dielectric ceramic structures which are snap-fitted together with a cavity formed therebetween for mounting the PTC heating layer, or a unitary dielectric ceramic structure with a cavity formed therebetween.

3. A PTC heater according to claim 2, wherein the U-shaped dielectric ceramic structure is one or a plurality of U-shaped dielectric ceramic plates arranged in sequence.

4. A PTC heater according to claim 1, wherein the dielectric layer is a soft dielectric film covering the PTC heating layer and the conductive metal sheet.

5. A PTC heater according to claim 1, wherein the PTC heating layer comprises a plurality of PTC ceramic sheets arranged in sequence or an integrated PTC ceramic sheet.

6. A PTC heater according to claim 5, wherein the dielectric ceramic sheet may be arranged between or/and at the end of the PTC ceramic sheets of the heat generating layer.

7. A PTC heater according to claim 1, wherein the welding-sealed end of the metal heat pipe is sealed by a metal piece welded to the end of the metal heat pipe, or the end of the metal heat pipe is flattened to directly weld and seal the flat port.

8. A PTC heater according to claim 1, wherein the interface flange is welded to the outer circumference of the metal heat pipe at the glue sealed end.

9. A manufacturing process of a PTC heater is characterized by comprising the following steps:

designing a PTC ceramic sheet according to the heating power to manufacture a PTC heating layer in the middle;

respectively attaching two conductive metal sheets to two sides of the PTC heating layer in a manner of connecting the PTC ceramic sheets in parallel to manufacture a conductive electrode;

respectively arranging a piece of dielectric ceramic chip at two ends of the PTC heating layer to manufacture the end insulation of the heating layer;

designing a hard dielectric ceramic structure to coat the PTC heating layer and the conductive metal sheet to form a dielectric layer;

cutting a formed metal heat conduction pipe with a corresponding length, polishing a pipe opening, and cleaning;

the PTC heating layer, the conductive metal sheet and the dielectric layer form a PTC heating core, and the PTC heating core penetrates into the metal heat conducting pipe;

the PTC heating core is contacted and compacted with the metal heat conduction pipe;

after the PTC heating core and the metal heat conduction pipe pass the electrical insulation test, the metal heat conduction pipe plug with the corresponding size is placed at the tail end of the metal heat conduction pipe for welding and sealing; or flattening the tail end of the metal heat conduction pipe, and directly welding and sealing the flat opening;

welding a corresponding liquid medium heating container interface flange manufactured in advance with a metal heat conduction pipe;

after the welding seam of the metal heat conduction pipe and the interface flange is cooled, the open end of the metal heat conduction pipe is glued and sealed.

10. A manufacturing process of a PTC heater is characterized by comprising the following steps:

designing a PTC ceramic sheet according to the heating power to manufacture a PTC heating layer in the middle;

respectively attaching two conductive metal sheets to two sides of the PTC heating layer in a manner of connecting the PTC ceramic sheets in parallel to manufacture a conductive electrode;

respectively arranging a piece of dielectric ceramic chip at two ends of the PTC heating layer to manufacture the end insulation of the heating layer;

cutting a soft dielectric film with a proper size, and coating the PTC heating layer and the conductive metal sheet to form a dielectric layer;

cutting a formed metal heat conduction pipe with a corresponding length, polishing a pipe opening, and cleaning;

placing the metal heat conduction pipe plug with the corresponding size at the tail end of the metal heat conduction pipe for welding and sealing, or flattening the tail end of the metal heat conduction pipe, and directly welding and sealing the flat opening;

welding a corresponding liquid medium heating container interface flange manufactured in advance with a metal heat conduction pipe;

the PTC heating layer, the conductive metal sheet and the dielectric layer form a PTC heating core, and the PTC heating core penetrates into the metal heat conducting pipe;

the PTC heating core is contacted and compacted with the metal heat conduction pipe;

after the PTC heating core and the metal heat conduction pipe pass the electric insulation test, the open end of the metal heat conduction pipe is glued and sealed.

Technical Field

The invention discloses a PTC heater and a manufacturing process thereof.

Background

PTC thermistors, also called PTC ceramics, belong to semiconductor materials with positive resistance temperature coefficient, and because of the outstanding advantages of safety, energy conservation, high efficiency and environmental protection, the PTC thermistors can avoid safety accidents such as dry burning fire, personal burn and scald, and can also intelligently control temperature, save electricity and reduce consumption in the using process, and are widely applied to the fields of household and industrial production heaters, such as air-conditioning electric auxiliary heaters, winter household heaters, warm fans, kitchen electric ovens, marmite heaters, electric rice cooker heaters, industrial drying boxes, medical appliance drying boxes and the like.

Due to the limitation of the existing manufacturing process of the PTC heater, the PTC thermistor is only limited to the heating of solid medium and gas medium at present. Since the PTC thermistor has been applied to the heater field, its application to liquid media, such as heating water media in household water heaters, heating oil media in industrial oil warmers, etc., is being continuously tried. In recent years, some patent materials related to the PTC heating water heater are also filed, most of the materials are only used for conceptual illustration, or are expected to be a concept, and most of the materials do not relate to the manufacturing process, so that the related PTC liquid medium heating patents are not practically converted into products, and finally some patents cannot be implemented and fail.

The application of the PTC heater in a liquid medium is restricted mainly because the problems of sealing, pressure resistance and electric insulation are not solved by the prior PTC heater manufacturing process. For example, when a PTC heater heats water medium in a water heater, if the existing organic silica gel sealing process is used, the sealing process can work well in a dry environment, but can be out of service in the water medium. On the other hand, the PTC heater in the water heater can endure certain water pressure (usually 0.8-1.6 MPa), and for the working environment, the silica gel encapsulation of the PTC heater cannot bear pressure, the sealing is damaged, and water seepage is caused in the heater, so that the heater is damaged and the electric leakage safety accident is caused. So far, the heating of the PTC heater in the liquid medium has not been practically applied, the heating mode aiming at the liquid medium is still the traditional resistance tube heater, and the defects of dry burning, fire hazard, energy consumption and low efficiency are existed in the using process.

Because the problems of sealing, pressure resistance and electric insulation are not solved all the time, a mode that a PTC heating core is separated from liquid and is not in direct contact with the liquid and the liquid is heated indirectly is adopted in many patents. For example, in patents CN201810295406.5, CN201721016862.9, CN200420014780.7, and CN03224401.0, a liquid medium is indirectly heated by the PTC heat generating core to heat the outer shell of the liquid chamber or the pipe wall of the liquid heating pipeline, and the indirect heating manner in these patents increases heat loss, so the heat efficiency is not ideal, and the processing process is rather complicated, the manufacturing cost is increased, and the popularization and use are difficult in the market.

Disclosure of Invention

In order to solve the problems of sealing, pressure resistance and electric insulation of the PTC heater in a liquid medium, the existing PTC heater manufacturing process is changed, a new manufacturing process is developed, and a new product is obtained through the process.

The technical scheme adopted by the invention is as follows:

a PTC heater comprises a PTC heating layer, a conductive metal sheet, a dielectric layer and a metal heat conduction pipe; the PTC heating layer consists of PTC ceramic plates; one end of the metal heat conduction pipe is welded and sealed, and the other end of the metal heat conduction pipe is open; the PTC heating layer is positioned in the metal heat conducting pipe, and two sides of the PTC heating layer are attached with the conductive metal sheets; the dielectric layer coats the PTC heating layer and the conductive metal sheet, and the conductive metal sheet extends out of one side of the dielectric layer and extends to the open end of the metal heat conduction pipe to be externally used for connecting a power supply to supply power to the PTC heating layer for heating; the PTC heating layer, the conductive metal sheet and the dielectric layer form a heating core, one end of the heating core is contacted with the welding sealing end of the metal heat conduction pipe, and the other end of the heating core is sealed at the opening end of the metal heat conduction pipe in a gluing manner.

As a further technical scheme, the dielectric layer is hard dielectric ceramic (such as alumina-based ceramic).

Furthermore, the hard dielectric ceramic is a pair of U-shaped dielectric ceramic structures which are buckled together, and a cavity for installing the PTC heating layer is formed in the middle of the U-shaped dielectric ceramic structures, or the hard dielectric ceramic is an integral dielectric ceramic structure with a middle cavity.

Furthermore, the pair of U-shaped dielectric ceramic structures buckled together are respectively one or a plurality of U-shaped dielectric ceramic plates arranged in sequence.

As a further technical scheme, the dielectric layer is a soft dielectric film (such as a polyimide-based film) and covers the PTC heating layer and the conductive metal sheet.

As a further technical scheme, the PTC heating layer comprises a plurality of PTC ceramic plates which are sequentially arranged; or an integral sheet of PTC ceramic.

As a further technical scheme, the welding sealing end of the metal heat conduction pipe is sealed by a metal sheet welded at the end of the metal heat conduction pipe, or the end of the metal heat conduction pipe is flattened and directly welded and sealed to a flat opening.

The invention also provides a manufacturing process of the PTC heater, which comprises the following steps:

1, arranging PTC ceramic plates with corresponding specifications and numbers in order according to heating power design to manufacture a PTC heating layer in the middle;

2, respectively attaching two conductive metal sheets to two sides of the PTC heating layer in a way of connecting the PTC ceramic sheets in parallel to manufacture a conductive electrode;

3, respectively arranging a dielectric ceramic plate at two ends of the middle PTC heating layer to manufacture the end insulation of the heating layer;

4 designing a hard dielectric ceramic (such as alumina-based ceramic) structure to coat the PTC heating layer and the conductive metal sheet to form a dielectric layer;

5, cutting the formed metal heat conduction pipe (aluminum alloy, copper alloy or stainless steel and the like) with the corresponding length, and polishing the pipe opening for cleaning.

6, the PTC heating core is composed of the middle PTC heating layer, the conductive metal sheet and the dielectric layer and penetrates into the metal heat conduction pipe;

7, compacting the PTC heating core in contact with the metal heat conduction pipe through a rolling process;

8, after the electrical insulation test of the PTC heating core and the metal heat conduction pipe is passed, the metal heat conduction pipe plug with the corresponding size is placed at the tail end of the metal heat conduction pipe for welding and sealing;

9, butting a corresponding interface flange of the liquid medium heating container, which is manufactured in advance, with the metal heat conduction pipe, wherein the interface flange is made of metal and can be made of aluminum alloy, copper alloy or stainless steel and the like which are made of the same material as the metal heat conduction pipe. Welding the front and back surfaces of the butt joint seam of the metal heat conduction pipe and the interface flange;

10 after the welding seam of the metal heat conduction pipe and the heater interface flange is cooled, coating organic silica gel at the open end of the metal heat conduction pipe for sealing;

11. carrying out 1.6-2.0 MPA sealing water pressure test on the PTC heater according to a certain safety coefficient of actual working conditions, detecting the pressure-resistant sealing performance of a plugging welding seam at the tail end of the metal heat conduction pipe, and detecting the pressure-resistant sealing performance of the welding seam of the metal heat conduction pipe and the interface flange;

furthermore, the dielectric layer of the PTC heater adopts a soft dielectric film (such as a polyimide-based film), the welding process is carried out before the PTC heating core penetrates into the metal heat conduction pipe, the burning damage of the soft dielectric film caused by the high temperature of welding is prevented, and the manufacturing process of the PTC heater comprises the following steps:

1, arranging PTC ceramic plates with corresponding specifications and numbers in order according to heating power design to manufacture a PTC heating layer in the middle;

2, respectively attaching two conductive metal sheets to two sides of the PTC heating layer in a way of connecting the PTC ceramic sheets in parallel to manufacture a conductive electrode;

3, respectively arranging a dielectric ceramic plate at two ends of the middle PTC heating layer to manufacture the end insulation of the heating layer;

4 cutting a soft dielectric film with a proper size, and coating the PTC heating layer and the conductive metal sheet to form a dielectric layer;

5, cutting the formed metal heat conduction pipe (aluminum alloy, copper alloy or stainless steel and the like) with the corresponding length, and polishing the pipe opening for cleaning.

6, placing the metal heat conduction pipe plug with the corresponding size at the tail end of the metal heat conduction pipe for welding and sealing;

7, butting a corresponding liquid medium heating container interface flange which is manufactured in advance with the metal heat conduction pipe, wherein the interface flange is made of metal and can be aluminum alloy, copper alloy or stainless steel and the like which are made of the same material as the metal heat conduction pipe. Welding the front and back surfaces of the butt joint seam of the metal heat conduction pipe and the interface flange;

8, the PTC heating core is composed of the middle PTC heating layer, the conductive metal sheet and the dielectric layer and penetrates into the metal heat conduction pipe;

9, compacting the PTC heating core in contact with the metal heat conduction pipe through a rolling process;

after the electrical insulation test of the 10PTC heating core and the metal heat conduction pipe is passed, coating organic silica gel at the open end of the metal heat conduction pipe for sealing;

11, carrying out 1.6-2.0 MPA sealing water pressure test on the PTC heater according to a certain safety coefficient of actual working conditions, detecting the pressure-resistant sealing performance of a plugging welding seam at the tail end of the metal heat conduction pipe, and detecting the pressure-resistant sealing performance of a welding seam of a flange interface of the metal heat conduction pipe and a sealing interface;

furthermore, the tail end of the metal heat conduction pipe can be sealed by welding without adopting a plug, and the tail end of the metal heat conduction pipe can be flattened on a press machine to directly weld and seal the flat opening;

furthermore, the welding process is determined according to the materials of the metal heat conduction pipe and the connecting flange and the actual working condition, when the metal heat conduction pipe and the connecting flange are made of stainless steel, an argon arc welding mode or a laser welding mode is adopted, and if the metal heat conduction pipe is made of aluminum or copper, the connecting flange is made of stainless steel, and the welding mode is adopted; manual welding or automatic welding of a production line is selected according to production batch and production efficiency.

Furthermore, the number and the arrangement mode of the PTC ceramic plates are calculated and designed according to the actual power requirement, and in order to increase the heat transfer area, the dielectric ceramic plates can be clamped between the PTC ceramic plates on the heating layer.

Furthermore, in order to ensure good conductivity and facilitate the arrangement and installation of the PTC ceramic plate and the dielectric ceramic plate on site, a proper amount of conductive adhesive glue can be coated between the PTC ceramic plate and the conductive metal sheet.

Furthermore, in order to ensure good thermal conductivity and facilitate the arrangement and installation of the dielectric ceramic plate on site, a proper amount of heat-conducting adhesive can be coated between the dielectric ceramic plate and the metal heat-conducting pipe as well as between the dielectric ceramic plate and the conductive metal plate.

Furthermore, the shape, size and connection mode of the interface flange of the PTC heater are determined according to the actual working condition requirement of the liquid heating container, for example, the shape can be circular, square, oval and the like.

Furthermore, the metal heat conducting pipe can be bent at a certain angle or radian according to the use requirement.

The invention has the beneficial effects that:

the PTC heater manufactured by the process has the key point of solving the problems of pressure-resistant sealing and liquid medium sealing failure in the prior process, and has the outstanding advantage that the PTC heater can be placed in a liquid medium, in particular a liquid medium with pressure for use. The port of the metal heat conducting pipe of the PTC heater is welded and sealed in the manufacturing process, the existing silica gel sealing process is replaced, and meanwhile, the joint of the metal heat conducting pipe and the interface flange is welded. Compared with a cementing structure, the welding structure can be placed in a liquid medium for a long time without failure, and can bear enough working pressure without leakage safety accidents caused by the fact that sealing leakage liquid permeates into the PTC heater. For example, in a widely used household water storage type water heater, the heater needs to be soaked in a water medium for a long time and simultaneously bears the water pressure of about 1MPa in the water heater, which is a working environment in which the PTC heater manufactured by the existing process cannot be used. The liquid medium in the sealed container is heated under certain working pressure, and the PTC heater manufactured by the process can be used for such working tasks.

The PTC heater manufactured by the process can be used for heating solid media and gas media; it can also be used for heating liquid medium, such as heating water, heating various oils, heating various chemical liquids, etc.; can work under atmospheric pressure; the device can also work in a sealed container with pressure, and has strong universality and wide application.

The dielectric layer of the invention adopts the material with strong polarization performance and large dielectric constant, and plays a role of high-quality electrical isolation and insulation between the PTC heating layer and the metal heat conduction pipe. The tuning dielectric layer according to the process may be a hard dielectric ceramic (e.g., alumina-based ceramic) or a soft dielectric film (e.g., polyimide-based film).

The hard dielectric ceramic is designed into a pair of U-shaped dielectric ceramic structures which are buckled together, and a hole cavity for installing the PTC heating layer is formed in the middle of the U-shaped dielectric ceramic structures, or the hard dielectric ceramic is an integral dielectric ceramic structure with a middle hole cavity.

And the U-shaped dielectric ceramic structures are buckled together and are respectively one or a plurality of U-shaped dielectric ceramic plates which are sequentially arranged. The number of the PTC ceramic plates can be flexibly adjusted according to the heating power in the manufacturing process of the PTC heater, the number of the U-shaped dielectric ceramic plates can be flexibly arranged, the U-shaped dielectric ceramic plates can be used for carrying out electric isolation on the butt-joint cladding of the PTC ceramic plates, the operation is convenient, the combination is simple, and the integral compaction of the heater is convenient after the assembly; meanwhile, the U-shaped dielectric ceramic chip is simple in structure, simple in manufacturing process and low in raw material cost.

Of course, it is understood that the hard dielectric ceramic can be made into an integral dielectric ceramic structure with a middle hole cavity for installing the PTC heating layer according to the accurate length of the PTC heating layer.

Adopt soft dielectric film, the construction is simple, and the flexible operation cuts out the dielectric film of suitable size, generates heat the layer and the cladding of conductive metal piece 2 ~ 3 layers to PTC, carries out reliable electrical isolation to generating heat core and metal heat pipe.

The assembly type, butt joint type, buckling type, integral type and cladding type assembly process of the dielectric layer has unified and standard operation and strong universality, is suitable for assembly line, automation, industrialization and large-scale production, greatly reduces the production cost of the PTC heater, improves the market competitiveness of the PTC heater, and is beneficial to the popularization of the PTC heater in various industries.

The PTC heater is developed and applied in civil life and industrial production, realizes direct heating of various media, has high thermal efficiency, no open fire and no dry burning, eliminates the hidden danger of high-temperature over-burning accidents, improves the safety and stability of equipment, saves energy, reduces energy consumption and is green and environment-friendly. For the life of common people, the user experience of the household appliances is improved, and the life quality of people is improved; for industrial production, a new process is introduced, the cost is reduced, the income is increased, and the industrial upgrading is promoted.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the application and, together with the description, serve to explain the application and are not intended to limit the application.

FIG. 1 is a front view of a PTC heater in full section;

FIG. 2 is a plan view of the PTC heater;

FIG. 3 is a side view in full section of the PTC heater;

FIG. 4 is a front view of the PTC heater in full section;

FIG. 5 is a schematic diagram of a multi-piece U-shaped dielectric ceramic structure with a dielectric layer fastened up and down;

FIG. 6 is a U-shaped dielectric ceramic structure with a dielectric layer fastened up and down;

FIG. 7 shows a top-to-bottom fastened monolithic U-shaped dielectric ceramic (end seal) structure for the dielectric layer;

FIG. 8 is a schematic diagram of a multi-piece U-shaped dielectric ceramic structure with left and right buckled dielectric layers;

FIG. 9 is a left-right buckled integral U-shaped dielectric ceramic structure of the dielectric layer;

FIG. 10 shows a structure in which the dielectric layer is a left-right buckled integral U-shaped dielectric ceramic (end seal);

FIG. 11 is a dielectric layer with a porous monolithic dielectric ceramic structure or a soft dielectric thin film coating;

FIG. 12 is a diagram showing a dielectric layer being a porous monolithic dielectric ceramic (end-seal) structure or a soft dielectric film coating (end-pack);

in the figure: the PTC heater comprises a PTC ceramic plate 1, a conductive metal plate 2, a dielectric layer 3, a metal heat-conducting pipe 4, a dielectric ceramic plate at the end part of a PTC heating layer 5, a metal heat-conducting pipe end plug 6, a metal heat-conducting pipe end plug welding line 7, a metal heat-conducting pipe and interface flange welding line 8, a PTC heater interface flange 9, organic silica gel 10 and a metal heat-conducting pipe end flat mouth welding line 11.

Detailed Description

It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.

It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present application. As used herein, the singular forms "a", "an", and/or "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof;

as described in the background art, the problems of sealing, pressure resistance and electrical insulation in the prior art have not been solved, and many patents have adopted a way of indirectly heating liquid by separating the PTC heating core from the liquid without direct contact. For example, in patents CN201810295406.5, CN201721016862.9, CN200420014780.7, and CN03224401.0, a liquid medium is indirectly heated by the PTC heat generating core to heat the outer shell of the liquid chamber or the pipe wall of the liquid heating pipeline, and the indirect heating manner in these patents increases heat loss, so the heat efficiency is not ideal, and the processing process is rather complicated, the manufacturing cost is increased, and the popularization and use are difficult in the market.

In order to solve the above technical problems, the present application proposes a PTC heater, as shown in fig. 1 to 4, which includes a PTC heating layer, two conductive metal sheets, a dielectric layer, and a metal heat pipe.

The PTC heating layer consists of PTC ceramic sheets and is positioned in the metal heat conduction pipe, the two conductive metal sheets are respectively attached to two sides of the PTC heating layer and extend out of the metal heat conduction pipe to be used for connecting a power supply to supply power to the PTC heating layer for heating;

the dielectric layer is wrapped on the PTC heating layer and the outer sides of the two conductive metal sheets and is in contact with the metal heat conduction pipe;

one end of the metal heat conduction pipe is welded and sealed, and the other end of the metal heat conduction pipe is welded with the sealing interface flange, so that the isolation and pressure-resistant sealing of the liquid medium and original devices in the metal heat conduction pipe are realized when the PTC heater works.

PTC generates heat layer, conductive metal piece, dielectric layer constitution generate heat the core, generate heat the core and penetrate in the metal conduction pipe, one end and the contact of metal conduction pipe welding seal end, and the other end is sealed through organic silica gel at the open end department of metal conduction pipe.

In this embodiment, the dielectric layer may be a hard dielectric ceramic (e.g., alumina-based ceramic) having various shapes, specifically as follows:

the first hard dielectric ceramic is a vertically engaging structure, and includes an upper U-shaped dielectric ceramic layer and a lower U-shaped dielectric ceramic layer, as shown in fig. 5, 6, and 7; the upper U-shaped dielectric ceramic layer and the lower U-shaped dielectric ceramic layer are buckled together to form a rectangular cavity for mounting the PTC heating layer.

Further, in fig. 5, the upper U-shaped dielectric ceramic layer and the lower U-shaped dielectric ceramic layer each include a plurality of U-shaped dielectric ceramic sheets arranged in sequence, and in this embodiment, the upper U-shaped dielectric ceramic layer and the lower U-shaped dielectric ceramic layer each include four U-shaped dielectric ceramic sheets arranged in sequence; it is understood that the number of the U-shaped dielectric ceramic plates in other embodiments is not limited to four in the present embodiment, and the specific number and size are determined according to the length of the PTC heating layer; the reason why the upper U-shaped dielectric ceramic layer and the lower U-shaped dielectric ceramic layer are made into the small size is not the whole structure mainly because the power requirements are different in practical application, so the number of the PTC ceramic sheets of the PTC heating layer is not determined, and in order to adapt to the requirements of the PTC heating layer with different power, the corresponding upper U-shaped dielectric ceramic layer and the lower U-shaped dielectric ceramic layer are also made into the small size structure which can be used in any combination.

Further, in fig. 6, the upper U-shaped dielectric ceramic layer and the lower U-shaped dielectric ceramic layer are designed to be a one-piece structure, which is suitable for the case of producing only a fixed power heater, and the whole upper U-shaped dielectric ceramic layer and the whole lower U-shaped dielectric ceramic layer can be customized for a certain power.

Furthermore, the upper U-shaped dielectric ceramic layer and the lower U-shaped dielectric ceramic layer may be of a one-piece U-shaped dielectric ceramic sheet structure that is fastened up and down, and the ends are sealed, as shown in fig. 7. This structure eliminates the need for mounting the PTC heating layer end dielectric ceramic sheet 5 shown in fig. 1 in the manufacturing.

The second hard dielectric ceramic is a left-right buckling structure, as shown in fig. 8, 9, and 10, and the specific structure refers to the upper-lower structure, which is not described herein again. Specifically, the structure may be a multi-piece U-shaped dielectric ceramic sheet structure that is fastened left and right, as shown in fig. 8. It can be a structure of a whole U-shaped dielectric ceramic plate buckled left and right, as shown in fig. 9. It may be a one-piece U-shaped dielectric ceramic sheet structure (end seal) that is snapped right and left, as shown in fig. 10. This structure eliminates the need for mounting the PTC heating layer end dielectric ceramic sheet 5 shown in fig. 1 in the manufacturing.

The third type of hard dielectric ceramic is a monolithic dielectric ceramic structure with rectangular cavities as shown in fig. 11. Further, a monolithic dielectric ceramic (end seal) structure with a rectangular cavity is also possible, as shown in fig. 12. This structure eliminates the need for mounting the PTC heating layer end dielectric ceramic sheet 5 shown in fig. 1 in the manufacturing.

As a further technical scheme, the dielectric layer can be a soft dielectric film (such as a polyimide-based film), and the PTC heating layer and the conductive metal sheet are coated to form the dielectric layer, and the pattern is as shown in figures 11 and 12.

As a further technical scheme, the PTC heating layer comprises a plurality of PTC ceramic plates which are sequentially arranged; the quantity and the arrangement mode of the PTC sheets are calculated and designed according to the actual power requirement; in order to increase the heat transfer area, the dielectric ceramic plates can be clamped between the PTC ceramic plates of the middle layer; the power of the plurality of PTC ceramic plates can be the same or different, and the PTC ceramic plates are arranged according to actual power requirements.

Of course, it is understood that the PTC ceramic sheet of the PTC heating layer may also be used in a whole sheet by calculating the accurate length according to the heating power requirement.

Furthermore, in order to ensure good conductivity and facilitate the arrangement and installation of the PTC ceramic plate and the dielectric ceramic plate on site, a proper amount of conductive adhesive glue can be coated between the PTC ceramic plate and the conductive metal sheet.

Furthermore, in order to ensure good thermal conductivity and facilitate the arrangement and installation of the dielectric ceramic plate on site, a proper amount of heat-conducting adhesive can be coated between the dielectric ceramic plate and the metal heat-conducting pipe as well as between the dielectric ceramic plate and the conductive metal plate.

As a further technical solution, as shown in fig. 1; the welding sealing end of the metal heat conduction pipe is plugged by a metal sheet welded at the end part of the metal heat conduction pipe; alternatively, as shown in fig. 4, the end of the metal heat transfer pipe is flattened and directly welded and sealed to the flat port.

The manufacturing process of the PTC heater comprises the following steps:

1, arranging PTC ceramic plates 1 with corresponding specifications and numbers in order according to the design of heating power to manufacture a PTC heating layer in the middle, as shown in a full-section front view 1 of figure 1.

2, respectively attaching two conductive metal sheets 2 to two sides of the PTC heating layer in a way of connecting the PTC ceramic sheets in parallel to manufacture conductive electrodes, as shown in a full-section front view 1 of figure 1.

3, respectively arranging a dielectric ceramic plate 5 at two ends of the middle PTC heating layer to manufacture the end insulation of the heating layer. As shown in the front view 1 of fig. 1 in full section.

4 designing a hard dielectric ceramic (such as alumina-based ceramic) structure, coating the PTC heating layer and the conductive metal sheet to form a dielectric layer 3, as shown in a front view 1 of a full section of FIG. 1.

5, cutting the formed metal heat conduction pipe 4 (aluminum alloy, copper alloy or stainless steel and the like) with the corresponding length, and polishing the pipe opening for cleaning.

6 the PTC heating core is composed of the middle PTC heating layer, the conductive metal sheet and the dielectric layer, and penetrates into the metal heat conducting pipe 4, as shown in the front view 1 of the full section of fig. 1.

7, compacting the PTC heating core in contact with the metal heat conduction pipe through a rolling process.

After the electrical insulation test of the PTC heating core and the metal heat conduction pipe is passed, the metal heat conduction pipe plug 6 with the corresponding size is placed at the tail end of the metal heat conduction pipe for welding and sealing, specifically, the tail end of the metal heat conduction pipe plug weld 7 shown in fig. 1.

9, butting a corresponding interface flange 9 of the liquid medium heating container, which is manufactured in advance, with the metal heat conduction pipe, wherein the interface flange is made of metal, and can be aluminum alloy, copper alloy or stainless steel and the like which are made of the same material as the metal heat conduction pipe. The front and back sides of the butt joint of the metal heat pipe and the sealing interface flange are welded, specifically, the weld 8 of the metal heat pipe and the interface flange shown in fig. 1 is provided.

10 after cooling the metal heat pipe and the interface flange weld seam 8, coating organic silica gel 10 at the open end of the metal heat pipe for sealing, as shown in fig. 1; the entire PTC heater has been designed by this step. In the subsequent process, the PTC heater can be subjected to 1.6-2.0 MPA sealing water pressure test according to a certain safety factor of the actual working condition, the pressure-resistant sealing performance of the plugging welding line at the tail end of the metal heat conduction pipe is detected, and the pressure-resistant sealing performance of the welding line of the metal heat conduction pipe and the interface flange is detected.

Furthermore, the dielectric layer adopts a soft dielectric film (such as polyimide-based film), the welding process is carried out before the PTC heating core penetrates into the metal heat conduction pipe, the burning damage of the soft dielectric film caused by high welding temperature is prevented, and the manufacturing process steps of the PTC heater are as follows:

1, arranging PTC ceramic plates 1 with corresponding specifications and numbers in order according to the design of heating power to manufacture a PTC heating layer in the middle, as shown in a full-section front view 1 of figure 1.

2, respectively attaching two conductive metal sheets 2 to two sides of the PTC heating layer in a way of connecting the PTC ceramic sheets in parallel to manufacture conductive electrodes, as shown in a full-section front view 1 of figure 1.

3, respectively arranging a dielectric ceramic plate 5 at two ends of the middle PTC heating layer to manufacture the end insulation of the heating layer. As shown in the front view 1 of fig. 1 in full section.

4 cutting a soft dielectric film (such as polyimide-based film) with proper size, and coating the PTC heating layer and the conductive metal sheet to form a dielectric layer 3;

5, cutting the formed metal heat conduction pipe 4 (aluminum alloy, copper alloy or stainless steel and the like) with the corresponding length, and polishing the pipe orifice for cleaning;

6, placing a metal heat conduction pipe plug 6 with a corresponding size at the tail end of the metal heat conduction pipe for welding and sealing, specifically, a welding seam 7 at the tail end of the metal heat conduction pipe as shown in fig. 1.

7, butting a corresponding liquid medium heating container interface flange 9 which is manufactured in advance with the metal heat conduction pipe, wherein the interface flange is made of metal and can be aluminum alloy, copper alloy or stainless steel and the like which are made of the same material as the metal heat conduction pipe. And (3) welding the front and back sides of a butt joint of the metal heat conduction pipe and the interface flange, specifically, welding seams 8 of the metal heat conduction pipe and the interface flange shown in fig. 1.

The PTC heating core is composed of the middle PTC heating layer, the conductive metal sheet and the dielectric layer 8, and penetrates into the metal heat conduction pipe 4, as shown in the front view 1 of the full section of fig. 1.

9, compacting the PTC heating core in contact with the metal heat conduction pipe through a rolling process;

after the electrical insulation test of the 10PTC heating core and the metal heat conduction pipe is passed, coating organic silica gel 10 at the open end of the metal heat conduction pipe for sealing; the entire PTC heater has been designed by this step. In the subsequent process, the PTC heater can be subjected to 1.6-2.0 MPA sealing water pressure test according to a certain safety factor of the actual working condition, the pressure-resistant sealing performance of the plugging welding line at the tail end of the metal heat conduction pipe is detected, and the pressure-resistant sealing performance of the welding line of the metal heat conduction pipe and the interface flange is detected.

Further, the end of the metal heat pipe may be sealed by welding without using a plug, and the end of the metal heat pipe may be flattened on a press machine to directly seal the flat opening by welding, as shown in fig. 4 by the flat opening welding seam 11 at the end of the metal heat pipe.

Furthermore, the welding process is determined according to the materials of the metal heat conduction pipe and the interface flange and the actual working condition, when the metal heat conduction pipe and the interface flange are made of stainless steel, an argon arc welding mode or a laser welding mode is adopted, and if the metal heat conduction pipe is made of aluminum or copper, the connection flange is made of stainless steel, and the metal heat conduction pipe and the interface flange are welded in a brazing mode; manual welding or automatic welding of a production line is selected according to production batch and production efficiency.

Furthermore, the number and the arrangement mode of the PTC ceramic sheets are calculated and designed according to the actual power requirement, and in order to increase the heat transfer area, the dielectric ceramic sheets can be clamped between the PTC ceramic sheets on the heating layer.

Furthermore, the shape, size and connection mode of the sealing interface flange of the PTC heater are determined according to the actual working condition requirement of the liquid heating container, for example, the shape can be circular, square, oval and the like.

Furthermore, in order to ensure good conductivity and facilitate the arrangement and installation of the PTC ceramic plate and the dielectric ceramic plate on site, a proper amount of conductive adhesive glue can be coated between the PTC ceramic plate and the conductive metal sheet.

Furthermore, in order to ensure good thermal conductivity and facilitate the arrangement and installation of the dielectric ceramic plate on site, a proper amount of heat-conducting adhesive can be coated between the dielectric ceramic plate and the metal heat-conducting pipe as well as between the dielectric ceramic plate and the conductive metal plate.

Furthermore, the metal heat conducting pipe can be bent at a certain angle or radian according to the use requirement.

Furthermore, the PTC heater manufactured by the process can be used for heating solid media and gas media; it can also be used for heating liquid medium, such as heating water, heating various oils, heating various chemical liquids, etc.; can work under atmospheric pressure; the device can also work in a sealed container with pressure, and has strong universality and wide application.

The PTC heater manufactured by the process has the key point of solving the problems of pressure-resistant sealing and liquid medium sealing failure in the existing process, and has the outstanding advantage that the PTC heater can be placed in a liquid medium, in particular a liquid medium with pressure for use. The port of the metal heat conducting pipe of the PTC heater is welded and sealed in the manufacturing process, the existing silica gel sealing process is replaced, and meanwhile, the joint of the metal heat conducting pipe and the sealing interface flange is welded. Compared with a cementing structure, the welding structure can be placed in a liquid medium for a long time without failure, and can bear enough working pressure without leakage safety accidents caused by the fact that sealing leakage liquid permeates into the PTC heater. For example, in a widely used household water storage type water heater, the heater needs to be soaked in a water medium for a long time and simultaneously bears the water pressure of about 1MPa in the water heater, which is a working environment in which the PTC heater manufactured by the existing process cannot be used. The liquid medium in the sealed container is heated under certain working pressure, and the PTC heater manufactured by the process can be used for such working tasks.

The development and application of the PTC heater in civil life and industrial production can eliminate the hidden danger of high-temperature over-burning accidents, improve the safety and stability of equipment, improve the user experience of household appliances, improve the life quality of people, save energy, reduce energy consumption, protect environment and improve the production and processing technology.

The above description is only a preferred embodiment of the present application and is not intended to limit the present application, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present application shall be included in the protection scope of the present application.