WO2016011927A1 - 一种电制热器及其制备方法 - Google Patents

一种电制热器及其制备方法 Download PDF

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Publication number
WO2016011927A1
WO2016011927A1 PCT/CN2015/084556 CN2015084556W WO2016011927A1 WO 2016011927 A1 WO2016011927 A1 WO 2016011927A1 CN 2015084556 W CN2015084556 W CN 2015084556W WO 2016011927 A1 WO2016011927 A1 WO 2016011927A1
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WO
WIPO (PCT)
Prior art keywords
electric heating
heat sink
heating element
ptc
insulating layer
Prior art date
Application number
PCT/CN2015/084556
Other languages
English (en)
French (fr)
Inventor
谢彦君
Original Assignee
宋正贤
谢彦君
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CN201410348403.5A external-priority patent/CN104144530B/zh
Application filed by 宋正贤, 谢彦君 filed Critical 宋正贤
Priority to KR1020177004729A priority Critical patent/KR20170044658A/ko
Priority to US15/327,918 priority patent/US20170223776A1/en
Priority to JP2017524080A priority patent/JP2017525125A/ja
Priority to CN201580032481.7A priority patent/CN107079531A/zh
Publication of WO2016011927A1 publication Critical patent/WO2016011927A1/zh

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H9/00—Details
    • F24H9/18—Arrangement or mounting of grates or heating means
    • F24H9/1854—Arrangement or mounting of grates or heating means for air heaters
    • F24H9/1863—Arrangement or mounting of electric heating means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H3/00—Air heaters
    • F24H3/02—Air heaters with forced circulation
    • F24H3/04—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element
    • F24H3/0405—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element using electric energy supply, e.g. the heating medium being a resistive element; Heating by direct contact, i.e. with resistive elements, electrodes and fins being bonded together without additional element in-between
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H9/00—Details
    • F24H9/18—Arrangement or mounting of grates or heating means
    • F24H9/1854—Arrangement or mounting of grates or heating means for air heaters
    • F24H9/1863—Arrangement or mounting of electric heating means
    • F24H9/1872—PTC
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/0004—Devices wherein the heating current flows through the material to be heated
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
    • H05B3/32—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulators on a metallic frame
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/40—Heating elements having the shape of rods or tubes
    • H05B3/42—Heating elements having the shape of rods or tubes non-flexible
    • H05B3/48—Heating elements having the shape of rods or tubes non-flexible heating conductor embedded in insulating material
    • H05B3/50—Heating elements having the shape of rods or tubes non-flexible heating conductor embedded in insulating material heating conductor arranged in metal tubes, the radiating surface having heat-conducting fins
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/017—Manufacturing methods or apparatus for heaters
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/02—Heaters using heating elements having a positive temperature coefficient
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/03—Heaters specially adapted for heating hand held tools

Definitions

  • the invention relates to an electric heating device (or electric heater) and a preparation method thereof, in particular to a PTC electric heating device which does not use a metal flat tube and has a higher heat exchange efficiency and a preparation method thereof.
  • PTC is the abbreviation of "Positive Temperature Coefficient”.
  • PTC materials have the characteristics of thermal, current limiting, delay and other switching characteristics and no contact, no noise, long service life. Therefore, as a new type of thermistor material, its main use can be divided into switch and heat. Large category. For example, in the field of switches, it can be applied to refrigerators, motor transformer protection, program-controlled switch protection and mosquito repellents, hair curlers, electric irons and other small household appliances. In the field of heat generation, the heat-generating PTC has various characteristics such as stable performance, rapid temperature rise, and small influence of fluctuations in power supply voltage, and is widely used in various heater products such as a heater, a dryer, an air curtain, and an air conditioner.
  • PTC electric heating device adopts PTC thermosensitive polymer or ceramic component, which is composed of several single pieces combined with corrugated heat-dissipating aluminum strip bonded by high-temperature adhesive, which has small thermal resistance and high heat exchange efficiency. specialty.
  • the biggest feature is that the safety is high. When the fan is blocked, the PTC electric heater is not fully cooled, and the power automatically drops sharply. At this time, the surface temperature of the PTC electric heater is maintained at the Curie temperature (generally 220 ° C), so as not to cause the "redness" phenomenon of the surface of the electric heating tube heater, greatly reducing the probability of accidents.
  • the basic structure of the PTC electric heating device on the market includes a rectangular metal tube (or a metal sleeve or a flat tube) having a rectangular cross section, and an electric heating element and an insulating layer are arranged in the metal flat tube, and the electric heating element is positive
  • the negative electrode sheet and the PTC element located between the electrode sheets, the insulating layer material is a plastic film, and the electric heating element is wrapped, and the heat dissipating component is pasted on the two large heat dissipating surfaces outside the metal flat tube (or Heat sink),
  • the heat dissipating component comprises a continuous bending and corrugated aluminum strip and two aluminum side plates welded on the corrugated aluminum strip and the lower two sides, and the outer side of the metal flat tube and the aluminum side plate on the side of the heat dissipating component pass heat conduction
  • the glues are glued to each other, as shown in Figure 1. Therefore, the current PTC electric heating device on the market has a low heat transfer efficiency.
  • Cipheral Patent No. CN201119017Y discloses a PTC electric heater, which has a longitudinal section of a heat dissipating component formed into a plurality of triangles arranged side by side. The structure improves the heat transfer efficiency of the PTC electric heater, but the heat transfer efficiency is limited to a limited extent, and the side-by-side arrangement also increases the amount of material used.
  • Chinese patent CN201146614Y discloses a PTC electric heater which is sealed with an insulating filler at the end of a PTC core tube (metal flat tube), although the patent improves the insulation waterproof and dustproof performance of the PTC electric heater, but The heat transfer efficiency of the PTC electric heater is lower.
  • Cipheral Patent No. CN103179701A discloses a heat generating element for an electric heating device for a motor vehicle, which improves the insulating layer in the prior art by several supporting points arranged in the circumferential direction of the container, CN101902845A, CN102668691A CN102434968A and CN103179700A all have improved the existing PTC electric heating device, but they have not changed the defects of low heat transfer efficiency and high manufacturing cost of the existing PTC electric heating device.
  • the invention provides an electric heating device which does not include a metal flat tube and a preparation method thereof, so as to improve the heat exchange efficiency of the current electric heating device, increase the volume power density, reduce the thermal resistance of the intermediate link, and reduce the manufacturing cost.
  • the invention provides an electric heating device comprising at least one PTC electric heating element and a heat sink;
  • the PTC electric heating element includes positive and negative electrodes and a PTC element between the positive and negative electrodes; the heat sink is located on an outer surface of the PTC electric heating element;
  • the heat sink defined by the present invention refers to an element that dissipates heat generated by the PTC electric heating element into the air.
  • the heat sink comprises a plurality of orderedly arranged fins; or the heat sink comprises a plurality of orderedly arranged fins and at least one side panel arranged along the fin arrangement direction, and more preferably The fins are bonded or welded to the side plates.
  • the material of the heat sink may be any metal with good thermal conductivity, such as stainless steel, aluminum, aluminum alloy, etc., and is preferably an aluminum alloy.
  • the above heat sink including the two side plates may be a commonly used heat dissipating aluminum strip (or aluminum strip).
  • An insulating layer is disposed between the heat sink and the PTC electric heating element.
  • an insulating layer is disposed on the surface of the heat sink that is not in contact with the PTC electric heating element.
  • non-contact surface is equivalent to the “separated surface”.
  • the insulating layer has both insulating and heat conducting functions, and may also be referred to as an insulating and thermally conductive layer.
  • the above electric heater of the present invention may be of any one of the structures A)-C):
  • the electric heater comprises at least one PTC electric heating element and at least two heat sinks;
  • the heat sink comprises a plurality of orderedly arranged fins and two side plates arranged along the direction in which the fins are arranged, the plurality of orderedly arranged fins being located between the two side plates, and the wings Bonding or welding between the sheet and the side panel;
  • each of the PTC heating elements is disposed between each adjacent two of the heat sinks, and the heat sink is attached to the PTC electric heating element;
  • An insulating layer is disposed between the heat sink and the PTC electric heating element.
  • the electric heater comprises at least one PTC electric heating element and at least two heat sinks;
  • the heat sink comprises a plurality of ordered arrays of fins; or the heat sink comprises a plurality of ordered arrays of fins and a side panel arranged along the fin arrangement direction, the plurality of ordered arrays of fins Located on the same side of the side panel, and the fins are bonded or welded to the side panels;
  • each of the PTC heating elements is disposed between each adjacent two of the heat sinks, and the heat sink is attached to the PTC electric heating element;
  • An insulating layer is disposed between the heat sink and the PTC electric heating element.
  • the electric heater comprises at least one PTC electric heating element and at least two heat sinks;
  • the heat sink comprises a plurality of ordered arrays of fins; or the heat sink comprises a plurality of ordered arrays of fins and a side panel arranged along the fin arrangement direction, the plurality of ordered arrays of fins Located on the same side of the side panel, and the fins are bonded or welded to the side panels;
  • each of the PTC heating elements is disposed between each adjacent two of the heat sinks, and the heat sink is attached to the PTC electric heating element;
  • An insulating layer is disposed on a surface of the heat sink that is not in contact with the PTC electric heating element.
  • a spacer may be further disposed between the plurality of ordered fins.
  • the outer surface of the part of the PTC electric heating element or the PTC electric heating element which is not in contact with the heat sink may also be provided.
  • the electric heater further includes a seal that seals at least a portion of the exposed PTC element between the positive and negative electrodes; more preferably, the ends and sides of the PTC electric heating element are sealed.
  • the insulating layer material may be any one or more of a polymer insulating material, a ceramic insulating material (including a ceramic powder and a ceramic insulating coating), and a ceramic composite insulating material.
  • the insulating layer material is preferably a ceramic, more preferably a ceramic-doped silica gel to provide a better thermal conductivity.
  • the insulating layer is made of silica gel, silicone resin, inorganic silicon, polyimide, polyester imine, Teflon, epoxy resin, acrylate adhesive, acrylic adhesive, benzoxazine, Any one or more of ceramic-doped silica gel.
  • the silica gel comprises silicone silica gel.
  • the material in the material of the insulating layer is diluted by a diluent.
  • the diluent is preferably a silicone oil.
  • the insulating layer is made of any one or more of silica gel and ceramic-doped silica gel, and the diluent is silicone oil.
  • the weight ratio of the diluent is from 10% to 50%.
  • the surface of the silicone insulating layer is coated with a thermal conductive silica gel, and then the heat sink is adhered to the outer surface of the PTC electric heating element that has been sprayed with the silicone insulating layer.
  • the method of providing the insulating layer is a combination of one or several of coating, flat, and wrapping. Among them, it is more preferable to adopt a coating method.
  • coating also referred to as coating, refers to the general term for the coating or adhesive construction process.
  • the coating method is a combination of one or more of spraying, brushing, roll coating, depositing, dip coating, dispensing, screen printing, roll coating, electrophoresis, and knife coating. Among them, it is more preferable to adopt a method of spraying, dipping, or depositing.
  • the spraying method of the insulating material includes plasma spraying, flame spraying, explosive spraying, high pressure spraying, and normal temperature spraying.
  • An electric heater provided by the present invention does not include a metal flat tube.
  • the metal flat tube may also be referred to as an aluminum flat tube or an aluminum tube.
  • the present invention provides a method of preparing an electric heater, the method comprising the following steps:
  • Step 1 stacking and fixing the positive electrode, the PTC element and the negative electrode in the stated order to form a PTC electric heating element
  • Step 2 contacting the heat sink with at least one outer surface of the PTC electric heating element; and making the surface of the heat sink not in contact with the PTC electric heating element uncharged.
  • step 2 preferably comprises:
  • the heat sheets are alternately arranged, and the heat sink is attached to the outer surface of the PTC electric heating element to form an electric heater;
  • An insulating layer is disposed between the heat sink and the PTC electric heating element; or an insulating layer is disposed on a surface of the heat sink that is not in contact with the PTC electric heating element.
  • the insulating layer and heat sink setting method are selected from the group consisting of:
  • the insulating layer is disposed on a surface of the heat sink that is not in contact with the PTC heating element, and then the surface of the heat sink not provided with the insulating layer is attached to the PTC electric heating element; or
  • the heat sink is brought into contact with the PTC heating element, and then an insulating layer is provided on the exposed surface.
  • the preferred measures may further include: Step 3, installing a fastening buckle or a fastening bolt on the outside of the electric heater prepared in the step 2.
  • the preferred measures may further include: Step 3, installing the outer frame outside the electric heater prepared in the step 2.
  • the outer frame further includes at least one fixing hole, and the fixing holes are located at two sides of the outer frame.
  • the electric heater further comprises at least one electrically conductive interface, the positive electrode and/or the negative electrode being connected to the wire via the interface.
  • connection portion is provided with an electrical connection point, and the positive electrode is connected to the wire through the electrical connection point.
  • connection portion is provided with an electrical connection point, and the negative electrode is connected through the electrical connection point line.
  • the insulating layer material may be any one or more of a polymer insulating material, a ceramic insulating material (including a ceramic powder and a ceramic insulating coating), and a ceramic composite insulating material.
  • the insulating layer material is preferably a ceramic, more preferably a ceramic-doped silica gel to provide a better thermal conductivity.
  • the ceramic is, for example, an aluminum nitride powder and/or an alumina powder.
  • the insulating layer is made of silica gel, silicone resin, inorganic silicon, polyimide, polyester imine, Teflon, epoxy resin, acrylate adhesive, acrylic adhesive, benzoxazine, Any one or more of ceramic-doped silica gel.
  • the silica gel comprises silicone silica gel.
  • the material in the material of the insulating layer is diluted via a diluent.
  • the diluent is preferably a silicone oil.
  • the insulating layer is made of any one or more of silica gel and ceramic-doped silica gel, and the diluent is silicone oil.
  • the weight ratio of the diluent is from 10% to 50%.
  • the surface of the silicone insulating layer is coated with a thermally conductive silicone, and then the heat sink is bonded to the outer surface of the electrode to which the silicone insulating layer has been sprayed.
  • the method of providing the insulating layer is a combination of one or several of coating, flat, and wrapping. Among them, it is more preferable to adopt a coating method.
  • coating also referred to as coating, refers to the general term for the coating or adhesive construction process.
  • the coating method is spray coating, brush coating, roll coating, deposition, dip coating, dispensing, wire mesh A combination of one or more of printing, rolling, electrophoresis, and knife coating.
  • the spraying method of the insulating material includes plasma spraying, flame spraying, explosive spraying, high pressure spraying, and normal temperature spraying.
  • the positive and negative electrodes and the PTC element may be connected by an adhesive, and the binder is preferably silica gel.
  • the surface of the electrode in contact with the PTC element is an inner surface (or inner side), and the surface of the electrode in contact with the heat sink is an outer surface (or outer side);
  • the surface of the side plate in contact with the fin is an inner surface, and the surface opposite to the inner surface is an outer surface;
  • the electrode includes a positive electrode and a negative electrode; and if the side plate is also an electrode, the inner surface of the side plate is also an outer surface of the electrode
  • the electric heating and electric heating according to the present invention have the same meanings, and both refer to the conversion of electrical energy into thermal energy.
  • the heat sink is located on an outer surface of the electrode.
  • Another electric heater provided by the present invention includes at least one PTC electric heating element and a heat sink;
  • the PTC electric heating element is composed of a plurality of PTC elements; the heat sink is located on an outer surface of the PTC electric heating element;
  • the heat sink comprises a conductive bottom plate, the fins are connected to the bottom plate, and the bottom plate is in contact with the PTC element.
  • the surface of the fin that is not in contact with the bottom plate is not charged, and more preferably, the surface of the fin that is not in contact with the bottom plate is provided with an insulating layer, or an insulating layer is disposed between the fin and the bottom plate.
  • the electric heating device provided by the invention does not use the metal flat tube in the conventional technology, which not only saves cost, but also reduces the thermal resistance of the intermediate part of the metal flat tube, improves the heat exchange efficiency, and increases the volume. Power density.
  • the electric heating device of the invention can be used in known electric heating systems or places, such as air conditioners, electric heaters, dryers and the like.
  • the term "uncharged surface” means that the surface of the heat sink exposed to the air is not charged, so there is no risk of electric leakage or no risk of electric shock to the person.
  • the surface of the heat sink of the present invention is uncharged, and may be any of the following conditions: one is that the surface of the heat sink is coated with an insulating layer, the surface of the insulating layer is not charged; and the other is that the heat sink is separated from the PTC electric heating element by an insulating layer. If isolated from the electrodes, the metal on the surface of the heat sink is exposed to air, but its surface is not charged.
  • the heat sink is attached to the PTC electric heating element, and preferably the heat sink is located on an outer surface of the electrode.
  • the heat sink of the present invention is attached to the PTC electric heating element, and may be any of the following cases: 1.
  • the heat sink is in direct contact with the PTC electric heating element, such as direct contact with the electrode, and there is no insulating layer in the middle;
  • the outer surface of the electric heating element has an insulating layer, and the heat sink is attached to the outer surface of the PTC electric heating element with the insulating layer, that is, the heat sink is attached to the insulating layer.
  • the present invention includes the following positive effects:
  • the cost can be greatly reduced on the one hand, and the heat transfer resistance can be reduced on the other hand, and the heating efficiency can be improved.
  • new insulating and thermally conductive materials such as silica gel doped with thermally conductive particles
  • new construction processes such as coating or spraying
  • FIG. 1 is a schematic structural view of a heat sink according to Embodiment 1 of the present invention.
  • FIG. 2 is a schematic structural view of a position of a heat sink and an insulating layer according to Embodiment 1 of the present invention
  • FIG. 3 is a schematic structural view of a PTC electric heating element according to Embodiment 1 of the present invention.
  • FIG. 4 is a schematic structural view of a position of a PTC electric heating element and an insulating layer in Embodiment 1 of the present invention
  • FIG. 5 is a schematic view showing the internal structure of an aluminum tube of an electric heater according to the prior art
  • FIG. 6 is a schematic structural view of an electric heater according to Embodiment 1 of the present invention.
  • FIG. 7 is a schematic structural view of an electric heating device with an outer frame according to the present invention.
  • FIG. 8 is a schematic structural view of a heat sink according to Embodiment 2 of the present invention.
  • FIG. 9 is a schematic structural view showing a positional relationship between a heat sink, an insulating layer, and an electrode sheet according to Embodiment 2 of the present invention.
  • FIG. 10 is a schematic structural view of an electric heater according to Embodiment 2 of the present invention.
  • FIG. 11 is a schematic structural view of a position of a heat sink and an insulating layer in Embodiment 3 of the present invention.
  • FIG. 12 is a schematic structural view of an electric heater according to Embodiment 3 of the present invention.
  • FIG. 13 is a schematic structural view of an electric heater according to Embodiment 4 of the present invention.
  • FIG. 14 is a schematic structural view of a heat sink according to Embodiment 8 of the present invention.
  • Figure 15 is a schematic structural view of an electric heater according to Embodiment 8 of the present invention.
  • FIG. 16 is a schematic structural view of an electric heater according to Embodiment 9 of the present invention.
  • a side plate that is in contact with the PTC electric heating element is defined as a bottom plate
  • a side plate that is not in contact with the PTC electric heating element is defined as a top plate. Therefore, one heat sink may include a bottom plate and a top plate, or one heat sink may include two bottom plates; of course, if the bottom plate is an electrode, the heat sink may not include the bottom plate.
  • the heat sink has at least the following types.
  • the first heat sink is composed of a set of fins and two side plates (two side plates are one top plate and one bottom plate); the second heat sink is By a group
  • the fins are composed of a side plate (top plate); the third type of fin is composed of only one set of fins; of course, other forms of fins may be provided in addition to the above.
  • the bottom plate described in the embodiment of the present invention may be a sub-part of the heat sink, an electrode for conducting, or a sub-part of the heat sink and an electrode for conducting.
  • FIG. 1 it is a schematic view of an aluminum heat sink 9 (or heat dissipating fin, or heat dissipating component, or aluminum heat dissipating strip or aluminum strip) provided by the present invention.
  • the heat sink 9 of the present embodiment is a heat sink 91 composed of a set of fins 1 and side plates 2 located on both sides of the fin 1.
  • an insulating layer 3 is provided on the surface of the heat sink 91 which is in contact with the PTC heating element 6, that is, outside the bottom plate 21. That is, the insulating layer 3 is provided between the heat sink 91 and the PTC heating element 6, so that the surface of the heat sink 91 that is not in contact with the PTC heating element 6 is not charged.
  • FIG. 3 it is a schematic diagram of a PTC electric heating element 6 (or PTC electrode strip assembly) provided by the present invention.
  • the PTC element 4 is vertically positive and negative electrode sheets 5, and the positive and negative electrode sheets 5 are made of stainless steel.
  • the insulating layer 3 is provided on the outer surface of the PTC heating element 6.
  • the upper and lower outer surfaces of the PTC heating element 6 are sprayed with insulating silica gel or insulating silica gel doped with ceramic powder as the insulating layer 3, and the left and right surfaces of the PTC heating element 6 can also be sprayed with high-pressure insulating silica gel. Insulation is insulated from the outside, and the exposed portions of the front and rear ends of the PTC heating element 6 (except at the electrode tab ears) may be insulated.
  • the insulating foam layer or the insulating silica gel doped with ceramic powder may be used as the insulating layer 3 on the side of the aluminum heat sink 91 that is in contact with the PTC heating element 6.
  • the arrangement positions of the two insulating layers 3 may be selected one by one or both.
  • the PTC heating element 6 and the heat sink 91 are alternately arranged in order, and the bonding is cured.
  • a PTC electric heater formed by stacking the PTC heating element 6 and the heat sink 91 is laminated; wherein the insulating layer 3 is sprayed between the PTC heating element 6 and the heat sink 91.
  • the above thermal conductive silica gel may be selected from the same silicone material as the insulating layer 3, or may be different.
  • the spraying of the insulating silica gel and the coating of the thermal silica gel can be carried out in one process step or in two process steps.
  • the insulating silica gel to be sprayed can be diluted prior to spraying to reduce its viscosity; for example, it can be diluted with 10%-50% silicone oil.
  • the thermal conductivity coefficient (such as Al 2 O 3 ceramic powder) can be doped to increase the thermal conductivity thereof, and the doping ratio is comprehensively evaluated according to the thermal conductive effect and the bonding effect, for example, the doping ratio can be 10%-50%.
  • the outer part is an outer frame 20, and the outer frame 20 is mounted with a conductive connection port through which the wires connect the positive and negative electrode pieces to an external power source.
  • the PTC electric heating device 10 is formed by stacking the PTC heating element 6 and the heat sink 9 in the interior.
  • FIG. 5 is a schematic cross-sectional view of a PTC electric heating element with an aluminum flat tube 8 in the prior art.
  • the PTC electric heating element with the aluminum flat tube 8 of the prior art includes a centrally disposed PTC element 4, positive and negative electrode sheets 5 on both sides, an insulating film 7 on the outside, and an outermost aluminum.
  • the flat tube 8 is then connected to the integral PTC electric heating element with the aluminum flat tube 8 to obtain a heat dissipating effect. It can be seen from the above that the PTC electric heater of the prior art has a complicated structure and many components.
  • the insulation layer is set by the spraying process, which will facilitate the automatic process design of mass production to replace the existing manual production process.
  • the beneficial effect is that the production efficiency is greatly improved, the existing labor of about 2/3 can be reduced, the mass production quality is stable and reliable, and the production cost is greatly reduced.
  • a conventional polyimide film is replaced with silica gel as an insulating layer.
  • the insulating silica gel can also be used as a bonding material, which helps to reduce the contact thermal resistance between the contact faces, which is helpful for improving the heat transfer performance, and the silica gel can be further improved by doping the heat conductive particles (such as ceramic powder).
  • FIG. 8 is a schematic structural diagram of a heat sink according to an embodiment of the present invention.
  • the heat sink 9 of the present embodiment is another heat sink 92.
  • the heat sink 92 is composed of the fin 1 and the side panel 2 on one side (ie, the top panel 22), that is, the heat sink 92 does not include Base plate 21.
  • the side plate 2 (i.e., the bottom plate 21) on the other side is used as the electrode sheet 5
  • the insulating layer 3 is provided on the outer side of the electrode sheet 5
  • the heat sink 92 as shown in Fig. 8 is bonded to the electrode sheet.
  • the electric heater of this embodiment can be realized by bonding two sets of components as shown in Fig. 9 to both sides of a plurality of PTC elements 4 to form an electric heater of the present invention.
  • An insulating layer 3 is provided between the heat sink 92 and the PTC heating element 6.
  • the electric heater of this embodiment can also be realized by bonding two sets of heat sinks 92 as shown in FIG. 8 to the two sides of the PTC electric heating element 6 with the insulating layer 3 as shown in FIG. 4 to form the implementation of the present invention.
  • An insulating layer 3 is provided between the heat sink 92 and the PTC heating element 6.
  • the insulating layer 3 is disposed on the surface of the positive and negative electrode sheets 5 (or the bottom plate 21) in contact with the fins 1; that is, the surface of the heat sink 92 that is not in contact with the PTC electric heating element 6 is not charged.
  • connection manner between the fin 1 and the bottom plate 21 is bonding, but it may be a fastening method such as a press-fit connection, a screw connection, a snap connection, etc., and is not limited thereto; between the fin 1 and the top plate 22
  • the connection method is bonding, but it may also be a fastening method such as welding, press fitting, screwing, snapping, etc., and is not limited thereto.
  • the insulating layer 3 is provided by a combination of one or several of coating, flattening, and wrapping.
  • the coating method of the insulating layer 3 is a combination of one or several of spraying, brushing, roll coating, dip coating, dispensing, screen printing, roll coating, electrophoresis, and blade coating.
  • the spraying method includes ceramic powder high-temperature melt spraying and solution spraying, but is not limited thereto.
  • the material of the insulating layer 3 is a polymer insulating material or a ceramic insulating material or a polymer composite insulating material doped with ceramic.
  • the insulating layer 3 is made of rubber, resin, or plastic.
  • the insulating layer 3 is made of silicone or inorganic silicon, or Polyimide, or polyesterimide, or epoxy resin, or acrylate adhesive, or acrylic adhesive.
  • the inner surface of the bottom plate 21 is provided with the insulating layer 3, so that the fins 1 and the top plate 22 no longer require an additional insulating treatment.
  • FIG. 10 is a schematic structural view of a second embodiment of an electric heater according to the present invention.
  • the electric heater is directly connected to the PTC electric heating element 6 by the heat sink 92, and an insulating layer 3 is disposed between the heat sink 92 and the PTC electric heating element 6 with respect to the prior art as shown in FIG.
  • the special positive and negative electrode sheets 5, the insulating film 7, and the aluminum flat tube 8 are omitted, so that a relatively simple structure is obtained.
  • the outer side of the bottom plate 21 functions as the positive and negative electrode sheets 5, thereby achieving the insulation requirement, greatly simplifying the structure, and improving the thermal efficiency.
  • FIG. 11 is a schematic structural view of a heat sink and an outer insulating layer according to a third embodiment of the present invention, which is provided with an insulation on the heat sink 91 shown in FIG. 1 except for a surface that is in contact with the PTC element 4.
  • Layer 3. As shown in the figure, the fins include fins 1 and side plates 2 disposed on both sides; and except for the outer side of the bottom plate 21, the entire fins 1 (including the sides), the inside and the sides of the bottom plate 21, and the top plate 22 The outer side and both sides are insulated to obtain the insulating layer 3 as shown.
  • the insulating layer 3 is provided on the heat sink 91 at a portion not in contact with the PTC element 4, so that the surface of the heat sink 91 which is not in contact with the PTC element 4 is electrically insulated or uncharged.
  • the bottom plate 21 serves as an electrode sheet at the same time.
  • the method for disposing the insulating layer 3 may be: placing two fins 91 on both sides of a plurality of PTC elements 4 to form a PTC electric heater; after forming the PTC electric heater, the counter electrode After the ear is wrapped or otherwise protected, the overall dip coating is achieved.
  • the electric heater can also be realized as follows: firstly, the PTC electric heating element 6 is formed, and then a set of fins 1 and a top plate 22 are respectively disposed on both sides of the PTC electric heating element 6 to form an uninsulated electric heating. Then, the uninsulated electric heater is dip coated with the insulating layer 3 to form an electric heater having an insulating function according to the present invention.
  • the material of the insulating layer 3 is a polymer insulating material or a ceramic insulating material or a polymer composite insulating material doped with ceramic.
  • the polymer insulating material is a combination of any one or several of silicone, resin, and plastic.
  • FIG. 12 is a schematic structural view of an electric heater according to Embodiment 3 of the present invention.
  • a PTC element 4 and two fins 91 are included, the structures of which are formed by superposing each other.
  • the structure in the prior art is also simplified in the embodiment, including the elimination of the special positive and negative electrode sheets 5 on both sides, the outer insulating film 7, and the outermost aluminum flat tube. 8, so that a more concise structure.
  • the surface on which the PTC element 4 and the heat sink 91 are connected i.e., the outer surface of the bottom plate 21
  • the other portions except the electrode tab are insulated, so that the outer surface of the bottom plate 21 The effect of conducting electricity to the electrode sheets.
  • One side panel 2 of the heat sink 9 (ie, the bottom plate 21) simultaneously serves as the electrode sheet 5 of the PTC electric heating element 6, thereby saving special positive and negative effects. Electrode sheet.
  • the heat sink can be divided into two types: one is to use the fin 1, the bottom plate 21 and the top plate 22 as the heat sink 91 of the embodiment; the other is to use the fin 1 and the top plate 22 as the present embodiment.
  • the insulating layer 3 is provided at a portion where the heat sink 91 is not in contact with the PTC element 4, and the surface of the heat sink 91 that is not in contact with the PTC element 4 is electrically or uncharged.
  • the heat sink 9 is as shown in FIG.
  • the heat sink 92, the surface of the heat sink 92 that is not in contact with the PTC heating element 6, is electrically or uncharged.
  • the basic structure and principle of the electric heater of this embodiment are substantially the same as those of the above embodiment 2, except that the electric heater has three heat sinks and two PTC electric heaters.
  • the heat sink has double fins 1.
  • the fins on both sides are composed of a double fin 1, an intermediate partition and a top plate;
  • the middle fin is composed of a double fin 1 and an intermediate partition.
  • the insulating layer 3 is disposed between the heat sink and the PTC heating element 6.
  • the arrangement of the double-layer fins 1 can obtain a more excellent heat dissipation effect, and the special electrode sheets can be saved.
  • the fifth embodiment of the present embodiment is the same as that of the first embodiment except that the material of the insulating layer 3 is Al 2 O 3 ceramic powder, on the outer surface of the bottom plate 21 of the PTC electric heating element 6 or the outer surface of the heat sink 91.
  • the thermal spray has an Al 2 O 3 ceramic layer.
  • the positive and negative electrode sheets 5 and the PTC element 4 are fixed to form the PTC electric heating element 6, and the polyimide film is flatly bonded and bonded to the outer surface of the PTC electric heating element 6.
  • the positive and negative electrode sheets 5 and the PTC element 4 are fixed to form a PTC electric heating element 6, and the PTC electric heating element 6 is wrapped with a polyimide film (that is, by wrapping), and only the electrodes are exposed.
  • the tabs of the sheet 5 are used to connect external wires.
  • An adhesive is applied to one side of the heat sink 91 in contact with the PTC heating element 6, and the heat sink 91 is bonded to the outer surface of the PTC electric heating element 6.
  • FIG. 14 is composed of only one set of fins
  • FIG. 15 is a schematic structural view of the eighth embodiment of the electric heater of the present invention.
  • the eighth embodiment differs from the second embodiment in that the eighth embodiment is composed of two PTC electric heating elements 6 and three heat sinks, wherein the two heat sinks on the upper and lower sides are as shown in FIG.
  • the heat sink 92 shown is a heat sink 93 (i.e., fin 1) as shown in FIG.
  • FIG 16 is a schematic view showing the structure of a ninth embodiment of the electric heater of the present invention.
  • the ninth embodiment differs from the first embodiment in that the ninth embodiment comprises a plurality of (for example, two) PTC electric heating elements 6 and a plurality (for example, three, that is, one more than the PTC electric heating elements).
  • the heat sink is composed of all the heat sinks as the heat sink 91 shown in FIG. Relatively speaking, the structure integrated with multi-layer PTC electric heating elements is more suitable for automotive air conditioning PTC electric heating device applications.
  • the PTC component provided by the present invention comprises a ceramic PTC and a polymer PTC, wherein it can be applied to various heating fields, and is particularly suitable for the field of air conditioning heating, and the connection method used is mainly bonding, and an insulating layer is provided.
  • the main mode is coating, but is not limited thereto.

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Abstract

一种电制热器及其制备方法，所述电制热器包括至少一个PTC电热元件（6）、散热片（91）；所述PTC电热元件（6）包括正负电极片（5）以及位于正负电极片（5）之间的PTC元件（4）；所述散热片（91）位于所述PTC电热元件（6）的外表面；所述散热片（91）上，与所述PTC电热元件（6）不接触的表面不带电，该电制热器并未使用现有技术中的铝扁管或铝管，不但节约了成本，而且减少了铝扁管中间环节的热阻，提高了换热效率，增加了体积功率密度。

Description

一种电制热器及其制备方法 技术领域
本发明涉及一种电制热器(或称电加热器)及其制备方法，尤其涉及一种具有更高换热效率的不使用金属扁管的PTC电制热器及其制备方法。
背景技术
PTC是“正温度系数(Positive Temperature Coefficient)”的英文缩写。PTC材料具有热敏、限流、延时等的开关特性和无触点、无噪声、使用寿命长的特点，因此，作为一种新型热敏电阻材料，其主要用途可分为开关和发热两大类别。例如，在开关领域，其可应用于冰箱启动、电机变压器保护、程控交换机保护及驱蚊器、卷发烫发器、电熨斗等小家电产品。在发热类领域中，利用发热类PTC性能稳定、升温迅速、受电源电压波动影响小等特性，制成大量应用于取暖器、干衣机、风幕机、空调等的各种加热器产品。
PTC电制热器(或称PTC电加热器)采用PTC热敏高分子或陶瓷元件，由若干单片组合后与波纹散热铝条经高温胶粘结组成，具有热阻小、换热效率高的特点。其最大特点在于安全性高，即遇风机故障堵转时，PTC电制热器因散热不充分，功率自动急剧下降，此时PTC电制热器的表面温度维持在居里温度左右(一般为220℃)，从而不致产生电热管类加热器表面的“发红”现象，大大降低了发生事故的几率。
目前市面上的PTC电制热器，其基本结构包括一截面为矩形的金属扁管(或称金属套管，或称扁管)，在金属扁管内设置电热元件和绝缘层，电热元件由正负电极片、以及位于电极片之间的PTC元件组成，绝缘层材料为塑料薄膜，将电制热元件包裹，在金属扁管外侧的两个较大的散热面上粘贴有散热元件(或称散热片)，散热元件包括一段连续弯折呈波纹状的铝带和焊接在波纹状铝带上、下两面的两条铝边板，金属扁管外壁与散热元件一侧的铝边板通过导热胶相互粘贴，详见附图1。因此，目前市面上的PTC电制热器传热效率较低。
目前已有多种现有技术对PTC电制热器进行了改进，例如：中国专利CN201119017Y公开了一种PTC电制热器，其将散热元件的纵剖面做成多个并排排列的三角形，这种结构提高了PTC电制热器的传热效率，但是其传热效率的提高程度有限，且并排排列的形式也增加了材料用量。中国专利CN201146614Y公开了一种PTC电制热器，其在PTC芯管(金属扁管)的端部用绝缘填料密封，虽然该专利提高了PTC电制热器的绝缘防水防尘性能，但是其使PTC电制热器的传热效率更低。中国专利CN103179701A公开了一种用于机动车辆的电制热装置的生热元件，通过设置在容器的周向方向上的几个支撑尖物，以改进现有技术中的绝缘层，CN101902845A、CN102668691A、CN102434968A、CN103179700A均对现有PTC电制热器提出了改进，但其均未改变现有PTC电制热器传热效率低、制造成本高的缺陷。
发明内容
本发明提供了一种不包括金属扁管的电制热器及其制备方法，以提高目前电制热器的换热效率，增加体积功率密度，减少中间环节的热阻，并降低制造成本。
本发明提供的一种电制热器，包括至少一个PTC电热元件、散热片；
所述PTC电热元件包括正负电极以及位于正负电极之间的PTC元件；所述散热片位于所述PTC电热元件的外表面；
所述散热片上，与所述PTC电热元件不接触的表面不带电。
本发明定义的散热片，是指将PTC电热元件生成的热量散向空气中的元件。优选地，所述散热片包含若干有序排列的翅片；或者，所述散热片包含若干有序排列的翅片和至少一沿所述翅片排列方向布置的边板，并且，更优选为所述翅片与所述边板之间粘接或焊接。当然，除了上述优选的散热片结构之外，还可以有其他的散热片结构，比如具有翅片、边板以及中间隔板的 散热片。
优选地，所述散热片的材质可以为任意导热性能好的金属，如不锈钢、铝、铝合金等，并优选为铝合金。上述包含有两边板的散热片可以是常用的散热铝条(或称铝条)。
所述散热片与所述PTC电热元件之间设置有绝缘层。或者，所述散热片上在与所述PTC电热元件不接触的表面设置有绝缘层。
其中，“不接触的表面”与“相隔开的表面”意思等同。
其中，所述绝缘层，其同时具备绝缘和导热功能，也可称为绝缘导热层。
本发明上述电制热器，可以是包括A)-C)中的任意一种结构：
A)所述电制热器包括至少一个PTC电热元件和至少两个散热片；
所述散热片包含若干有序排列的翅片和两个沿所述翅片排列方向布置的边板，所述若干个有序排列的翅片位于两个边板之间，并且，所述翅片与所述边板之间粘接或焊接；
并且，每个所述PTC电热元件均设置于每相邻的两个所述散热片之间，且所述散热片与所述PTC电热元件相贴合；
所述散热片与所述PTC电热元件之间设置有绝缘层。
B)所述电制热器包括至少一个PTC电热元件和至少两个散热片；
所述散热片包含若干有序排列的翅片；或者，所述散热片包含若干有序排列的翅片和一个沿所述翅片排列方向布置的边板，所述若干有序排列的翅片位于所述边板的同一侧，并且，所述翅片与所述边板之间粘接或焊接；
并且，每个所述PTC电热元件均设置于每相邻的两个所述散热片之间，且所述散热片与所述PTC电热元件相贴合；
所述散热片与所述PTC电热元件之间设置有绝缘层。
C)所述电制热器包括至少一个PTC电热元件和至少两个散热片；
所述散热片包含若干有序排列的翅片；或者，所述散热片包含若干有序排列的翅片和一个沿所述翅片排列方向布置的边板，所述若干有序排列的翅片位于所述边板的同一侧，并且，所述翅片与所述边板之间粘接或焊接；
并且，每个所述PTC电热元件均设置于每相邻的两个所述散热片之间，且所述散热片与所述PTC电热元件相贴合；
所述散热片上，在与所述PTC电热元件不接触的表面设置有绝缘层。
本发明上述的散热片中，所述若干个有序排列的翅片之间还可以设有隔板。
其中，在上述电制热器中，如果存在不与散热片接触的PTC电热元件或PTC电热元件的一部分，则在所述不与散热片接触的PTC电热元件或PTC电热元件的一部分的外表面也可以设置所述绝缘层。
优选地，所述电制热器还包括密封件，所述密封件将至少正负电极之间暴露的PTC元件的部分进行密封；更优选为将PTC电热元件两端和侧部密封。
优选地，所述绝缘层材质可以为高分子绝缘材料、陶瓷绝缘材料(包括陶瓷粉末和陶瓷绝缘涂料)、和掺杂有陶瓷的高分子复合绝缘材料中的任意一种或几种。所述绝缘层材料优选为陶瓷，更为优选为掺杂有陶瓷的硅胶，以提供更好的导热效果。
优选地，所述绝缘层材质为硅胶、有机硅树脂、无机硅、聚酰亚胺、聚酯亚胺、特氟龙、环氧树脂、丙烯酸酯类胶粘剂、丙烯酸类胶粘剂、苯并噁嗪、掺杂有陶瓷的硅胶中的任意一种或几种。其中，所述硅胶包括有机硅硅胶。
其中，优选地，所述绝缘层材质中的材料中经由稀释剂进行稀释。所述稀释剂优选为硅油。
在一种优选实施例中，所述绝缘层材质为硅胶、掺杂陶瓷的硅胶中的任意一种或几种，所述稀释剂为硅油。
本发明上述内容中，在所述绝缘层材质中的材料与所述稀释剂组成的混合物中，所述稀释剂、优选为硅油的重量比例为10％-50％。
在一种优选实施例中，在所述硅胶绝缘层表面再涂覆导热硅胶，然后再将所述散热片粘接于已喷涂好所述硅胶绝缘层的所述PTC电热元件外表面。
优选地，设置绝缘层的方法为涂覆、平贴、以及绕包中的一种或数种的组合。其中，更优选为采用涂覆的方式。
本发明所谓涂覆，也可称涂敷，是指涂料或胶粘剂施工工艺的统称。
优选地，所述涂覆方法为喷涂、刷涂、辊涂、沉积、浸涂、点胶、丝网印、滚涂、电泳、以及刮涂中的一种或数种的组合。其中，更优选为采用喷涂、浸渍、沉积的方式。
绝缘材料的所述喷涂方法包括等离子喷涂、火焰喷涂、***喷涂、高压喷涂、常温喷涂等方式。
本发明提供的一种电制热器不包括金属扁管。所述金属扁管也可称为铝扁管或称铝管。
另外，本发明提供一种电制热器的制备方法，所述方法包括如下步骤：
步骤1：将正电极、PTC元件和负电极依照所述顺序叠放并固定，形成PTC电热元件；
步骤2：将散热片与至少一个所述PTC电热元件外表面接触；并且使所述散热片上，与所述PTC电热元件不接触的表面不带电。
其中，步骤2优选为包括：
提供所述PTC电热元件和所述散热片，并将所述PTC电热元件与所述散 热片交替排布，所述散热片贴合在所述PTC电热元件外表面，形成电制热器；
其中，在所述散热片与所述PTC电热元件之间设置有绝缘层；或者，所述散热片上，在与所述PTC电热元件不接触的表面设置有绝缘层。
在一种优选实施例中，绝缘层和散热片设置方法选自：
将所述绝缘层设置在所述PTC电热元件的外表面，然后将所述散热片贴合到所述PTC电热元件外表面；或者，
将所述绝缘层设置在所述散热片的与所述PTC电热元件接触的一面，然后将所述散热片贴合到所述PTC电热元件外表面；或者，
将所述绝缘层设置在散热片不与PTC电热元件接触的表面，然后将散热片未设置绝缘层的表面与PTC电热元件贴合；或者，
将散热片与PTC电热元件接触，然后在暴露的表面上设置绝缘层。
在本发明的一种优选实施例中，还包括设置密封件的步骤，所述密封件将至少正电极、负电极之间暴露的PTC元件的部分进行密封；并优选为所述硅胶密封件将所述PTC电热元件的两端和/或两侧进行密封。
上述制备方法中，优选措施还可以包括：步骤3，在步骤2制备的电制热器外侧安装紧固卡扣或紧固螺栓。
上述制备方法中，优选措施还可以包括：步骤3，在步骤2制备的电制热器外侧安装外框。
更优选地，所述外框上还包括至少一个固定孔，所述固定孔位于所述外框的两侧。
优选地，所述电制热器还包括至少一个导电接口，所述正电极和/或所述负电极通过所述接口与导线连接。
优选地，所述连接部上设置电连接点，正电极通过所述电连接点连接导线。
优选地，所述连接部上设置电连接点，负电极通过所述电连接点连接导 线。
优选地，所述绝缘层材质可以为高分子绝缘材料、陶瓷绝缘材料(包括陶瓷粉末和陶瓷绝缘涂料)、和掺杂有陶瓷的高分子复合绝缘材料中的任意一种或几种。所述绝缘层材料优选为陶瓷，更为优选为掺杂有陶瓷的硅胶，以提供更好的导热效果。
所述陶瓷如氮化铝粉末和/或氧化铝粉末。
优选地，所述绝缘层材质为硅胶、有机硅树脂、无机硅、聚酰亚胺、聚酯亚胺、特氟龙、环氧树脂、丙烯酸酯类胶粘剂、丙烯酸类胶粘剂、苯并噁嗪、掺杂有陶瓷的硅胶中的任意一种或几种。其中，所述硅胶包括有机硅硅胶。
其中，优选地，所述绝缘层材质中的材料经由稀释剂进行稀释。所述稀释剂优选为硅油。
在一种优选实施例中，所述绝缘层材质为硅胶、掺杂陶瓷的硅胶中的任意一种或几种，所述稀释剂为硅油。
本发明上述内容中，在所述绝缘层材质中的材料与所述稀释剂组成的混合物中，所述稀释剂、优选为硅油的重量比例为10％-50％。
在一种优选实施例中，在所述硅胶绝缘层表面再涂覆导热硅胶，然后再将所述散热片粘接于已喷涂好所述硅胶绝缘层的所述电极外表面。
优选地，设置绝缘层的方法为涂覆、平贴、以及绕包中的一种或数种的组合。其中，更优选为采用涂覆的方式。
本发明所谓涂覆，也可称涂敷，是指涂料或胶粘剂施工工艺的统称。
优选地，所述涂覆方法为喷涂、刷涂、辊涂、沉积、浸涂、点胶、丝网 印、滚涂、电泳、以及刮涂中的一种或数种的组合。其中，更优选为采用喷涂、浸渍、沉积的方式。
绝缘材料的所述喷涂方法包括等离子喷涂、火焰喷涂、***喷涂、高压喷涂、常温喷涂等方式。
本发明上述内容中，所述正负极与PTC元件之间可以通过粘结剂进行连接，所述粘结剂优选为硅胶。
本发明上述内容中，在没有特别说明的情况下：所述电极与PTC元件接触的表面为内表面(或内侧)，所述电极与散热片接触的表面为外表面(或外侧)；所述边板与翅片接触的表面为内表面，与内表面相对的表面为外表面；所述电极包括正电极和负电极；若边板同时也是电极，则边板的内表面也是电极的外表面；本发明所述的电制热与电加热具有相同的含义，均是指将电能转化为热能。
本发明上述内容中，所述散热片位于所述电极的外表面。
本发明提供的另一种电制热器，其包括至少一个PTC电热元件、散热片；
所述PTC电热元件由若干PTC元件组成；所述散热片位于所述PTC电热元件的外表面；
所述散热片上，与所述PTC电热元件不接触的表面不带电。
其中，优选地，所述散热片包括导电的底板，翅片连接在底板上，底板与PTC元件接触。
其中，翅片与底板不接触的表面不带电，更优选为：翅片与底板不接触的表面设有绝缘层，或者翅片与底板之间设置绝缘层。
应当理解的是，上述内容中，各个方面以及各种优选实施例之间，可以由本领域技术人员不受限制的进行组合，并且所述组合也在本发明范围内。
本发明提供的电制热器，并未使用常规技术中的金属扁管，不但节约了成本，而且减少了金属扁管中间环节的热阻，提高了换热效率，增加了体积 功率密度。
本发明所述的电制热器，可用于已知的电加热***或场所，如空调、电暖气、烘干机等各种电制热器。
本发明上述内容中，所谓表面不带电是指，散热片暴露于空气中的表面不带电，故不会有漏电危险或对人不会有触电危险。优选的，本发明所谓的散热片表面不带电，可以是如下任意情况：一是散热片表面涂覆有绝缘层，绝缘层表面不带电；另一是散热片通过绝缘层与PTC电热元件隔离，如与电极隔离，散热片表面的金属虽然是暴露于空气中，但其表面不带电。
本发明上述内容中，所述散热片与所述PTC电热元件相贴合，优选为所述散热片位于电极的外表面。优选地，本发明所述散热片与所述PTC电热元件相贴合，可以是如下任意情况：一、散热片与PTC电热元件直接接触，如与电极直接接触，中间没有绝缘层；二、PTC电热元件外表面有绝缘层，散热片贴合在带绝缘层的PTC电热元件外表面，即散热片贴合在绝缘层上。
在上述基础上，本发明包括以下积极效果：
在现有的PTC电制热器基础上，通过减少金属扁管等不必要元件，一方面可以大幅度降低成本，另一方面可以减少传热热阻，提高制热效率。
通过引入新的产品结构、新的绝缘导热材料(如掺杂导热粒子的硅胶)和新的施工工艺(如涂覆或喷涂)，不仅实现了绝缘功能并大幅度改善绝缘层的传热性能，而且还可以方便实现大批量自动化生产，从而有效提高生产效率，提高批量质量的稳定性，减少约2/3原有人工，大幅度降低生产成本。
附图说明
图1为本发明实施例一中的散热片的结构示意图；
图2为本发明实施例一中的散热片和绝缘层位置的结构示意图；
图3为本发明实施例一中的PTC电热元件的结构示意图；
图4为本发明实施例一中的PTC电热元件和绝缘层位置的结构示意图；
图5为现有技术下的电制热器铝管截面内部结构示意图；
图6为本发明实施例一中的电制热器的结构示意图；
图7为本发明加装外框的一种电制热器的结构示意图；
图8为本发明实施例二中的散热片的结构示意图；
图9为本发明实施例二中的散热片、绝缘层和电极片位置关系的结构示意图；
图10为本发明实施例二中的电制热器的结构示意图；
图11为本发明实施例三中的散热片和绝缘层位置的结构示意图；
图12为本发明实施例三中的电制热器的结构示意图；
图13为本发明实施例四中的电制热器的结构示意图；
图14为本发明实施例八中的一种散热片的结构示意图；
图15为本发明实施例八中的电制热器的结构示意图；
图16为本发明实施例九中的电制热器的结构示意图；
其中，1-翅片；2-边板；3-绝缘层；4-PTC元件；5-电极片；6-PTC电热元件；7-绝缘膜；8-铝扁管(或铝管)；9-散热片；10-本发明电制热器；20-外框；21-底板；22-顶板；91-散热片一；92-散热片二；93-散热片三。
具体实施方式
以下，将会参照附图描述本发明的实施方式。在实施方式中，相同构造的部分使用相同的附图标记并且省略描述。
值得指出的是，为了更清楚地说明，特做如下定义：与PTC电热元件相接触的一侧边板定义为底板，不与PTC电热元件相接触的一侧边板定义为顶板。故一个散热片中可能包括一个底板和一个顶板，或一个散热片中可能包括两个底板；当然，若底板为电极，则散热片也可以不包括底板。
本发明实施例中所述散热片至少有如下几种，第一种散热片是由一组翅片和两个边板组成(两个边板为一个顶板一个底板)；第二种散热片是由一组 翅片和一个边板(顶板)组成；第三种散热片是仅由一组翅片组成；当然，除以上几种之外还可以有其他形式的散热片。
本发明实施例中所述的底板，既可以是属于散热片的一个子零件，也可以是用于导电的电极，还可以同时是散热片的一个子零件和用于导电的电极。
实施例一
如图1所示，为本发明提供的一个铝制散热片9(或称散热翅片、或称散热元件、或铝散热条、或铝条)示意图。本实施例散热片9是由一组翅片1和位于翅片1两侧的边板2组成的散热片91。如图2所示，散热片91上在与PTC电热元件6相贴合的表面(即底板21外侧)设置了绝缘层3。即在散热片91与PTC电热元件6之间设置有绝缘层3，以使得散热片91上与PTC电热元件6不接触的表面不带电。
如图3所示，为本发明提供的一个PTC电热元件6(或称PTC电极条组件)示意图，PTC元件4上下分别为正负电极片5，正负电极片5材质为不锈钢。如图4所示，绝缘层3设置在PTC电热元件6的外表面。
在PTC电热元件6上下外表面(即电极片外表面)通过高压喷涂绝缘硅胶或掺杂有陶瓷粉末的绝缘硅胶作为绝缘层3，在PTC电热元件6左右两侧表面也可通过高压喷涂绝缘硅胶以与外界绝缘，还可以在PTC电热元件6前后两端(电极片极耳处除外)外露部分进行绝缘处理。当然，作为上述的替代选择，也可在铝制散热片91上与PTC电热元件6相接触的一面通过高压喷涂绝缘硅胶或掺杂有陶瓷粉末的绝缘硅胶作为绝缘层3。该两种绝缘层3的设置位置，可以二选一，也可以同时选择二者。
然后通过涂覆导热硅胶，将PTC电热元件6与散热片91依次交替排布，粘接固化连接。如图6中，为PTC电热元件6与散热片91交叉叠放形成的PTC电制热器；其中，PTC电热元件6与散热片91之间喷涂有绝缘层3。
上述导热硅胶可以选择与绝缘层3相同的硅胶材料，也可以有所不同。绝缘硅胶的喷涂和导热硅胶的涂覆，可以在一次工艺步骤中实现，也可以分两次工艺步骤实现。待喷涂的绝缘硅胶可在喷涂之前先进行稀释，以降低其粘度；比如可用10％-50％的硅油进行稀释。导热硅胶和绝缘硅胶中，均可通过掺杂导热粒子(如Al2O3陶瓷粉末)以提高其导热系数，掺杂比例依据导热效果和粘接效果等进行综合评估，比如掺杂比例可以是10％-50％。
图7中，外部为外框20，外框20上安装有导电连接口，导线通过所述导电连接口将正负电极片与外部电源连接在一起。内部为PTC电热元件6与散热片9交叉叠放形成PTC电制热器10。
参阅图5为现有技术下的带铝扁管8的PTC电热元件截面结构示意图。如图中所示，现有技术下的带铝扁管8的PTC电热元件包括设置于中心的PTC元件4、两侧的正负电极片5、在外部的绝缘膜7、以及最外侧的铝扁管8，之后才将整体的带铝扁管8的PTC电热元件与普通散热片9相连接，以得到散热效果。由此可知，现有技术下的PTC电制热器结构繁杂、部件较多。
实际大批量生产中，通过喷涂工艺来设置绝缘层，将有利于自动化大批量生产的工艺设计，以替代现有的手工生产工艺。其有益效果是生产效率大幅度提高，可减少约2/3的现有人工，且批量生产质量稳定可靠，生产成本将大幅度降低。
本实施例中，以硅胶作为绝缘层替代传统的聚酰亚胺薄膜。具有绝缘功能的硅胶同时可作为粘接材料，这有利于减少接触面之间的接触热阻，对提高传热性能很有帮助，而且硅胶还可以通过掺杂导热粒子(如陶瓷粉)进一步提高其导热性能；比如掺杂有氮化铝粉末或氧化铝粉末之后的硅胶其导热系数可达2.0W/m·K以上，而传统聚酰亚胺薄膜的导热系数仅约0.2W/m·K。这些显著的技术效果是传统聚酰亚胺薄膜绝缘结构难以达到的。
实施例二
参阅图8，为本发明实施例二散热片的结构示意图。如图中所示，本实施例的散热片9为另一种的散热片92，散热片92由翅片1和一侧的边板2(即顶板22)组成，即该散热片92不包含底板21。如图9所示，将另一侧的边板2(即底板21)作为电极片5，将电极片5外侧设置绝缘层3，然后将如图8所示的散热片92粘接于电极片5的外侧。
本实施例电制热器可以通过如下方式实现：将二组如图9所示部件粘接于若干PTC元件4两侧，形成本发明电制热器。该散热片92与PTC电热元件6之间设置有绝缘层3。
本实施例电制热器也可以通过如下方式实现：将二组如图8所示散热片92分别粘接于如图4所示带绝缘层3的PTC电热元件6两侧，形成本发明实施例的电制热器。该散热片92与PTC电热元件6之间设置有绝缘层3。
在本实施例中，绝缘层3设置于正负电极片5(或者说底板21)在与翅片1相接触的面上；即散热片92上与PTC电热元件6不接触的表面不带电。
其中，本实施例中翅片1与底板21间的连接方式为粘结，但也可以为压合连接、螺接、卡接等紧固方式，不局限于此；翅片1与顶板22间的连接方式为粘结，但也可以为焊接、压合连接、螺接、卡接等紧固方式，不局限于此。绝缘层3设置的方法为涂覆、平贴和绕包中的一种或数种的组合。绝缘层3的涂覆方法为喷涂、刷涂、辊涂、浸涂、点胶、丝网印、滚涂、电泳、以及刮涂中的一种或数种的组合。且喷涂方法有陶瓷粉末高温熔融喷涂和溶液喷涂，但不局限于此。绝缘层3的材质为高分子绝缘材料或陶瓷绝缘材料或掺杂有陶瓷的高分子复合绝缘材料。或者，所述绝缘层3材质为橡胶、或者树脂、或者塑料。再或者，所述绝缘层3材质为有机硅、或者无机硅、或 者聚酰亚胺、或者聚酯亚胺、或者环氧树脂、或者丙烯酸酯类胶粘剂、或者丙烯酸类胶粘剂。
这样，本实施例中，底板21内侧表面设置绝缘层3，使得翅片1和顶板22不再需要额外的绝缘处理。
结合图10，为本发明电制热器实施例二的结构示意图。如图中可知，电制热器由散热片92与PTC电热元件6直接相连构成，并在散热片92与PTC电热元件6之间设置有绝缘层3，相对于如图5所示现有技术，本实施例电制热器省去了专门的正负电极片5、绝缘膜7、以及铝扁管8，使得得到较为简洁的结构。其中，底板21外侧起到了正负电极片5的功能效果，从而既实现了绝缘要求，又大大简化了结构，且提升了热效率。
实施例三
参阅图11，为本发明实施例三中的散热片和外部绝缘层的结构示意图，其为在如图1所示的散热片91上除与PTC元件4相贴合的表面之外设置有绝缘层3。如图中所示，散热片包括翅片1和设置于两侧的边板2；且除底板21外侧之外，整个翅片1(包括侧面)、底板21内侧和两侧、以及顶板22内外侧和两侧均进行绝缘处理，从而得到如图所示的绝缘层3。即散热片91上在与PTC元件4不接触的部位设置绝缘层3，使得散热片91上与PTC元件4不接触的表面电绝缘或不带电。该实施例中底板21同时作为电极片。
本实施例中，绝缘层3的设置方法可以是：将两个散热片91设置于若干PTC元件4两侧，做成PTC电制热器；在做成PTC电制热器之后，对电极极耳进行包裹或其他保护处理后，进行整体浸涂实现。
本实施例中，电制热器也可以如下实现：首先做成PTC电热元件6，然后再在PTC电热元件6两侧各设置一组翅片1和一个顶板22，形成不绝缘的电制热器；然后再将此不绝缘的电制热器通过浸涂绝缘层3，形成本发明具有绝缘功能的电制热器。
绝缘层3的材质为高分子绝缘材料或陶瓷绝缘材料或掺杂有陶瓷的高分子复合绝缘材料。其中，高分子绝缘材料为有机硅、树脂、以及塑料中的任意一种或数种的组合。
参阅图12，为本发明实施例三中的电制热器的结构示意图。如图中所示，该实施例中，包括有PTC元件4和两个散热片91，其结构由相互叠加组合而成。类似于上述的实施例二，本实施例中同样简化了现有技术中的结构，包括省去了两侧专门的正负电极片5、在外部的绝缘膜7、以及最外侧的铝扁管8，使得得到较为简洁的结构。如图中所示，PTC元件4和散热片91相连接的面上(即底板21外表面)不进行绝缘处理，除电极极耳之外的其它位置均进行绝缘处理，从而底板21外表面起到电极片导电的效果。
这样，既实现了绝缘要求，又大大简化了结构，且提升了热效率，散热片9的一侧边板2(即底板21)同时作为PTC电热元件6的电极片5，节省了专门的正负电极片。
在本实施例中，散热片可以有两种划分方式：一种是将翅片1、底板21和顶板22作为本实施例散热片91；另一种是将翅片1和顶板22作为本实施例散热片92。
绝缘层3设置于散热片91在与PTC元件4不接触的部位，散热片91上与PTC元件4不接触的表面电绝缘或不带电。或者说，散热片9为图8所示 的散热片92，散热片92上与PTC电热元件6不接触的表面电绝缘或不带电。
实施例四
参阅图13，如图中所示，本实施例电制热器的基本结构和原理与上述实施例二大致相同，其不同之处在于，该电制热器具有三个散热片和两个PTC电热元件；散热片具有双层翅片1。两侧的散热片由双层翅片1、中间隔板和顶板组成；中间的散热片由双层翅片1和中间隔板组成。绝缘层3设置在散热片与PTC电热元件6之间。
这样，双层翅片1的设置能够得到更为优良的散热效果，且节约了专门的电极片。
实施例五
类似图6所示，本实施例五大部分与实施例一相同，所不同的是，绝缘层3材料为Al2O3陶瓷粉末，在PTC电热元件6的底板21外表面或者散热片91外表面热喷涂有Al2O3陶瓷层。
上述喷涂陶瓷涂层性能检测如下：
绝缘电阻>20MΩ、电气强度1800VDC@1min、漏电<2mA；
耐温性：-45至260℃；
导热性：20～30W/m·K；
热膨胀系数：8.8×10-6/℃。
实施例六
参照实施例一，将正负电极片5和PTC元件4固定形成PTC电热元件6，将聚酰亚胺薄膜平贴并粘接在PTC电热元件6外表面。
在散热片91与PTC电热元件6接触的一面涂覆粘结剂，将两个散热片91 粘结到PTC电热元件6两侧表面。
实施例七
参照实施例一，将正负电极片5和PTC元件4固定，制成PTC电热元件6，用聚酰亚胺膜将所述PTC电热元件6包裹(即采用绕包的方式)，仅露出电极片5的极耳用于连接外部导线。
在散热片91与PTC电热元件6接触的一面涂覆粘结剂，将散热片91粘结到PTC电热元件6的外表面。
实施例八
如图14所示的散热片仅由一组翅片组成，图15为本发明电制热器实施例八的结构示意图。参照实施例二，本实施例八与实施例二所不同之处在于本实施例八由两个PTC电热元件6与三个散热片组成，其中上下两侧的两个散热片为如图8所示的散热片92，中间一个散热片为如图14所示的散热片93(即翅片1)。
实施例九
图16为本发明电制热器实施例九的结构示意图。参照实施例一，本实施例九与实施例一所不同之处在于本实施例九由多个(如两个)PTC电热元件6与多个(如三个，即数量比PTC电热元件多一个)散热片组成，其中所有散热片均为如图1所示的散热片91。相对来说，该种集成有多层PTC电热元件的结构更适合于汽车空调PTC电制热器应用。
值得指出的是，本发明提供的PTC元件，包括陶瓷PTC和高分子PTC，其中，可运用于各个加热领域，尤其适合空调加热领域，且所使用的连接方式主要为粘结，设置绝缘层的主要方式为涂覆，但不局限于此。
以上实施例仅为本发明的数个较佳实施例，对本发明而言仅仅是说明性的，而非限制性的。本专业技术人员理解，在本发明权利要求所限定的精神和范围内可对其进行许多改变、修改、以及等效替换，但都将落入本发明的保护范围内。因此，在不脱离本发明的精神和范围下所作的均等变换和修改，都应涵盖在本发明的范围内。

Claims (22)

  1. 一种电制热器，其特征在于，包括至少一个PTC电热元件、散热片；
    所述PTC电热元件包括正负电极以及位于正负电极之间的PTC元件；所述散热片位于所述PTC电热元件的外表面；
    所述散热片上，与所述PTC电热元件不接触的表面不带电。
  2. 根据权利要求1所述的电制热器，其特征在于，所述散热片与所述PTC电热元件之间设置有绝缘层，或者，所述散热片上在与所述PTC电热元件不接触的表面设置有绝缘层。
  3. 根据权利要求2所述的电制热器，其特征在于，所述绝缘层材质选自高分子绝缘材料、陶瓷绝缘材料、和掺杂有陶瓷的高分子复合绝缘材料中的任意一种或几种。
  4. 根据权利要求3所述的电制热器，其特征在于，所述绝缘层材质选自硅胶、有机硅树脂、无机硅、聚酰亚胺、特氟龙、聚酯亚胺、环氧树脂、丙烯酸酯类胶粘剂、丙烯酸类胶粘剂、苯并噁嗪、掺杂有陶瓷的硅胶中的任意一种或几种。
  5. 根据权利要求2-4中任意一项所述的电制热器，其特征在于，所述绝缘层材质中的材料经由稀释剂进行稀释。
  6. 根据权利要求5所述的电制热器，其特征在于，所述绝缘层材质为硅胶、掺杂陶瓷的硅胶中的任意一种或几种，所述稀释剂为硅油。
  7. 根据权利要求6所述的电制热器，其特征在于，在所述绝缘层材质中的材料与所述稀释剂组成的混合物中，所述稀释剂重量比例为10％-50％。
  8. 根据权利要求6所述的电制热器，其特征在于，在所述硅胶绝缘层表面再 涂覆导热硅胶，然后再将所述散热片粘接于已喷涂好所述硅胶绝缘层的所述PTC电热元件外表面。
  9. 根据权利要求2所述的电制热器，其特征在于，设置所述绝缘层的方法选自涂覆、平贴、以及绕包中的一种或数种的组合。
  10. 根据权利要求9所述的电制热器，其特征在于，设置所述绝缘层的涂覆方法选自喷涂、刷涂、辊涂、沉积、浸涂、点胶、丝网印、滚涂、电泳、以及刮涂中的一种或数种的组合。
  11. 根据权利要求1所述的电制热器，其特征在于，所述电制热器包括至少一个PTC电热元件和至少两个散热片；
    所述散热片包含若干有序排列的翅片和两个沿所述翅片排列方向布置的边板，所述若干个有序排列的翅片位于两个边板之间，并且，所述翅片与所述边板之间粘接或焊接；
    并且，每个所述PTC电热元件均设置于每相邻的两个所述散热片之间，且所述散热片与所述PTC电热元件相贴合；
    所述散热片与所述PTC电热元件之间设置有绝缘层。
  12. 根据权利要求1所述的电制热器，其特征在于，所述电制热器包括至少一个PTC电热元件和至少两个散热片；
    所述散热片包含若干有序排列的翅片；或者，所述散热片包含若干有序排列的翅片和一个沿所述翅片排列方向布置的边板，所述若干有序排列的翅片位于所述边板的同一侧，并且，所述翅片与所述边板之间粘接或焊接；
    并且，每个所述PTC电热元件均设置于每相邻的两个所述散热片之间，且所述散热片与所述PTC电热元件相贴合；
    所述散热片与所述PTC电热元件之间设置有绝缘层。
  13. 根据权利要求1所述的电制热器，其特征在于，所述电制热器包括至少一个PTC电热元件和至少两个散热片；
    所述散热片包含若干有序排列的翅片；或者，所述散热片包含若干有序排列的翅片和一个沿所述翅片排列方向布置的边板，所述若干有序排列的翅片位于所述边板的同一侧，并且，所述翅片与所述边板之间粘接或焊接；
    并且，每个所述PTC电热元件均设置于每相邻的两个所述散热片之间，且所述散热片与所述PTC电热元件相贴合；
    所述散热片上，在与所述PTC电热元件不接触的表面设置有绝缘层。
  14. 根据权利要求1所述的电制热器，其特征在于，所述电制热器不包括金属扁管。
  15. 一种如权利要求1所述的电制热器的制造方法，其特征在于，
    步骤1：将正电极、PTC元件和负电极依照所述顺序叠放并固定，形成PTC电热元件；
    步骤2：将散热片与至少一个PTC电热元件外表面接触；并且使所述散热片上，与所述PTC电热元件不接触的表面不带电。
  16. 根据权利要求15所述的方法，其特征在于，步骤2包括：
    提供所述PTC电热元件和所述散热片，并将所述PTC电热元件与所述散热片交替排布，所述散热片贴合在所述PTC电热元件外表面，形成电制热器；
    其中，在所述散热片与所述PTC电热元件之间设置有绝缘层；或者，所述散热片上，在与所述PTC电热元件不接触的表面设置有绝缘层。
  17. 根据权利要求16所述的方法，其特征在于，绝缘层和散热片设置方法选自：
    将所述绝缘层设置在所述PTC电热元件的外表面，然后将所述散热片贴合到 所述PTC电热元件外表面；或者，
    将所述绝缘层设置在所述散热片的与所述PTC电热元件接触的一面，然后将所述散热片贴合到所述PTC电热元件外表面；或者，
    将所述绝缘层设置在散热片不与PTC电热元件接触的表面，然后将散热片未设置绝缘层的表面与PTC电热元件贴合；或者，
    将散热片与PTC电热元件接触，然后在暴露的表面上设置绝缘层。
  18. 根据权利要求16或17所述的方法，其特征在于，设置绝缘层的方法选自涂覆、平贴、以及绕包中的一种或数种的组合。
  19. 根据权利要求18所述的方法，其特征在于，所述涂覆方法为喷涂、刷涂、辊涂、沉积、浸涂、点胶、丝网印、滚涂、电泳、以及刮涂中的一种或数种的组合。
  20. 根据权利要求16或17所述的方法，其特征在于，所述绝缘层材质选自高分子绝缘材料、陶瓷绝缘材料、和掺杂有陶瓷的高分子复合绝缘材料中的任意一种或几种。
  21. 根据权利要求20所述的方法，其特征在于，所述绝缘层材质选自掺杂有陶瓷的硅胶。
  22. 一种电制热器，其特征在于，包括至少一个PTC电热元件、散热片；
    所述PTC电热元件由若干PTC元件组成；所述散热片位于所述PTC电热元件的外表面；
    所述散热片上，与所述PTC电热元件不接触的表面不带电。
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US20170223776A1 (en) 2017-08-03

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