Patent Publication Number: US-2018031271-A1

Title: Ptc liquid heater

Description:
CROSS REFERENCE 
     This application claims the benefit and priority of Chinese Application No. 201620805310.5, filed Jul. 28, 2016. The entire disclosures of each of the above applications are incorporated herein by reference. 
     FIELD OF THE INVENTION 
     The present invention relates to a heater, particularly to a PTC liquid heater. 
     BACKGROUND 
     Currently, PTC (Positive Temperature Coefficient) livid heaters have been widely applied in household appliances, such as SPA pools, entertainment pools, water dispensers, foot baths, and other industrial products. 
     One type of common PTC heaters in the prior art comprises a heat conductor and a PTC heating element. A plurality of ducts are provided within the heat conductor, some of the ducts being used for placing PTC heating elements while some of the ducts being used for liquid passage. The heat conductors of some of the PTC heaters employ metal materials without an anti-corrosion treatment, which are prone to corrosion after long-term use. 
     If chemical substances such as oxidizing disinfectants are contained in water, the oxidation and corrosion of the heat conductor will be accelerated, easily leading to the leakage of liquid from the ducts inside the heat conductor, and increasing safety risks. 
     SUMMARY 
     A technical problem to be solved by the present invention is to provide a PTC liquid heater in order to overcome the defect that the PTC heaters in the prior art are prone to corrosion during long-term use. 
     The above-mentioned technical problems are solved in the present invention by the following technical solution: 
     A PTC (Positive Temperature Coefficient) liquid heater can be provided comprising a heating assembly and a housing. The heating assembly can include a heat conductor having at least one accommodating cavity, a PTC heat generation assembly disposed in the at least one accommodating cavity, a sheath having a cavity for accommodating the heat conductor and the PTC heat generation assembly. The housing can have a water inlet and a water outlet. The heating assembly at least partially passes through the housing. 
     In some embodiments, the heat conductor can be configured in a cylindrical shape, and the at least one accommodating cavity being configured in the heat conductor in an axial direction of the cylinder. 
     In some embodiments, the sheath can comprise a penetrating sleeve, the heat conductor and the PTC heat generation assembly being disposed in the sleeve, and an inner surface of the sleeve abuts against an outer surface of a side wall of the heat conductor. 
     In some embodiments, the sheath can comprise a sleeve end cover that is disposed at one end of the sleeve, and an edge of the sleeve end cover is connected to an edge of an end portion of the sleeve. 
     In some embodiments, the sheath can comprise a flange that is connected to an outer surface of one end of the sleeve and extend outwardly. 
     In some embodiments, the sleeve can be configured as a straight, round tube. 
     In some embodiments, the sleeve and the sleeve end cover can be made of corrosion-resistant heat-conducting material. 
     In some embodiments, the housing can comprise a main body, a first end cover and a second end cover. The main body can have a tubular cavity, allowing a fluid to flow through the tubular cavity. The first end cover can be connected to a first end of the main body, and at least one first through hole is arranged on the first end cover. The second end cover can be connected to a second end of the main body, and at least one second through hole is arranged on the second end cover. The heating assembly can pass through the first and second through holes. 
     In some embodiments, the first end cover can be detachably connected to the first end of the main body, and the second end cover can be detachably connected to the second end of the main body. 
     In some embodiments, the first end cover can be integrally formed with the main body, and the second end cover can be detachably connected to the second end of the main body. 
     In some embodiments, the first and second through holes can be configured in round shape. 
     In some embodiments, the housing can further comprise first seals that are disposed at the first through hole of the first end cover and the second through hole of the second end cover, respectively. 
     In some embodiments, the housing can further comprise a second seal that is disposed at an opening of the first end of the main body of the housing. 
     In some embodiments, the housing can further comprise a second seal that is disposed at an opening of the second end of the main body of the housing. 
     In some embodiments, the housing can further comprise a first fixing member and a second fixing member. The first fixing member can be connected to the first end cover, and the first fixing member comprising at least one third through hole can be arranged on the first fixing member. The second fixing member can be connected to the second end cover, and the second fixing member comprising at least one fourth through hole can be arranged on the second fixing member. And the heating assembly can pass through the third and fourth through holes. 
     In some embodiments, the first seals can be disposed between the first end cover and the first fixing member, and can be disposed between the second end cover and the second fixing member, respectively. 
     In some embodiments, the third and fourth through holes can be configured in round. shape. 
     In some embodiments, the flange of the sheath of the heating assembly can be sandwiched between the first seal at the second end of the main body of the housing and the second fixing member. 
     In some embodiments, the housing can further comprise at least one partition plate that is disposed in the cavity of the main body in the longitudinal direction of the tubular cavity. Two opposite first ends of the partition plate can be connected to two opposite first side walls of the main body, and at least one of two opposite second ends of the partition plate can be connected to at least one of the first and second end covers. And the sleeves can be disposed on two sides of the partition plate. And the length of the partition plate being less than that of the tubular cavity. 
     In some embodiments, at least one partition plate disposed in the tubular cavity in the longitudinal direction, two opposite first ends of the partition plate being connected to two opposite first side walls of the main body, two opposite second ends of the partition plate being connected to the first cover and second end cover, and at least one fifth through hole is arranged on, the partition plate. 
     In some embodiments, the water inlet and the water outlet can be formed on the main portion of the housing. 
     In some embodiments, the housing can comprise a main body and a first end cover. The main body can have a box-shaped cavity and an opening, and the main body can comprise a water inlet and a water outlet. The first end cover can be connected to both the opening portion of the main body and the heating assembly. And the heating assembly can be at least partially disposed in the cavity of the main body. 
     In some embodiments, the sheath of the heating assembly can be connected to the first end cover. 
     In some embodiments, a flange of the sheath can be connected to the first end cover. 
     In some embodiments, the first end cover can have a first through hole, and the heating assembly may pass through the first through hole. 
     In some embodiments, the housing can further comprise a second seal, which is disposed between an end portion of the opening of the main body and the first end cover. 
     In some embodiments, the housing can comprise a main body that has a box-shaped cavity and an opening, and the main body can have a water inlet and a water outlet. The heating assembly can be connected to an end portion of the opening of the main body. And the heating assembly is at least partially disposed in the cavity of the main body. 
     In some embodiments, the flange of the sheath of the heating assembly can be connected to the end portion of the opening of the main body. 
     In some embodiments, the housing can further comprise a second seal, which is disposed between a surface on one side of the flange of the sheath and an end face of the opening of the main body. 
     In some embodiments, the housing is made of plastic. 
     The positive progressive effects of the present invention lie in: 
     The PTC liquid heater of the present invention has a better corrosion resistance, and can greatly extend the service life of the liquid PTC heater and prevent electric leakage accidents. The PTC liquid heater has a simple structure and low costs, and is convenient to assemble, especially in that the water pipes can be replaced, facilitating future maintenance. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above-mentioned and other features, characteristics and advantages of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings and embodiments, and in the accompanying drawings, like reference numbers indicate like features, in which: 
         FIG. 1  is a first overall structural schematic view of a first embodiment of a PTC liquid heater of the present invention. 
         FIG. 2  is a second overall structural schematic view of the first embodiment of the PTC liquid heater of the present invention. 
         FIG. 3  is a third overall structural schematic view of the first embodiment of the PTC liquid heater of the present invention. 
         FIG. 4  is a sectional view of the first embodiment of the PTC liquid heater of the present invention, which is taken in the longitudinal direction. 
         FIG. 5  is a first exploded view of the first embodiment of the PTC liquid heater of the present invention. 
         FIG. 6  is a second exploded view of the first embodiment of the PTC liquid heater of the present invention. 
         FIG. 7  is an exploded schematic view of a heating assembly in the first embodiment of the PTC liquid heater of the present invention. 
         FIG. 8  is a first overall structural schematic view of a second embodiment of a PTC liquid heater of the present invention. 
         FIG. 9  is a second overall structural schematic view of the second embodiment of the PTC liquid heater of the present invention. 
         FIG. 10  is a sectional view of the second embodiment of the PTC liquid heater of the present invention, which is taken in the longitudinal direction. 
         FIG. 11  is a first exploded view of the second embodiment of the PTC liquid heater of the present invention. 
         FIG. 12  is a second exploded view of the second embodiment of the PTC liquid heater of the present invention. 
         FIG. 13  is an exploded schematic view of a heating assembly in the second embodiment of the PTC liquid heater of the present invention. 
         FIG. 14  is an exploded view of the third embodiment of the PTC liquid heater of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     To make the above-mentioned object, features and advantages of the present invention apparent, and easily understood, a detailed description of particular embodiments of the present invention is made in conjunction with the drawings. 
     Embodiments of the present invention will now be described in detail with reference to the accompanying drawings. Reference now be made in detail to preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. The same reference numerals in all the figures denote the same or similar parts wherever possible. Furthermore, although the terms used in the present invention are selected from well-known common terms, some of the terms mentioned in the description of the present invention may be selected by the applicant according to his or her judgement, and the detailed meaning thereof is described in the relevant section described herein. Furthermore, the present invention must be understood, not simply by the actual terms used but also by the meanings encompassed by each term. 
     First Embodiment 
       FIG. 1  is a first overall structural schematic view of a first embodiment of a PTC liquid heater of the present invention.  FIG. 2  is a second overall structural schematic view of the first embodiment of the PTC liquid heater of the present invention.  FIG. 3  is a third overall structural schematic view of the first embodiment of the PTC liquid heater of the present invention.  FIG. 4  is a sectional view of the first embodiment of the PTC liquid heater of the present invention, which is taken in the longitudinal direction.  FIG. 5  is a first exploded view of the first embodiment of the PTC liquid heater of the present invention.  FIG. 6  is a second exploded view of the first embodiment of the PTC liquid heater of the present invention.  FIG. 7  is an exploded schematic view of a heating assembly in the first embodiment of the PTC liquid heater of the present invention. 
     As shown in  FIGS. 1-7 , the present invention discloses a PTC liquid heater, which can include a heating assembly  10  and a housing  20 . The heating assembly  10  can include a heat conductor  11 , a PTC heat generation assembly  12  and a sheath  13 , at least one accommodating cavity  111  can be provided in the heat conductor  11 , the PTC heat generation assembly  12  can be at least partially disposed in the at least one accommodating cavity  111 , and the sheath  13  can be provided with a cavity for accommodating the heat conductor  11  and the PTC heat generation assembly  12 . In addition, a water inlet  30  and a water outlet  40  can be disposed on the housing  20 . 
     The heat conductor  11  can be in the shape of a cylinder, and the at least one accommodating cavity  111  can be disposed in the heat conductor  11  in an axial direction of the cylinder. 
     The sheath  13  can include a penetrating sleeve  131 , and the beat conductor  11  and the PTC heat generation assembly  12  can be disposed in the sleeve  131  such that an inner surface of the sleeve  131  abuts against an outer surface of a side wall of the heat conductor  11 . The sheath  13  also can comprise a sleeve end cover, which is disposed at one end of the sleeve  131 , such that an edge of the sleeve end cover can be connected to an edge of an end portion of the sleeve  131 . The sheath  13  can also comprise a flange  132 , the flange  132  is connected to an outer surface of one end of the sleeve  131  and extends outwardly. The sleeve  131  herein may be a straight, round tube, and the material of the sleeve  131  and the sleeve end cover can be made of corrosion-resistant heat-conducting material, such as stainless steel or stainless iron. 
     The housing  20  can include a main body  21 , a first end cover  22  and a second end cover  23 , and the main body  21  can be provided with a tubular cavity, which allows a fluid to flow through. The first end cover  22  can be connected to a first end of the main body  21 , and the first end cover  22  can be provided with at least one first through hole  221 . The second end cover  23  can be connected to a second end of the main body  21 , and the second end cover  23  can be provided with at least one second through hole  231 . The heating assembly  10  can pass through the first through hole  221  and the second through hole  231 . The first through hole  221  and the second through hole  231  herein can be round. The water inlet  30  and the water outlet  40  can be disposed on the main body  21  of the housing  20 . The heating assembly  10  can at least partially pass through the housing  20 . 
     The first end cover  22  herein can be disposed to be detachably connected to the first end of the main body  21 , and the second end cover  23  can be likewise disposed to be detachably connected to the second end of the main body  21 . Alternatively, the first end cover  22  can be disposed to be integrally formed with the main body  21 , and the second end cover  23  can he disposed to be detachably connected to the second end of the main body  21 , 
     The housing  20  also can include first seals  25 , and the first seals  25  can be disposed at the first through hole  221  of the first end cover  22  and the second through hole  231  of the second end cover  23 . The housing  20  can include a second seal  26 , and the second seal  26  can be disposed at an opening of the first end of the, main body  21  of the housing  20 . Alternatively, the second seal  26  can be disposed at an opening of the second end of the main body  21  of the housing  20 . 
     The housing  20  can include a first fixing member  27  and a second fixing member  28 . The first fixing member  27  can be connected to the first end cover  22 , and the first fixing member  27  can be provided with at least one third through hole  271  corresponding to the first through hole  221 . The second fixing member  28  can be connected to the second end cover  23 , and the second fixing member  28  can be provided with at least one fourth through hole  281  corresponding to the second through hole  231 . In this way, the heating assembly  10  can pass through the third through hole  271  and the fourth through hole  281 . The third through hole  271  and the fourth through hole  281  herein can be round. 
     The first seals  25  can be disposed between the first end cover  22  and the first fixing member  27 , and between the second end cover  23  and the second fixing member  28 . In addition, the flange  132  may be sandwiched between the first seal  25  at the second end of the main body  21  and the second fixing member  28 . 
     The housing  20  can also include at least one partition plate  50 , and the at least one partition plate  50  can be disposed in the cavity of the main body  21  in the longitudinal direction of the tubular cavity. The length of the partition plate  50  herein can be less than that of the tubular cavity, two opposite first end portions of the partition plate  50  can be connected to two opposite first side walls of the main body  21 , at least one of two opposite second end portions of the partition plate  50  can be connected to at least one of the first end cover  22  and the second end cover  23 , and the sleeve  131  can be disposed on two sides of the at least one partition plate  50 . 
     Second Embodiment 
       FIG. 8  is a first overall structural schematic view of a second embodiment of a PTC liquid heater of the present invention.  FIG. 9  is a second overall structural schematic view of the second embodiment of the PTC liquid heater of the present invention.  FIG. 10  is a sectional view of the second embodiment of the PTC liquid heater of the present invention, which is taken in the longitudinal direction.  FIG. 11  is a first exploded view of the second embodiment of the PTC liquid heater of the present invention.  FIG. 12  is a second exploded view of the second embodiment of the FTC liquid heater of the present invention.  FIG. 13  is an exploded schematic view of a heating assembly in the second embodiment of the PTC liquid heater of the present invention. 
     As shown in  FIGS. 8-13 , the present invention discloses a PTC liquid heater, which can include a heating assembly  100  and a housing  200 . The heating assembly  100  can include a heat conductor  110 , a PTC heat generation assembly  120  and a sheath  130 , at least one accommodating cavity  1101  can be disposed in the heat conductor  110 , the PTC heat generation assembly  120  can be at least partially disposed in the at least one accommodating cavity  1101 , and the sheath  130  can be provided with a cavity for accommodating the heat conductor  110  and the PTC heat generation assembly  120 . In addition, a water inlet  300  and a water outlet  400  can be disposed on the housing  200 . 
     The heat conductor  110  can be in the shape of a cylinder, and the at least one accommodating cavity  1101  can be disposed in the heat conductor  110  in an axial direction of the cylinder. 
     The sheath  130  can include a penetrating sleeve  131 , and the heat conductor  110  and the PTC heat generation assembly  120  can be disposed in the sleeve  131  such that an inner surface of the sleeve  131  abuts against an outer surface of a side wall of the heat conductor  110 . The sheath  130  can also include a sleeve end cover  133 , and the sleeve end cover  133  can be disposed at one end of the sleeve  131 , such that an edge of the sleeve end cover  133  can be connected to an edge of an end portion of the sleeve  131 . The sheath  130  can also include a flange  132 , the flange  132  can be connected to an outer surface of one end of the sleeve  131  and can extend outwardly. The sleeve  131  herein may be a straight, round tube, and the material of the sleeve  131  and the sleeve end cover  133  can be made of corrosion-resistant heat-conducting material, such as stainless steel or stainless iron. 
     The housing  200  can include a main body  210 , the main body  210  in this embodiment can be provided with a box-shaped cavity and an opening, and a water inlet  300  and a water outlet  400  can be disposed on the main body  210 . The heating assembly  100  can be connected to the end portion of the opening of the main body  210 , and the heating assembly  100  can be at least partially disposed in the cavity of the main body  210 . 
     The flange  132  herein can be connected to the end portion of the opening of the main body  210 . 
     The housing  200  can also include a second seal  220 , and the second seal  220  can be disposed between the surface on one side of the flange  132  and the end face of the opening of the main body  210 . 
     The housing  200  can also include at least one partition plate  500 , and the at least one partition plate  500  can be disposed in the cavity of the main body  210  in the longitudinal direction of the tubular cavity. The length of the partition plate  500  herein can be less than that of the tubular cavity, two opposite first end portions of the partition plate  500  can be connected to two opposite first side walls of the main body  210 , at least one of two opposite second end portions of the partition plate  500  is connected to the first end cover  220 , and the sleeve  131  can be disposed on two sides of the at least one partition plate  500 . 
     Third Embodiment 
       FIG. 14  is an exploded view of the third embodiment of the PTC heater of the present invention. 
     As shown in  FIG. 14 , the present invention also discloses a yet further PTC liquid heater, the structure of which is substantially the same as that of the second embodiment, except that the housing  600  can include a main body  610  and a first end cover  620 . The main body  610  can be provided with a box-shaped cavity and an opening, and a water inlet and a water outlet CM he disposed on the main body  610 . The first end cover  620  can be connected to the opening portion of the main body  610 , and the first end cover  620  can be connected to the heating assembly  100 . The heating assembly  100  can at least partially pass through the housing  600 . The heating assembly  100  can at least partially be disposed in the cavity of the main body  610 . 
     The sheath  130  of the heating assembly  100  can be connected to the first end cover  620 . The flange  132  of the sheath  130  can be connected to the first end cover  620 . The first end cover  620  can be provided with a first through hole  621 , and the heating assembly  100  can pass through the first through hole  621 . The flange  132  of the sheath  130  can be connected to the end portion of the opening of the main body  610 . 
     The housing  600  can also include a second seal  630 , and the second seal  630  can be disposed between the end portion of the opening of the main body  610  and the first end cover  620 . 
     In a particular embodiment, a sealing ring may also be disposed between the flange  132  of the sheath  130  and the first end cover  620  at the first through hole  621  of the first end cover  620 . 
     Of course, the housings in the first to third embodiments described above may be made of plastic. 
     The PTC heat generation assembly  12  in the above embodiments can include a group of heat generation ceramic sheets, two electrode sheets may be disposed on two sides of the group of heat generation ceramic sheets, multiple layers of insulating films are wound around the outer sides of the group of heat generation ceramic sheets and the two electrode sheets, and the outermost layer may be an aluminum profile envelope; its the actual implementation process, in order to enhance the insulating properties of the PTC heat generation assembly  12 , a ceramic insulating plate may be disposed on the outer sides of the group of heat generation ceramic sheets and the two electrode sheets or between the multiple layers of insulating films. 
     The PTC heating generation  12  can include a PTC heating element, a first electrode, a second electrode, a first protection layer, a second protection layer, a first interlayer, and a second interlayer. The PTC heating element has a first side and a second side. The first electrode and the second electrode can be positioned on the first side of the PTC heating element and the second side of the PTC heating element respectively. The first insulating interlayer can be located between the first protection layer and the first electrode. The second insulating interlayer can be located between the second protection layer and the second electrode. The first protection layer and the second protection layer can have a greater hardness in comparison with the first and second insulating interlayer. 
     Moreover, the PTC heating generation  12  can further include a heat conductive housing. The first interlayer and second insulating interlayer are placed into the heat conductive housing. A first side wall and a second side wall of the heat conductive housing are inwardly curved. 
     In summary, the PTC liquid heater of the present invention has a better corrosion resistance, and can greatly extend the service life of the liquid PTC heater and prevent electric leakage accidents. The PTC liquid heater has a simple structure and low costs, and is convenient to assemble, especially in that the water pipes can be replaced, facilitating future maintenance. 
     The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention. The foregoing embodiments may be implemented individually or in any combination. However, these alterations and modifications all fall within the scope of protection of the present invention.