Disclosure of Invention
The invention provides a heating device and a manufacturing method thereof, which aim to solve the problem that the welding quality of climbing is affected due to the fact that a slope exists at a welding joint of a blocking rib and the periphery of the blocking rib.
In order to solve the technical problems, the invention adopts the following technical scheme:
A heating device comprises a first cover plate provided with a continuous bulge with a bent section and a straight section; the second cover plate is attached to the opposite side of the first cover plate opposite to the bulge and is covered with the inner cavity of the bulge to form a cavity, the first cover plate and the second cover plate are positioned at the cavity to form a flowing area for fluid to flow, and through holes for communicating the cavity are formed at two ends of the bulge; a circumferential weld welded to the first cover plate and the second cover plate and sealed outside the flow region; a gap weld welded at the gap between the adjacent straight sections of the protrusion, and one end of the gap weld, which is positioned at the opening of the gap, is jointed with the annular weld; and the heat generated by the heating element is transferred to the cavity through the heat-conducting plate and the second cover plate.
In one embodiment, the clearance between the root parts of adjacent straight sections of the protrusions is L1, and the L1 value is 1-6mm.
In one embodiment, the cross section of the chamber is trapezoidal, and the width of the chamber gradually decreases away from the second cover plate.
In one embodiment, the edge of the first cover plate is bent and extended to cover the side edge of the second cover plate, so that a folded edge close to or/and attached to the side edge of the second cover plate is formed.
In one embodiment, a plurality of slots are arranged on the side surface of the heat conducting plate, which is attached to the second cover plate.
In one embodiment, a plurality of blocking points are arranged on one side of the heat conducting plate, which faces the heating element, and the blocking points lean against the side edge of the heating element.
In one embodiment, the hem height is greater than the thickness of the second cover plate.
In one embodiment, the heating element is S-shaped, U-shaped, C-shaped, and Z-shaped.
In one embodiment, the first cover plate and the second cover plate are made of hardware materials, the first cover plate, the second cover plate and the heat conducting plate are made of hardware materials, the first cover plate and the second cover plate are made of stainless steel, the heat conducting plate is made of aluminum or aluminum alloy, and the heating element is made of a heating tube of an aluminum alloy shell.
The manufacturing method of the heating device comprises the following steps:
step S1: stamping the joint surface of the first cover plate to form continuous bulges, and selecting a second cover plate which can be covered with the joint surface of the first cover plate;
Step S2: cleaning and drying the surfaces of the first cover plate and the second cover plate;
step S3: covering and compacting the first cover plate and the second cover plate, sequentially welding and dotting along the gaps at the root parts of the straight sections of the bulges towards the opening direction of the first cover plate and the second cover plate to form a plurality of welding spots, and sequentially and continuously welding along the gaps and through the plurality of welding spots according to the dotting sequence to form a gap welding seam; then, sequentially welding the end parts of the gap welding seams, which are positioned at the gap openings, serving as welding points to form closed annular welding seams which surround the bulges;
step S4: the heat conducting plate is attached to one side, away from the cavity, of the second cover plate, and the heat conducting plate is welded and fastened with the second cover plate;
step S5: the heating piece is attached to one side, away from the second cover plate, of the heat conducting plate, and the heating piece and the heat conducting plate are welded and fastened.
According to the technical scheme, the invention has the following beneficial effects:
According to the invention, through the bulge arranged on the first cover plate, the annular welding seam formed around the periphery of the bulge and the extension welding seam connected with the annular welding seam and extending to the root gap of the adjacent straight section of the bulge, the annular welding seam and the extension welding seam play a role in sealing the periphery of the cavity, the whole welding process is positioned on the plane of the first cover plate, so that the climbing welding required during the welding and sealing is effectively avoided, the sealing performance of the welding is improved, meanwhile, the difficulty of the welding is reduced, and the sealing performance of the fluid during the use of the cavity is greatly improved; the heating device with low cost is realized through simple space layout, structural cooperation and mature manufacturing process, and the device can realize the heating of cold water and can also realize two functions of changing cold water into steam after heating.
Through the welding method to heating device, adopt earlier to bellied clearance spot welding, secondly weld bellied clearance from inside to outside in proper order, finally weld the welding seam outer end in proper order, form around bellied ring limit welding seam, avoid bellied clearance part to bulge easily when follow-up welding, influence welded leakproofness.
Detailed Description
A preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.
As shown in fig. 1, 3 and 5, a heating device comprises a first cover plate 1 provided with a continuous protrusion 7 with curved and straight sections; the second cover plate 2 is attached to the opposite side of the first cover plate 1 relative to the bulge 7 and is covered with the inner cavity of the bulge 7 to form a cavity 9, the first cover plate 1 and the second cover plate 2 are positioned at the cavity 9 to form a flowing area for fluid to flow, and through holes 8 for communicating with the cavity 9 are formed at two ends of the bulge 7; a circumferential weld welded to the first cover plate 1 and the second cover plate 2 and sealed outside the flow region; a gap welding line which is welded at the gap between the adjacent straight sections of the protrusion 7 and is positioned at one end of the gap opening to be jointed with the annular welding line; the heat conducting plate 3 and the heating piece 4 which are sequentially attached to the second cover plate 2 and back to the cavity 9, and heat generated by the heating piece 4 is transferred to the cavity 9 through the heat conducting plate 3 and the second cover plate 2. The matching of the straight section and the curved section of the protrusion 7 is used for improving the length of the protrusion 7 located on the first cover plate 1, preferably in a serpentine shape, for example, the straight section is arranged in parallel, the curved section is located at the junction of the adjacent straight sections, through holes 8 are formed in two ends of the protrusion 7, after the first cover plate 1 and the second cover plate 2 are covered, fluid can flow from one end of the cavity 9 to the other end, but the fluid is very easy to directly flow out from a gap between the first cover plate 1 and the second cover plate 2, so that the fluid is not easy to flow from the formed cavity 9, the stroke of the fluid is short, the heating effect is affected, the fluid can only flow from the through hole 8 at one end to the through hole 8 at the other end along the trend of the protrusion 7 through welding and extending the welding seam, gas and liquid can flow into the cavity 9, preferably into the water, the water flows in the cavity 9, the heating element 4 heats the heat, and transfers the heat to the cavity 9 through the second cover plate 2, heats the cold water in the cavity 9, and simultaneously heats the cold water in the cavity 9 to form steam, and enables the hot water or steam to flow out from the through hole 8 at the other end.
The heat conducting plate 3 transfers the heat of the heating element 4 to the second cover plate 2, wherein the second cover plate 2, the heat conducting plate 3 and the heating element 4 are sequentially bonded and fastened together by adopting a brazing process, the heat is transferred to the heat conducting plate 3 through the heating element 4, the heat conducting plate 3 transfers the heat to the second cover plate 2, the second cover plate 2 transfers the heat to the chamber 9 after being heated, cold water in the chamber 9 is heated, and the heated uniformity of the water body is improved.
As shown in fig. 1, a water nozzle 6 is installed at each through hole 8, the water nozzle 6 is preferably welded at the through hole 8 by laser, the water nozzle 6 is used for introducing cold water into the chamber 9 or discharging hot water/steam in the chamber 9, the cold water is heated through the second cover plate 2 in the process of passing through the chamber 9, and the water body is heated and discharged from the water nozzle 6 at the other end along the chamber 9, so that hot water or steam can be used later. The two ends of the first cover plate 1 are respectively provided with a fixed bracket 12, and the fixed brackets 12 are connected in a laser welding or butt welding mode, so that the fixed brackets 12 are convenient to mount with household appliances.
As shown in fig. 1 and 5, the first cover plate 1 and the second cover plate 2 are attached and fixed by welding, preferably by laser welding, and a laser beam of 0.5-1mm is used.
As shown in fig. 3 and 5, the gaps between the adjacent straight sections of the protrusions 7 are L1, the value of L1 is 1-6mm, preferably 2-4mm, if the value of the gaps L1 is larger, the manufacturing cost of the product is increased, and the space occupancy rate is increased; if the value of the gap L1 is smaller, the manufacturing difficulty is increased, and the process difficulty of laser welding is increased, and specific welding cases are as follows: when the first cover plate 1 and the second cover plate 2 are welded, for example, the first cover plate 1 with the L1 value of 2mm is adopted, the laser beam is in 0.5mm, the first cover plate 1 and the second cover plate 2 are in cover welding, the laser beam is welded along the outward direction of the gap L1, deviation occurs in the laser beam welding, and if the deviation of the line is within 1.5mm, the laser beam is in a controllable range; if the laser beam is adopted for 1mm, the deviation is still 1.5mm, when the laser beam is welded, the laser beam is easily deviated to the side edge of the bulge 7, the side edge of the bulge 7 is a single layer and is not attached to the second cover plate 2, the laser beam is easily broken down into a single-layer inclined plane, the sealing of a product is damaged, and the whole welding process is influenced.
As shown in fig. 3, the cross section of the chamber 9 is trapezoidal, and the width of the chamber 9 in the direction away from the second cover plate 2 gradually decreases, that is, the top side length of the chamber 9 is smaller than the bottom side length of the chamber 9, the bottom end surface of the chamber 9 is attached to the second cover plate 2, the contact area between the water body in the chamber 9 and the second cover plate 2 is increased, the heating effect of the water body in the chamber 9 is improved, and instant heating is realized.
As shown in fig. 2 and 3, the edge of the first cover plate 1 is bent and extended to cover the side edge of the second cover plate 2 to form a folded edge close to or/and attached to the side edge of the second cover plate 2, the height of the folded edge is at least greater than the thickness of the second cover plate 2, the folded edge is used for covering the side edges of the second cover plate 2 and the heat conducting plate 3, and the limit effect is achieved on the second cover plate 2 and the heat conducting plate 3, so that the first cover plate 1 and the second cover plate 2 relatively move during welding, and the welding accuracy is affected; the height of the folded edge is larger than the thickness of the second cover plate 2, the folded edge can extend to the side edge part of the heat conducting plate 3 and also can extend to cover the whole side edge of the heat conducting plate 3, the top end of the protrusion 7 is pressed during welding, the first cover plate 1, the second cover plate 2 and the heat conducting plate 3 are conveniently and simultaneously limited, the subsequent spot welding positioning is facilitated, and the welding process of the first cover plate 1 and the second cover plate 2 is completed; the second cover plate 2, the heat conducting plate 3 and the heating piece 4 are sequentially bonded and fastened together by adopting a brazing process, and the arrangement of the folded edges is beneficial to overcoming the deformation problem in the forming and brazing processes so as not to cause arching of products, the shape of the second cover plate is not attractive, the assembly is affected, and even the cracking of the products is caused.
As shown in fig. 1 and 6, a plurality of fine grooves 10 are formed in the side surface, where the heat conducting plate 3 is attached to the second cover plate 2, wherein the fine grooves 10 are arranged to facilitate the discharge of broken impurities and gas during the welding of the heat conducting plate 3.
As shown in fig. 1 and 6, a plurality of baffle points 11 are arranged on the side, facing the heating element 4, of the heat conducting plate 3, the baffle points 11 lean against the side edge of the heating element 4, and the baffle edges 11 conveniently play a limiting role on the heating element 4. The heat conducting plate 3 is provided with a plurality of holes, the holes can penetrate through a plurality of screws, the holes are connected in a punching and riveting mode, the heating element 4 is accurately positioned, the height value of a baffle point is 2-10mm, preferably 3-6mm, and the baffle point is used for limiting the heating element 4 so as to prevent the heating element 4 from deviating from the heat conducting plate 3 during welding.
As shown in fig. 1, 4 and 6, the heating element 4 is preferably electrically heated and welded on the side wall of the heat conducting plate 3, the heating element 4 is S-shaped, U-shaped, C-shaped and Z-shaped to increase the bonding area and improve the heat conducting effect, the temperature limiting element 5 is arranged at the center of the bending part of the heating element 4, so that the installation space can be saved, the temperature limiting element 5 is fixed on the heat conducting plate 3, that is, the temperature limiting element 5 is fixed and bonded on the heat conducting plate 3 by adopting a screw, the type of the temperature limiting element 5 is not limited, and can be an electronic temperature controller, such as an NTC thermistor electronic temperature controller, or can be a mechanical temperature controller, such as a kick mechanical temperature controller.
The first cover plate 1, the second cover plate 2 and the heat conducting plate 3 are all made of hardware materials, wherein the first cover plate 1 and the second cover plate 2 are preferably made of stainless steel materials, the heat conducting plate 3 is preferably made of pure aluminum or aluminum alloy, the heat conductivity coefficient of the heat conducting plate is about 200-230W/(m.K), the heat conducting performance is improved compared with that of a plurality of other metals such as steel and copper, the heating element 4 is preferably a heating tube with an S-shaped aluminum alloy shell, the bonding area between the heating element and the heat conducting plate 3 is increased, and the heat conducting effect is improved.
The manufacturing method of the heating device comprises the following steps:
Step S1: stamping the joint surface of the first cover plate 1 to form continuous bulges 7, and selecting a second cover plate 2 which can be covered with the joint surface of the first cover plate 1;
step S2: the surfaces of the first cover plate 1 and the second cover plate 2 are cleaned and dried;
Step S3: the first cover plate 1 and the second cover plate 2 are covered and pressed, dotting is sequentially welded along the gaps of the straight-section root parts of the bulges 7 towards the opening direction of the bulges to form a plurality of welding spots, and then continuous welding is sequentially performed through the plurality of welding spots along the gaps and according to the dotting sequence to form a gap welding seam; then, the end part of the gap welding line, which is positioned at the opening of the gap, is used as a welding point, and the welding points are sequentially welded to form a closed annular welding line which surrounds the bulge 7;
Step S4: the heat-conducting plate 3 is attached to one side, away from the cavity 9, of the second cover plate 2, and the heat-conducting plate 3 and the second cover plate 2 are welded and fastened;
step S5: the heating element 4 is attached to one side of the heat conducting plate 3, which is away from the second cover plate 2, and the heating element 4 and the heat conducting plate 3 are welded and fastened;
step S6: and (3) carrying out surface treatment on the heating device formed in the step S6.
In the step, the bonding surface of the first cover plate 1 refers to the surface bonded with the second cover plate 2, the bonding surface of the first cover plate 1 is stamped to form the protrusion 7, and meanwhile, the first cover plate 1 can also be stamped at the edge to form a folded edge, so that the second cover plate 2 is convenient to limit, in the step S3, the top end of the protrusion 7 is pressed, the gaps L1 of the roots of adjacent straight sections of the protrusion 7 are sequentially spot-welded from inside to outside through laser beams, after the spot welding is finished, namely, the first cover plate 1 and the second cover plate 2 realize welding spot positioning, and can be sequentially welded along the welding spots through the laser beams from the gap L1 inside to form a welding seam from inside to outside, one end of one welding seam facing outwards is selected to be sequentially welded and connected, so as to form a circular edge welding seam surrounding the protrusion 7, namely, the periphery of the chamber 9 can be sealed through the circular edge welding seam, and the extending welding seam extending into the gap L1 are combined to separate adjacent straight sections of the protrusion 7, so that a chamber 9 for fluid flow is formed.
The mode can effectively discharge the air in the middle parts of the first cover plate 1 and the second cover plate 2, and if the periphery of the bulge 7 is welded at first and the welding seam is closed, the clearance L1 part of the bulge 7 is easy to bulge in the subsequent welding, so that the tightness of the whole welding is affected.
In the step S4 and the step S5, the second cover plate 2, the heat conducting plate 3 and the heating piece 4 are all brazed, so that the contact area is increased, and the heat transfer efficiency is improved; in step S6, the surface treatment may be surface polishing or cleaning with a cleaning agent, and may be specifically selected according to the need.
Therefore, the heating device with low cost is realized through simple space layout, structural cooperation and mature manufacturing process, and the device can realize the heating of cold water and can also realize two functions of changing the cold water into steam after heating.
The above-described embodiments are merely illustrative of the preferred embodiments of the present invention and are not intended to limit the scope of the present invention, and various modifications and improvements made by those skilled in the art to the technical solution of the present invention should fall within the scope of protection defined by the claims of the present invention without departing from the spirit of the present invention.