Embedded integrated metal resistor ceramic heating element and preparation process

Abstract

The invention discloses an embedded integrated metal resistor ceramic heating body and a preparation process. Comprising a ceramic body, a metal heating wire and an electrode plate, the ceramic body is provided with a heating cavity and is in a cup shape, the back of the ceramic body is provided with an embedded groove, the metal heating wire is annular and is provided with a fracture, the metal heating wire is inserted into the embedded groove and is filled with a heating wire sealing compound material, and at least two pin wires are arranged on the metal heating wire. The pin line extends to the bottom of the ceramic body, and the bottom of the ceramic body is provided with two electrode plates. The metal heating wire is used for replacing an original thick-film resistor, the ceramic sintering temperature can be higher and the heating performance is more stable by means of the characteristics of the metal heating wire, meanwhile, the metal heating wire is simpler to mount by adopting an embedded mounting form, the manufacturing process is greatly optimized, the manufacturing process is simpler, and the manufacturing cost is reduced. And the manufacturing cost is also reduced synchronously.

Description

Technical Field

[0001] This invention relates to the field of heating element technology, and in particular to an embedded integrated metal resistive ceramic heating element and its preparation process. Background Technology

[0002] As we all know, a heating element is a device that generates heat when electricity is applied, and it is mainly used in various electrical appliances. It is also used in some small electronic products, such as e-cigarettes. In these small electronic products, the heating elements used are also small and adapted to the electronic device, such as small ceramic heating elements.

[0003] Currently, existing small ceramic heating elements have the following problems:

[0004] (1) The heating components are mainly thick film resistors. The product manufacturing process is complicated and the manufacturing cost is high. First, the ceramic substrate is sintered, then the thick film resistor is screen printed on the ceramic substrate, then multiple layers of ceramic tape are stacked on it, and finally it is sintered together with the ceramic body.

[0005] (2) Thick film resistors have poor high temperature resistance and require low ceramic sintering temperature, thus limiting their application range;

[0006] (3) Thick film resistors are less stable than metal resistors and have poorer heating stability.

[0007] Therefore, it is necessary to optimize the structure of existing small ceramic heating elements. Summary of the Invention

[0008] To address the shortcomings of the existing technology, the present invention aims to provide an embedded integrated metal resistive ceramic heating element and its preparation process.

[0009] To achieve the above objectives, the present invention adopts the following technical solution:

[0010] An embedded integrated metal resistive ceramic heating element includes a ceramic body, a metal heating wire, and electrode plates. The ceramic body has a heating cavity and is cup-shaped. An embedded groove is formed on the back of the ceramic body. The metal heating wire is annular and has a break. The metal heating wire is inserted into the embedded groove and filled with heating wire sealing material. The metal heating wire has at least two lead wires that extend to the bottom of the ceramic body. Two electrode plates are provided at the bottom of the ceramic body, and the electrode plates are respectively connected to the corresponding lead wires.

[0011] Preferably, the electrode sheet has a downwardly bent fixing foot at its end, the ceramic body has a groove at its bottom, the fixing foot is placed at the bottom of the groove, and the groove is filled with electrode sheet sealing material.

[0012] A fabrication process for an embedded integrated metal resistive ceramic heating element includes the following steps:

[0013] Step 1: Determine the ceramic forming process and main ceramic raw materials: Determine the ceramic forming process and main ceramic raw materials based on the application scenarios, functional requirements and product structure of the ceramic heating element product;

[0014] Step 2, Metal heating wire selection and fabrication: Select appropriate metal materials to fabricate the metal resistor based on the size, resistance value and other functional requirements of the ceramic heating element for the heating resistor;

[0015] Step 3: Ceramic heating element product production drawing design: Based on the structural design of the ceramic heating element product, combined with the ceramic molding process and the main ceramic raw materials and metal heating wires selected, the production drawing design of the product is carried out;

[0016] Step 4: Adjust and determine the ceramic formula: Adjust the ceramic formula to meet the functional requirements of the ceramic heating element product and facilitate the forming of the ceramic green body, and determine the corresponding ceramic shrinkage ratio;

[0017] Step 5: Ceramic mold making: According to the production drawing of the ceramic heating element and the ceramic shrinkage ratio, make a ceramic mold and set a reserved space on the ceramic pot body according to the required size of the metal heating wire to form an embedded groove.

[0018] Step 6: Ceramic green body forming: Prepare ceramic green bodies according to the proposed forming process;

[0019] Step 7, Ceramic Firing: Select an appropriate firing process to fire the ceramic green body according to the functional requirements of the ceramic heating element, the main raw materials of the ceramic, and the ceramic green body forming process;

[0020] Step 8, Product Assembly: Embed the metal heating wire into the inner groove of the ceramic body, then fill and seal it with heating wire sealant and cure it.

[0021] Step 9, Vibration washing and polishing: Vibration washing and polishing are performed on the fired ceramic products to make the product surface smoother;

[0022] Step 10, Product Inspection and Testing: This includes product appearance and size inspection and product performance testing.

[0023] By adopting the above-mentioned solution, this invention replaces the original thick film resistor with a metal heating wire. Relying on the characteristics of the metal heating wire, the ceramic sintering temperature can be higher and the heating performance is more stable. At the same time, the embedded installation method makes the installation of the metal heating wire simpler, greatly optimizes the manufacturing process, simplifies the manufacturing process, and reduces manufacturing costs. Attached Figure Description

[0024] Fig. 1 This is a structural schematic diagram of an embodiment of the present invention.

[0025] Fig. 2 This is a schematic diagram of the back structure according to an embodiment of the present invention.

[0026] Fig. 3 This is an exploded view of the structure of an embodiment of the present invention.

[0027] Fig. 4 This is a process flow diagram of an embodiment of the present invention. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0029] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0030] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection. They can refer to a mechanical connection or an electrical connection. They can refer to a direct connection or an indirect connection through an intermediate medium, and they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0031] like Figs. 1 to 4As shown, this embodiment provides an embedded integrated metal resistance ceramic heating element, including a ceramic body 1, a metal heating wire 2, and electrode plates 3. The ceramic body 1 is provided with a heating cavity 4 and is cup-shaped. An embedded groove 5 is opened on the back of the ceramic body 1. The metal heating wire 2 is ring-shaped and has a break (it can also be straight before insertion and can be inserted along the embedded groove). The metal heating wire 2 is inserted into the embedded groove 5 and filled by heating wire sealing material 6. At least two lead wires 7 are provided on the metal heating wire 2. The lead wires 7 extend to the bottom of the ceramic body 1. Two electrode plates 3 are provided at the bottom of the ceramic body 1. The electrode plates 3 are respectively connected to the corresponding lead wires 7.

[0032] In this embodiment, a metal heating wire 2 is used to replace the original thick film resistor. Relying on the characteristics of the metal heating wire 2, the ceramic sintering temperature can be higher and the heating performance is more stable. At the same time, the embedded installation method makes the installation of the metal heating wire 2 simpler, greatly optimizes the manufacturing process, simplifies the manufacturing process, and reduces manufacturing costs.

[0033] Furthermore, in order to securely install the electrode sheet 3, the end of the electrode sheet 3 in this embodiment is provided with a downwardly bent fixing foot 8, the bottom of the ceramic body 1 is provided with a groove 9, the fixing foot 8 is placed at the bottom of the groove 9, the groove 9 is filled with electrode sheet sealing material 10, and after solidification, the electrode sheet 3 can be fixed.

[0034] A fabrication process for an embedded integrated metal resistive ceramic heating element includes the following steps:

[0035] Step 1: Determine the ceramic forming process and main ceramic raw materials: Determine the ceramic forming process and main ceramic raw materials based on the application scenarios, functional requirements and product structure of the ceramic heating element product;

[0036] Step 2, Selection and fabrication of metal heating wire 2: Select a suitable metal material to fabricate the metal resistor based on the size, resistance value and other functional requirements of the ceramic heating element for the heating resistor;

[0037] Step 3: Ceramic heating element product production drawing design: Based on the structural design of the ceramic heating element product, combined with the ceramic molding process and the main ceramic raw materials and metal heating wires selected, the production drawing design of the product is carried out;

[0038] Step 4: Adjust and determine the ceramic formula: Adjust the ceramic formula to meet the functional requirements of the ceramic heating element product and facilitate the forming of the ceramic green body, and determine the corresponding ceramic shrinkage ratio;

[0039] Step 5: Ceramic mold making: According to the production drawing of the ceramic heating element and the ceramic shrinkage ratio, make a ceramic mold. Set a reserved space on the ceramic pot body 1 according to the required size of the metal heating wire 2 to form an embedded groove 5.

[0040] Step 6: Ceramic green body forming: Prepare ceramic green bodies according to the proposed forming process;

[0041] Step 7, Ceramic Firing: Select an appropriate firing process to fire the ceramic green body according to the functional requirements of the ceramic heating element, the main raw materials of the ceramic, and the ceramic green body forming process;

[0042] Step 8, Product Assembly: Embed the metal heating wire 2 into the inner groove 5 of the ceramic body 1, and then fill and seal it with heating wire sealant 6 and cure it.

[0043] Step 9, Vibration washing and polishing: Vibration washing and polishing are performed on the fired ceramic products to make the product surface smoother;

[0044] Step 10, Product Inspection and Testing: This includes product appearance and size inspection and product performance testing.

[0045] Its primary current application is in atomizing e-liquid in electronic cigarette products. The designed resistance is 0.33±0.05Ω, the atomization temperature is 250℃, the atomization time is 40 seconds per cycle, and the number of atomization cycles is no less than 100.

[0046] In step 1, hot pressing ceramic molding process is selected, and 95% alumina is selected as the main ceramic raw material;

[0047] In step 2, an etched mesh made of iron-chromium material is selected as the metal heating wire 2, with a length of 40.2 mm, a width of 2 mm, a thickness of 0.1 mm, and a resistance of 0.33±0.05Ω; the bottom electrode plate 3 is a 0.1 mm thick silver-plated copper sheet.

[0048] In step 3, the production drawing of the product was designed based on the properties of 95% alumina ceramic material and the size of the iron-chromium etched mesh; an embedded groove with a width of 0.3mm and a depth of 2mm was designed around the ceramic body; two grooves with a length of 5.2mm, a width of 1.2mm and a depth of 0.7mm were designed at the electrode plate, and a groove was designed at the pin line position to accurately install the metal heating wire;

[0049] In step 4, because the ceramic product has many grooves and a thin wall, the flowability of the ceramic slurry was fully considered when formulating the ceramic formula. Therefore, the final ceramic formula was determined to be 94% calcined alumina, 3% calcined talc, 3% Suzhou clay, plus 13% paraffin wax and 0.3% oleic acid, and the corresponding ceramic shrinkage ratio was determined to be 14%.

[0050] In step 5, a ceramic mold is made with a shrinkage rate of 14%;

[0051] In step 7, the ceramic green body is fired at a wax removal temperature of 900℃ and a sintering temperature of 1650℃. The final fired ceramic product has a complete appearance and its dimensions are within the tolerance range.

[0052] In step 9, the specific assembly steps of the product are as follows:

[0053] The first step is to embed the two electrode plates into the two grooves at the bottom of the ceramic body, and then fill and seal them with electrode plate sealant.

[0054] The second step is to embed the etched mesh (metal heating wire) into the embedded groove around the ceramic body 30 minutes after the first step is completed, and then fill and seal it with heating wire sealant. The electrode sheet sealant and the heating wire sealant are made of inorganic high temperature resistant adhesive, which can be cured naturally or at high temperature.

[0055] The third step is to use a laser welding device to weld the etched mesh (metal heating wire) leads onto the two electrode plates after the sealant has cured. This completes the assembly.

[0056] In step 10, product inspection and testing include:

[0057] a. Product appearance and size inspection (full inspection): After the ceramic pot is assembled, its size is checked by an automatic size inspection device and found to be within the design tolerance range;

[0058] b. Resistance value test (full inspection): After the ceramic pot is assembled, its resistance value is tested with a resistance testing instrument and found to be within the design tolerance range;

[0059] c. Performance Testing (10 samples): Simulated product application scenarios were tested. The results showed good heating effect, large smoke volume at 250℃, and excellent atomization effect. After 100 atomization cycles, the ceramic pot remained intact. The resistance was stable at room temperature (0.3544Ω~0.3567Ω) and at 250℃ (0.3702Ω~0.3744Ω), consistently within the design tolerance range. The test conclusion is that the product performed well in all functional tests, exhibiting stable performance, good reliability and consistency, and meeting the minimum service life and functional requirements of the product.

[0060] The above are merely preferred embodiments of the present invention and do not limit the scope of the patent. Any equivalent structural or procedural transformations made based on the description and drawings of the present invention, or direct or indirect applications in other related technical fields, are similarly included within the scope of patent protection of the present invention.

Claims

1. An embedded integrated metal resistive ceramic heating element and its preparation process, characterized in that: The device includes a ceramic body, a metal heating wire, and electrode plates. The ceramic body has a heating cavity and is cup-shaped. An embedded groove is formed on the back of the ceramic body. The metal heating wire is ring-shaped and has a break. The metal heating wire is inserted into the embedded groove and filled with heating wire sealing material. The metal heating wire has at least two lead wires that extend to the bottom of the ceramic body. Two electrode plates are provided at the bottom of the ceramic body, and the electrode plates are connected to the corresponding lead wires.

2. The embedded integrated metal resistive ceramic heating element and its preparation process as described in claim 1, characterized in that: The electrode sheet has a downwardly bent fixing foot at its end, and the bottom of the ceramic body has a groove. The fixing foot is placed at the bottom of the groove, and the groove is filled with electrode sheet sealing material.

3. A fabrication process for an embedded integrated metal resistive ceramic heating element, characterized in that: Includes the following steps: Step 1: Determine the ceramic forming process and main ceramic raw materials: Determine the ceramic forming process and main ceramic raw materials based on the application scenarios, functional requirements and product structure of the ceramic heating element product; Step 2, Metal heating wire selection and fabrication: Select appropriate metal materials to fabricate the metal resistor based on the size, resistance value and other functional requirements of the ceramic heating element for the heating resistor; Step 3: Ceramic heating element product production drawing design: Based on the structural design of the ceramic heating element product, combined with the ceramic molding process and the main ceramic raw materials and metal heating wires selected, the production drawing design of the product is carried out; Step 4: Adjust and determine the ceramic formula: Adjust the ceramic formula to meet the functional requirements of the ceramic heating element product and facilitate the forming of the ceramic green body, and determine the corresponding ceramic shrinkage ratio; Step 5: Ceramic mold making: According to the production drawing of the ceramic heating element and the ceramic shrinkage ratio, make a ceramic mold and set a reserved space on the ceramic pot body according to the required size of the metal heating wire to form an embedded groove. Step 6: Ceramic green body forming: Prepare ceramic green bodies according to the proposed forming process; Step 7, Ceramic Firing: Select an appropriate firing process to fire the ceramic green body according to the functional requirements of the ceramic heating element, the main raw materials of the ceramic, and the ceramic green body forming process; Step 8, Product Assembly: Embed the metal heating wire into the inner groove of the ceramic body, then fill and seal it with heating wire sealant and cure it. Step 9, Vibration washing and polishing: Vibration washing and polishing are performed on the fired ceramic products to make the product surface smoother; Step 10, Product Inspection and Testing: This includes product appearance and size inspection and product performance testing.

4. The fabrication process of an embedded integrated metal resistive ceramic heating element as described in claim 3, characterized in that: In step 1, hot pressing ceramic molding process is selected, and 95% alumina is selected as the main ceramic raw material.

5. The fabrication process of an embedded integrated metal resistive ceramic heating element as described in claim 4, characterized in that: In step 2, an etched mesh made of iron-chromium material is selected as the metal heating wire 2, with a length of 40.2 mm, a width of 2 mm, a thickness of 0.1 mm, and a resistance of 0.33±0.05Ω; the bottom electrode plate 3 is a 0.1 mm thick silver-plated copper sheet.

6. The fabrication process of an embedded integrated metal resistive ceramic heating element as described in claim 5, characterized in that: In step 3, a production drawing was designed for the product based on the properties of 95% alumina ceramic material and the size of the iron-chromium etched mesh. An embedded groove with a width of 0.3 mm and a depth of 2 mm was designed around the ceramic body. Two grooves with a length of 5.2 mm, a width of 1.2 mm, and a depth of 0.7 mm were designed at the electrode plate. A slot was also designed at the pin position to accurately install the metal heating wire.

7. The fabrication process of an embedded integrated metal resistive ceramic heating element as described in claim 6, characterized in that: In step 4, because the ceramic product has many grooves and a thin wall, the flowability of the ceramic slurry was fully considered when formulating the ceramic formula. Therefore, the final ceramic formula was determined to be 94% calcined alumina, 3% calcined talc, 3% Suzhou clay, plus 13% paraffin wax and 0.3% oleic acid, and the corresponding ceramic shrinkage ratio was determined to be 14%. In step 5, a ceramic mold is made with a shrinkage rate of 14%.

8. The fabrication process of an embedded integrated metal resistive ceramic heating element as described in claim 7, characterized in that: In step 7, the ceramic green body is fired at a wax removal temperature of 900℃ and a sintering temperature of 1650℃. The final fired ceramic product has a complete appearance and its dimensions are within tolerance.

9. The fabrication process of an embedded integrated metal resistive ceramic heating element as described in claim 8, characterized in that: In step 9, the specific assembly steps of the product are as follows: The first step is to embed the two electrode plates into the two grooves at the bottom of the ceramic body, and then fill and seal them with electrode plate sealant. The second step is to embed the metal heating wire into the embedded groove around the ceramic body 30 minutes after the first step is completed, and then fill and seal it with heating wire sealant. The electrode sheet sealant and the heating wire sealant are made of inorganic high temperature resistant adhesive, which can be cured naturally or at high temperature. The third step is to weld the metal heating wire leads onto the two electrode plates using a laser welding device after the sealant has cured. This completes the assembly.

10. The fabrication process of an embedded integrated metal resistive ceramic heating element as described in claim 9, characterized in that: In step 10, product inspection and testing include: a. Product appearance and size inspection: After the ceramic pot is assembled, its size is checked by an automatic size inspection device and found to be within the design tolerance range; b. Resistance value test: After the ceramic pot is assembled, its resistance value is tested with a resistance testing instrument and found to be within the design tolerance range; c. Performance testing of 10 samples: Simulated product application scenarios were tested. The results showed good heating effect, large smoke volume at 250℃, and good atomization effect. After 100 atomization cycles, the ceramic pot remained intact. The resistance was stable at room temperature (0.3544Ω~0.3567Ω) and at 250℃ (0.3702Ω~0.3744Ω), consistently within the design tolerance range. The test conclusion is that the product performed well in all functional tests, with stable performance, good reliability and consistency, and meets the minimum service life and functional requirements of the product.

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