Ceramic Block Electrode Stress Reduction
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Solution Overview
Problem
Ceramic blocks with built-in electrodes face issues of cracking due to residual stress at the connection points between the sheet electrode and the drawn-out conductor, which affects the adsorption force and thermal responsiveness.
Innovation Solution
A ceramic block design where a cylindrical thin film drawn-out conductor is connected perpendicularly to the sheet electrode, reducing residual stress and preventing cracking, along with a manufacturing method involving lamination and firing of insulating ceramic sheets with a sheet electrode and through hole for conductor attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the distance from the bearing surface to the sheet electrode is reduced to improve adsorption force and thermal responsiveness, then the mechanical strength and dielectric strength of the ceramic sheet deteriorate due to thinning
Solution Approach 1:
The invention introduces a through-hole structure that extends vertically through the ceramic sheet, allowing the conductor to pass through the thickness direction. This dimensional approach enables electrical connection without requiring lateral extension that would compromise the ceramic sheet's structural integrity, thus maintaining strength while achieving thin design for improved thermal responsiveness.
Solution Approach 2:
The conductor is nested within the through-hole of the ceramic sheet, with the insulating member surrounding the conductor. This nested configuration allows the conductor to be embedded deep within the ceramic structure, achieving close proximity to the bearing surface for improved thermal responsiveness while the insulating member protects the conductor and maintains the ceramic sheet's mechanical strength.
2Speed
If the distance from the bearing surface to the sheet electrode is reduced to improve adsorption force and thermal responsiveness, then the dielectric strength of the ceramic sheet deteriorates due to thinning
Solution Approach 1:
An insulating member is introduced as an intermediary element that surrounds the conductor within the through-hole. This insulating member acts as a mediator that prevents electrical breakdown between the conductor and the ceramic sheet, thereby maintaining dielectric strength even when the ceramic sheet is thinned to improve thermal responsiveness.
Solution Approach 2:
The insulating member is nested around the conductor within the through-hole, creating a protected pathway for electrical connection. This nested configuration ensures that the conductor is electrically isolated from the ceramic sheet walls, maintaining dielectric strength while allowing the ceramic sheet to be thinner for improved thermal responsiveness.
3Stability of the object's composition
If a conventional connection method is used between the sheet electrode and the drawn-out conductor, then residual stress concentrates at the connecting sections, but cracking becomes inevitable due to differential thermal expansion and contraction
Solution Approach 1:
The insulating member serves as an intermediary that surrounds the conductor within the through-hole, distributing the stress from differential thermal expansion and contraction. This intermediary structure prevents stress concentration at any single point, thereby preventing cracking while maintaining electrical connectivity between the sheet electrode and the drawn-out conductor.
Solution Approach 2:
The insulating member acts as a flexible protective shell around the conductor, accommodating the differential thermal expansion and contraction between the ceramic sheet and the conductor. This flexible enclosure allows for thermal cycling without creating rigid stress concentrations that would lead to cracking, thus improving crack resistance while maintaining electrical connectivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces the likelihood of cracking in thin ceramic sheets and electrodes, enhancing the mechanical strength and thermal responsiveness of the ceramic block while maintaining electrical connectivity.
Implementation Method 1
The ceramic block is formed by firing laminated insulation ceramic sheets
Implementation Method 2
a drawn-out conductor for supplying voltage to the sheet electrode, the drawn-out conductor extending through the second insulating ceramic sheet and being connected to the inner edge of the sheet electrode
Data Source
AI summary
A ceramic block with a built in electrode, including a first insulating ceramic sheet having a bearing surface, a sheet electrode having an inner edge and extending generally parallel to the bearing surface, a second insulating ceramic sheet disposed to enclose the sheet electrode between the second insulating ceramic sheet and the first insulating ceramic sheet, and a cylindrical, thin film shaped drawn-out conductor perpendicularly connected to the inner edge of the sheet electrode to supply voltage to the sheet electrode. The drawn-out conductor is attached to the inner wall of a through hole of the second insulating ceramic sheet, and an insulating ceramic shaft is packed into the through hole.