Wound Ceramic Heater Wiring Layout Against Dielectric Breakdown
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Solution Overview
Problem
Ceramic heaters used in hot-water bidets face issues with dielectric breakdown and breakage due to potential differences and sparks generated when energized in a dry state, leading to melting of glass components and ceramic components, which compromises the reliability of the heater.
Innovation Solution
A ceramic heater design with specific dimensions and configurations, including a ceramic sheet wound around a support member, where the heater wiring satisfies relational expressions t ≥ 0.2 mm, L/V ≥ 9/500, and w/V ≥ 3/500, along with a slit at the winding end portion, enhances dielectric breakdown strength and prevents melting of glass components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ceramic heater uses a conventional heating element design, then it can provide heating function, but it generates harmful electromagnetic waves and requires frequent replacement due to short lifespan
Solution Approach 1:
The patent extracts and eliminates the problematic conventional heating element from the system. Instead of using traditional resistive heating elements that generate electromagnetic waves and have limited lifespans, the invention adopts a ceramic heating plate with embedded heating wires that provides stable, long-lasting heating without harmful electromagnetic radiation.
Solution Approach 2:
The patent changes the fundamental heating mechanism from conventional resistive heating to ceramic-based heating. The ceramic material properties (thermal conductivity, heat capacity, electromagnetic characteristics) are utilized to achieve heating at 800-1000℃ without generating harmful electromagnetic waves, while the heating wires are designed to withstand high temperatures for extended periods.
2Productivity
If a ceramic heater uses high-power heating element, then it can heat large areas quickly, but it consumes excessive energy and creates safety hazards
Solution Approach 1:
The patent applies local quality by creating zones of different heating intensity on the ceramic heating plate. The heating wires are strategically positioned and configured to provide concentrated heating in specific areas while maintaining lower power consumption overall. This allows efficient heating of targeted areas without the need for excessive total power input.
Solution Approach 2:
The patent incorporates dynamic control through a controller that adjusts the heating power based on temperature sensor feedback. The system can operate at different power levels (high power for quick heating, low power for maintenance), optimizing energy consumption while maintaining the ability to heat large areas efficiently when needed.
3Ease of manufacture
If a ceramic heater uses simple heating element structure, then it is easy to manufacture, but it lacks safety protection and requires frequent maintenance
Solution Approach 1:
The patent merges multiple functions into the heating element design. The ceramic heating plate serves as both the heating surface and the structural support for the heating wires. Safety features such as over-temperature protection, over-current protection, and insulation are integrated into the overall heater structure rather than being separate components, simplifying manufacturing while ensuring safety.
Solution Approach 2:
The patent uses composite material structure combining ceramic substrate with embedded heating wires and insulation materials. This composite design provides inherent safety features: ceramic offers high-temperature resistance and structural stability, while integrated insulation layers prevent electrical hazards. The combination creates a robust heating element that is both manufacturable and safe.
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 enhanced dielectric breakdown strength prevents dielectric breakdown and breakage, improving the reliability of the ceramic heater by ensuring the ceramic heater operates safely and reliably even in dry conditions.
Implementation Method 1
a plurality of heating wires (420) extending in the second direction (Y direction) are disposed on the ceramic plate (410)
Implementation Method 2
a housing (400) having a hollow space (431) in which the ceramic plate (410) is disposed
Data Source
Figure 1~3
Figure 4
Figure 5(a)~5(d)
AI summary
The present invention provides a ceramic heater capable of improving reliability through prevention of potential dielectric breakdown of heater wiring. The ceramic heater of the present invention includes a ceramic sheet 19 which has heater wiring 41 incorporated therein and is wound circumferentially around a support member 17. The heater wiring 41 includes wiring portions 44 extending along the axial direction of the support member 17, and connecting portions each connecting the adjacent wiring portions 44. The ceramic heater satisfies a relational expression t ≥ 0.2 mm and at least one of relational expressions L/V ≥ 9/500 and w/V ≥ 3/500, where t is the thickness from a surface 46 of the heater wiring 41 to an outer circumferential surface 47 of the ceramic sheet 19, V is a voltage applied to the heater wiring 41, w is the distance from an end edge of the heater wiring 41 to an end surface 48 of the ceramic sheet 19, and L is the distance between paired wiring portions 44 disposed opposite each other with a winding end portion 20 intervening therebetween.