Ceramic Heater Connection Structure for Oxidation and Heat Insulation
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Solution Overview
Problem
Existing ceramic structures with internal conductors exposed to external portions face issues such as oxidation and inefficient heat transfer due to conventional machining methods that do not effectively manage the transition from internal to external connections.
Innovation Solution
A ceramic structure design with a base body and internal conductor featuring a first space and second space, where the second space is smaller than the first, and a conductor layer extending along the surface, along with a manufacturing method involving ceramic green sheets, conductor placement, and controlled opening formation to enhance connection and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional machining methods are used to expose internal conductors, then the manufacturing process is simple, but oxidation occurs and heat transfer efficiency is poor
Solution Approach 1:
The space is divided into a first space (larger cross-sectional area) and a second space (smaller cross-sectional area) along the depth direction. This segmentation allows the internal conductor to be exposed in a controlled manner, reducing oxidation risk while maintaining manufacturing feasibility through staged opening formation.
Solution Approach 2:
The patent transitions from conventional 2D surface exposure to a 3D multi-space structure. By creating stacked first and second spaces with different cross-sectional areas along the depth direction, the internal conductor is exposed more effectively while maintaining insulation, resolving the contradiction between oxidation resistance and manufacturing simplicity.
2Reliability
If the space cross-sectional area is constant in the depth direction, then manufacturing is easier, but heat insulation performance is insufficient
Solution Approach 1:
The space is segmented into multiple regions (first space and second space) with different cross-sectional areas. The first space has a larger area for heat dissipation, while the second space has a smaller area for insulation, creating an optimized thermal management structure without excessive complexity.
Solution Approach 2:
Different regions of the space have different cross-sectional areas tailored to their specific functions. The first space region has a larger area for heat transfer, while the second space region has a smaller area for insulation, implementing local quality optimization to resolve the contradiction between heat insulation performance and structural complexity.
3Ease of operation
If the internal conductor is exposed to the external portion, then connection is enabled, but oxidation and damage risk increase
Solution Approach 1:
The exposure path is segmented into first and second spaces with different characteristics. The first space provides initial exposure while the second space provides protected exposure with smaller cross-sectional area, enabling connection capability while reducing oxidation and damage risk through controlled, staged exposure.
Solution Approach 2:
The multi-space structure acts as an intermediary between the internal conductor and the external environment. By creating a staged exposure path through first and second spaces, the conductor is connected to external portions while being protected from direct environmental exposure, reducing oxidation and damage risk.
4Manufacturing precision
If machining is performed after firing, then precision is high, but the base body is prone to damage
Solution Approach 1:
The opening formation is performed as a preliminary action during the green sheet stacking stage, before the firing process. By forming the first and second spaces in the unfired green sheets, the subsequent firing process consolidates the structure without requiring damaging post-fire machining, achieving both precision and integrity.
Solution Approach 2:
The space structure is preliminarily formed in the green sheets before firing. This preliminary formation allows precise opening creation when the material is more compliant, and the subsequent firing process strengthens the base body while maintaining the pre-formed openings, resolving the contradiction between precision and integrity.
Data Source
AI summary
A heater includes a base body and an internal conductor. The base body is made of ceramic. The internal conductor is located inside the base body and includes a connection portion. The base body includes a space extending from the connection portion to a lower surface of the base body. The space includes a first space and a second space. The first space contacts with the connection portion. The second space connects the first space and an outer side of the lower surface of the base body, and is smaller than the first space in a planar perspective of the lower surface of the base body.