Ceramic Heater Coupon Connector Layout for Stable Fluid Flow
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Solution Overview
Problem
Existing ceramic heater coupons face issues with surface-mounted electrical connections being prone to damage and disrupting fluid flow in handheld appliances, as these connections are exposed and lack stability.
Innovation Solution
A ceramic heater coupon design featuring connectors with first and second connecting arms that span the thickness of the ceramic block, providing a stable and robust electrical connection point, with recesses for mechanical and electrical attachment, and optional strain relief to manage thermal mismatch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surface-mounted electrical connections are used on the ceramic heater coupon, then electrical connection is achieved, but the connection is prone to damage and disruption to fluid flow
Solution Approach 1:
The connector transitions from surface-mounted (2D) connections to through-thickness (3D) connections by extending connecting arms from both the first and second surfaces of the ceramic heater coupon to meet at the heater trace location, creating a robust three-dimensional connection structure that eliminates fluid flow disruption while maintaining electrical connectivity
Solution Approach 2:
The connecting arms are recessed into the ceramic heater coupon thickness, with the first connecting arm recessed from the first surface and the second connecting arm recessed from the second surface, nesting the connection structure within the ceramic body to minimize protrusion and fluid flow interference
2Ease of manufacture
If surface-mounted electrical connections are made proud of the heater coupon surface, then electrical connection is established, but the connection points are vulnerable to damage
Solution Approach 1:
The connector design incorporates recesses in the ceramic heater coupon that accommodate the connecting arms, providing mechanical protection and strain relief before damage can occur. The recessed structure cushions the connecting arms against external forces and thermal mismatch stresses
Solution Approach 2:
The connector utilizes thermal expansion parameter changes by allowing the connecting arms to expand and contract within the recessed spaces during thermal cycling, accommodating differential thermal expansion between the ceramic heater coupon and metal connecting arms without causing failure
3Stability of the object's composition
If connectors are placed at the end of the ceramic block, then alignment and robustness are improved, but the connector may interfere with fluid flow path
Solution Approach 1:
The connector is segmented into two separate connecting arms positioned at opposite surfaces of the ceramic heater coupon, allowing each arm to be independently optimized for alignment stability while the combined structure minimizes fluid flow interference compared to a single large end-mounted connector
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 enhances the reliability of electrical connections while minimizing disruption to fluid flow, ensuring a robust and stable connection that maintains thermal efficiency and accuracy in temperature sensing.
Implementation Method 1
a heater having a ceramic heater coupon... at least one heater trace formed within the ceramic block
Data Source
AI summary
A heater coupon including a ceramic block having a first surface and a second surface, at least one heater trace formed within the ceramic block and a connector for electrically connecting the at least one heater trace to an external wire wherein the connector comprises a first connecting arm for connecting with respect to the first surface of the ceramic block and a second connecting arm for connecting with respect to the second surface of the ceramic block. The connector may be located at an end of the ceramic block. The ceramic block may be formed from a plurality of layers of ceramic material. The at least one heater trace may be screen printed onto one of the layers of ceramic sheet that form the ceramic block. The ceramic block may be provided with a first recess for accommodating the first connecting arm and a second recess for accommodating the second connecting arm.