Ceramic Heater with Partitioned Metal Support
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Solution Overview
Problem
Existing vehicle-mounted heating systems face challenges in rapidly raising temperature in extremely cold environments and are prone to thermal shock, leading to resistance variations and potential cracking in the joining portions of the heater and metal support member.
Innovation Solution
A heater design featuring a columnar ceramic body with a heat generating resistor, a tubular metal support member, and a lid body that separates spaces to prevent cold air ingress and thermal shock, using materials like silicon nitride ceramics and Ni-based alloys to enhance durability and insulation, and a brazing material for strong bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heater is used in extremely cold environments, then the heating function is needed, but thermal shock causes resistance variations and cracking in the joining portions
Solution Approach 1:
The patent divides the internal space of the metal support member into a front end-side space and a rear end-side space using a partition wall. This segmentation isolates the joining portion (located in the front end-side space) from the rear end-side space where temperature variations occur, thereby protecting the joining portion from thermal shock while maintaining overall structural integrity.
Solution Approach 2:
The partition wall acts as an intermediary barrier between the front end-side space (containing the joining portion) and the rear end-side space (exposed to temperature changes). This intermediary structure prevents direct thermal transmission to the joining portion, reducing thermal shock effects and resistance variations.
2Strength
If the metal support member is directly attached to the heater main body, then structural support is provided, but cold air ingress causes thermal shock to the joining portion
Solution Approach 1:
The metal support member's internal space is segmented into front and rear sections by the partition wall. This segmentation creates a protected zone (front end-side space) for the joining portion that is isolated from cold air ingress occurring in the rear end-side space, while the overall tubular structure maintains structural support functionality.
Solution Approach 2:
The partition wall serves as an intermediary barrier that prevents cold air from the rear end-side space from reaching the joining portion in the front end-side space. This intermediary structure blocks the harmful effect of cold air ingress while allowing the metal support member to maintain its structural support function.
3Stability of the object's composition
If the heater main body and metal support member are joined, then structural integrity is achieved, but resistance variations occur due to thermal expansion differences
Solution Approach 1:
The partition wall segments the metal support member's internal space, creating a thermally isolated environment for the joining portion. This segmentation prevents temperature variations in the rear end-side space from affecting the joining portion, thereby stabilizing electrical resistance while maintaining structural integrity through the brazed connection.
Solution Approach 2:
The partition wall acts as an intermediary that decouples the thermal environment from the joining portion. This intermediary structure allows the brazed joint to maintain structural integrity while protecting the electrical connection from resistance variations caused by thermal expansion differences between materials.
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 design effectively reduces resistance variations and protects the joining portions from thermal shock, ensuring consistent performance and extended lifespan by isolating the joining area from cold air and allowing controlled air pressure adjustments.
Implementation Method 1
a heat generating resistor embedded within the ceramic body
Implementation Method 2
protecting a joining portion from thermal shock
Implementation Method 3
a brazing material for strong bonding
Data Source
AI summary
A heater of the present disclosure includes: a columnar heater main body including a ceramic body, and a heat generating resistor embedded within the ceramic body, the heat generating resistor being drawn out at a rear end portion of the ceramic body to a side surface of the heater main body; a tubular metal support member attached to the side surface of the heater main body, the metal support member including a first region joined via a bonding material to the heater main body and a second region spaced away from the heater main body, the metal support member being configured so as to open toward the rear end portion; and a lid body which is disposed between the heater main body and the second region to separate front end-side space and rear end-side space of the heater.