Ceramic Heater Structure with Reaction Zone for Air Tightness
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Solution Overview
Problem
Conventional ceramic structures in glow plugs experience a gap at the boundary between the ceramic substrate and the conductor layer, leading to leakage and reduced air tightness over time, which affects their durability and heat resistance.
Innovation Solution
A ceramic structure with a conductor layer containing a glass component, a brazing filler material covering the conductor layer's surfaces, and a reaction zone formed between the ceramic substrate, conductor layer, and brazing filler material, which prevents gap formation by reacting to create a strong, oxide-containing bond that enhances adhesion and air tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional ceramic structure with conductor layer and brazing filler material is used, then the glow plug can be manufactured with standard processes, but a gap forms at the boundary between ceramic substrate and conductor layer over time, causing leakage and reduced air tightness
Solution Approach 1:
The patent applies preliminary action by forming a reaction zone between the ceramic substrate, conductor layer, and brazing filler material before operational stresses occur. This reaction zone, created through controlled thermal and chemical reactions during manufacturing, pre-establishes a bonded interface that prevents gap formation during long-term operation, thereby maintaining air tightness over time.
Solution Approach 2:
The patent employs composite materials by creating a reaction zone that combines ceramic substrate, conductor layer with glass component, and brazing filler material into an integrated structure. This composite reaction zone exhibits enhanced adhesion properties and resistance to thermal cycling, preventing separation and gap formation at the boundaries during prolonged operation.
2Strength
If the boundary between ceramic substrate and conductor layer is simplified, then manufacturing complexity is reduced, but adhesion strength decreases leading to gap formation and leakage
Solution Approach 1:
The patent applies parameter changes by modifying the chemical and physical parameters of the boundary region through controlled reactions. The reaction zone involves thermal and chemical parameter changes that transform the interface properties, creating a graded transition region with enhanced adhesion strength while managing the complexity through controlled process parameters.
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 prevents gap formation between the ceramic substrate and conductor layer, ensuring stable long-term operation and improved air tightness, maintaining high heat resistance and durability of the ceramic heater and glow plug.
Implementation Method 1
a reaction zone of the ceramic substrate, the conductor layer, and the brazing filler material in a boundary region between the ceramic substrate, the conductor layer, and the brazing filler material
Implementation Method 2
a brazing filler material covering the surfaces, including the side surfaces, of the conductor layer
Implementation Method 3
a resistive element is buried in the ceramic substrate of the ceramic structure
Data Source
AI summary
The ceramic structure of the present invention includes a ceramic substrate, a conductor layer containing a glass component and disposed on a surface of the ceramic substrate, and a brazing filler material covering the surfaces, including the side surfaces, of the conductor layer. A reaction zone of the ceramic substrate, the conductor layer, and the brazing filler material located in a boundary region between the ceramic substrate, the conductor layer, and the brazing filler material.