Ceramic Heater Terminal Merging for Thermal Efficiency
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Solution Overview
Problem
Conventional ceramic heaters require an increased number of power feed terminals as the number of heating resistors increases, leading to enlarged support members and enhanced heat escape, which is undesirable for thermal efficiency.
Innovation Solution
A ceramic heater design featuring multiple heating resistor element groups with shared ends and a reduced number of power feed terminals, utilizing a three-phase power adjuster or DC/Single-phase power adjuster to independently control current through each group, thereby minimizing the number of terminals and reducing the support member's diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of heating resistors is increased to provide more heating zones with independent current control, then the heating control capability is improved, but the number of power feed terminals must be increased which enlarges the support member diameter and increases heat escape
Solution Approach 1:
Multiple heating resistor element groups share common power feed terminals. Specifically, multiple groups share a first power feed terminal and multiple groups share a second power feed terminal, reducing the total number of terminals required. This merging approach allows independent control of each heating zone while minimizing the support member diameter and associated heat escape.
Solution Approach 2:
Power feed terminals serve multiple functions by being shared among multiple heating resistor element groups. Each terminal is connected to multiple groups, allowing a single terminal to supply power to several heating zones simultaneously, thereby reducing the overall terminal count.
2Manufacturing precision
If the number of power feed terminals is increased to supply current to each heating resistor independently, then the heating precision is improved, but the support member diameter must be enlarged which increases the joining area and heat escape
Solution Approach 1:
The patent merges the function of multiple terminals into fewer terminals by having multiple heating resistor element groups share common terminals. This reduces the support member diameter while maintaining the ability to independently control heating in each zone through power adjustment means.
3Adaptability or versatility
If the support member diameter is enlarged to accommodate more power feed terminals, then more heating zones can be supported, but the heat escape from the base body via the support member increases
Solution Approach 1:
Multiple heating resistor element groups share common power feed terminals, which reduces the number of terminals and consequently the support member diameter. This merging strategy enables support for multiple heating zones while minimizing the heat escape path through the support member.
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
This design allows for independent control of heat generation across heating resistor groups while reducing the number of power feed terminals, minimizing heat escape and improving thermal uniformity and efficiency.
Implementation Method 1
a heating resistor included in the ceramic base body... each including one or more connected heating resistor elements... power feed terminals which respectively supply powers
Data Source
AI summary
The ceramic heater includes: a ceramic base body made of ceramic and having an upper surface on which an object to be heated is to be placed; a heating resistor included in the ceramic base body; and a cylindrical shaft made of ceramic and connected to a center part of a lower surface of the ceramic base body. The heating resistor includes six heating resistor element groups each including one or more connected heating resistor elements. Among these, three heating resistor element groups each have both ends each connected to the corresponding end of another one of the heating resistor element groups. Power feed terminals which respectively supply powers to a total of three ends composed of these both ends are connected to the total of three ends.