Conductive Ceramic Heating Element with Integrated Sensor
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Solution Overview
Problem
Existing heating elements face challenges in efficient low-cost mass production and accurate temperature measurement, particularly in ensuring reliable thermal contact and separate electrical insulation between heating and temperature sensor units.
Innovation Solution
A heating element comprising a heating unit and a temperature sensor unit, both made from epoxy-based or glass-based compositions or sol-gel solutions with up to 90% conductive powders, are electrically insulated and mechanically supported by a heat transfer unit, allowing for efficient production and accurate temperature measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional temperature sensor is arranged next to or inside the heat transfer block using a heat resistive foil, then the temperature measurement is provided, but the manufacturing complexity and cost increase due to separate assembly steps and additional components
Solution Approach 1:
The heating element and temperature sensor are integrated into a single monolithic structure formed from a single piece of conductive ceramic material through sintering. The heating element comprises conductive ceramic material with embedded heating conductors, while the temperature sensor comprises the same or similar conductive ceramic material with embedded sensor elements. This merging eliminates separate assembly steps, reduces manufacturing complexity, and lowers production costs while maintaining accurate temperature measurement capability.
Solution Approach 2:
The conductive ceramic material serves multiple functions simultaneously: it provides the structural matrix for both the heating element and temperature sensor, acts as a thermal conductor for heat distribution, provides electrical insulation between heating and sensing circuits, and enables direct temperature measurement at the heat transfer interface. This multi-functionality reduces the number of components needed and simplifies the overall device structure.
2Reliability
If the heating unit and temperature sensor are provided as separate units, then electrical insulation can be ensured, but the manufacturing efficiency and production cost are reduced
Solution Approach 1:
The heating element and temperature sensor are manufactured as a single integrated unit from one piece of conductive ceramic material using a unified sintering process. The conductive ceramic material inherently provides electrical insulation between the heating conductors and temperature sensor elements while maintaining thermal conductivity for efficient heat transfer. This integration maintains reliable electrical insulation through material properties rather than mechanical separation, thereby significantly improving manufacturing efficiency and productivity.
3Power
If conventional wire coils are used for heating elements, then the heating function is provided, but the manufacturing cost and production complexity increase due to manual winding and assembly processes
Solution Approach 1:
The manual mechanical process of winding wire coils is replaced by embedding pre-formed heating conductors into the conductive ceramic matrix during the sintering process. The heating conductors are positioned within molds or fixtures before sintering, and the ceramic material is formed around them in a single automated manufacturing step. This substitution of mechanical winding with a ceramic forming process dramatically simplifies manufacturing, enables mass production, and reduces labor costs while maintaining the required heating power output.
4Loss of energy
If pressure is applied to ensure good thermal contact between the heating element and aluminium block, then thermal contact is improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The heating element and heat transfer block are both made from the same conductive ceramic material with matching thermal and mechanical properties. This homogeneity ensures uniform thermal contact and heat distribution across the interface without requiring additional pressure application or complex mounting mechanisms. The material's inherent properties provide consistent thermal coupling, eliminating the need for separate pressure application steps and reducing assembly complexity.
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 enables efficient, low-cost mass production of heating elements with improved thermal performance and accurate temperature measurement, ensuring reliable operation across various applications.
Implementation Method 1
a composition comprising a sol-gel solution in which up to about 90% of said solution is a conductive powder in a uniform stable dispersion
Implementation Method 2
the heating unit comprising a first composition, the first composition comprising an epoxy-based or glass-based composition or a composition comprising a sol-gel solution in which up to about 90% of said solution is a conductive powder
Data Source
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AI summary
The present invention concerns: A heating element (10) comprising a heating unit (12), a heat transfer unit (14) and a temperature sensor unit (16), the heating unit comprising a first composition, the first composition comprising an epoxy-based or glass-based composition or a composition comprising a sol-gel solution in which up to about 90% of said solution is a conductive powder in a uniform stable dispersion and said solution conductive powder is a member selected from the group consisting of metals, ceramics, interceramics and semi-conductors and the temperature sensor comprising a second composition, the second composition comprising an epoxy-based or glass-based composition or a composition comprising a composition comprising a sol-gel solution in which up to about 90% of said solution is a conductive powder in a uniform stable dispersion and said solution conductive powder is a member selected from the group consisting of metals, ceramics, interceramics and semi-conductors, the heating unit and the temperature sensor unit being provided as two units, which are electrically insulated from each other and which are mechanically supported by the heat transfer unit. The invention also relates to a method of heating an appliance and to a method of providing a heating element.