Embedded Terminal Board Structure for Ceramic Heater Reliability

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing board-like structures and heater systems face challenges in efficiently connecting and distributing power to resistance heating elements, leading to issues with heat distribution and thermal stress, which can result in reduced reliability and increased risk of damage.

Innovation Solution

A board-like structure comprising an insulating base body with a resistance heating element and terminal members that include an insulating terminal base part and a conductor layer, where the terminal members are partially embedded within the base body and exposed on the lower surface, allowing for efficient power connection and reducing thermal stress through optimized conductor placement and material selection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional power supply structures are used to connect to ceramic heaters, then power can be supplied to the heating element, but thermal stress increases and reliability decreases

Engineering Contradiction:

Improvereliability of power distributionVSAvoidthermal stress

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a terminal member as an intermediary component between the external power supply and the internal conductor. This terminal member includes an insulating terminal base part and a conductor layer, creating a buffered connection that reduces direct thermal stress on the ceramic heater while maintaining electrical connectivity. The terminal member acts as a mediator that absorbs and distributes thermal and mechanical stresses.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The terminal member is constructed as a composite structure combining an insulating terminal base part (made of insulating material) and a conductor layer (made of conductive material). This composite design allows the structure to simultaneously provide electrical conduction, thermal insulation, and mechanical strength, thereby reducing thermal stress concentration while maintaining power distribution functionality.

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If the terminal member is partially embedded in the base body, then structural integrity improves, but manufacturing complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing process

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The terminal member is partially embedded within the insulating base body, creating a nested structure where the conductor layer and terminal base part are positioned inside the base body cavity. This nesting arrangement improves structural integrity by anchoring the terminal member firmly while allowing it to remain exposed at the lower surface for electrical connection. The nested design provides stability without requiring complex external mounting structures.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Productivity

If the conductor layer is positioned on the surface of the terminal base part, then electrical connection efficiency improves, but thermal stress concentration increases

Engineering Contradiction:

Improvepower distribution efficiencyVSAvoidthermal stress concentration

Core Design Contradiction:

ProductivityVSStress or pressure

Solution Approach 1:

The conductor layer is positioned specifically on the surface of the terminal base part at the lower surface region, creating a localized conductive path. This local quality arrangement ensures efficient electrical connection at the connection point while the insulating terminal base part maintains thermal insulation in other areas. The conductor layer's surface positioning optimizes electrical contact without causing widespread thermal stress concentration, as the insulating base part distributes and isolates thermal loads.

Inventive Principle:

Principle #3Local quality

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 power distribution to the heating element, reduces thermal stress, and improves the structural integrity of the board-like structure, leading to more efficient heat transfer and prolonged component lifespan.

Implementation Method 1

The internal conductor is a resistance heating element

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS11856659B2Board-like structure and heater system

Publication Date: 2023.12.26 KYOCERA CORP

AI summary

A board-like structure includes a base body, an internal conductor, and a terminal member. The base body is an insulating member including an upper surface and a lower surface on an opposite side to the upper surface. The internal conductor runs along the upper surface and the lower surface inside the base body. The terminal member is at least partially located inside the base body, is exposed to an external portion of the base body at the lower surface, and is electrically connected to the internal conductor. The terminal member includes an insulating terminal base part and a conductor layer on a surfaces of the terminal base part.