Fluid heating ceramic heater
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Solution Overview
Problem
Ceramic heaters used in warm water washing systems face issues with scale adhesion due to hard water, which can lead to clogging, and existing coatings that thicken to improve durability hinder heat conduction.
Innovation Solution
A tubular ceramic heater with an outer glass-based coating layer and a thinner inner glass-based coating layer, both with surface roughness of 0.5 µm or less, to prevent scale adhesion while maintaining heat conduction efficiency and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coating thickness of the coating layer is increased to secure durability, then the durability of the coating layer is improved, but the heat conduction efficiency deteriorates
Solution Approach 1:
The coating layer is divided into two distinct segments: an outer coating layer with thickness of 5-20 μm for durability and scale resistance, and an inner coating layer with thickness of 1-5 μm for heat conduction. This segmentation allows each layer to optimize its function independently, resolving the contradiction between durability and heat conduction efficiency.
Solution Approach 2:
Different regions of the coating structure are assigned different thicknesses and properties. The outer surface has a thicker coating for durability, while the inner surface near the heat generation resistor has a thinner coating for efficient heat transfer. This local differentiation of quality resolves the contradiction by optimizing each region for its specific function.
2Object-affected harmful factors
If the coating thickness is increased to prevent scale adhesion, then the scale resistance is improved, but the heat transfer to fluid deteriorates
Solution Approach 1:
The coating is segmented into outer and inner layers with different thicknesses optimized for their respective functions. The outer layer (5-20 μm) provides scale resistance, while the inner layer (1-5 μm) maintains heat transfer efficiency to the fluid, resolving the contradiction between scale prevention and heat transfer.
Solution Approach 2:
The coating thickness is locally optimized: thicker at the outer surface for scale resistance and thinner at the inner surface for heat transfer. This local quality differentiation allows the system to simultaneously achieve both scale adhesion prevention and efficient heat transfer to the fluid.
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
Effectively suppresses scale adhesion and enhances heat transfer to the fluid while ensuring the durability of the outer coating layer, preventing clogging and maintaining efficient water temperature increase.
Implementation Method 1
a tubular ceramic body having a heat generation resistor
Implementation Method 2
an outer coating layer containing glass as a main component and coating an outer peripheral surface of the ceramic body; and an inner coating layer containing glass as a main component and coating an inner peripheral surface of the ceramic body
Data Source
Figure 1~2
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AI summary
A fluid heating ceramic heater can suppress adhesion of scale to a surface of the ceramic heater over an extended time period, and efficiently conduct heat generated from a heat generation resistor to fluid. The ceramic heater has a ceramic body, an outer coating layer and an inner coating layer. The ceramic body has a heat generation resistor. The outer coating layer and the inner coating layer contain glass as a main component and coat a surface of the ceramic body. The outer coating layer and the inner coating layer are formed so that the inner coating layer is thinner than the outer coating layer.