Hybrid Electrode Assembly for High-Temperature Ionization
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Solution Overview
Problem
Conventional electrode arrangements for ionization devices face challenges such as high reject rates due to surface flatness requirements, limited operating temperatures, and incompatibility with explosive environments, leading to increased manufacturing costs and restricted applications.
Innovation Solution
A hybrid resistance carrier is used, combining a plastic base carrier with a ceramic carrier, allowing for the use of conventional resistance pastes that can withstand higher temperatures and reducing the risk of short circuits, while maintaining electrical integrity and enabling use in potentially explosive environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional screen printing with polymer-based resistor paste is used on plastic substrate, then processing temperature can be kept below 250°C, but operating temperature is limited to below 80°C and resistance value changes continuously at higher temperatures
Solution Approach 1:
The patent uses a composite substrate combining plastic and ceramic materials. The ceramic portion allows the resistor paste to be fired at high temperatures (850°C) while the plastic portion remains below its melting point, enabling the use of conventional high-temperature resistor pastes on a partially plastic substrate. This composite structure resolves the contradiction between processing temperature and resistance stability.
2Manufacturing precision
If surface flatness requirements are enforced to ensure consistent resistor track thickness, then manufacturing precision is improved, but reject rate increases to up to 50%
Solution Approach 1:
The patent applies different quality requirements to different regions of the substrate. The ceramic carrier portion is manufactured with high flatness precision for resistor printing, while the plastic base carrier has relaxed flatness tolerances. This local differentiation allows the overall product to meet functional requirements without subjecting the entire substrate to stringent flatness controls, thereby reducing reject rates.
3Ease of manufacture
If polymer-based resistor paste is used to accommodate plastic substrate temperature limits, then processing is simplified, but the electrode arrangement becomes unsuitable for ATEX environments due to short-circuit behavior
Solution Approach 1:
By combining plastic and ceramic in a hybrid substrate, the invention enables the use of conventional high-temperature resistor pastes that can withstand ATEX environment temperatures without short-circuiting. The ceramic portion provides the necessary thermal stability while the plastic portion maintains ease of manufacturing, thus expanding application versatility without sacrificing manufacturability.
4Reliability
If conventional high-temperature resistor paste is used directly on plastic substrate, then resistance value stability is improved, but the plastic substrate deforms or melts due to excessive processing temperature
Solution Approach 1:
The hybrid substrate structure allows the ceramic carrier to bear the high firing temperature (850°C) required for conventional resistor paste processing, while the plastic base carrier remains protected and maintains its structural integrity. The ceramic acts as a thermal barrier and functional platform, enabling high-temperature processing without damaging the plastic components.
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 hybrid carrier design significantly reduces manufacturing costs and scrap rates, allows for efficient ion generation across a wide voltage range, and ensures reliable operation in diverse environments, including those subject to ATEX regulations.
Implementation Method 1
the ceramic support can be produced comparatively easily and cost-effectively with a high-quality, flat surface that is particularly easy to print evenly
Implementation Method 2
specifying an electrode arrangement with a hybrid resistance carrier, which has a plastic base carrier and a ceramic carrier, which are connected to one another
Implementation Method 3
an ionization device is used to generate ions and can also be referred to as an ionizer or ioniser
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to an electrode arrangement (1) for an ionization device, a method for manufacturing an electrode arrangement (1), a base carrier (2), a high-voltage resistance arrangement (3), and an electrode (6) for an electrode arrangement (1) according to the invention. The present invention is based on the general concept of providing an electrode arrangement (1) with a hybrid resistance carrier comprising a plastic base carrier (2) and a ceramic carrier (4) which are connected to one another, in particular by material bonding, positive locking, force-locking, and/or bonding, wherein electrodes (6) of the electrode arrangement (1) are fixed to the plastic base carrier (2).