Ozone Generating Element Glass Ceramic Protective Layer
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Solution Overview
Problem
Conventional ozone generating elements experience a decrease in ozone generation due to degradation of the protective layer, primarily because glass-based protective films have low heat resistance and are prone to carbonization during electric discharge.
Innovation Solution
The use of a protective layer made from glass ceramic, which provides improved heat resistance and reduces the likelihood of carbonization, along with co-firing with the dielectric and electrode layers to enhance structural integrity and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a glass-based protective film is used to cover the discharge electrode, then the electrode is protected from direct exposure, but the protective film degrades at high temperatures causing carbonization of the electrode and decreased ozone generation
Solution Approach 1:
The patent changes the material parameter of the protective layer from glass to glass ceramic, which fundamentally alters the thermal properties. Glass ceramic maintains the protective function while providing superior heat resistance, preventing degradation at the high temperatures generated during electric discharge operation.
Solution Approach 2:
The patent employs glass ceramic, which is a composite material combining crystalline phases with glassy matrices. This composite structure provides both the protective characteristics of glass and the high-temperature stability of ceramics, resolving the contradiction between protectiveness and heat resistance.
2Ease of manufacture
If glass-based protective film is used, then manufacturing is simpler, but the material degrades during operation leading to carbonization and loss of ozone generation capability
Solution Approach 1:
By changing the material from glass to glass ceramic, the patent maintains ease of application through similar processing techniques while dramatically improving operational reliability. The glass ceramic can be applied using conventional methods but provides sustained performance without degradation during prolonged operation.
3Productivity
If co-firing of dielectric layer and protective layer is implemented, then structural integrity is enhanced and manufacturing efficiency is improved, but process complexity increases
Solution Approach 1:
The patent merges the firing processes for the dielectric layer and protective layer into a single co-firing operation. This consolidation eliminates separate processing steps, reduces manufacturing time, and improves overall efficiency while the enhanced structural integration provides long-term operational benefits.
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 approach significantly reduces and prevents the decrease in ozone generation by protecting the discharge electrode from carbonization and allows for a more robust and cost-effective manufacturing process with reduced steps and material costs.
Implementation Method 1
A method for manufacturing the ozone generating element includes a step of co-firing of the dielectric layer with the protective layer
Implementation Method 2
a high alternating-current voltage is applied between the discharge electrode and the induction electrode to generate electric discharge around the discharge electrode. Thus, ozone is generated from an oxygen around the discharge electrode
Data Source
AI summary
An ozone generating element includes a laminated body including stacked dielectric layers. A discharge electrode is provided on a first of the dielectric layers. An induction electrode is provided on a second of the dielectric layers that is opposed to the discharge electrode with the first dielectric layer interposed therebetween. A protective layer is arranged on the first dielectric layer so as to cover the discharge electrode, and includes a glass ceramic.