Porous Ceramic Heating Body Fabrication for Uniform Heat Distribution
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Solution Overview
Problem
Porous ceramic heating bodies in prior art exhibit uneven heating due to the periphery of resistance wires or films being hotter than the rest of the body, leading to inefficient heating processes.
Innovation Solution
A method for fabricating a porous ceramic heating body involving a mixture of diatomaceous earth, pore-forming agents, nano-silica solution, deionized water, resistive slurry, and organic solvent, followed by ball-milling, defoaming, molding, drying, discharging of pore-forming agents, sintering, and electrode leading, which results in a uniformly heated composite with high heating efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heating wire or resistive slurry is applied to the surface of the porous ceramic body, then the porous ceramic body can be used as a heating source, but the periphery of the resistance wire or resistance heating film becomes relatively hotter resulting in uneven heating
Solution Approach 1:
The invention merges the heating function directly into the porous ceramic body by incorporating resistive slurry during the sintering process, rather than applying it as a separate surface layer. This integration ensures uniform heat generation throughout the entire heating body, eliminating the peripheral overheating issue caused by surface-applied heating elements.
Solution Approach 2:
The invention creates a composite heating body by combining porous ceramic material with resistive slurry during the sintering process. The resistive slurry is embedded within the ceramic matrix, forming a composite structure that provides both the porous characteristics needed for atomization and the resistive heating properties, with uniform heat distribution throughout the composite material.
2Productivity
If traditional surface heating methods are used, then the heating body can be manufactured with simple processes, but the heating efficiency is reduced due to uneven heating
Solution Approach 1:
The heating function is merged into the bulk of the porous ceramic body through co-sintering with resistive slurry, transforming the heating structure from a surface layer to a volumetric distributed system. This enables uniform energy distribution throughout the heating body, significantly improving heating efficiency and eliminating energy waste associated with peripheral overheating.
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 method ensures uniform heating of the entire porous ceramic heating body, overcoming the issue of uneven heating and achieving high heating efficiency, while allowing for simple and large-scale production.
Implementation Method 1
discharging of pore-forming agent: placing the green body obtained in the step D) into a graphite crucible and burying it into isolating powders, and then discharging the pore-forming agent of the green body buried in the isolating powders using a box furnace under normal pressure
Implementation Method 2
sintering: placing the green body obtained in the step E) into a graphite crucible and burying it into isolating powders, and then sintering the green body buried in the isolating powders using a box furnace under normal pressure, and the sintering atmosphere is oxygen
Implementation Method 3
resistive slurry accounting for 20-35%
Data Source
AI summary
A method for fabricating a porous ceramic heating body, and a method of fabricating a heating body. The method for fabricating includes, in sequence, mixing, ball-milling, defoaming, molding, and drying, pore-forming agent discharging, sintering, and electrode leading. The whole method is simple, and by using a box furnace to sinter the green body under an oxidizing atmosphere and normal pressure, the fabricated ceramic heating body is heated uniformly and the heating efficiency is high.