Square Ceramic Heating Element Structure for Stable Temperature Zones
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Solution Overview
Problem
Existing ceramic electric heating elements suffer from inconsistent temperature zones due to gradual movement of temperature zones during use, leading to reduced product strength and shortened service life.
Innovation Solution
A square block-type ceramic electric heating element with a specific layered structure comprising an outer conductive layer, outer resistive layer, inner insulating layer, and inner insulating reinforcement layer, allowing for sintering in any orientation and eliminating the longitudinal slot, thus ensuring controlled temperature zones and improved product strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a longitudinal slot is provided in the ceramic body to control temperature zones, then the temperature control is improved, but the product strength is reduced and quality defects occur
Solution Approach 1:
The patent removes the longitudinal slot from the ceramic body entirely, extracting the problematic feature that caused strength reduction and quality defects. Instead of having a slot extending through the ceramic body, the temperature control is achieved through the layered structure configuration without requiring a through-slot, thereby maintaining product strength while still enabling temperature zone control.
Solution Approach 2:
The patent applies local quality by creating different temperature zones through the layered structure (outer conductive layer, outer resistive layer, inner insulating layer, and inner insulating reinforcement layer) rather than relying on a longitudinal slot. The temperature control is achieved locally through the thermal properties and arrangement of different layers, eliminating the need for a through-slot that compromised structural integrity.
2Duration of action of stationary object
If a functional layered structure is used to control temperature zones, then the service life is prolonged, but the temperature zones become inconsistent during use due to gradual movement
Solution Approach 1:
The patent employs a nested layered structure where the inner insulating reinforcement layer is positioned within the outer resistive layer, and the inner insulating layer is positioned within the outer conductive layer. This nested arrangement creates interlocking layers that resist relative movement, maintaining temperature zone consistency throughout the service life while prolonging the element's durability.
Solution Approach 2:
The patent uses a composite layered structure combining different materials with distinct thermal and mechanical properties. The outer conductive layer, outer resistive layer, inner insulating layer, and inner insulating reinforcement layer work together as a composite system where each layer contributes to both temperature control and structural stability, preventing layer movement and maintaining consistent temperature zones during extended use.
3Ease of manufacture
If a vertical-state sintering process is used, then the ceramic body can be sintered from top to bottom, but the processing efficiency is reduced and product pass rate is limited
Solution Approach 1:
The square block-type ceramic heating element design provides universality in the sintering process, allowing the ceramic body to be sintered in any orientation (vertical, horizontal, or inclined) rather than requiring a specific vertical-state orientation. This multi-functional sintering capability eliminates process constraints, enables faster furnace loading, and significantly improves processing efficiency and product pass rate while maintaining ease of manufacture.
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 product strength, extends service life, increases production pass rate, and simplifies the production process, achieving a pass rate of over 95% and a switching life of greater than 100,000 times.
Implementation Method 1
an outer resistive layer, an inner insulating layer and an inner insulating reinforcement layer, wherein the outer conductive layer is located at upper segments on two sides of the outer resistive layer
Data Source
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AI summary
The present invention is a square block-type ceramic electric heating body, which comprises an outer conductive layer, an outer resistive layer, an inner insulating layer and an inner insulating reinforcement layer, wherein the outer conductive layer is located at upper segments on two sides of the outer resistive layer, and a positive electrode site and a negative electrode site are provided on an end face of the outer conductive layer. The cross section of the square block-type ceramic electric heating body is a square structural body. The square block-type ceramic electric heating body further comprises a head conductive layer, which wraps around a bottom end of the outer resistive layer. The premature fracture caused by cyclic impacts of thermal stresses is avoided, and changes in resistance distribution and migration of a temperature region brought about by the continuous expansion of a stress crack are also avoided.