TixOy Thermal Spray Heater Resistivity Stability
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Solution Overview
Problem
Conventional heat generating components using tungsten thermal spray coatings experience changes in volume resistivity when used at high temperatures for extended periods, leading to inaccurate temperature control and uneven temperature distribution.
Innovation Solution
A heat generating component with a thermal sprayed coating containing TixOy (where 0<y/x<2.0) is used, providing stable volume resistivity even at high temperatures, comprising a substrate with a thin coating heater part made of titanium oxide with a specific ratio of oxygen to titanium atoms, which maintains suitable resistivity and reduces changes over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If tungsten thermal spray coating is used for heater, then high melting point and initial heating performance are achieved, but volume resistivity changes when used at high temperature for extended periods
Solution Approach 1:
The patent changes the material composition parameters by using titanium oxide (TiO2) with specific oxygen-to-titanium atomic ratios (0.5 < y/x < 2.0) instead of tungsten. This parameter change in material composition maintains high temperature resistance while ensuring stable volume resistivity during extended high-temperature operation.
Solution Approach 2:
The patent employs composite material structure with thermal spray coating containing titanium oxide as the primary heating material. This composite approach combines the advantages of high melting point (from titanium oxide) with stable electrical properties (controlled oxygen-to-titanium ratio), resolving the contradiction between temperature resistance and resistivity stability.
2Ease of manufacture
If tungsten is used as thermal spray material, then initial heater characteristics are good, but oxidation occurs at high temperature leading to volume resistivity change
Solution Approach 1:
The patent replaces tungsten (expensive and oxidation-prone) with titanium oxide (more cost-effective and oxidation-resistant). Although titanium oxide requires precise compositional control, it provides superior chemical stability at high temperatures and maintains manufacturing ease through thermal spray processes.
Solution Approach 2:
The patent creates a chemically stable environment by using titanium oxide which forms a protective oxide layer, effectively creating an inert-like protective barrier that prevents further oxidation and compositional changes during high-temperature operation.
3Stability of the object's composition
If titanium dioxide is used for thermal spray coating, then chemical stability is high, but volume resistivity is too high to function as heater
Solution Approach 1:
The patent applies local quality control by precisely controlling the oxygen-to-titanium atomic ratio within the range 0.5 < y/x < 2.0. This localized compositional control creates regions with optimal balance between chemical stability (from titanium oxide) and electrical conductivity (required for heating function).
Solution Approach 2:
The patent changes the stoichiometric parameters of titanium oxide by controlling the oxygen-to-titanium ratio to be less than the standard TiO2 ratio (where y/x = 2.0). This parameter adjustment reduces volume resistivity from the extremely high values of pure TiO2 to levels suitable for heating applications, while maintaining adequate chemical stability.
4Duration of action of stationary object
If heater is used repeatedly at high temperature, then temperature control function is maintained, but volume resistivity changes causing inaccurate temperature control
Solution Approach 1:
The patent provides beforehand cushioning by selecting titanium oxide with controlled oxygen-to-titanium ratio, which inherently resists oxidation and compositional changes during high-temperature service. This pre-selected material stability prevents the volume resistivity drift that would otherwise occur during repeated high-temperature operation, maintaining temperature control accuracy throughout the service life.
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 component ensures accurate and uniform temperature control by maintaining consistent volume resistivity, even after repeated high-temperature exposure, enhancing stability and performance as a heater.
Implementation Method 1
a thin coating heater part formed on the substrate part, wherein the thin coating heater part comprises a thermal sprayed coating containing TixOy
Data Source
AI summary
Provided is a heat generating component of which volume resistivity hardly varies even if used repeatedly at a high temperature for a long period of time. Since a thin coating heater part (13) formed on a substrate part (12) is composed of a thermal sprayed coating containing TixOy (wherein, 0<y/x<2.0 is satisfied), obtained is a heat generating component (11) having volume resistivity which is suitable for a heater and hardly varies even if prescribed temperature change and temperature keeping are repeated.