EP2941090B1 - Heater - Google Patents

Heater Download PDF

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Publication number
EP2941090B1
EP2941090B1 EP13869090.4A EP13869090A EP2941090B1 EP 2941090 B1 EP2941090 B1 EP 2941090B1 EP 13869090 A EP13869090 A EP 13869090A EP 2941090 B1 EP2941090 B1 EP 2941090B1
Authority
EP
European Patent Office
Prior art keywords
ceramic structure
heater
groove portion
heating resistor
ceramic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP13869090.4A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP2941090A1 (en
EP2941090A4 (en
Inventor
Tomo SHIMABUKURO
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kyocera Corp
Original Assignee
Kyocera Corp
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Filing date
Publication date
Application filed by Kyocera Corp filed Critical Kyocera Corp
Publication of EP2941090A1 publication Critical patent/EP2941090A1/en
Publication of EP2941090A4 publication Critical patent/EP2941090A4/en
Application granted granted Critical
Publication of EP2941090B1 publication Critical patent/EP2941090B1/en
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Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/40—Heating elements having the shape of rods or tubes
    • H05B3/42—Heating elements having the shape of rods or tubes non-flexible
    • H05B3/48—Heating elements having the shape of rods or tubes non-flexible heating conductor embedded in insulating material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23Q—IGNITION; EXTINGUISHING-DEVICES
    • F23Q7/00—Incandescent ignition; Igniters using electrically-produced heat, e.g. lighters for cigarettes; Electrically-heated glowing plugs
    • F23Q7/001—Glowing plugs for internal-combustion engines
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/10—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
    • H05B3/12—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material
    • H05B3/14—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material the material being non-metallic
    • H05B3/141—Conductive ceramics, e.g. metal oxides, metal carbides, barium titanate, ferrites, zirconia, vitrous compounds
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/027—Heaters specially adapted for glow plug igniters

Definitions

  • the present invention relates to a heater according to the preamble of claim 1 and that is used for a hair iron, a water heater, an oxygen sensor, an air-fuel ratio sensor, a glow plug, various types of combustors, a semiconductor manufacturing apparatus, etc.
  • a heater of the aforementioned type is known from DE 20 22 282 A1 , for example.
  • One example of heaters for use in a hair iron and so on is a ceramic heater described in Japanese Unexamined Patent Application Publication No. 2006-40882 (hereinafter referred to as Patent Literature (PTL) 1).
  • the ceramic heater described in PTL 1 includes a ceramic base body, a heating section in the ceramic base body, and a lead section in the ceramic base body, the lead section being connected to the heating section.
  • EP 0 635 993 A1 also discloses a ceramic heater.
  • the heating section (heating resistor) includes two linear portions arrayed side by side, and a folded portion connecting those linear portions to each other.
  • a portion of the ceramic base body (ceramic structure) which is positioned between the two arrayed linear portions near the folded portion, tends to be heated to high temperature.
  • a surface of the ceramic structure exhibits a temperature distribution that a region (hereinafter referred to as a "maximally heating region") facing the above-mentioned portion of the ceramic base body takes the highest temperature, and that the temperature gradually lowers as a distance from the maximally heating region increases with the maximally heating region being a center.
  • the present invention provides a heater according to claim 1.
  • a heater 100 according to one embodiment of the present invention will be described in detail below with reference to the drawings.
  • Fig. 1 is a perspective view of the heater 100 according to one embodiment of the present invention.
  • Fig. 2(a) is a partial enlarged view representing, in enlarged scale, an area A of the heater 100 illustrated in Fig. 1
  • Fig. 2(b) is a sectional view taken along a B-B' cross-section.
  • the heater 100 according to one embodiment of the present invention includes a ceramic structure 1, a heating resistor 2, power feeders 3, and lead terminals 7.
  • the heating resistor 2 and the power feeders 3 are illustrated by broken lines in a way of seeing through the ceramic structure 1.
  • the heater 100 is, for example, used for a hair iron, a water heater, an oxygen sensor, an air-fuel ratio sensor, a glow plug, a semiconductor manufacturing apparatus, and so on.
  • the ceramic structure 1 serves as a member for holding the heating resistor 2 and the power feeders 3 therein. Because the heating resistor 2 and the power feeders 3 are disposed inside the ceramic structure 1, environmental resistance of the heating resistor 2 and the power feeders 3 can be improved.
  • the ceramic structure 1 is a rod-like member.
  • the ceramic structure 1 is made of a ceramic material, e.g., alumina, silicon nitride, aluminum nitride, or silicon carbide.
  • a short side of an outer periphery of the ceramic structure 1 has a length of 25 mm, and a long side thereof has a length of 25 mm.
  • a length of the ceramic structure 1 in the longitudinal direction is 50 mm.
  • the heating resistor 2 is a member that generates heat when a current is supplied to it.
  • the heating resistor 2 is embedded in the ceramic structure 1.
  • the heating resistor 2 faces a surface (hereinafter referred to as a "principal surface") of the ceramic structure 1, the surface including the long side of the outer periphery of the ceramic structure 1 and the side of the ceramic structure 1 in the longitudinal direction.
  • the heating resistor 2 includes two linear portions 22 arrayed side by side, and a folded portion 21 connecting those linear portions 22 to each other and having outer and inner circumferences each of which has a semicircular shape.
  • the heating resistor 2 is illustrated by broken lines in a way of seeing through the ceramic structure 1.
  • the folded portion 21 of the heating resistor 2 is disposed near a fore end of the ceramic structure 1, and the linear portions 22 extend from respective ends of the folded portion 21 toward the rear end side of the ceramic structure 1.
  • the heating resistor 2 is made of a conductive ceramic material, e.g., tungsten carbide.
  • the heating resistor 2 has a line width of 0.2 to 1.5 mm and a thickness of 0.3 to 3 mm, for example.
  • the curvature radius of the folded portion 21 is, for example, 0.15 to 1 mm at the inner circumference and 0.5 to 2 mm at the outer circumference.
  • the heat generated from the heating resistor 2 is conducted through the ceramic structure 1 and is radiated to the outside from surfaces of the ceramic structure 1.
  • the power feeders 3 are a pair of wiring members that electrically connects the heating resistor 2 to a power supply (not illustrated) outside the ceramic structure 1 in cooperation with the lead terminals 7.
  • the power feeders 3 are mostly embedded in the ceramic structure 1, and are electrically connected at one ends to the heating resistor 2. Stated in another way, respective one ends of the power feeders 3 are electrically connected to different ends of the heating resistor 2.
  • respective other ends of the power feeders 3 are led out to the surface of the ceramic structure 1 at the rear end side and are connected to the different lead terminals 7 for connection to the external power supply.
  • the power feeders 3 are formed linearly as wired lines that are routed inside the ceramic structure 1.
  • the power feeders 3 are each made of a conductive ceramic material, e.g., tungsten carbide, and formed as a wired line having lower resistance than the heating resistor 2.
  • Each of the power feeders 3 has a line width of, e.g., 0.2 to 2 mm and a thickness of, e.g., 0.3 to 4 ⁇ m.
  • the lead terminals 7 are rod-like conductive members that electrically connect the power feeders 3 to the external power supply.
  • the lead terminals 7 are joined respectively to the power feeders 3 that are led out to different surfaces of the ceramic structure 1 at the side opposite to the side where the heating resistor 2 is disposed.
  • the lead terminals 7 are made of, e.g., nickel.
  • the lead terminals 7 and the power feeders 3 are joined to each other by employing, e.g., a brazing alloy.
  • a silver solder is used as the brazing alloy.
  • Dimensions of each of the lead terminals 7 are, for example, 0.2 to 2 mm in width, 0.2 to 2 mm in thickness, and 10 mm or more in length.
  • the heating resistor 2 includes the two linear portions 22 arrayed side by side, and the folded portion 21 connecting those linear portions 22 to each other.
  • a portion of the ceramic structure 1 which is positioned between the two arrayed linear portions 22 near the folded portion 21, tends to be heated to high temperature. Therefore, a surface of the ceramic structure 1 takes high temperature particularly in a region (maximally heating region 10) that faces the above-mentioned portion of the ceramic base body.
  • the maximally heating region 10 is denoted by a two-dot-chain line.
  • the ceramic structure 1 includes, in the surface of its region at the side closer to the fore end than the maximally heating region 10, a groove portion 4 surrounding the folded portion 21 of the heating resistor 2 in opposing relation.
  • the groove portion 4 is in the form of a rectangular frame surrounding the folded portion 21 in opposing relation. Therefore, the surface of a portion of the ceramic structure 1 where the groove portion 4 is formed (i.e., a bottom surface of the groove portion 4) can be positioned closer to the heating resistor 2 than the surface of a region around such a portion. With that arrangement, temperature in the surface of the portion of the ceramic structure 1 where the groove portion 4 is formed is more apt to increase.
  • the groove portion 4 in which temperature is more apt to increase is formed near the maximally heating region 10, the temperature difference between the maximally heating region 10 and a region in the vicinity of the former can be reduced. Hence unevenness of temperature distribution in a surface of the heater 100 can be suppressed. As a result, long-term reliability of the heater 100 can be improved.
  • the groove portion 4 is formed in a square shape dimensioned, for example, such that a width is 0.15 mm, a depth is 0.1 mm, and one side of an outer periphery is 2 mm.
  • a region surrounded by the groove portion 4 is positioned at the side closer to the fore end of the ceramic structure 1 than the maximally heating region 10.
  • a part of the groove portion 4, the part being positioned closest to the rear end of the ceramic structure 1 is positioned at the side closer to the fore end of the ceramic structure 1 than the maximally heating region 10.
  • the groove portion 4 when looking at a cross-section of the ceramic structure 1 sectioned in a direction perpendicular to the surface of the ceramic structure 1, the groove portion 4 preferably has a curved shape. With that feature, thermal stress generated upon the ceramic structure 1 being heated to the high temperature can be suppressed from being concentrated in the groove portion 4.
  • a slope of the groove portion 4 at the inner peripheral side is more moderate than that at the outer peripheral side.
  • the groove portion 4 may be formed in a circular ring shape. With that feature, thermal stress generated upon the ceramic structure 1 being heated to the high temperature can be suppressed from being concentrated in the groove portion 4.
  • a projection 5 may be formed on the surface of the ceramic structure 1 along the outer periphery of the groove portion 4 in continuous relation. With the presence of the projection 5 surrounding the groove portion 4, when gas is supplied and flows around the heater 100, the gas is even more likely to stay in the groove portion 4.
  • the projection 5 is formed at a height of 0.01 mm or more as measured from the region surrounded by the groove portion 4.
  • the projection 5 when looking at a cross-section of the ceramic structure 1 sectioned in the direction perpendicular to the surface of the ceramic structure 1, the projection 5 may have a curved shape. With that feature, when gas is supplied and flows around the heater 100, the gas can more easily flow into the inside surrounded by the projection 5. As a result, the gas can be efficiently combusted at the inside surrounded by the projection 5.
  • the shape of the projection 5 may be, e.g., circular-arc or semi-elliptic.
  • a recess 6 may be formed, instead of the groove portion 4 surrounding the folded portion 21 in opposing relation, in a region of the surface of the ceramic structure 1, the region overlapping the folded portion 21.
  • the recess 6 is formed in a region of a surface of the ceramic structure 1, the surface facing the folded portion 21 and the region overlapping the folded portion 21, the surface of a portion of the ceramic structure 1 where the recess 6 is formed (i.e., a bottom surface of the recess 6) can be positioned closer to the heating resistor 2 than the surface of a region around such portion.
  • the recess 6 in which temperature is more apt to increase is formed near the maximally heating region 10, the temperature difference between the maximally heating region 10 and a region in the vicinity of the former can be reduced. Hence unevenness of temperature distribution in the surface of the heater 100 can be suppressed. As a result, long-term reliability of the heater 100 can be improved.
  • the outer circumference of the folded portion 21 has the curvature radius of 1 mm, the recess 6 is formed in a square shape dimensioned, for example, such that a depth is 0.1 mm and one side of an outer periphery is 2 mm.
  • the region where the recess 6 overlaps the folded portion 21 is positioned at the side closer to the fore end of the ceramic structure 1 than the maximally heating region 10.
  • a part of the recess 6, the part being positioned closest to the rear end of the ceramic structure 1 is positioned at the side closer to the fore end of the ceramic structure 1 than the maximally heating region 10.
  • the recess 6 when looking at a cross-section of the ceramic structure 1 sectioned in the direction perpendicular to the surface of the ceramic structure 1, the recess 6 may have a curved shape. With that feature, concentration of thermal stress generated upon the ceramic structure 1 being heated to the high temperature can be suppressed in the recess 6.
  • a recess 61 may be formed in overlapped relation to a region of a surface of the ceramic structure 1 at the side opposite to the surface where the recess 6 is formed, the region facing the folded portion 21 of the heating resistor 2.
  • the shape of the ceramic structure 1 is not limited to the above-mentioned square rod, and it may be a round rod. Furthermore, a fore end portion of the ceramic structure 1 may have a hemisphere shape.
  • the folded portion 21 of the heating resistor 2 is not always limited to the form folded into a semicircular shape as illustrated in the drawings, and it may be folded into a an acute-angular shape or a polygonal shape, e.g., a rectangular shape.
  • the folded portion 21 of the heating resistor 2, which faces the surface of the ceramic structure 1, is not always required to be formed such that the folded portion 21 and the linear portions 22 face the surface of the ceramic structure 1 in parallel as illustrated in the drawings.
  • the folded portion 21 may face the surface of the ceramic structure 1 in a state inclined relative to the same.
  • conductive pastes each containing conductive ceramic powder, a resin binder, etc. and becoming one of the heating resistor 2 and the power feeders 3 after firing are prepared. Furthermore, a ceramic paste containing insulating ceramic powder, a resin binder, etc. and becoming an insulating base body, which constitutes the ceramic structure 1, after firing is prepared.
  • a compact made of the conductive paste, having a predetermined shape, and becoming the heating resistor 2 is formed, for example, by the injection molding method using the conductive paste for the heating resistor 2.
  • the metallic mold is filled with the conductive paste for the power feeders 3, and compacts made of the conductive paste, having predetermined shapes, and becoming the power feeders 3 are formed integrally with the above-mentioned compact. This leads to a state where the compacts of the heating resistor 2 and the power feeders 3 connected to the heating resistor 2 are held in the metallic mold.
  • the compact of the heater 100 including the groove portion 4 or the recess 6, which has the desired shape and size, in the surface of the ceramic structure 1 can be obtained by a method of raising pressure applied to eject an ejection pin when the compact is released from the metallic mold, or by a method of cutting a principal surface of the compact.
  • the heater 100 can be fabricated by firing the obtained compact at about 1700°C.
  • the firing is preferably performed in an atmosphere of non-oxidizing gas, e.g., hydrogen gas.
  • the heater 100 according to EXAMPLE of the present invention was fabricated as follows.
  • the heating resistor 2 was fabricated by injection molding, namely by injecting a conductive paste, which contained 50% by mass of tungsten carbide powder, 35% by mass of silicon nitride powder, and 15% by mass of a resin binder, into a metallic mold.
  • the metallic mold was filled with the above-mentioned conductive paste becoming the power feeders 3, whereby the power feeders 3 were formed and connected to the heating resistor 2.
  • the heater 100 was formed in which the heating resistor 2 and the power feeders 3 were embedded in the ceramic structure 1, the heating resistor 2 including the folded portion 21 near the fore end of the ceramic structure 1.
  • Sample 1 a sample was fabricated in which the recess 6 in a depth of 50 ⁇ m with one side having a length of 2.3 mm was formed in a region of a principal surface (5 mm x 30 mm) of the ceramic structure 1, the region being positioned at the fore end side of the ceramic structure 1 and overlapping the folded portion 21. Furthermore, metallic molds having various shapes were prepared, and heaters 100 (Samples 2 to 4) having principal surfaces different in configuration from that of Sample 1 were fabricated. Those Samples each had dimensions of 5 mm in thickness, 10 mm in width, and 30 mm in length, and they were different only in configuration of the principal surface from Sample 1.
  • the groove portion 4 in a depth of 50 ⁇ m with one side having a length of 2.3 mm was formed in the principal surface in such a configuration that an inner wall surface at the inner side is inclined more moderately than an inner wall surface at the outer side.
  • the groove portion 4 in a depth of 50 ⁇ m with one side having a length of 2.3 mm was formed in the principal surface, and the projection 5 having a height of 20 ⁇ m was further formed in a state surrounding the groove portion 4.
  • each sample was set in a gas heater, and an ignition temperature of the gas heater was examined.
  • an endurance test was carried out by repeating a cycle of, after supplying a current for 30 sec at the ignition temperature, raising temperature at the fore end of the ceramic structure up to 1200°C, and then stopping the supply of the current for 60 sec.
  • the heaters 100 of Samples 1 to 4 continued the normal operation even after the number of cycles reached 230000 or more.
  • a crack occurred in the principal surface of the ceramic structure 1 near the maximally heating region 10 when the number of cycles reached about 60000.
  • a temperature distribution in a region from the fore end of the ceramic structure 1 to the maximally heating region 10 was measured by employing a radiation thermometer.
  • the temperature distribution in the surface of the ceramic structure 1 was measured under the condition that, after raising the temperature at the fore end of the ceramic structure 1 up to 1200°C, the ceramic structure 1 was left to stand for 5 min in a state keeping application of a voltage.
  • the temperature in the maximally heating region of the ceramic structure was 1240°C, and the temperature at the fore end of the ceramic structure was 1200°C.
  • the temperature in the maximally heating region 10 was 1250°C, the temperature at the fore end was 1230°C, and the temperature in the recess 6 was 1240°C.
  • the temperature in the maximally heating region 10 was 1250°C, the temperature at the fore end was 1230°C, and the temperature in the groove portion 4 was 1240°C.
  • the temperature in the maximally heating region 10 was 1250°C
  • the temperature at the fore end was 1230°C
  • the temperature in the groove portion 4 was 1240°C.
  • the temperature in the maximally heating region 10 was 1250°C
  • the temperature at the fore end was 1230°C
  • the temperature in the groove portion 4 was 1240°C.
  • the temperature difference in the principal surface of the ceramic structure was relatively large, i.e., 40°C, in the heater of Comparative Example 1, while the relevant temperature difference was relatively small, i.e., 20°C, in the heaters 100 of Samples 1 to 4.
  • unevenness of the temperature distribution in the principal surface of the ceramic structure 1 can be reduced by employing the configuration of the heater 100 of the present invention. Consequently, it was also understood that a possibility of the occurrence of a crack in the principal surface of the ceramic structure 1 can be reduced even with repeated use of the heater 100.
  • Samples 2 to 4 and Comparative Example 1 were each set inside a casing for the test, the casing being provided with a gas inlet. While continuously supplying gas to flow into the casing, measurement was performed on a time until the gas was ignited after starting supply of a current to each of the heaters 100 of Samples 2 to 4 and the heater of Comparative Example 1, and a time until extinction after stopping the supply of the current.
  • the gas was prepared by evaporating diesel fuel.
  • the heaters 100 of Samples 2 and 3 the time until the ignition was within 40 sec.
  • the time until the ignition took 60 sec.
  • the time until the ignition is shortened by 20 sec and ignitibility is improved in comparison with the heater of Comparative Example 1.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Resistance Heating (AREA)
EP13869090.4A 2012-12-27 2013-12-27 Heater Active EP2941090B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2012284051 2012-12-27
PCT/JP2013/085105 WO2014104293A1 (ja) 2012-12-27 2013-12-27 ヒータ

Publications (3)

Publication Number Publication Date
EP2941090A1 EP2941090A1 (en) 2015-11-04
EP2941090A4 EP2941090A4 (en) 2016-08-17
EP2941090B1 true EP2941090B1 (en) 2018-02-21

Family

ID=51021362

Family Applications (1)

Application Number Title Priority Date Filing Date
EP13869090.4A Active EP2941090B1 (en) 2012-12-27 2013-12-27 Heater

Country Status (3)

Country Link
EP (1) EP2941090B1 (ja)
JP (1) JP5960845B2 (ja)
WO (1) WO2014104293A1 (ja)

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2022282C3 (de) * 1970-05-06 1980-05-29 Villamosipari Kutato Intezet, Budapest Verfahren zur Herstellung eines elektrischen Heizelementes
JPS54150727U (ja) * 1978-04-14 1979-10-19
JPH0129427Y2 (ja) * 1985-12-27 1989-09-07
JPH03183942A (ja) * 1989-12-14 1991-08-09 Ngk Spark Plug Co Ltd センサのヒータ構造
EP0635993B1 (en) * 1993-07-20 2000-05-17 TDK Corporation Ceramic heater
JP4555151B2 (ja) 2004-06-25 2010-09-29 日本特殊陶業株式会社 セラミックヒータ、およびそのセラミックヒータを備えたグロープラグ
US7223942B2 (en) * 2004-06-29 2007-05-29 Ngk Spark Plug Co., Ltd. Ceramic heater, glow plug, and ceramic heater manufacturing method
FR2898960B1 (fr) * 2006-03-21 2008-05-30 Renault Sas Bougie de prechauffage pour moteur a combustion
JP5171335B2 (ja) * 2008-03-25 2013-03-27 日本特殊陶業株式会社 セラミックヒータ及びグロープラグ

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
None *

Also Published As

Publication number Publication date
EP2941090A1 (en) 2015-11-04
JPWO2014104293A1 (ja) 2017-01-19
JP5960845B2 (ja) 2016-08-02
WO2014104293A1 (ja) 2014-07-03
EP2941090A4 (en) 2016-08-17

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