EP3101997B1 - Heater - Google Patents
Heater Download PDFInfo
- Publication number
- EP3101997B1 EP3101997B1 EP15742735.2A EP15742735A EP3101997B1 EP 3101997 B1 EP3101997 B1 EP 3101997B1 EP 15742735 A EP15742735 A EP 15742735A EP 3101997 B1 EP3101997 B1 EP 3101997B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- ceramic body
- insulating member
- heater
- metal tube
- 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.)
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- 239000000919 ceramic Substances 0.000 claims description 127
- 229910052751 metal Inorganic materials 0.000 claims description 77
- 239000002184 metal Substances 0.000 claims description 77
- 238000010438 heat treatment Methods 0.000 claims description 36
- 239000000853 adhesive Substances 0.000 claims description 22
- 230000001070 adhesive effect Effects 0.000 claims description 22
- 239000000843 powder Substances 0.000 claims description 16
- 229910010293 ceramic material Inorganic materials 0.000 claims description 6
- 238000012986 modification Methods 0.000 description 16
- 230000004048 modification Effects 0.000 description 16
- 230000008646 thermal stress Effects 0.000 description 13
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 12
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 12
- 239000002002 slurry Substances 0.000 description 9
- 238000005219 brazing Methods 0.000 description 8
- 238000001035 drying Methods 0.000 description 8
- 239000000945 filler Substances 0.000 description 8
- 239000000463 material Substances 0.000 description 6
- 238000009413 insulation Methods 0.000 description 4
- 150000004767 nitrides Chemical class 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 229920002313 fluoropolymer Polymers 0.000 description 3
- 239000004811 fluoropolymer Substances 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 239000007769 metal material Substances 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 2
- NEIHULKJZQTQKJ-UHFFFAOYSA-N [Cu].[Ag] Chemical compound [Cu].[Ag] NEIHULKJZQTQKJ-UHFFFAOYSA-N 0.000 description 2
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 230000007774 longterm Effects 0.000 description 2
- 229910052750 molybdenum Inorganic materials 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 2
- 229910052709 silver Inorganic materials 0.000 description 2
- 239000004332 silver Substances 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 229910052721 tungsten Inorganic materials 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- QRJOYPHTNNOAOJ-UHFFFAOYSA-N copper gold Chemical compound [Cu].[Au] QRJOYPHTNNOAOJ-UHFFFAOYSA-N 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229910052702 rhenium Inorganic materials 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
Images
Classifications
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- 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
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H1/00—Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters
- F24H1/0018—Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters using electric energy supply
-
- 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
- H05B3/02—Details
- H05B3/06—Heater elements structurally combined with coupling elements or holders
-
- 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
- H05B3/78—Heating arrangements specially adapted for immersion heating
-
- 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
- H05B2203/012—Heaters using non- flexible resistive rods or tubes not provided for in H05B3/42
-
- 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
- H05B2203/021—Heaters specially adapted for heating liquids
-
- 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
- H05B2203/022—Heaters specially adapted for heating gaseous material
-
- 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 heaters according to the preamble of claim 1 used as heaters for heating fluid or heaters for heating gas, for example.
- Patent Literature 1 A ceramic sheathed heater described in Japanese Unexamined Patent Application Publication No. 10-247584 (hereinafter, referred to as Patent Literature 1) is known as a heater used as a heater for heating fluid or a heater for heating gas.
- the ceramic sheathed heater described in Patent Literature 1 includes a closed-bottom tubular body formed of metal and a ceramic body disposed in the closed-bottom tubular body.
- the ceramic body includes a heating resistor therein.
- the ceramic sheathed heater includes an insulating powder between the closed-bottom tubular body and the ceramic body.
- the ceramic sheathed heater described in Patent Literature 1 may be used in a circumstance where external vibrations are transferred to the ceramic sheathed heater.
- the vibrations may cause the insulating powder to move inside the closed-bottom tubular body with respect to the ceramic body.
- the insulating powder may be unevenly dispersed such that the insulating powder exists in a larger amount at a certain position and exists in a smaller amount at a certain position.
- the ceramic body and the closed-bottom tubular body may partly come in contact with each other at the position where the insulating powder exists in the smaller amount.
- a surface of the ceramic body may have a difference in temperature, because the portion of the ceramic body in contact with the closed-bottom tubular body has higher heat dissipation properties than the portion in contact with the insulating powder.
- the ceramic sheathed heater generates heat of a temperature higher than a widely employed temperature, higher thermal stress may occur on the ceramic body, leading to a reduction in durability of the ceramic sheathed heater.
- JP S47 21384 B discloses a heater according to the initially-mentioned type.
- the present invention was made in view of the above-described problem. It is an object of the present invention to reduce the thermal stress on the ceramic body so as to improve the durability of the ceramic sheathed heater.
- the present invention provides a heater according to claim 1. Further embodiments of the present invention are described in the dependent claims.
- a heater includes a ceramic body having a columnar shape or a tubular shape, a heating resistor in the ceramic body, a metal tube in which the ceramic body is disposed, and an insulating member disposed between the ceramic body and the metal tube.
- the insulting member includes a tubular portion in contact with an outer circumferential surface of the ceramic body at an inner circumferential surface thereof and in contact with an inner circumferential surface of the metal tube at an outer circumferential surface thereof.
- the heater 100 includes a ceramic body 1 having a columnar shape, a heating resistor 2 in the ceramic body 1, a metal tube 3 in which the whole of the ceramic body 1 is disposed, and an insulating member 4 including a tubular portion 40 and disposed between the ceramic body 1 and the metal tube 3.
- the ceramic body 1 is configured to protect the heating resistor 2.
- the shape of the ceramic body 1 is a columnar shape or a tubular shape. Examples of the columnar shape include a cylinder and a prism. The columnar shape discussed herein may look like a plate shape depending on the direction of view.
- the ceramic body 1 has a columnar shape having an oblong main surface. Examples of the tubular shape include a circular tubular shape and a square tubular shape.
- the ceramic body 1 is a sintered body obtained by sintering an insulating ceramic material shaped into a predetermined shape.
- the insulating ceramic body include an alumina sintered body, a silicon nitride sintered body, and an aluminum nitride sintered body.
- the alumina sintered body is preferably employed from a productivity perspective.
- the ceramic body 1 may have a main surface having a length of 30 mm and a width of 3 mm and may have a thickness of 1 mm in a direction perpendicular to the main surface, for example.
- the heating resistor 2 is a resistor configured to generate heat by using a current flowing therein.
- the heating resistor 2 is disposed in the ceramic body 1. In other words, the heating resistor 2 is buried in the ceramic body 1.
- the shape of the heating resistor 2 is linear.
- the heating resistor 2 of the heater 100 according to the present embodiment has a bent portion at a position closer to a first end of the ceramic body 1 than to the center and is connected to two lead-out portions 5 at a second end side.
- the lead-out portions 5 are configured to electrically connect the heating resistor 2 with an external power supply.
- the lead-out portions 5 each have a first end connected to the heating resistor 2 and a second end positioned outside the ceramic body 1. The second end of each lead-out portion 5 positioned outside the ceramic body 1 is connected to an electrode 6 on the surface of the ceramic body 1.
- the heating resistor 2 and the lead-out portions 5 are each formed of a metal material.
- the metal material include W, Mo, and Re.
- the heating resistor 2 may have a width of 0.3 mm, an entire length of 30 mm, and a thickness of 25 ⁇ m , for example.
- the lead-out portions 5 each may have a width of 0.7 mm, an entire length of 10 mm, and a thickness of 30 ⁇ m , for example.
- the electrodes 6 are each configured to electrically connect the lead-out portion 5 with a lead 7.
- the electrodes 6 are disposed on two positions of an outer surface of the ceramic body 1 at the second end side. Specifically, the electrode 6 is disposed on each main surface of the ceramic body 1.
- the electrodes 6 each have a square shape when viewed in a direction parallel to the main surface of the ceramic body 1.
- the electrodes 6 each may have a length of 5 mm measured in a direction parallel to the longitudinal direction of the ceramic body 1, a length of 2.5 mm measured in a direction perpendicular to the longitudinal direction of the ceramic body 1, and a thickness of 20 ⁇ m , for example.
- the electrodes 6 are each electrically connected to the heating resistor 2 through the lead-out portion 5.
- the electrodes 6 are each formed of W, Mo, or Re, for example.
- the leads 7 are configured to conduct electricity from an external power supply to the heating resistor 2.
- the leads 7 are separately disposed for the corresponding electrodes 6.
- the leads 7 each have a first end connected to the electrode 6 and a second end positioned outside the metal tube 3. A portion of each lead 7 positioned outside the metal tube 3 is connected to an external power supply (not illustrated).
- the lead 7 and the electrode 6 are connected to each other with a brazing filler metal 8. Examples of the brazing filler metal 8 include a silver brazing filler metal, a gold-copper brazing filler metal, and a silver-copper brazing filler metal.
- the lead 7 is formed of Ni, for example.
- the lead 7 is covered by an insulating tube 9 except for the portion connected to the electrode 6 and the portion connected to the external power supply.
- the tube 9 is formed of a resin material, for example. In particular, the tube 9 is preferably formed of a fluoropolymer having high heat resistance.
- the leads 7 each may have a diameter of 0.4 mm and a length of 50 mm, for example.
- the tubes 9 used for the corresponding leads 7 each may have an outer diameter of 1 mm and a length of 45 mm, for example.
- the portion of the lead 7 that is not covered by the tube 9 and positioned adjacent to the electrode 6 may have a length of about 2 mm, for example.
- the metal tube 3 is configured to heat an object to be heated while being in contact with the object.
- the object to be heated by the heater 100 is a liquid such as water and oil, or a gas such as air and nitrogen, for example.
- the metal tube 3 has a circular tubular shape.
- the whole of the ceramic body 1 is disposed in the metal tube 3.
- the metal tube 3 has an inner diameter larger than the outer diameter of the ceramic body 1 such that a gap having an enough size to accommodate the insulating member 4 having an insulating cover 10 and the tubular portion 40 is formed between the inner circumferential surface of the metal tube 3 and the outer circumferential surface of the ceramic body 1.
- a first end of the metal tube 3 is closed by a metal lid 11.
- the metal lid 11 has a disc shape having a diameter equal to the outer diameter of the metal tube 3.
- the metal tube 3 may have an inner diameter of 4 mm, an outer diameter of 5 mm, and a length of 40 mm, for example.
- the metal tube 3 is formed of a metal material such as stainless steel, aluminum, copper, or titanium, for example.
- stainless steel is preferably used in view of processability, strength, and heat resistance.
- the insulating cover 10 is configured to provide insulation between the leads 7 and the metal tube 3 and insulation between the electrodes 6 and the metal tube 3.
- the insulating cover 10 surrounds the electrodes 6 together with the first end of each lead 7.
- the insulating cover 10 is a sheet-like member.
- the insulating cover 10 is formed of an insulating material such as a fluoropolymer, for example.
- the insulating cover 10 may have a thickness of about 0.2 mm and a length of about 6 mm, for example.
- the insulating cover 10 is not necessarily limited to the sheet-like member.
- the insulating cover 10 may be a tubular member, for example.
- the insulating cover 10 is a solid member, but the configuration of the insulating cover 10 is not limited thereto.
- the insulating cover 10 may be a semisolid member such as a gel, or may be a hardened semisolid member, for example.
- the insulating member 4 is configured to prevent the ceramic body 1 from being in contact with the metal tube 3.
- the insulating member 4, which includes a tubular portion 40, is in contact with an outer circumferential surface of the ceramic body 1 at an inner circumferential surface thereof and in contact with an inner circumferential surface of the metal tube 3 at an outer circumferential surface thereof.
- the insulating member 4 is formed of a ceramic material such as alumina and aluminum nitride.
- the insulating member 4 may be an inorganic hardened product obtained, for example, by inserting the ceramic body 1 into the metal tube 3, filling a space between the ceramic body 1 and the metal tube 3 with a solution including an inorganic adhesive, water, and the above-described ceramic material (alumina or alumina nitride, for example) in the form of powder, and then drying the solution so as to be hardened such that the ceramic material and the component of the inorganic adhesive are in contact with each other and combined strongly due to mutual influence.
- the inorganic adhesive include water dispersible silica sol and water dispersible alumina sol.
- the insulating member 4 When the insulating member 4 is formed of an inorganic adhesive, the insulating member 4 preferably has porosity larger than that of the ceramic body 1. This configuration enables, when thermal stress occurs in the heater 100 at a position inner than the metal tube 3, the insulating member 4 to change its shape to absorb the thermal stress. This reduces the possibility that the ceramic body 1 will have a crack.
- the porosity is compared by the following method. Specifically, the insulating member 4 and the ceramic body 1 are each cut to have a cross section. Then, the porosity is calculated by determining a ratio of an area of voids per unit area.
- an organic adhesive such as an epoxy resin and a silicon resin, for example, may also be used as a material of the insulating member 4.
- the material of the insulating member 4 may be suitably selected depending on the usage environment of the heater 100.
- the insulating member 4 formed of the above-described inorganic adhesive is preferably employed, because such an insulating member 4 is able to withstand temperatures of up to about 800°C.
- the dimension of the insulating member 4 may be set such that the tubular portion 40 has an inner diameter of 3 mm ⁇ 1 mm, which is the same as the outer diameter of the ceramic body 1, and an outer diameter of 4 mm, which is the same as the inner diameter of the metal tube 3, and a length of 20 mm, for example.
- the insulating member 4 is disposed between the metal tube 3 and the ceramic body 1, preventing the uneven dispersion. This reduces the possibility that the metal tube 3 and the ceramic body 1 will partly come in contact with each other, and thus reduces the possibility that the surface of the ceramic body 1 will have a large difference in temperature. Thus, the possibility that the thermal stress will occur on the ceramic body 1 is reduced. As a result, the durability of the heater 100 is improved.
- the insulating member 4 is preferably a joining layer as described above.
- the insulating member 4 enables the ceramic body 1 and the metal tube 3 to be connected to each other, improving the contact between the insulating member 4 and the ceramic body 1 and the contact between the insulating member 4 and the metal tube 3. This allows heat to be readily transferred from the ceramic body 1 to the metal tube 3. As a result, temperature rise performance of the heater 100 is improved.
- the above-described inorganic adhesive or organic adhesive may be used as an adhesive.
- the inorganic hardened product using the inorganic adhesive enables the ceramic body 1 and the metal tube 3 to be connected to each other.
- the insulating member 4 preferably includes a ceramic powder. This increases the strength of the insulating member 4. As a result, the heater 100 has higher long-term reliability.
- the ceramic powder in the insulating member 4 and the main component of the ceramic body 1 be formed of the same ceramic material. This reduces a difference in thermal expansion between the insulating member 4 and the ceramic body 1. As a result, generation of thermal stress in the heater 100 while the temperature increases or decreases is reduced.
- the contact between the metal tube 3 and the ceramic body 1 is not preferable in view of durability of the heater 100. This is based on the following reason. If the ceramic body 1 has a crack due to thermal stress caused by a difference in thermal expansion between the ceramic body 1 and the metal tube 3, the crack may be developed to reach the heating resistor 2 in the ceramic body 1. In such a case, a resistance value of the heating resistor 2 may change. This may prevent the heater 100 from generating heat of a predetermined temperature.
- the possibility that the resistance value of the heating resistor 2 will change due to the crack is reduced, resulting in a reduction of the possibility that the heater 100 will not be able to generate heat of a predetermined temperature.
- the thermal stress due to a difference in thermal expansion between the insulating member 4 and the ceramic body 1 may locally concentrate on the ceramic body 1.
- the ceramic body 1 may have a crack.
- the insulating member 4 also preferably has the configuration that reduces the crack development. This is described later.
- the metal lid 11 closing the first end of the metal tube 3 and the ceramic body 1 define a space 12 therebetween.
- the space 12 may have a length of 0.2 to 2 mm in the longitudinal direction of the ceramic body 1, for example. In particular, since the length of the space 12 is 0.2 mm or more, the ceramic body 1 and the metal lid 11 are less likely to come in contact with each other even when the ceramic body 1 and the metal lid 11 are thermally expanded by heat generated by the heater 100.
- the insulating member 4 has a tubular shape having open ends, but the shape of the insulating member 4 is not limited thereto. Specifically, the insulating member 4 may be closed at one end, another end, or both the ends. In other words, the insulating member 4 may have the tubular portion 40 and a portion closing an opening at one end or at another end of the tubular portion 40, or portions closing openings at both the ends. As illustrated in Fig. 2 , in the heater 100 according to the first modification, the first end of the insulating member 4 is in contact with the entire inner surface of the metal lid 11.
- the second end of the insulating member 4 is positioned in the opening of the metal tube 3 at the second end side.
- the insulating member 4 surrounds the ceramic body 1 together with the insulating cover 10, the electrodes 6, and the portions of the tubes 9 covering the leads 7, and is in contact with a second-end-side portion of the ceramic body 1 without any gap therebetween. Since the insulating member 4 covers the whole of the ceramic body 1, the ceramic body 1 is air-tightly sealed. As a result, the ceramic body 1 in the heater 100 has improved environmental resistance.
- the heater 100 includes the insulating cover 10 as in the above-described embodiment, but the configuration of the heater 100 is not limited thereto. Specifically, the insulating cover 10 may be eliminated from the heater 100, and the insulating member 4 may directly cover the electrodes 6. The insulating member 4 covering the whole of the ceramic body 1 together with the electrodes 6 provides insulation between the electrodes 6 and the metal tube 3.
- the heater 100 does not include the space 12, but the configuration of the heater 100 is not limited thereto.
- the heater 100 according to this modification may include the space 12 as in the above-described embodiment. This configuration reduces the thermal stress caused by the difference in thermal expansion between the ceramic body 1 and the metal lid 11.
- the insulating member 4 in this modification may be produced as described below. Specifically, the leads 7 are disposed on the electrodes 6 on the ceramic body 1 and are connected thereto with a silver-copper brazing filler metal or a silver brazing filler metal. Then, the insulating cover 10 formed of a fluoropolymer is disposed to cover the electrodes 6 and the brazed portion. The ceramic body 1 to which the electrodes 6, the leads 7, and the insulating cover 10 are attached as described above is disposed in the metal tube 3, and then a slurry solution is filled in the metal tube 3 to the upper surface so as not to have air bubbles between the ceramic body 1 and the metal tube 3.
- the slurry solution is obtained by mixing an inorganic adhesive and water with ground ceramic such as alumina and alumina nitride, for example (ceramic powder).
- ground ceramic such as alumina and alumina nitride, for example (ceramic powder).
- water in the slurry solution is evaporated slowly by preliminary drying at 100°C or less for about 30 minutes.
- the preliminary drying is preferably performed at a temperature of 70 to 80°C, because if the drying is performed at 100°C or more, water is boiled to generate air bubbles, leading to a decrease in strength and deterioration in external appearance.
- drying is performed at 250°C for 30 minutes to dry and harden the inorganic adhesive component.
- the insulating member 4 is produced.
- the insulating member 4 may be formed of ceramic or may be formed of an organic adhesive.
- the insulating member 4 is composed of one component, but the configuration of the insulating member 4 is not limited thereto.
- the tubular portion 40 of the insulating member 4 may include a first portion 41 and a second portion 42 each having a tubular shape.
- the tubular portion 40 of the insulating member 4 includes the first portion 41 and the second portion 42.
- the first portion 41 is positioned at the first end side of the metal tube 3, and the second portion 42 is positioned at the second end side of the metal tube 3.
- the first portion 41 and the second portion 42 each have a tubular shape, and an end surface of the first portion 41 and an end surface of the second surface 42 are in contact with each other.
- the insulating member 4 includes a plurality of portions, if one of the portions (the first portion 41, for example) has a crack, the development of the crack stops between the two portions (the first portion 41 and the second portion 42), reducing the possibility that the crack will develop to reach another portion (the second portion 42, for example). This reduces the possibility that the crack in the insulating member 4 will develop in the insulating member 4 to largely deform the insulating member 4.
- the heating resistor 2 is disposed on the first end side of the ceramic body 1, and the first portion 41 surrounds an entire portion of the ceramic body 1 corresponding to the heating resistor 2. Since the first portion 41 surrounds the heating resistor 2, most of the heat generated by the heating resistor 2 is transferred to the first portion 41.
- the insulating member 4 includes separate portions of the first portion 41 and the second portion 42, an interface exists between the first portion 41 and the second portion 42, reducing the amount of heat transferred from the first portion 41 to the second portion 42. This reduces the possibility that the heat generated by the heating resistor 2 will be transferred to the second portion 42 and escape to the second end side of the heater 100.
- the first portion 41 and the second portion 42 may be formed of the same material, but may be formed of different materials.
- the first portion 41 preferably has higher thermal conductivity than the second portion 42, for example.
- the first portion 41 having higher thermal conductivity enables the heat generated by the heating resistor 2 to transfer rapidly to the metal tube 3.
- the second portion 42 having lower thermal conductivity reduces the possibility that the heat generated by the heating resistor 2 will be released to the outside from the side of the leads 7. This configuration enables the heater 100 to have a higher rate of temperature rise.
- the thermal conductivity of the first portion 41 may be made higher than that of the second portion 42 by allowing the first portion 41 and the second portion 42 to have different amounts of the ceramic powder in the inorganic adhesive, for example. More specifically, if the inorganic adhesive is water dispersible silica sol and the ceramic is alumina, for example, the amount of alumina in the first portion 41 may be made larger than that in the second portion 42. Alternatively, the thermal conductivity may be adjusted by allowing the first portion 41 and the second portion 42 to include different ceramic powders or different inorganic adhesives.
- the thermal conductivity of the first portion 41 may be made higher than that of the second portion 42 by adjusting a proportion of air bubbles in the inorganic adhesive to be larger in the second portion 42 than in the first portion 41, for example.
- the thermal conductivity of the second portion 42 is able to be made smaller by increasing the amount of air bubbles in the inorganic adhesive.
- the increase in the amount of air bubbles in the second portion enables the second portion to readily absorb the thermal stress, reducing the possibility that the generated thermal stress will be applied to the lead 7, for example. As a result, the heater 100 has higher long-term reliability.
- the heater 100 includes the insulating cover 10 as in the above-described embodiment, but the configuration of the heater 100 is not limited thereto. Specifically, the insulating cover 10 may be eliminated from the heater 100, and the insulating member 4 may directly cover the electrodes 6. The insulating member 4 covering the whole of the ceramic body 1 together with the electrodes 6 provides insulation between the electrodes 6 and the metal tube 3.
- the heater 100 does not include the space 12, but the configuration of the heater 100 is not limited thereto.
- the heater 100 according to this modification preferably has the space 12 as in the above-described embodiment. This configuration reduces the thermal stress caused by the difference in thermal expansion between the ceramic body 1 and the metal lid 11.
- the first portion 41 and the second portion 42 may be produced as described below. Initially, an electrode ceramic body 1 to which the electrodes 6, the leads 7, and the insulating cover 10 are attached is inserted into the metal tube 3 with the opening at the first end closed by the metal lid 11. Then, a portion of the metal tube 3 at the first end side is filled with a slurry solution obtained by mixing an inorganic adhesive and water with ground ceramic such as alumina and nitride aluminum, for example (ceramic powder). Then, water in the slurry solution is evaporated slowly at 100°C or less for 30 minutes, and then the slurry solution is hardened by drying in a high-temperature environment to form the first portion 41.
- a slurry solution obtained by mixing an inorganic adhesive and water with ground ceramic such as alumina and nitride aluminum, for example (ceramic powder). Then, water in the slurry solution is evaporated slowly at 100°C or less for 30 minutes, and then the slurry solution is hardened by drying in a
- the insulating member 4 may be formed of ceramic or an organic adhesive.
Description
- The present invention relates to heaters according to the preamble of
claim 1 used as heaters for heating fluid or heaters for heating gas, for example. - A ceramic sheathed heater described in Japanese Unexamined Patent Application Publication No.
10-247584 Patent Literature 1 includes a closed-bottom tubular body formed of metal and a ceramic body disposed in the closed-bottom tubular body. The ceramic body includes a heating resistor therein. The ceramic sheathed heater includes an insulating powder between the closed-bottom tubular body and the ceramic body. - The ceramic sheathed heater described in
Patent Literature 1 may be used in a circumstance where external vibrations are transferred to the ceramic sheathed heater. In such a case, the vibrations may cause the insulating powder to move inside the closed-bottom tubular body with respect to the ceramic body. Thus, the insulating powder may be unevenly dispersed such that the insulating powder exists in a larger amount at a certain position and exists in a smaller amount at a certain position. As a result, the ceramic body and the closed-bottom tubular body may partly come in contact with each other at the position where the insulating powder exists in the smaller amount. If the heating resistor generates heat in such a state, a surface of the ceramic body may have a difference in temperature, because the portion of the ceramic body in contact with the closed-bottom tubular body has higher heat dissipation properties than the portion in contact with the insulating powder. In particular, if the ceramic sheathed heater generates heat of a temperature higher than a widely employed temperature, higher thermal stress may occur on the ceramic body, leading to a reduction in durability of the ceramic sheathed heater. -
JP S47 21384 B - The present invention was made in view of the above-described problem. It is an object of the present invention to reduce the thermal stress on the ceramic body so as to improve the durability of the ceramic sheathed heater.
- The present invention provides a heater according to
claim 1. Further embodiments of the present invention are described in the dependent claims. - A heater includes a ceramic body having a columnar shape or a tubular shape, a heating resistor in the ceramic body, a metal tube in which the ceramic body is disposed, and an insulating member disposed between the ceramic body and the metal tube. The insulting member includes a tubular portion in contact with an outer circumferential surface of the ceramic body at an inner circumferential surface thereof and in contact with an inner circumferential surface of the metal tube at an outer circumferential surface thereof.
-
-
Fig. 1 is a cross-sectional view illustrating a heater according to an embodiment. -
Fig. 2 is a cross-sectional view illustrating a heater according to a first modification. -
Fig. 3 is a cross-sectional view illustrating a heater according to a second modification. - Hereinafter, a
heater 100 according to an embodiment is described with reference to the drawings. - As illustrated in
Fig. 1 , theheater 100 includes aceramic body 1 having a columnar shape, aheating resistor 2 in theceramic body 1, ametal tube 3 in which the whole of theceramic body 1 is disposed, and aninsulating member 4 including atubular portion 40 and disposed between theceramic body 1 and themetal tube 3. - The
ceramic body 1 is configured to protect theheating resistor 2. The shape of theceramic body 1 is a columnar shape or a tubular shape. Examples of the columnar shape include a cylinder and a prism. The columnar shape discussed herein may look like a plate shape depending on the direction of view. In theheater 100 of the present embodiment, theceramic body 1 has a columnar shape having an oblong main surface. Examples of the tubular shape include a circular tubular shape and a square tubular shape. - The
ceramic body 1 is a sintered body obtained by sintering an insulating ceramic material shaped into a predetermined shape. Examples of the insulating ceramic body include an alumina sintered body, a silicon nitride sintered body, and an aluminum nitride sintered body. In particular, the alumina sintered body is preferably employed from a productivity perspective. When theceramic body 1 has the columnar shape, theceramic body 1 may have a main surface having a length of 30 mm and a width of 3 mm and may have a thickness of 1 mm in a direction perpendicular to the main surface, for example. - The
heating resistor 2 is a resistor configured to generate heat by using a current flowing therein. Theheating resistor 2 is disposed in theceramic body 1. In other words, theheating resistor 2 is buried in theceramic body 1. In addition, the shape of theheating resistor 2 is linear. Theheating resistor 2 of theheater 100 according to the present embodiment has a bent portion at a position closer to a first end of theceramic body 1 than to the center and is connected to two lead-outportions 5 at a second end side. The lead-outportions 5 are configured to electrically connect theheating resistor 2 with an external power supply. The lead-outportions 5 each have a first end connected to theheating resistor 2 and a second end positioned outside theceramic body 1. The second end of each lead-outportion 5 positioned outside theceramic body 1 is connected to anelectrode 6 on the surface of theceramic body 1. - The
heating resistor 2 and the lead-outportions 5 are each formed of a metal material. Examples of the metal material include W, Mo, and Re. Theheating resistor 2 may have a width of 0.3 mm, an entire length of 30 mm, and a thickness of 25 µm, for example. The lead-outportions 5 each may have a width of 0.7 mm, an entire length of 10 mm, and a thickness of 30 µm, for example. - The
electrodes 6 are each configured to electrically connect the lead-outportion 5 with alead 7. Theelectrodes 6 are disposed on two positions of an outer surface of theceramic body 1 at the second end side. Specifically, theelectrode 6 is disposed on each main surface of theceramic body 1. Theelectrodes 6 each have a square shape when viewed in a direction parallel to the main surface of theceramic body 1. Theelectrodes 6 each may have a length of 5 mm measured in a direction parallel to the longitudinal direction of theceramic body 1, a length of 2.5 mm measured in a direction perpendicular to the longitudinal direction of theceramic body 1, and a thickness of 20 µm, for example. Theelectrodes 6 are each electrically connected to theheating resistor 2 through the lead-outportion 5. Theelectrodes 6 are each formed of W, Mo, or Re, for example. - The
leads 7 are configured to conduct electricity from an external power supply to theheating resistor 2. Theleads 7 are separately disposed for thecorresponding electrodes 6. Theleads 7 each have a first end connected to theelectrode 6 and a second end positioned outside themetal tube 3. A portion of eachlead 7 positioned outside themetal tube 3 is connected to an external power supply (not illustrated). Thelead 7 and theelectrode 6 are connected to each other with abrazing filler metal 8. Examples of thebrazing filler metal 8 include a silver brazing filler metal, a gold-copper brazing filler metal, and a silver-copper brazing filler metal. Thelead 7 is formed of Ni, for example. Thelead 7 is covered by an insulatingtube 9 except for the portion connected to theelectrode 6 and the portion connected to the external power supply. Thetube 9 is formed of a resin material, for example. In particular, thetube 9 is preferably formed of a fluoropolymer having high heat resistance. - If the leads 7 are linear, the
leads 7 each may have a diameter of 0.4 mm and a length of 50 mm, for example. Thetubes 9 used for the corresponding leads 7 each may have an outer diameter of 1 mm and a length of 45 mm, for example. In addition, the portion of thelead 7 that is not covered by thetube 9 and positioned adjacent to theelectrode 6 may have a length of about 2 mm, for example. - The
metal tube 3 is configured to heat an object to be heated while being in contact with the object. The object to be heated by theheater 100 is a liquid such as water and oil, or a gas such as air and nitrogen, for example. In theheater 100 according to the present embodiment, themetal tube 3 has a circular tubular shape. The whole of theceramic body 1 is disposed in themetal tube 3. In other words, themetal tube 3 has an inner diameter larger than the outer diameter of theceramic body 1 such that a gap having an enough size to accommodate the insulatingmember 4 having an insulatingcover 10 and thetubular portion 40 is formed between the inner circumferential surface of themetal tube 3 and the outer circumferential surface of theceramic body 1. A first end of themetal tube 3 is closed by ametal lid 11. Themetal lid 11 has a disc shape having a diameter equal to the outer diameter of themetal tube 3. - The
metal tube 3 may have an inner diameter of 4 mm, an outer diameter of 5 mm, and a length of 40 mm, for example. Themetal tube 3 is formed of a metal material such as stainless steel, aluminum, copper, or titanium, for example. In particular, stainless steel is preferably used in view of processability, strength, and heat resistance. - The insulating
cover 10 is configured to provide insulation between theleads 7 and themetal tube 3 and insulation between theelectrodes 6 and themetal tube 3. - The insulating
cover 10 surrounds theelectrodes 6 together with the first end of eachlead 7. In theheater 100 according to the present embodiment, the insulatingcover 10 is a sheet-like member. The insulatingcover 10 is formed of an insulating material such as a fluoropolymer, for example. The insulatingcover 10 may have a thickness of about 0.2 mm and a length of about 6 mm, for example. The insulatingcover 10 is not necessarily limited to the sheet-like member. The insulatingcover 10 may be a tubular member, for example. In addition, in the present embodiment, the insulatingcover 10 is a solid member, but the configuration of the insulatingcover 10 is not limited thereto. The insulatingcover 10 may be a semisolid member such as a gel, or may be a hardened semisolid member, for example. - The insulating
member 4 is configured to prevent theceramic body 1 from being in contact with themetal tube 3. The insulatingmember 4, which includes atubular portion 40, is in contact with an outer circumferential surface of theceramic body 1 at an inner circumferential surface thereof and in contact with an inner circumferential surface of themetal tube 3 at an outer circumferential surface thereof. The insulatingmember 4 is formed of a ceramic material such as alumina and aluminum nitride. The insulatingmember 4 may be an inorganic hardened product obtained, for example, by inserting theceramic body 1 into themetal tube 3, filling a space between theceramic body 1 and themetal tube 3 with a solution including an inorganic adhesive, water, and the above-described ceramic material (alumina or alumina nitride, for example) in the form of powder, and then drying the solution so as to be hardened such that the ceramic material and the component of the inorganic adhesive are in contact with each other and combined strongly due to mutual influence. Examples of the inorganic adhesive include water dispersible silica sol and water dispersible alumina sol. - When the insulating
member 4 is formed of an inorganic adhesive, the insulatingmember 4 preferably has porosity larger than that of theceramic body 1. This configuration enables, when thermal stress occurs in theheater 100 at a position inner than themetal tube 3, the insulatingmember 4 to change its shape to absorb the thermal stress. This reduces the possibility that theceramic body 1 will have a crack. The porosity is compared by the following method. Specifically, the insulatingmember 4 and theceramic body 1 are each cut to have a cross section. Then, the porosity is calculated by determining a ratio of an area of voids per unit area. - In addition, an organic adhesive such as an epoxy resin and a silicon resin, for example, may also be used as a material of the insulating
member 4. The material of the insulatingmember 4 may be suitably selected depending on the usage environment of theheater 100. The insulatingmember 4 formed of the above-described inorganic adhesive is preferably employed, because such an insulatingmember 4 is able to withstand temperatures of up to about 800°C. - The dimension of the insulating
member 4 may be set such that thetubular portion 40 has an inner diameter of 3 mm × 1 mm, which is the same as the outer diameter of theceramic body 1, and an outer diameter of 4 mm, which is the same as the inner diameter of themetal tube 3, and a length of 20 mm, for example. - In the
heater 100 according to the present embodiment, instead of the insulating powder, which is unevenly dispersed due to vibrations such that the insulating powder exists in a larger amount at a certain position and exists in a smaller amount at a certain position, the insulatingmember 4 is disposed between themetal tube 3 and theceramic body 1, preventing the uneven dispersion. This reduces the possibility that themetal tube 3 and theceramic body 1 will partly come in contact with each other, and thus reduces the possibility that the surface of theceramic body 1 will have a large difference in temperature. Thus, the possibility that the thermal stress will occur on theceramic body 1 is reduced. As a result, the durability of theheater 100 is improved. - In addition, the insulating
member 4 is preferably a joining layer as described above. In such a case, the insulatingmember 4 enables theceramic body 1 and themetal tube 3 to be connected to each other, improving the contact between the insulatingmember 4 and theceramic body 1 and the contact between the insulatingmember 4 and themetal tube 3. This allows heat to be readily transferred from theceramic body 1 to themetal tube 3. As a result, temperature rise performance of theheater 100 is improved. The above-described inorganic adhesive or organic adhesive may be used as an adhesive. Thus, the inorganic hardened product using the inorganic adhesive enables theceramic body 1 and themetal tube 3 to be connected to each other. - In addition, as described above, the insulating
member 4 preferably includes a ceramic powder. This increases the strength of the insulatingmember 4. As a result, theheater 100 has higher long-term reliability. In addition, it is preferable that the ceramic powder in the insulatingmember 4 and the main component of theceramic body 1 be formed of the same ceramic material. This reduces a difference in thermal expansion between the insulatingmember 4 and theceramic body 1. As a result, generation of thermal stress in theheater 100 while the temperature increases or decreases is reduced. - As described above, the contact between the
metal tube 3 and theceramic body 1 is not preferable in view of durability of theheater 100. This is based on the following reason. If theceramic body 1 has a crack due to thermal stress caused by a difference in thermal expansion between theceramic body 1 and themetal tube 3, the crack may be developed to reach theheating resistor 2 in theceramic body 1. In such a case, a resistance value of theheating resistor 2 may change. This may prevent theheater 100 from generating heat of a predetermined temperature. - Compared to this, since the
tubular portion 40 of the insulatingmember 4 and themetal tube 3 are in contact with each other in theheater 100 according to the present embodiment, even if the crack occurs on the insulatingmember 4, development of the crack is suppressed at an interface between the insulatingmember 4 and theceramic body 1. In addition, since themetal tube 3 and theceramic body 1 are disposed away from each other, the surface of theceramic body 1 will not have a large difference in temperature, resulting in a reduction in occurrence of the crack. - Thus, the possibility that the resistance value of the
heating resistor 2 will change due to the crack is reduced, resulting in a reduction of the possibility that theheater 100 will not be able to generate heat of a predetermined temperature. However, if the crack in the insulatingmember 4 is developed in the insulatingmember 4 and the insulatingmember 4 is largely deformed, the thermal stress due to a difference in thermal expansion between the insulatingmember 4 and theceramic body 1 may locally concentrate on theceramic body 1. In such a case, theceramic body 1 may have a crack. In view of this, the insulatingmember 4 also preferably has the configuration that reduces the crack development. This is described later. - In addition, in the
heater 100 according to the present embodiment, themetal lid 11 closing the first end of themetal tube 3 and theceramic body 1 define aspace 12 therebetween. This reduces thermal stress generated in theceramic body 1 when a portion of theceramic body 1 at the first end side is thermally expanded by the heat generated by theheating resistor 2, since contact between theceramic body 1 and themetal lid 11 due to a difference in thermal expansion between theceramic body 1 and themetal lid 11 is prevented. This reduces the possibility that theceramic body 1 will have a crack, improving durability of theheater 100. Thespace 12 may have a length of 0.2 to 2 mm in the longitudinal direction of theceramic body 1, for example. In particular, since the length of thespace 12 is 0.2 mm or more, theceramic body 1 and themetal lid 11 are less likely to come in contact with each other even when theceramic body 1 and themetal lid 11 are thermally expanded by heat generated by theheater 100. - A first modification of the
heater 100 is described. In theheater 100 according to the above-described embodiment, the insulatingmember 4 has a tubular shape having open ends, but the shape of the insulatingmember 4 is not limited thereto. Specifically, the insulatingmember 4 may be closed at one end, another end, or both the ends. In other words, the insulatingmember 4 may have thetubular portion 40 and a portion closing an opening at one end or at another end of thetubular portion 40, or portions closing openings at both the ends. As illustrated inFig. 2 , in theheater 100 according to the first modification, the first end of the insulatingmember 4 is in contact with the entire inner surface of themetal lid 11. In addition, the second end of the insulatingmember 4 is positioned in the opening of themetal tube 3 at the second end side. At the second end side of themetal tube 3, the insulatingmember 4 surrounds theceramic body 1 together with the insulatingcover 10, theelectrodes 6, and the portions of thetubes 9 covering theleads 7, and is in contact with a second-end-side portion of theceramic body 1 without any gap therebetween. Since the insulatingmember 4 covers the whole of theceramic body 1, theceramic body 1 is air-tightly sealed. As a result, theceramic body 1 in theheater 100 has improved environmental resistance. - In this modification, the
heater 100 includes the insulatingcover 10 as in the above-described embodiment, but the configuration of theheater 100 is not limited thereto. Specifically, the insulatingcover 10 may be eliminated from theheater 100, and the insulatingmember 4 may directly cover theelectrodes 6. The insulatingmember 4 covering the whole of theceramic body 1 together with theelectrodes 6 provides insulation between theelectrodes 6 and themetal tube 3. - In addition, in this modification, unlike the above-described embodiment, the
heater 100 does not include thespace 12, but the configuration of theheater 100 is not limited thereto. Theheater 100 according to this modification may include thespace 12 as in the above-described embodiment. This configuration reduces the thermal stress caused by the difference in thermal expansion between theceramic body 1 and themetal lid 11. - The insulating
member 4 in this modification may be produced as described below. Specifically, theleads 7 are disposed on theelectrodes 6 on theceramic body 1 and are connected thereto with a silver-copper brazing filler metal or a silver brazing filler metal. Then, the insulatingcover 10 formed of a fluoropolymer is disposed to cover theelectrodes 6 and the brazed portion. Theceramic body 1 to which theelectrodes 6, theleads 7, and the insulatingcover 10 are attached as described above is disposed in themetal tube 3, and then a slurry solution is filled in themetal tube 3 to the upper surface so as not to have air bubbles between theceramic body 1 and themetal tube 3. The slurry solution is obtained by mixing an inorganic adhesive and water with ground ceramic such as alumina and alumina nitride, for example (ceramic powder). After the filling, water in the slurry solution is evaporated slowly by preliminary drying at 100°C or less for about 30 minutes. The preliminary drying is preferably performed at a temperature of 70 to 80°C, because if the drying is performed at 100°C or more, water is boiled to generate air bubbles, leading to a decrease in strength and deterioration in external appearance. After the preliminary drying, drying is performed at 250°C for 30 minutes to dry and harden the inorganic adhesive component. As a result, the insulatingmember 4 is produced. As in theheater 100 according to the above-described embodiment, the insulatingmember 4 may be formed of ceramic or may be formed of an organic adhesive. - A second modification of the
heater 100 is described. In theheater 100 according to the above-described embodiment, the insulatingmember 4 is composed of one component, but the configuration of the insulatingmember 4 is not limited thereto. Specifically, thetubular portion 40 of the insulatingmember 4 may include afirst portion 41 and asecond portion 42 each having a tubular shape. As illustrated inFig. 3 , in theheater 100 according to the second modification, thetubular portion 40 of the insulatingmember 4 includes thefirst portion 41 and thesecond portion 42. Thefirst portion 41 is positioned at the first end side of themetal tube 3, and thesecond portion 42 is positioned at the second end side of themetal tube 3. Thefirst portion 41 and thesecond portion 42 each have a tubular shape, and an end surface of thefirst portion 41 and an end surface of thesecond surface 42 are in contact with each other. As described above, since the insulatingmember 4 includes a plurality of portions, if one of the portions (thefirst portion 41, for example) has a crack, the development of the crack stops between the two portions (thefirst portion 41 and the second portion 42), reducing the possibility that the crack will develop to reach another portion (thesecond portion 42, for example). This reduces the possibility that the crack in the insulatingmember 4 will develop in the insulatingmember 4 to largely deform the insulatingmember 4. - In addition, in this modification, the
heating resistor 2 is disposed on the first end side of theceramic body 1, and thefirst portion 41 surrounds an entire portion of theceramic body 1 corresponding to theheating resistor 2. Since thefirst portion 41 surrounds theheating resistor 2, most of the heat generated by theheating resistor 2 is transferred to thefirst portion 41. In addition, since the insulatingmember 4 includes separate portions of thefirst portion 41 and thesecond portion 42, an interface exists between thefirst portion 41 and thesecond portion 42, reducing the amount of heat transferred from thefirst portion 41 to thesecond portion 42. This reduces the possibility that the heat generated by theheating resistor 2 will be transferred to thesecond portion 42 and escape to the second end side of theheater 100. - The
first portion 41 and thesecond portion 42 may be formed of the same material, but may be formed of different materials. When thefirst portion 41 and thesecond portion 42 are formed of different materials, thefirst portion 41 preferably has higher thermal conductivity than thesecond portion 42, for example. Thefirst portion 41 having higher thermal conductivity enables the heat generated by theheating resistor 2 to transfer rapidly to themetal tube 3. In addition, thesecond portion 42 having lower thermal conductivity reduces the possibility that the heat generated by theheating resistor 2 will be released to the outside from the side of theleads 7. This configuration enables theheater 100 to have a higher rate of temperature rise. - The thermal conductivity of the
first portion 41 may be made higher than that of thesecond portion 42 by allowing thefirst portion 41 and thesecond portion 42 to have different amounts of the ceramic powder in the inorganic adhesive, for example. More specifically, if the inorganic adhesive is water dispersible silica sol and the ceramic is alumina, for example, the amount of alumina in thefirst portion 41 may be made larger than that in thesecond portion 42. Alternatively, the thermal conductivity may be adjusted by allowing thefirst portion 41 and thesecond portion 42 to include different ceramic powders or different inorganic adhesives. - Alternatively, the thermal conductivity of the
first portion 41 may be made higher than that of thesecond portion 42 by adjusting a proportion of air bubbles in the inorganic adhesive to be larger in thesecond portion 42 than in thefirst portion 41, for example. The thermal conductivity of thesecond portion 42 is able to be made smaller by increasing the amount of air bubbles in the inorganic adhesive. In addition, the increase in the amount of air bubbles in the second portion enables the second portion to readily absorb the thermal stress, reducing the possibility that the generated thermal stress will be applied to thelead 7, for example. As a result, theheater 100 has higher long-term reliability. - In this modification, the
heater 100 includes the insulatingcover 10 as in the above-described embodiment, but the configuration of theheater 100 is not limited thereto. Specifically, the insulatingcover 10 may be eliminated from theheater 100, and the insulatingmember 4 may directly cover theelectrodes 6. The insulatingmember 4 covering the whole of theceramic body 1 together with theelectrodes 6 provides insulation between theelectrodes 6 and themetal tube 3. - In this modification, unlike the above-described embodiment, the
heater 100 does not include thespace 12, but the configuration of theheater 100 is not limited thereto. Theheater 100 according to this modification preferably has thespace 12 as in the above-described embodiment. This configuration reduces the thermal stress caused by the difference in thermal expansion between theceramic body 1 and themetal lid 11. - The
first portion 41 and thesecond portion 42 may be produced as described below. Initially, an electrodeceramic body 1 to which theelectrodes 6, theleads 7, and the insulatingcover 10 are attached is inserted into themetal tube 3 with the opening at the first end closed by themetal lid 11. Then, a portion of themetal tube 3 at the first end side is filled with a slurry solution obtained by mixing an inorganic adhesive and water with ground ceramic such as alumina and nitride aluminum, for example (ceramic powder). Then, water in the slurry solution is evaporated slowly at 100°C or less for 30 minutes, and then the slurry solution is hardened by drying in a high-temperature environment to form thefirst portion 41. Then, a slurry solution obtained by mixing an inorganic adhesive and water with ground ceramic such as alumina and nitride aluminum, for example, is filled. Then, water in the slurry solution is evaporated slowly at 100°C or less for 30 minutes, and then the slurry solution is hardened by drying in a high temperature environment to form thesecond portion 42. As in theheater 100 according to the above-described embodiment, the insulatingmember 4 may be formed of ceramic or an organic adhesive. -
- 100
- heater
- 1
- ceramic body
- 2
- heating resistor
- 3
- metal tube
- 4
- insulating member
- 40
- tubular portion
- 41
- first portion
- 42
- second portion
- 5
- lead-out portion
- 6
- electrode
- 7
- lead
- 8
- brazing filler metal
- 9
- tube
- 10
- insulating cover
- 11
- metal lid
- 12
- space
Claims (9)
- A heater (100) comprising:a ceramic body (1) having a columnar shape or a tubular shape;a heating resistor (2) in the ceramic body (1);a metal tube (3) in which the ceramic body (1) is disposed; andan insulating member (4) disposed between the ceramic body (1) and the metal tube (3), the insulting member including a tubular portion (40) in contact with an outer circumferential surface of the ceramic body (1) at an inner circumferential surface thereof and in contact with an inner circumferential surface of the metal tube (3) at an outer circumferential surface thereof,characterized in that the insulating member (4) has larger porosity than the ceramic body (1).
- The heater according to Claim 1, wherein the tubular portion (40) includes a first portion (41) and a second portion (42) each having a tubular shape, and the first portion (41) is disposed at a first end side of the ceramic body (1) and the second portion (42) is positioned at a second end side of the ceramic body (1).
- The heater according to Claim 1 or 2, wherein the heating resistor (2) is disposed on a first end side of the ceramic body (1), and the first portion (41) surrounds an entire portion of the ceramic body (1) corresponding to the heating resistor (2).
- The heater according to any one of Claims 1 to 3, further comprising a metal lid (11) closing an end of the metal tube (3), wherein the metal lid (11) and the ceramic body (1) define a space (12) therebetween.
- The heater according to any one of Claims 1 to 4, wherein the ceramic body (1) and the metal tube (3) are connected to each other by the insulating member (4).
- The heater according to any one of Claims 1 to 5, wherein the insulating member (4) comprises a ceramic material identical to a main component of the ceramic body (1) .
- The heater according to any one of Claims 1 to 6, wherein the insulating member (4) is an inorganic hardened product.
- The heater according to any one of Claims 1 to 6, wherein the insulating member (4) is a joining layer including an organic adhesive.
- The heater according to Claim 8, wherein the joining layer includes a ceramic powder.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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JP2014015190 | 2014-01-30 | ||
PCT/JP2015/052626 WO2015115585A1 (en) | 2014-01-30 | 2015-01-30 | Heater |
Publications (3)
Publication Number | Publication Date |
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EP3101997A1 EP3101997A1 (en) | 2016-12-07 |
EP3101997A4 EP3101997A4 (en) | 2017-09-13 |
EP3101997B1 true EP3101997B1 (en) | 2018-09-19 |
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EP15742735.2A Active EP3101997B1 (en) | 2014-01-30 | 2015-01-30 | Heater |
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EP (1) | EP3101997B1 (en) |
JP (1) | JP6194025B2 (en) |
CN (1) | CN106416424B (en) |
WO (1) | WO2015115585A1 (en) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
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JP6792539B2 (en) * | 2017-10-31 | 2020-11-25 | 日本特殊陶業株式会社 | Ceramic heater for fluid heating |
EP3876668A4 (en) * | 2018-10-31 | 2022-08-03 | Kyocera Corporation | Heater |
CN113455103A (en) * | 2019-02-28 | 2021-09-28 | 京瓷株式会社 | Heat exchange unit and cleaning device provided with same |
JPWO2021025032A1 (en) * | 2019-08-08 | 2021-02-11 |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CH532388A (en) * | 1971-06-23 | 1973-01-15 | Nouveaux Apps Pratiques Holding Sa | Heating element for household appliance used for making hot dogs |
JPS5759639B2 (en) * | 1973-04-03 | 1982-12-15 | Hitachi Netsu Kigu Kk | |
JPS5455839A (en) * | 1977-10-12 | 1979-05-04 | Hitachi Heating Appliance Co Ltd | Manufacturing method of sheathed heater |
JPS56132788A (en) * | 1980-03-22 | 1981-10-17 | Shiyouichi Horii | Sealed heater and method of producing same |
JP3784124B2 (en) | 1997-02-28 | 2006-06-07 | 京セラ株式会社 | Ceramic sheathed heater and fluid heating apparatus using the same |
DE10040021A1 (en) * | 2000-08-16 | 2002-02-28 | Schniewindt Kg C | Heating cartridge for converting electrical energy into heat has a tubular sleeve, a cartridge base to close off the sleeve on one side and a first ceramic body fitted coaxially to the sleeve and held inside it. |
JP2006059794A (en) * | 2004-07-20 | 2006-03-02 | Denso Corp | Ceramic heater |
-
2015
- 2015-01-30 EP EP15742735.2A patent/EP3101997B1/en active Active
- 2015-01-30 WO PCT/JP2015/052626 patent/WO2015115585A1/en active Application Filing
- 2015-01-30 JP JP2015560025A patent/JP6194025B2/en active Active
- 2015-01-30 CN CN201580005347.8A patent/CN106416424B/en active Active
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Also Published As
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CN106416424A (en) | 2017-02-15 |
JPWO2015115585A1 (en) | 2017-03-23 |
JP6194025B2 (en) | 2017-09-06 |
WO2015115585A1 (en) | 2015-08-06 |
EP3101997A4 (en) | 2017-09-13 |
CN106416424B (en) | 2019-08-23 |
EP3101997A1 (en) | 2016-12-07 |
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