EP3113575B1 - Heater and glowplug - Google Patents
Heater and glowplug Download PDFInfo
- Publication number
- EP3113575B1 EP3113575B1 EP15754614.4A EP15754614A EP3113575B1 EP 3113575 B1 EP3113575 B1 EP 3113575B1 EP 15754614 A EP15754614 A EP 15754614A EP 3113575 B1 EP3113575 B1 EP 3113575B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- lead terminal
- ceramic body
- heater
- metal cap
- conductor layer
- 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 79
- 229910052751 metal Inorganic materials 0.000 claims description 57
- 239000002184 metal Substances 0.000 claims description 57
- 238000010438 heat treatment Methods 0.000 claims description 37
- 239000004020 conductor Substances 0.000 claims description 25
- 239000007767 bonding agent Substances 0.000 claims description 10
- 230000000149 penetrating effect Effects 0.000 claims description 5
- 239000000463 material Substances 0.000 description 10
- 229910052581 Si3N4 Inorganic materials 0.000 description 8
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 8
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 6
- 238000007747 plating Methods 0.000 description 6
- 238000005219 brazing Methods 0.000 description 5
- 230000035882 stress Effects 0.000 description 5
- 238000012986 modification Methods 0.000 description 4
- 230000004048 modification Effects 0.000 description 4
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 3
- KGWWEXORQXHJJQ-UHFFFAOYSA-N [Fe].[Co].[Ni] Chemical compound [Fe].[Co].[Ni] KGWWEXORQXHJJQ-UHFFFAOYSA-N 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- 230000007774 longterm Effects 0.000 description 3
- 229910052759 nickel Inorganic materials 0.000 description 3
- 229910000679 solder Inorganic materials 0.000 description 3
- 239000010935 stainless steel Substances 0.000 description 3
- 229910001220 stainless steel Inorganic materials 0.000 description 3
- 239000010936 titanium Substances 0.000 description 3
- 241000587161 Gomphocarpus Species 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 230000005611 electricity Effects 0.000 description 2
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 2
- 229910052737 gold Inorganic materials 0.000 description 2
- 239000010931 gold Substances 0.000 description 2
- 239000003350 kerosene Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 239000007769 metal material Substances 0.000 description 2
- 229910052750 molybdenum Inorganic materials 0.000 description 2
- 150000004767 nitrides Chemical class 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- 230000008646 thermal stress Effects 0.000 description 2
- 229910052719 titanium Inorganic materials 0.000 description 2
- 229910052721 tungsten Inorganic materials 0.000 description 2
- 229910017944 Ag—Cu Inorganic materials 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910020968 MoSi2 Inorganic materials 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 229910000990 Ni alloy Inorganic materials 0.000 description 1
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 1
- 229910008814 WSi2 Inorganic materials 0.000 description 1
- NEIHULKJZQTQKJ-UHFFFAOYSA-N [Cu].[Ag] Chemical compound [Cu].[Ag] NEIHULKJZQTQKJ-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- QDWJUBJKEHXSMT-UHFFFAOYSA-N boranylidynenickel Chemical compound [Ni]#B QDWJUBJKEHXSMT-UHFFFAOYSA-N 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- VQCBHWLJZDBHOS-UHFFFAOYSA-N erbium(III) oxide Inorganic materials O=[Er]O[Er]=O VQCBHWLJZDBHOS-UHFFFAOYSA-N 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- WABPQHHGFIMREM-UHFFFAOYSA-N lead(0) Chemical compound [Pb] WABPQHHGFIMREM-UHFFFAOYSA-N 0.000 description 1
- 235000021180 meal component Nutrition 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 239000011224 oxide ceramic Substances 0.000 description 1
- 229910052574 oxide ceramic Inorganic materials 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 229910052761 rare earth metal Inorganic materials 0.000 description 1
- 229910021332 silicide Inorganic materials 0.000 description 1
- FVBUAEGBCNSCDD-UHFFFAOYSA-N silicide(4-) Chemical compound [Si-4] FVBUAEGBCNSCDD-UHFFFAOYSA-N 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
- FIXNOXLJNSSSLJ-UHFFFAOYSA-N ytterbium(III) oxide Inorganic materials O=[Yb]O[Yb]=O FIXNOXLJNSSSLJ-UHFFFAOYSA-N 0.000 description 1
- RUDFQVOCFDJEEF-UHFFFAOYSA-N yttrium(III) oxide Inorganic materials [O-2].[O-2].[O-2].[Y+3].[Y+3] RUDFQVOCFDJEEF-UHFFFAOYSA-N 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
- 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
- H05B3/02—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
- 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 for use in, for example, combustion vehicle heating systems, kerosene fan heaters, glow plugs for automobile engines, various sensors such as oxygen sensors, or measurement devices.
- the present invention also relates to glow plugs including the heaters.
- a ceramic heater described in, for example, Patent Document 1 is an example of heaters for use in combustion vehicle heating systems, kerosene fan heaters, glow plugs for automobile engines, various sensors such as oxygen sensors, or measurement devices.
- the ceramic heater described in Japanese Unexamined Utility Model Registration Application Publication No. 63-80456 (hereinafter referred to as Patent Document 1) includes a rod-shaped ceramic body in which a heating resistor is embedded, and a metal cap provided so as to cover a side surface of the ceramic body.
- the metal cap is electrically connected to the heating resistor, and serves as an electrode.
- the metal cap has a through hole at the center thereof. A lead terminal extends through the through hole, and the lead terminal is bonded to the metal cap in this state.
- the lead terminal when electricity is supplied to the heating resistor through the lead terminal, the lead terminal may be heated to a high temperature due to an inrush current that flows through the lead terminal. Accordingly, the metal cap may also be heated to a high temperature by heat transmitted from the lead terminal. As a result, there is a possibility that the lead terminal will be pulled out of the metal cap due to thermal expansion of the metal cap. Accordingly, it is difficult to improve the long-term reliability of the ceramic heater in heat cycles.
- JP 2002 257341 A discloses that a ceramic glow plug comprises a ceramic heater having a heating resistor on the forward end side and an electrode lead-out part being connected with the heating resistor. This document further discloses that the electrode lead-out part is exposed to the rear end face of the ceramic heater and a nail head pin forming an anode metal is brazed to the rear end face (cf. abstract) and that a cap is boned to the rear end face of the ceramic heater so as to cover the nail head pin (cf. paragraph [0023]).
- JP S62 175523 A discloses that a glow plug comprises a ceramic heater having a metal conducting wire and a terminal cap (cf. figure 3 ).
- JP S61 76824 A discloses a glow plug comprising a ceramic heater, a metal wire and a terminal cap (cf. figure 1 ) .
- JP S60 114630 A discloses that a glow plug comprises a heater rod made of ceramic, a conducting wire and a terminal cap (cf. figure 4 ).
- JP H04 43721 Y2 discloses that a glow plug comprises a ceramic sintered body, an external electrode taking out wire and an electrode clasp (cf. figure 3 ).
- the present invention provides a heater according to claim 1 and a glow plug according to claim 5. Further embodiments of the present invention are described in the dependent claims.
- Fig. 1 is a sectional view of the heater 10.
- the heater 10 includes a ceramic body 1, a heating resistor 2 embedded in the ceramic body 1, and a metal cap 4 that covers one end of the ceramic body 1.
- a conductor layer 3 is provided on the one end of the ceramic body 1.
- the hatched area shows the region in which the conductor layer 3 is provided.
- the ceramic body 1 is, for example, a rod-shaped component.
- the ceramic body 1 includes a tapered portion 11 at the one end thereof.
- the ceramic body 1 may be made of, for example, electrically insulating ceramics, such as oxide ceramics, nitride ceramics, or carbide ceramics. More specifically, alumina ceramics, silicon nitride ceramics, aluminum nitride ceramics, silicon carbide ceramics, etc., may be used.
- the ceramic body 1 is preferably made of a silicon nitride ceramic. Silicon nitride ceramics are advantageous in that silicon nitride, which is the main component, is strong, tough, highly insulative, and highly resistant to heat.
- the ceramic body 1 made of a silicon nitride ceramic may be obtained by, for example, mixing silicon nitride, which is the main component, with 5 to 15 mass% of a rare earth element oxide, such as Y 2 O 3 , Yb 2 O 3 , or Er 2 O 3 , which serves as a sintering additive, and 0.5 to 5 mass% of Al 2 O 3 ; forming the mixture into a predetermined shape; and performing hot-press firing at 1650°C to 1780°C.
- the length of the ceramic body 1 is set to, for example, 20 to 50 mm, and the diameter of the ceramic body 1 is set to, for example, 2.5 to 5 mm.
- the length of the ceramic body 1 is about 20 to 40 mm and the diameter of the ceramic body 1 is about 3 mm
- the length of the tapered portion 11 may be set to about 1.5 mm
- the diameter of the end surface of the tapered portion 11 may be set to about 1.5 mm.
- the ceramic body 1 is made of a silicon nitride ceramic and the heating resistor 2 is made of molybdenum (Mo) or tungsten (W), MoSi 2 or WSi 2 , for example, is preferably mixed and dispersed in the ceramic body 1.
- Mo molybdenum
- W tungsten
- MoSi 2 or WSi 2 for example, is preferably mixed and dispersed in the ceramic body 1.
- the coefficient of thermal expansion of the silicon nitride ceramic which is the base material, can be set to a value close to the coefficient of thermal expansion of the heating resistor 2, and the durability of the heater 10 can be increased.
- the heating resistor 2 is a resistor for generating heat, and generates heat when a current flows therethrough.
- the heating resistor 2 is embedded in the ceramic body 1.
- the heating resistor 2 is provided at the other end of the ceramic body 1.
- the heating resistor 2 includes a heating portion 21, which is a portion that mainly generates heat, and lead portions 22 that are connected to the heating portion 21.
- the heating portion 21 has a folded shape, such as a letter 'U' shape, and both ends thereof are separately connected to the respective lead portions 22.
- the heating portion 21 having the folded shape generates a maximum amount of heat in a central region of the folded portion.
- the distance from one end of the heating portion 21 to the other end of the heating resistor 2 in the length direction of the ceramic body 1 is set to, for example, 2 to 10 mm.
- the lead portions 22 are components for electrically connecting the heating portion 21 to an external power supply. One end of each lead portion 22 extends to a surface of the ceramic body 1, and the other end is connected to an end portion of the heating portion 21. The lead portions 22 are separately connected to both ends of the heating portion 21. One of the lead portions 22 extends to an end surface of the ceramic body 1 at the one end thereof. In Fig. 2 , the location at which the lead portion 22 extends to the end surface is indicated by the broken line. The other lead portion 22 extends to an outer peripheral surface of the ceramic body 1 in a region near the one end thereof.
- the heating resistor 2 may be made be made of a material having, for example, a carbide, nitride, or silicide of W, Mo, titanium (Ti) or the like as the main component.
- the heating resistor 2 may contain the same material as the material of the ceramic body 1, so that the ceramic body 1 and the heating resistor 2 have close coefficients of thermal expansion.
- the heating portion 21 has a high resistance, and generates a maximum amount of heat in a region around the folded portion.
- the resistance per unit length of the lead portions 22 is set to a value smaller than that of the heating portion 21 by, for example, making the content of the material of the ceramic body 1 in the lead portions 22 smaller than that in the heating portion 21, or making the cross section of the lead portions 22 larger than that of the heating portion 21.
- the conductor layer 3 is a component for electrically connecting the heating resistor 2 to an external electrode.
- the conductor layer 3 is provided on at least one end surface of the ceramic body 1. More specifically, the conductor layer 3 is provided on the outer peripheral surface and end surface of the tapered portion 11.
- the conductor layer 3 is electrically connected to the heating resistor 2.
- the conductor layer 3 includes a metallized layer and a plating layer stacked on the metallized layer.
- the metallized layer may be, for example, a metallized layer containing silver, copper, or titanium, or a metallized layer containing gold, nickel, or palladium (Pd).
- the plating layer may be, for example, a nickel boron plating layer, a gold plating layer, or a nickel plating layer.
- the thickness of the metallized layer may be set to, for example, about 5 to 40 ⁇ m. The thickness of the plating layer is preferably greater than or equal to, for example, 1 ⁇ m.
- the metal cap 4 is a meal component including a bottom portion 41 and a side portion 42.
- the metal cap 4 may be made of, for example, a metal material such as a stainless steel or an iron-nickel-cobalt (Fe-Ni-Co) alloy. In particular, from the viewpoint of thermal expansion, an iron-nickel-cobalt (Fe-Ni-Co) alloy is preferably used.
- the metal cap 4 is a component for strongly connecting the conductor layer 3 to the external electrode. As illustrated in Fig. 3 , the metal cap 4 is arranged so as to cover the one end of the ceramic body 1 and at least a portion of the conductor layer 3, and is electrically connected to the conductor layer 3.
- the metal cap 4 has a shape corresponding to the tapered shape of the one end of the ceramic body 1. More specifically, the bottom portion 41 has the shape of a substantially circular plate having a through hole 7 in a central region thereof.
- the side portion 42 is shaped such that the side portion 42 is substantially annular in cross section perpendicular to the axial direction of the ceramic body 1, and such that the side portion 42 expands as the distance from the bottom portion 41 increases.
- the metal cap 4 is attached to the ceramic body 1 such that the bottom portion 41 faces the one end of the ceramic body 1 and the side portion 42 extends from the one end so as to cover a portion of the side surface of the tapered portion 11 over an annular region.
- the side portion 42 has a slit 43.
- the shape of the metal cap 4 can be changed in accordance with the shape of the ceramic body 1 as appropriate.
- the heater 10 further includes a lead terminal 5 that extends through the through hole 7 and that is bonded to the metal cap 4.
- the lead terminal 5 is a component for electrically connecting the conductor layer 3 to the external electrode.
- the lead terminal 5 is made of, for example, a metal material such as nickel or a stainless steel.
- the lead terminal 5 is a linear component, and an end portion 9 thereof, which is disposed in a gap between the bottom portion 41 of the metal cap 4 and the conductor layer 3 provided on the end surface of the ceramic body 1, is bonded to the metal cap 4. Accordingly, the metal cap 4 and the lead terminal 5 can be more strongly bonded together than when the lead terminal 5 is simply bonded to the outer surface of the bottom portion 41 of the metal cap 4.
- the end portion 9 of the lead terminal 5, which is disposed in the gap includes a part that is outside the through hole 7 when viewed in a penetrating direction of the through hole 7. More specifically, the end portion 9 of the lead terminal, which is disposed in the gap between the metal cap 4 and the end surface of the ceramic body 1, extends over an area greater than the through hole 7. Therefore, even when there is a risk that the lead terminal 5 will be pulled out of the metal cap 4, such a risk can be reduced because the end portion 9 of the lead terminal 5 engages with the bottom portion 41 of the metal cap 4. As a result, the long-term reliability of the heater 10 in heat cycles can be improved.
- the end portion 9 of the lead terminal 5 extends over a disc-shaped region. Accordingly, the risk of occurrence of local stress concentration in the end portion 9 of the lead terminal 5 can be reduced. As a result, the durability of the lead terminal 5 can be increased.
- the end portion 9 of the lead terminal 5 is apart from the metal cap 4, and a conductive bonding agent 8, with which the metal cap 4, the conductor layer 3, and the end portion 9 of the lead terminal 5 are bonded together, is in the gap. Since the conductive bonding agent 8 is provided, when an external force that pulls the lead terminal 5, that is, an external force that presses the end portion 9 of the lead terminal 5 against the metal cap 4, is applied to the lead terminal 5, the bonding agent 8 serves as a layer that absorbs the external force. Therefore, the risk that the lead terminal 5 will be damaged can be reduced.
- the bonding agent 8 may be provided so as to spread over the space between the bottom portion 41 and the conductor layer 3 but not over the space between the side portion 42 and the conductor layer 3. In such a case, the thermal stress generated between the metal cap 4 and the ceramic body 1 can be reduced.
- the through hole 7 may be filled with the bonding agent 8. In such a case, the lead terminal 5 and the metal cap 4 can be strongly bonded together.
- the bonding agent 8 is preferably provided so as to not only fill the through hole 7 but also spread along the lead terminal 5 in a region outside the metal cap 4. In such a case, the lead terminal 5 and the metal cap 4 can be more strongly bonded together.
- the conductive bonding agent 8 may be, for example, a brazing material. In Figs. 1 to 3 , the bonding agent 8 is omitted to simplify the drawings.
- the end portion 9 of the lead terminal 5 is spaced from the conductor layer 3. Accordingly, even when the lead terminal 5 is heated to a high temperature due to the inrush current that flows while electricity is being supplied, the possibility that the stress will be generated between the lead terminal 5 and the conductor layer 3 can be reduced. As a result, the possibility that the conductor layer 3 will crack can be reduced.
- the end portion 9 of the lead terminal 5 is preferably separated from the conductor layer 3 by, for example, about 0.05 to 0.2 mm.
- the dimensions of the end portion 9 of the lead terminal 5 may be set, for example, as follows. For example, when the diameter of the ceramic body 1 is 3 mm, the inner diameter of the bottom portion 41 of the metal cap 4 is about 1.8 mm, the length of the side portion 42 of the metal cap 4 in the longitudinal direction of the ceramic body 1 is about 1.2 mm, the thickness of the bottom portion 41 and the side portion 42 is about 0.3 mm, and the diameter of the through hole 7 is about 0.1 to 0.7 mm, the diameter of the end portion 9 of the lead terminal 5 may be set to a value in the range of about 0.2 to 1.7 mm that is greater than the diameter of the through hole 7, and the thickness of the end portion 9 of the lead terminal 5 may be set to about 0.1 to 1 mm.
- a glow plug 100 includes the above-described heater 10 and a cylindrical metal member 6 attached to a portion of the side surface of the heater 10 that is adjacent to the tapered portion 11.
- the metal member 6 is a component for holding the ceramic body 1.
- the metal member 6 is a cylindrical component, and is provided so as to surround the one end of the ceramic body 1. In other words, the ceramic body 1 is inserted in the metal member 6.
- the metal member 6 is electrically connected to the other lead portion 22 that extends to the region near the one end of the ceramic body 1.
- the metal member 6 is made of, for example, a stainless steel, an iron-nickel-cobalt (Fe-Ni-Co) alloy, or a nickel alloy.
- the metal member 6 and the ceramic body 1 are bonded together with a brazing material.
- the brazing material is provided so as to surround the end portion of the ceramic body 1.
- the brazing material is provided in the form of a layer over the entire circumference of the end portion of the ceramic body 1. Accordingly, the metal member 6 and the ceramic body 1 are strongly bonded together.
- the brazing material may be, for example, silver-copper (Ag-Cu) solder, Ag solder, or Cu solder containing 5 to 30 mass% of glass component.
- the glow plug 100 includes the heater 10 in which the possibility that the lead terminal 5 will be pulled out is reduced, and therefore has an improved long-term reliability in heat cycles.
- the lead terminal 5 may have various shapes depending on the use thereof. More specifically, as illustrated in Fig. 5 , the lead terminal 5 may have a shape obtained by bending a single lead wire. More specifically, the lead terminal 5 may be L-shaped such that the end portion 9 thereof extends in a direction that crosses the penetrating direction of the through hole 7. In the case where the lead terminal 5 is shaped as illustrated in Fig. 5 , when a stress that pulls the lead terminal 5 in the penetrating direction of the through hole 7 is applied, the lead terminal 5 may be deformed so as to absorb the stress.
- the lead terminal 5 may be T-shaped such that the end portion 9 thereof extends in a direction that crosses the penetrating direction of the through hole 7. Also in this case, the possibility that the lead terminal 5 will be pulled out of the metal cap 4 can be reduced.
- the end portion 9 of the lead terminal 5 may be X-shaped such that two linear parts thereof intersect.
- the stress generated between the lead terminal 5 and the metal cap 4 can be distributed over a plurality of parts. Therefore, the possibility that the lead terminal 5 will be damaged can be reduced.
- the surface area of the end portion 9 of the lead terminal 5 is smaller than that in the case where the end portion 9 of the lead terminal 5 is disc-shaped. As a result, the amount of heat generated by the heating resistor 2 and transmitted to the lead terminal 5 can be reduced.
- the portion of the lead terminal 5 that extends in the axial direction and the disc-shaped end portion 9 may be formed either integrally, as illustrated in Fig. 1 , or separately. More specifically, as illustrated in Fig. 8 , the portion of the lead terminal 5 that extends in the axial direction may be formed in the shape of a nail, and the end portion 9 that extends over a region broader than a head 51 of the nail-shaped portion may be disposed between the through hole 7 and the head of the nail-shaped portion. In this case, when the lead terminal 5 is used in heat cycles, the possibility that the portion of the lead terminal 5 that extends in the axial direction and the end portion 9 will be separated from each other can be reduced.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Resistance Heating (AREA)
Description
- The present invention relates to heaters for use in, for example, combustion vehicle heating systems, kerosene fan heaters, glow plugs for automobile engines, various sensors such as oxygen sensors, or measurement devices. The present invention also relates to glow plugs including the heaters.
- A ceramic heater described in, for example,
Patent Document 1 is an example of heaters for use in combustion vehicle heating systems, kerosene fan heaters, glow plugs for automobile engines, various sensors such as oxygen sensors, or measurement devices. The ceramic heater described in Japanese Unexamined Utility Model Registration Application Publication No.63-80456 - However, in the ceramic heater described in
Patent Document 1, when electricity is supplied to the heating resistor through the lead terminal, the lead terminal may be heated to a high temperature due to an inrush current that flows through the lead terminal. Accordingly, the metal cap may also be heated to a high temperature by heat transmitted from the lead terminal. As a result, there is a possibility that the lead terminal will be pulled out of the metal cap due to thermal expansion of the metal cap. Accordingly, it is difficult to improve the long-term reliability of the ceramic heater in heat cycles. -
JP 2002 257341 A -
JP S62 175523 A figure 3 ). -
JP S61 76824 A figure 1 ) . -
JP S60 114630 A figure 4 ). -
JP H04 43721 Y2 figure 3 ). - The present invention provides a heater according to
claim 1 and a glow plug according toclaim 5. Further embodiments of the present invention are described in the dependent claims. -
-
Fig. 1 is a sectional view of a heater and a glow plug including the heater. -
Fig. 2 is a perspective view of one end of a ceramic body included in the heater illustrated inFig. 1 . -
Fig. 3 is a perspective view of a main part of the heater illustrated inFig. 1 . -
Fig. 4 is a sectional view of the main part of the heater illustrated inFig. 1 . -
Fig. 5 is a sectional view of a modification of the heater illustrated inFig. 1 . -
Fig. 6 is a perspective view of a lead terminal illustrating a modification of the heater illustrated inFig. 1 . -
Fig. 7 is a perspective view of a lead terminal illustrating a modification of the heater illustrated inFig. 1 . -
Fig. 8 is a sectional view of a modification of the heater illustrated inFig. 1 . - A
heater 10 will be described with reference to the drawings.Fig. 1 is a sectional view of theheater 10. As illustrated inFig. 1 , theheater 10 includes aceramic body 1, aheating resistor 2 embedded in theceramic body 1, and ametal cap 4 that covers one end of theceramic body 1. Although not illustrated inFig. 1 , as illustrated inFig. 2 , aconductor layer 3 is provided on the one end of theceramic body 1. InFig. 2 , the hatched area shows the region in which theconductor layer 3 is provided. - The
ceramic body 1 is, for example, a rod-shaped component. Theceramic body 1 includes atapered portion 11 at the one end thereof. Theceramic body 1 may be made of, for example, electrically insulating ceramics, such as oxide ceramics, nitride ceramics, or carbide ceramics. More specifically, alumina ceramics, silicon nitride ceramics, aluminum nitride ceramics, silicon carbide ceramics, etc., may be used. In particular, theceramic body 1 is preferably made of a silicon nitride ceramic. Silicon nitride ceramics are advantageous in that silicon nitride, which is the main component, is strong, tough, highly insulative, and highly resistant to heat. - The
ceramic body 1 made of a silicon nitride ceramic may be obtained by, for example, mixing silicon nitride, which is the main component, with 5 to 15 mass% of a rare earth element oxide, such as Y2O3, Yb2O3, or Er2O3, which serves as a sintering additive, and 0.5 to 5 mass% of Al2O3; forming the mixture into a predetermined shape; and performing hot-press firing at 1650°C to 1780°C. The length of theceramic body 1 is set to, for example, 20 to 50 mm, and the diameter of theceramic body 1 is set to, for example, 2.5 to 5 mm. When the length of theceramic body 1 is about 20 to 40 mm and the diameter of theceramic body 1 is about 3 mm, the length of thetapered portion 11 may be set to about 1.5 mm, and the diameter of the end surface of thetapered portion 11 may be set to about 1.5 mm. - When the
ceramic body 1 is made of a silicon nitride ceramic and theheating resistor 2 is made of molybdenum (Mo) or tungsten (W), MoSi2 or WSi2, for example, is preferably mixed and dispersed in theceramic body 1. In this case, the coefficient of thermal expansion of the silicon nitride ceramic, which is the base material, can be set to a value close to the coefficient of thermal expansion of theheating resistor 2, and the durability of theheater 10 can be increased. - The
heating resistor 2 is a resistor for generating heat, and generates heat when a current flows therethrough. Theheating resistor 2 is embedded in theceramic body 1. Theheating resistor 2 is provided at the other end of theceramic body 1. Theheating resistor 2 includes aheating portion 21, which is a portion that mainly generates heat, and leadportions 22 that are connected to theheating portion 21. Theheating portion 21 has a folded shape, such as a letter 'U' shape, and both ends thereof are separately connected to therespective lead portions 22. Theheating portion 21 having the folded shape generates a maximum amount of heat in a central region of the folded portion. The distance from one end of theheating portion 21 to the other end of theheating resistor 2 in the length direction of theceramic body 1 is set to, for example, 2 to 10 mm. - The
lead portions 22 are components for electrically connecting theheating portion 21 to an external power supply. One end of eachlead portion 22 extends to a surface of theceramic body 1, and the other end is connected to an end portion of theheating portion 21. Thelead portions 22 are separately connected to both ends of theheating portion 21. One of thelead portions 22 extends to an end surface of theceramic body 1 at the one end thereof. InFig. 2 , the location at which thelead portion 22 extends to the end surface is indicated by the broken line. Theother lead portion 22 extends to an outer peripheral surface of theceramic body 1 in a region near the one end thereof. - The
heating resistor 2 may be made be made of a material having, for example, a carbide, nitride, or silicide of W, Mo, titanium (Ti) or the like as the main component. Theheating resistor 2 may contain the same material as the material of theceramic body 1, so that theceramic body 1 and theheating resistor 2 have close coefficients of thermal expansion. Theheating portion 21 has a high resistance, and generates a maximum amount of heat in a region around the folded portion. The resistance per unit length of thelead portions 22 is set to a value smaller than that of theheating portion 21 by, for example, making the content of the material of theceramic body 1 in thelead portions 22 smaller than that in theheating portion 21, or making the cross section of thelead portions 22 larger than that of theheating portion 21. - The
conductor layer 3 is a component for electrically connecting theheating resistor 2 to an external electrode. Theconductor layer 3 is provided on at least one end surface of theceramic body 1. More specifically, theconductor layer 3 is provided on the outer peripheral surface and end surface of the taperedportion 11. Theconductor layer 3 is electrically connected to theheating resistor 2. Theconductor layer 3 includes a metallized layer and a plating layer stacked on the metallized layer. The metallized layer may be, for example, a metallized layer containing silver, copper, or titanium, or a metallized layer containing gold, nickel, or palladium (Pd). The plating layer may be, for example, a nickel boron plating layer, a gold plating layer, or a nickel plating layer. The thickness of the metallized layer may be set to, for example, about 5 to 40 µm. The thickness of the plating layer is preferably greater than or equal to, for example, 1 µm. - The
metal cap 4 is a meal component including abottom portion 41 and aside portion 42. Themetal cap 4 may be made of, for example, a metal material such as a stainless steel or an iron-nickel-cobalt (Fe-Ni-Co) alloy. In particular, from the viewpoint of thermal expansion, an iron-nickel-cobalt (Fe-Ni-Co) alloy is preferably used. Themetal cap 4 is a component for strongly connecting theconductor layer 3 to the external electrode. As illustrated inFig. 3 , themetal cap 4 is arranged so as to cover the one end of theceramic body 1 and at least a portion of theconductor layer 3, and is electrically connected to theconductor layer 3. Themetal cap 4 has a shape corresponding to the tapered shape of the one end of theceramic body 1. More specifically, thebottom portion 41 has the shape of a substantially circular plate having a throughhole 7 in a central region thereof. Theside portion 42 is shaped such that theside portion 42 is substantially annular in cross section perpendicular to the axial direction of theceramic body 1, and such that theside portion 42 expands as the distance from thebottom portion 41 increases. Themetal cap 4 is attached to theceramic body 1 such that thebottom portion 41 faces the one end of theceramic body 1 and theside portion 42 extends from the one end so as to cover a portion of the side surface of the taperedportion 11 over an annular region. Theside portion 42 has aslit 43. Accordingly, the possibility that thermal stress will be generated in themetal cap 4 due to a difference in the amount of thermal expansion between themetal cap 4 and theceramic body 1 can be reduced. The shape of themetal cap 4 can be changed in accordance with the shape of theceramic body 1 as appropriate. - The
heater 10 further includes alead terminal 5 that extends through the throughhole 7 and that is bonded to themetal cap 4. Thelead terminal 5 is a component for electrically connecting theconductor layer 3 to the external electrode. Thelead terminal 5 is made of, for example, a metal material such as nickel or a stainless steel. Thelead terminal 5 is a linear component, and anend portion 9 thereof, which is disposed in a gap between thebottom portion 41 of themetal cap 4 and theconductor layer 3 provided on the end surface of theceramic body 1, is bonded to themetal cap 4. Accordingly, themetal cap 4 and thelead terminal 5 can be more strongly bonded together than when thelead terminal 5 is simply bonded to the outer surface of thebottom portion 41 of themetal cap 4. - In addition, in the
heater 10, as illustrated inFigs. 3 and4 , theend portion 9 of thelead terminal 5, which is disposed in the gap, includes a part that is outside the throughhole 7 when viewed in a penetrating direction of the throughhole 7. More specifically, theend portion 9 of the lead terminal, which is disposed in the gap between themetal cap 4 and the end surface of theceramic body 1, extends over an area greater than the throughhole 7. Therefore, even when there is a risk that thelead terminal 5 will be pulled out of themetal cap 4, such a risk can be reduced because theend portion 9 of thelead terminal 5 engages with thebottom portion 41 of themetal cap 4. As a result, the long-term reliability of theheater 10 in heat cycles can be improved. - In the
heater 10, theend portion 9 of thelead terminal 5 extends over a disc-shaped region. Accordingly, the risk of occurrence of local stress concentration in theend portion 9 of thelead terminal 5 can be reduced. As a result, the durability of thelead terminal 5 can be increased. - In addition, in the
heater 10, as illustrated inFig. 4 , theend portion 9 of thelead terminal 5 is apart from themetal cap 4, and aconductive bonding agent 8, with which themetal cap 4, theconductor layer 3, and theend portion 9 of thelead terminal 5 are bonded together, is in the gap. Since theconductive bonding agent 8 is provided, when an external force that pulls thelead terminal 5, that is, an external force that presses theend portion 9 of thelead terminal 5 against themetal cap 4, is applied to thelead terminal 5, thebonding agent 8 serves as a layer that absorbs the external force. Therefore, the risk that thelead terminal 5 will be damaged can be reduced. - In addition, as illustrated in
Fig. 4 , thebonding agent 8 may be provided so as to spread over the space between thebottom portion 41 and theconductor layer 3 but not over the space between theside portion 42 and theconductor layer 3. In such a case, the thermal stress generated between themetal cap 4 and theceramic body 1 can be reduced. As illustrated inFig. 4 , the throughhole 7 may be filled with thebonding agent 8. In such a case, thelead terminal 5 and themetal cap 4 can be strongly bonded together. Thebonding agent 8 is preferably provided so as to not only fill the throughhole 7 but also spread along thelead terminal 5 in a region outside themetal cap 4. In such a case, thelead terminal 5 and themetal cap 4 can be more strongly bonded together. - The
conductive bonding agent 8 may be, for example, a brazing material. InFigs. 1 to 3 , thebonding agent 8 is omitted to simplify the drawings. - As illustrated in
Fig. 4 , in theheater 10, theend portion 9 of thelead terminal 5 is spaced from theconductor layer 3. Accordingly, even when thelead terminal 5 is heated to a high temperature due to the inrush current that flows while electricity is being supplied, the possibility that the stress will be generated between thelead terminal 5 and theconductor layer 3 can be reduced. As a result, the possibility that theconductor layer 3 will crack can be reduced. Theend portion 9 of thelead terminal 5 is preferably separated from theconductor layer 3 by, for example, about 0.05 to 0.2 mm. - The dimensions of the
end portion 9 of thelead terminal 5 may be set, for example, as follows. For example, when the diameter of theceramic body 1 is 3 mm, the inner diameter of thebottom portion 41 of themetal cap 4 is about 1.8 mm, the length of theside portion 42 of themetal cap 4 in the longitudinal direction of theceramic body 1 is about 1.2 mm, the thickness of thebottom portion 41 and theside portion 42 is about 0.3 mm, and the diameter of the throughhole 7 is about 0.1 to 0.7 mm, the diameter of theend portion 9 of thelead terminal 5 may be set to a value in the range of about 0.2 to 1.7 mm that is greater than the diameter of the throughhole 7, and the thickness of theend portion 9 of thelead terminal 5 may be set to about 0.1 to 1 mm. - Referring to
Fig. 1 again, aglow plug 100 includes the above-describedheater 10 and acylindrical metal member 6 attached to a portion of the side surface of theheater 10 that is adjacent to the taperedportion 11. - The
metal member 6 is a component for holding theceramic body 1. Themetal member 6 is a cylindrical component, and is provided so as to surround the one end of theceramic body 1. In other words, theceramic body 1 is inserted in themetal member 6. Themetal member 6 is electrically connected to theother lead portion 22 that extends to the region near the one end of theceramic body 1. Themetal member 6 is made of, for example, a stainless steel, an iron-nickel-cobalt (Fe-Ni-Co) alloy, or a nickel alloy. - The
metal member 6 and theceramic body 1 are bonded together with a brazing material. The brazing material is provided so as to surround the end portion of theceramic body 1. In other word, the brazing material is provided in the form of a layer over the entire circumference of the end portion of theceramic body 1. Accordingly, themetal member 6 and theceramic body 1 are strongly bonded together. - The brazing material may be, for example, silver-copper (Ag-Cu) solder, Ag solder, or Cu solder containing 5 to 30 mass% of glass component. The
glow plug 100 includes theheater 10 in which the possibility that thelead terminal 5 will be pulled out is reduced, and therefore has an improved long-term reliability in heat cycles. - The
lead terminal 5 may have various shapes depending on the use thereof. More specifically, as illustrated inFig. 5 , thelead terminal 5 may have a shape obtained by bending a single lead wire. More specifically, thelead terminal 5 may be L-shaped such that theend portion 9 thereof extends in a direction that crosses the penetrating direction of the throughhole 7. In the case where thelead terminal 5 is shaped as illustrated inFig. 5 , when a stress that pulls thelead terminal 5 in the penetrating direction of the throughhole 7 is applied, thelead terminal 5 may be deformed so as to absorb the stress. - Alternatively, as illustrated in
Fig. 6 , thelead terminal 5 may be T-shaped such that theend portion 9 thereof extends in a direction that crosses the penetrating direction of the throughhole 7. Also in this case, the possibility that thelead terminal 5 will be pulled out of themetal cap 4 can be reduced. - Alternatively, as illustrated in
Fig. 7 , theend portion 9 of thelead terminal 5 may be X-shaped such that two linear parts thereof intersect. In such a case, even when thelead terminal 5 is pulled in various directions, the stress generated between thelead terminal 5 and themetal cap 4 can be distributed over a plurality of parts. Therefore, the possibility that thelead terminal 5 will be damaged can be reduced. In addition, the surface area of theend portion 9 of thelead terminal 5 is smaller than that in the case where theend portion 9 of thelead terminal 5 is disc-shaped. As a result, the amount of heat generated by theheating resistor 2 and transmitted to thelead terminal 5 can be reduced. - The portion of the
lead terminal 5 that extends in the axial direction and the disc-shapedend portion 9 may be formed either integrally, as illustrated inFig. 1 , or separately. More specifically, as illustrated inFig. 8 , the portion of thelead terminal 5 that extends in the axial direction may be formed in the shape of a nail, and theend portion 9 that extends over a region broader than ahead 51 of the nail-shaped portion may be disposed between the throughhole 7 and the head of the nail-shaped portion. In this case, when thelead terminal 5 is used in heat cycles, the possibility that the portion of thelead terminal 5 that extends in the axial direction and theend portion 9 will be separated from each other can be reduced. -
- 1
- ceramic body
- 11
- tapered portion
- 2
- heating resistor
- 21
- heating portion
- 22
- lead portion
- 3
- conductor layer
- 4
- metal cap
- 41
- bottom portion
- 42
- side portion
- 43
- slit
- 5
- lead terminal
- 6
- metal member
- 7
- through hole
- 8
- bonding agent
- 9
- end portion
- 10
- heater
- 100
- glow plug
Claims (5)
- A heater (10) comprising:a ceramic body (1) having a rod shape;a heating resistor (2) embedded in the ceramic body;a conductor layer (3) on at least one end surface of the ceramic body, electrically connected to the heating resistor (2);a metal cap (4) attached to an end portion of the ceramic body (1) at a site near the end surface, the metal cap (4) covering at least a portion of the conductor layer (3) and the end surface with a gap therebetween and including a through hole (7); anda lead terminal (5) inserted in the through hole (7) and electrically connected to the conductor layer (3),wherein an end portion (9) of the lead terminal (5) disposed in the gap comprises a portion that is outside the through hole (7) when viewed in a penetrating direction of the through hole (7),wherein the metal cap (4) includes a bottom portion (41) and a side portion (42),the heater being characterised in that the metal cap (4)has a slit (43) connecting with the through hole (7) from the side portion (42).
- The heater (10) according to Claim 1, wherein the end portion (9) of the lead terminal (5) is disc-shaped.
- The heater (10) according to Claim 1 or 2, wherein the end portion (9) of the lead terminal (5) is apart from the metal cap (4), and a conductive bonding agent (8) that bonds the metal cap (4), the conductor layer (3), and the end portion (9) of the lead terminal (5) together is disposed in the gap.
- The heater (10) according to any one of Claims 1 to 3, wherein the end portion (9) of the lead terminal (5) is apart from the conductor layer (3).
- A glow plug (100) comprising:the heater (10) according to any one of Claims 1 to 4; anda cylindrical metal member (6) attached to the ceramic body (1), the cylindrical metal member (6) covering a side surface of the ceramic body (1) at a site near the end surface.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2014035719 | 2014-02-26 | ||
PCT/JP2015/055334 WO2015129722A1 (en) | 2014-02-26 | 2015-02-25 | Heater and glowplug |
Publications (3)
Publication Number | Publication Date |
---|---|
EP3113575A1 EP3113575A1 (en) | 2017-01-04 |
EP3113575A4 EP3113575A4 (en) | 2017-10-11 |
EP3113575B1 true EP3113575B1 (en) | 2019-12-18 |
Family
ID=54009039
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP15754614.4A Active EP3113575B1 (en) | 2014-02-26 | 2015-02-25 | Heater and glowplug |
Country Status (3)
Country | Link |
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EP (1) | EP3113575B1 (en) |
JP (1) | JP6204566B2 (en) |
WO (1) | WO2015129722A1 (en) |
Family Cites Families (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS60114630A (en) * | 1983-11-28 | 1985-06-21 | Jidosha Kiki Co Ltd | Method for manufacturing glow plug for diesel engine |
JPS60216126A (en) * | 1984-04-12 | 1985-10-29 | Ngk Spark Plug Co Ltd | Two-wire type ceramic glow plug |
JPS6176824A (en) * | 1984-09-19 | 1986-04-19 | Jidosha Kiki Co Ltd | Manufacturing method of glow plug for diesel engine |
JPH0443721Y2 (en) * | 1985-04-17 | 1992-10-15 | ||
JPS62175523A (en) * | 1986-01-27 | 1987-08-01 | Jidosha Kiki Co Ltd | Glow plug for diesel engine |
JPS6391432A (en) * | 1986-10-03 | 1988-04-22 | Jidosha Kiki Co Ltd | Manufacture of glow plug for diesel engine |
JPH037734Y2 (en) * | 1986-11-10 | 1991-02-26 | ||
JPH07167434A (en) * | 1993-12-15 | 1995-07-04 | Nippondenso Co Ltd | Glow plug |
JP2002257341A (en) * | 2001-02-26 | 2002-09-11 | Kyocera Corp | Ceramic glow plug |
JP2005315447A (en) * | 2004-04-27 | 2005-11-10 | Kyocera Corp | Ceramic heater and glow plug |
KR101195918B1 (en) * | 2008-01-29 | 2012-10-30 | 쿄세라 코포레이션 | Ceramic heater and glow plug |
DE102009048643B4 (en) * | 2009-09-30 | 2013-11-28 | Borgwarner Beru Systems Gmbh | Glow plug and method for connecting a pin made of a functional ceramic with a metal sleeve |
-
2015
- 2015-02-25 JP JP2016505248A patent/JP6204566B2/en active Active
- 2015-02-25 EP EP15754614.4A patent/EP3113575B1/en active Active
- 2015-02-25 WO PCT/JP2015/055334 patent/WO2015129722A1/en active Application Filing
Non-Patent Citations (1)
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None * |
Also Published As
Publication number | Publication date |
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JP6204566B2 (en) | 2017-09-27 |
WO2015129722A1 (en) | 2015-09-03 |
JPWO2015129722A1 (en) | 2017-03-30 |
EP3113575A4 (en) | 2017-10-11 |
EP3113575A1 (en) | 2017-01-04 |
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