GB2608618A - Thick film heating element - Google Patents

Thick film heating element Download PDF

Info

Publication number
GB2608618A
GB2608618A GB2109730.8A GB202109730A GB2608618A GB 2608618 A GB2608618 A GB 2608618A GB 202109730 A GB202109730 A GB 202109730A GB 2608618 A GB2608618 A GB 2608618A
Authority
GB
United Kingdom
Prior art keywords
fibres
thick film
heating element
film heating
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.)
Pending
Application number
GB2109730.8A
Other versions
GB202109730D0 (en
Inventor
Johannes Petrus Peeters Ward
Johannes Kloppers Gradus
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ferro Techniek BV
Original Assignee
Ferro Techniek BV
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Ferro Techniek BV filed Critical Ferro Techniek BV
Priority to GB2109730.8A priority Critical patent/GB2608618A/en
Publication of GB202109730D0 publication Critical patent/GB202109730D0/en
Priority to CN202221743456.3U priority patent/CN217789917U/en
Publication of GB2608618A publication Critical patent/GB2608618A/en
Pending legal-status Critical Current

Links

Classifications

    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05BELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00Ohmic-resistance heating
    • H05B3/68Heating arrangements specially adapted for cooking plates or analogous hot-plates
    • H05B3/688Fabrication of the plates
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05BELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00Ohmic-resistance heating
    • H05B3/10Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
    • H05B3/12Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material
    • H05B3/14Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material the material being non-metallic
    • H05B3/141Conductive ceramics, e.g. metal oxides, metal carbides, barium titanate, ferrites, zirconia, vitrous compounds
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05BELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00Ohmic-resistance heating
    • H05B3/10Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
    • H05B3/12Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material
    • H05B3/14Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material the material being non-metallic
    • H05B3/148Silicon, e.g. silicon carbide, magnesium silicide, heating transistors or diodes
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05BELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00Ohmic-resistance heating
    • H05B3/20Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/22Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
    • H05B3/26Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base
    • H05B3/262Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base the insulating base being an insulated metal plate
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05BELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00Ohmic-resistance heating
    • H05B3/68Heating arrangements specially adapted for cooking plates or analogous hot-plates
    • H05B3/72Plates of sheet metal
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05BELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/002Heaters using a particular layout for the resistive material or resistive elements
    • H05B2203/003Heaters using a particular layout for the resistive material or resistive elements using serpentine layout
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05BELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/013Heaters using resistive films or coatings
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05BELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/017Manufacturing methods or apparatus for heaters
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05BELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/033Heater including particular mechanical reinforcing means
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05BELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/034Heater using resistive elements made of short fibbers of conductive material

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Surface Heating Bodies (AREA)
  • Resistance Heating (AREA)

Abstract

A thick film heating element 1 comprises a substrate 2, an insulating layer 3 formed on the substrate, one or more heater tracks 5 formed on the insulating layer and one or more connection pads 4 connected to the one or more heater tracks, wherein at least one of the insulating layer, heater track, and connection pads include glass or ceramic fibres, for example as a composite material in a matrix of glass or ceramic material, such as a ceramic matrix composite (CMC) material. The heating element may further include a cover layer or a temperature sensor track including glass or ceramic fibres. Ceramics such as boron nitride or alumina may be used as fibres to add strength to the layers. The thermal conductivity of the layers may be increased by adding fibres of a ceramic with high thermal conductivity such as silicon carbide or silicon nitride. The fibres may be introduced into an enamel which is then sprayed or screen printed onto the substrate to form the insulating layer, or the enamel and fibres may be sprayed separately onto the substrate.

Description

Thick Film Heating Element Field of the Invention
[0001] The present invention relates to thick film heating elements and methods of manufacture.
Background of the Invention
[0002] Thick film heating elements generally comprise one or more heating tracks that are screen printed as an ink or paste onto an insulating substrate and fired to form tracks of high electrical resistivity. Connecting tracks or pads may be printed in a separate layer, with a different type of ink or paste, and fired to form connecting tracks and pads of low resistivity.
[0003] The insulating substrate may be of an electrically insulating material, such as ceramic, or may be metallic with an insulating surface layer. Thick film heating elements with metal substrates are typically manufactured by applying an electrical insulating layer onto a metal substrate and subsequently forming heater tracks onto the surface of the insulating layer. The insulating layer can be a glass or ceramic material applied using a screen printing technique or a more conventional vitreous enamelling process. The metal substrate is most commonly stainless steel. The firing temperature and other characteristics of the insulating materials, heater tracks and pads have to be compatible with the characteristics of the metal. In addition, a protective ceramic or glass covering layer may added. This can also be applied by spraying or by screen printing and is subsequently fired.
[0004] Further details of thick film technology are described for example in White N. (2017) Thick Films pages 707-709 & 712 in: Kasap S., Capper P. (eds) Springer Handbook of Electronic and Photonic Materials. The thick film paste may comprise an active material, a glass frit and an organic vehicle or carrier. The glass frit remains after firing and forms part of the structure of the thick film resistor. Hence, 'thick film' refers to a specific type of resistor with a characteristic structure and properties and is not merely a comparative term or a reference to a product when manufactured by a particular process.
[0005] The heater tracks and the connection pads comprise metal particles, typically silver, platinum or palladium or a mixture of two or more of these, and glass. They are applied to the insulating layer by screen printing in the form of a paste which is then dried and fired as described above [0006] Because the thick film materials consist of glass or ceramic, they have low tensile strength and care must be taken during the design and processing and use to ensure that the materials are subjected to compressive forces rather than tensile. This is typically done by choosing materials for the substrate which have coefficients of thermal expansion greater than the coefficient of thermal expansion of the thick film materials and insulating layer. The result is that as the thick film heater cools down after the firing process the thick film materials and insulating layer are subjected to compressive stresses. Sometimes the substrate is bowed, either before or after the firing processes to put the thick film materials under compressive stress. Even so a common failure mode is cracking of the insulating layer due to thermal shock.
[0007] Another issue is the connection of the heater track to the power supply. It is common practice to provide a connection pad of low resistance material at the ends of the heater track. This consists of a material similar to the heater track but with very low resistance so there is no significant heating in the connection area. The connection pad overlaps the end of the heater track to provide a good electrical connection. The connection of the pad to a power supply can be made using sprung contacts. These are typically a copper alloy and are provided with a low resistance silver face either by electroplating or by attaching a silver contact of the type typically found in a switch.
[0008] However, a cheaper and more compact connection can be made by soldering wires directly to the connection pads. The soldering process can cause failures of the heating element, for example due to the solder shrinking volumetrically on freezing. This is especially prevalent with the lead free Sn/Ag/Cu and Sn/Cu/Ni alloys. As the solder freezes and shrinks it applies stress to the connection pad which exceeds the strength of the bond between the pad and the heater track or the strength of the pad, heater track or insulating layer in the area of the connection pad.
[0009] A thick film element with a steel substrate requires an electrically insulating layer between the substrate and the heater tracks. In common with most materials which are electrical insulators, the glass or ceramic materials are poor thermal conductors. Even though the insulating layers are relatively thin, in the order of 100p.m, there can still be a significant temperature gradient through the layer, increasing the temperature of the heater tracks. The running temperature of the tracks limits the power which can be dissipated by the heater. If the thermal conductivity of the insulating layer is increased the power density or heat flux can be increased. The result is that a heating element of a given power can be made smaller or more power can be delivered by an element of a given size.
[0010] It is also desirable to be able to measure the temperature on the surface of a thick film heater. This can be done by printing a sensor with a material which has a relatively large change of resistance with temperature. Most of these materials have a negative temperature coefficient of resistance. It is also possible to use the resistance of the heater track as a sensor. The choice of materials with suitable coefficients of resistance is limited.
Statement of the Invention
[0011] Aspects of the invention are defined by the accompanying claims.
[0012] At least some embodiments of the invention involve a solution to the above problems which increase the strength of the thick film materials and insulating layer. The mechanical failure of glass and ceramics is typically by brittle fracture initiated by cracks which propagate at faults such as scratches in the material. In at least some embodiments, certain properties of the insulating layer are improved by the use of ceramic matrix composite materials (CMC's). These composite materials have ceramic fibres embedded in a ceramic matrix. The ceramic fibres increase the stress needed to propagate the cracks through the matrix, thus increasing the energy expended during crack propagation. When through-thickness cracks begin to form across the matrix, the fibres bridge the cracks without fracturing, thus increasing the tensile strength of the material. The ceramic fibre reinforcement increases the composite material's initial resistance to crack propagation and avoids abrupt brittle failure compare to a monolithic ceramic.
Brief Description of the Drawings
[0013] Specific embodiments of the present invention will now be described with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a thick film heating element in an embodiment of the invention; Figure 2 is an exploded perspective view of the thick film heating element in the embodiment; and Figure 3 is a cross-section of the thick film heating element in the embodiment.
Description of Embodiments
[0014] Figures 1-3 show a thick film heating element 1 comprising a substrate 2 with an insulating layer 3 of enamel. The substrate 2 may be made of steel, such as ferritic stainless steel. In a method of manufacture of the thick film heating element 1, the insulating layer 3 is formed on the substrate 2 and connection pads 4 and one or more heating tracks 5 are formed on the insulating layer 3 using a thick film printing and firing process, for example as described above. An overglaze layer or layers (not shown) may be formed over the heating tracks 5, leaving the connection pads 4 exposed.
[0015] In the embodiment, one or more of the insulating layer 3, connection pads 4, heater tracks 5 and overglaze layer(s) include glass or ceramic fibres, for example as a composite material in a matrix of glass or ceramic material. There are a number of conventional ways of introducing a ceramic matrix to the spaces between the fibres including sintering, deposition of the matrix from a gas mixture, chemical reaction, and pyrolysis. None of these methods are compatible with the two typical methods of applying insulating layer 3 or heater tracks 5 to the substrate 2: these are spraying, such as but not limited to, electrophoretic spraying, and flame spraying and screen printing.
[0016] In one method according to an embodiment, ceramic fibres are introduced into the enamel which is sprayed or the paste which is screen printed to form the insulating layer 3 after firing. In an alternative method according to the embodiment, the enamel and ceramic fibres are sprayed separately onto the substrate 2 and are then fired to form the insulating layer [0017] The size of the fibres and the amount of fibre in the matrix and the materials of the matrix and fibres determine the properties of the composite material. The length of fibre used in CMC materials can be up to 4 or 5 mm, and in practice the fibres are at least 0.5 mm long.
The diameter can vary from 1 i_tm to 50 However the size of fibres is limited by the application construction method and thickness of the insulating layer 3 and heater tracks 5.
The size of fibres in the heater tracks or connector pads are limited by the size of the holes in the printing screen.
[0018] In the insulating layer 3 the fibres may be long enough to break through the surface of the insulating layer 3. This can cause issues when the heater tracks 5 are subsequently screen printed but they can also provide a good bond between the heater tracks S and the insulating layer 3.
[0019] The fibres may be composed of one or more of a range of materials. The insulating layer 3 consists mainly of glass and this can be strengthened using glass and/or ceramic fibres. Ceramics such as boron nitride or alumina may be used as fibres to add strength to the insulating layer 3, heater track(s) S or connection pads 4. The thermal conductivity of the insulating layer 3, heater track(s) 5 or connection pads 4 can be increased by adding fibres of a ceramic with high thermal conductivity such as silicon carbide or silicon nitride.
[0020] In a variant of the embodiment, a temperature sensor track may be deposited using thick film technology on the insulating layer alongside and separate from the heater track(s) so as to sense the temperature of the heater track(s) S. The addition of ceramic fibres with low electrical resistance provides materials with temperature coefficients of resistance which make them suitable for such temperature sensor tracks. The addition of the fibres allows the temperature coefficient of resistance to be adjusted so that the properties of the sensor match the intended application. Fibres of silicon carbide are amongst those suitable for this application.
Alternative Embodiments [0021] Alternative embodiments which may occur to the skilled person on reading the above description may nevertheless fall within the scope of the following claims.

Claims (13)

  1. Claims 1. A thick film heating element comprising a substrate, an insulating layer formed on the substrate, one or more heater tracks formed on the insulating layer and one or more connection pads connected to the one or more heater tracks, wherein at least one of the insulating layer, heater track or tracks, and connection pad or pads include glass or ceramic fibres.
  2. 2. Thick film heating element of claim 1, further comprising a cover layer formed over the heater track or tracks, the cover layer including glass or ceramic fibres.
  3. 3. Thick film heating element of claim 1 or claim 2, further comprising one or more temperature sensor tracks including glass or ceramic fibres.
  4. 4. Thick film heating element of claim 3, wherein the temperature sensor track or tracks include fibres of silicon carbide.
  5. 5. Thick film heating element of any preceding claim, wherein the fibres are in a matrix of a different glass or ceramic material to that of the fibres.
  6. 6. Thick film heating element of any one of claims 1 to 4, wherein the fibres are in a matrix of the same glass or ceramic material as that of the fibres.
  7. 7. Thick film heating element consisting in part of a ceramic matrix composite material including glass or ceramic fibres.
  8. 8. Thick film heating element of any preceding claim, where the fibres are between 0.5mm and 5mm long.
  9. 9. Thick film heating element of any preceding claim, where the fibres are between 1p.m and 504m in diameter.
  10. 10. Thick film heating element of any preceding claim, where the fibres consist of glass.
  11. 11. Thick film heating element of any preceding claim, where the fibres consist of a ceramic oxide, nitride or carbide or aluminium, boron or silicon.
  12. 12. A method of manufacturing the thick film heating element of any preceding claim, wherein the fibres are introduced into an enamel which is then sprayed or screen printed onto the substrate to form the insulating layer.
  13. 13. A method of manufacturing the thick film heating element of any one of claims 1 to 11, wherein an enamel and fibres are sprayed separately onto the substrate to form the insulating layer.
GB2109730.8A 2021-07-06 2021-07-06 Thick film heating element Pending GB2608618A (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB2109730.8A GB2608618A (en) 2021-07-06 2021-07-06 Thick film heating element
CN202221743456.3U CN217789917U (en) 2021-07-06 2022-07-06 Thick film heating element

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB2109730.8A GB2608618A (en) 2021-07-06 2021-07-06 Thick film heating element

Publications (2)

Publication Number Publication Date
GB202109730D0 GB202109730D0 (en) 2021-08-18
GB2608618A true GB2608618A (en) 2023-01-11

Family

ID=77274399

Family Applications (1)

Application Number Title Priority Date Filing Date
GB2109730.8A Pending GB2608618A (en) 2021-07-06 2021-07-06 Thick film heating element

Country Status (2)

Country Link
CN (1) CN217789917U (en)
GB (1) GB2608618A (en)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105139916A (en) * 2015-06-30 2015-12-09 苏州洋杰电子有限公司 Carbon powder doped molybdenum-based thick film resistance paste and preparation method thereof
CN106328251A (en) * 2016-08-18 2017-01-11 陆川县华鑫电子厂 Thick film resistor paste and preparation method thereof
CN112992405A (en) * 2021-04-27 2021-06-18 西安宏星电子浆料科技股份有限公司 High-pressure-resistant and bending-resistant stainless steel substrate insulating medium slurry

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105139916A (en) * 2015-06-30 2015-12-09 苏州洋杰电子有限公司 Carbon powder doped molybdenum-based thick film resistance paste and preparation method thereof
CN106328251A (en) * 2016-08-18 2017-01-11 陆川县华鑫电子厂 Thick film resistor paste and preparation method thereof
CN112992405A (en) * 2021-04-27 2021-06-18 西安宏星电子浆料科技股份有限公司 High-pressure-resistant and bending-resistant stainless steel substrate insulating medium slurry

Also Published As

Publication number Publication date
CN217789917U (en) 2022-11-11
GB202109730D0 (en) 2021-08-18

Similar Documents

Publication Publication Date Title
US6222166B1 (en) Aluminum substrate thick film heater
EP2237638B1 (en) Ceramic heater, and oxygen sensor and hair iron having the ceramic heater
CN100584128C (en) Ceramic heater and heating iron using same
JPH07312301A (en) Resistor element
EP1774571B1 (en) In-line heater for use in semiconductor wet chemical processing and method of manufacturing the same
JP2001297857A (en) Ceramic heater for semiconductor manufacture and inspection device
US8138881B2 (en) Coated wire and film resistor
US20170208649A1 (en) Heater
GB2608618A (en) Thick film heating element
JP6096622B2 (en) Ceramic heater
KR20010030871A (en) Heating element and method for producing the same
KR20080010894A (en) Ceramic component and method for the same
JP2641530B2 (en) Manufacturing method of chip-shaped electronic component
JP4044245B2 (en) Silicon nitride ceramic heater
US7632537B2 (en) Circuits including a titanium substrate
JPH09245946A (en) Ceramic heater
JP4596622B2 (en) Ceramic heater and wafer heating device using the same
CN219370713U (en) Glass-based surface-mounted ignition resistor
JP3072303B2 (en) heater
JPH10172734A (en) Ceramic heating and manufacture thereof
JPS6337587A (en) Ceramic heater
JP2595612B2 (en) Method of forming heat-resistant insulation structure
JPH04317472A (en) Method for bonding insulators
JPH09153328A (en) Chip fuse
Kuzel et al. Resistors screen printed on ceramic-coated steel substrates