Ceramic heater

• US 5,264,681 A
• Filed: 02/07/1992
• Issued: 11/23/1993
• Est. Priority Date: 02/14/1991
• Status: Expired due to Term

• Current Assignee: NGK Spark PLUG Company Limited
• Original Assignee: NGK Spark PLUG Company Limited
• Inventors: Iwai, Masakazu, Horiki, Kiminori, Nozaki, Shunkichi, Suzuki, Yasuhiko, Tatematsu, Kazuho
• Primary Examiner(s): Reynolds, Bruce A.
• Assistant Examiner(s): SWITZER, MICHAEL
• Application Number:
  US07/832,315
• Time in Patent Office: 655 Days
• Field of Search: 219/552, 219/270, 219/544, 219/546, 219/548, 219/553, 338/327, 123/145 A, 123/145 R, 361/264, 431/191, 431/209, 431/258, 431/262, 431/263
• US Class Current: 219/544
• CPC Class Codes: F23Q 7/22 Details
• CPC Class Codes: H05B 3/12 characterised by the composition or nature of the conductive material
• CPC Class Codes: H05B 3/283 the insulating material being an inorganic material, e.g. ceramic

Abstract

The invention relates to a ceramic heater for use, e.g., as a glow plug for a diesel engine or as an igniter for an oil or gas burner. The ceramic heater has a nonoxide ceramic body having a heating part and a supporting part and a heating resistor embedded in the heating part of the ceramic body. The material of the heating resistor is W, WC, tungsten alloy or a metal nitride such as TiN or TaN. According to the invention the heating part of the ceramic body is formed of aluminum nitride ceramic, which is high in heat conductivity and resistant to oxidation at high temperatures, at least in a core region in contact with the heating resistor, and the supporting part is formed of silicon nitride ceramic which is low in heat conductivity at least in a surface region. The ceramic body is made by uniting a heating part entirely formed of aluminum nitride ceramic and a supporting part entirely formed of silicon nitride ceramic with interposal of a joint part which is formed of mixed ceramic of aluminum nitride and silicon nitride with a gradient of the proportion of aluminum nitride to silicon nitride, or by thoroughly covering a core formed of aluminum nitride ceramic with silicon nitride ceramic.

Claims

1. A ceramic heater having a sintered nonoxide ceramic body, which has a heating part and a supporting part, and a heating resistor which is embedded in the heating part of the ceramic body,

characterized in that said heating part of said ceramic body is formed of an aluminum nitride based ceramic at least in a core region thereof which is in contact with and encloses said heating element, and that said supporting part is formed of a silicon nitride based ceramic at least in a surface region thereof.

2. A ceramic heater according to claim 1, wherein the principal material of said heating resistor is selected from the group consisting of elemental tungsten, tungsten carbide (WC) and tungsten alloys.

3. A ceramic heater according to claim 1, wherein the principal material of said heating resistor is a metal nitride.

4. A ceramic heater according to claim 3, wherein said metal nitride is selected from the group consisting of TiN and TaN.

6. A ceramic heater according to claim 1, wherein said ceramic body has an elongate shape, said heating part being contiguous to one end of the elongate ceramic body and substantially entirely formed of said aluminum nitride based ceramic, said supporting part being contiguous to the opposite end of the elongate ceramic body and substantially entirely formed of said silicon nitride based ceramic.

9. A ceramic heater according to claim 1, wherein said heating part of said ceramic body has a covering region which encloses said core region and is formed of said silicon nitride based ceramic.

10. A ceramic heater according to claim 1, wherein said supporting part of said ceramic body has a core region which is covered by said surface region, contiguous to said core region of said heating part and formed of said aluminum nitride based ceramic.

11. A ceramic heater according to claim 10, wherein said ceramic body has an elongate shape, said heating part being contiguous to one end of the elongate ceramic body, said supporting part being contiguous to the opposite end of the elongate ceramic body.

12. A ceramic heater according to claim 1, wherein said heating resistor is made of a wire.

13. A ceramic heater according to claim 1, wherein said heating resistor is made of a film.

14. A ceramic heater according to claim 13, wherein said heating resistor is formed by a thick-film printing process using a paste containing a powder of the material of the heating resistor.

27. A ceramic heater according to claim 1, wherein said heating part of said ceramic body is formed of an aluminum nitride based ceramic comprising 100 parts by weight AlN, 1 part by weight Y₂ O₃ and 3 parts by weight of wax.

5. A ceramic heater having a sintered nonoxide ceramic body, which has a heating part and a supporting part, and a heating resistor which is embedded in the heating part of the ceramic body,

characterized in that said heating part of said ceramic body is formed of an aluminum nitride based ceramic at least in a core region thereof which is in contact with and encloses said heating element, and that said supporting part is formed of a silicon nitride based ceramic at least in a surface region thereof, and wherein said ceramic body has a joint part which is interposed between said heating part and said supporting part and is formed of a mixed ceramic containing both aluminum nitride and silicon nitride with a gradient of the proportion of aluminum nitride to silicon nitride such that said proportion becomes maximal in one end region of the joint part adjacent to said heating part and minimal in the opposite end region adjacent to said supporting part.

15. A ceramic heater according to claim 5, wherein the principal material of said heating resistor is selected from the group consisting of elemental tungsten, tungsten carbide (WC) and tungsten alloys.

16. A ceramic heater according to claim 5, wherein the principal material of said heating resistor is a metal nitride.

17. A ceramic heater according to claim 16, wherein said metal nitride is selected from the group consisting of TiN and TaN.

18. A ceramic heater according to claim 5, wherein said heating resistor is made of a wire.

19. A ceramic heater according to claim 5, wherein said heating resistor is made of a film.

20. A ceramic heater according to claim 19, wherein said heating resistor is formed by a thick-film printing process using a paste containing a powder of the material to the heating resistor.

7. A ceramic heater having a sintered nonoxide ceramic body, which has a heating part and a supporting part, and a heating resistor which is embedded in the heating part of the ceramic body,

characterized in that said heating part of said ceramic body is formed of an aluminum nitride based ceramic at least in a core region thereof which is in contact with and encloses said heating element, and that said supporting part is formed of a silicon nitride based ceramic at least in a surface region thereof, and wherein:

said ceramic body has an elongate shape, said heating part being contiguous to one end of the elongate ceramic body and substantially entirely formed of said aluminum nitride based ceramic, said supporting part being contiguous to the opposite end of the elongate ceramic body and substantially entirely formed of said silicon nitride based ceramic; and

said elongate ceramic body has a joint part which is interposed between said heating part and said supporting part and is formed of a mixed ceramic containing both aluminum nitride and silicon nitride with a gradient of the proportion of aluminum nitride to silicon nitride such that said proportion becomes maximal in one end region of the joint part adjacent to said heating part and minimal in the opposite end region of the joint part adjacent to said supporting part.

8. A ceramic heater according to claim 7, wherein said joint part consists of a plurality of segments which are different from each other in the proportion of aluminum nitride to silicon nitride, in each of said plurality of segments the proportion of aluminum nitride to silicon nitride being substantially uniform.

21. A ceramic heater according to claim 7, wherein the principal material of said heating resistor is selected from the group consisting of elemental tungsten, tungsten carbide (WC) and tungsten alloys.

22. A ceramic heater according to claim 7, wherein the principal material of said heating resistor is a metal nitride.

23. A ceramic heater according to claim 22, wherein said metal nitride is selected from the group consisting of TiN and TaN.

24. A ceramic heater according to claim 7, wherein said heating resistor is made of a wire.

25. A ceramic heater according to claim 7, wherein said heating resistor is made of a film.

26. A ceramic heater according to claim 25, wherein said heating resistor is formed by a thick-film printing process using a paste containing a powder of the material to the heating resistor.