News | INNOVACERA

Ceramic quadrupole for mass spectrometer

The performance of the quadrupole, one of the core components of a mass spectrometer, directly determines the resolution, sensitivity and stability of the instrument. Traditional metal quadrupoles are gradually being replaced by high-performance ceramic quadrupoles due to problems such as insufficient thermal stability and mass discrimination effect.

Material selection of ceramic quadrupoles

1.Material comparison

Material	Al2O3	AlN	BeO	SiC
Thermal conductivity	20-30 W/mK	170-200 W/mK	300 W/mK	120-200 W/mK
Dielectric loss	Medium	Low	Very low	Low
Coefficient of thermal expansion	8.0×10⁻⁶/K	4.5×10⁻⁶/K	7.5×10⁻⁶/K	4.0×10⁻⁶/K

2.Key material performance requirements

-High thermal conductivity: fast heat dissipation, reducing field distortion caused by thermal deformation.

-Low dielectric loss: avoid radio frequency (RF) signal attenuation.

-High dimensional stability: extremely low thermal expansion under temperature fluctuations (CTE matching metal electrodes).

Manufacturing process of ceramic quadrupole

1.Precision molding technology

-Isostatic pressing: ensure uniform density of the blank (critical for rods with aspect ratio > 20:1).

-CNC milling: diamond tool processing of high-precision surfaces (within 5μm tolerance).

2.Surface metallization:

-Sputtering gold/platinum (thickness 0.5-1μm) to ensure electrode conductivity.

-Laser resistance trimming: Adjust the electrode shape to optimize the field distribution.

3.Quality Inspection

-Morphology detection: white light interferometer to measure surface roughness (Ra＜0.1μm).

-Electrical test: dielectric constant/loss tangent value determination (tanδ＜0.001 at 1MHz).

Technical advantages of ceramic quadrupoles

1.Performance improvement

-Improved resolution: Low thermal deformation of ceramics improves field stability and mass resolution can reach 0.1 amu.

-Extended life: Resistant to ion bombardment, life is 3-5 times longer than metal rods (especially suitable for ICP-MS).

2. Applications

-Gas chromatography-mass spectrometry (GC-MS): AlN quadrupoles reduce thermal drift and are suitable for long-term analysis.

-Portable mass spectrometer: Lightweight ceramics (40% lighter than stainless steel) help miniaturize equipment.

Ceramic quadrupole is gradually replacing metal quadrupole because of its high thermal stability, low dielectric loss and long life, and has become the standard of high-end mass spectrometers.

Innovacera specializes in the production of ceramic components for quadrupole mass spectrometry, including ceramic filament holders, ceramic orifice plates, ceramic heaters, etc. If you have any inquiry, please kindly contact us.

Advanced Aluminum Nitride Heaters Revolutionize High-Temperature Applications

Aluminum nitride heater is mainly made of aluminum nitride ceramic material, it is a high-performance heating element that can withstand extreme temperatures and provide efficient heat distribution, it revolutionizes high-temperature applications.

Aluminum Nitride Ceramic Heaters Features:

Fast heating and cooling:

It can quickly reach high temperature in a very short time, such as some data show that it can reach 600°C in 5 seconds, which is the best performance in heating equipment.

High-speed cooling capacity, can quickly respond to temperature changes, improve work efficiency.

Excellent heat conductivity:

With excellent thermal conductivity, AlN heater can quickly and evenly transfer the heat to the entire heating area to ensure the uniform heating effect which can improve heating quality and work efficiency.

Low thermal expansion:

It can maintain stable size and shape in high temperature environment so that to ensure long-term stable operation of heating equipment.

High electrical insulation:

Using special materials and process design, with electrical insulation performance, effectively prevent the occurrence of leakage and short circuit and other safety hazards, to ensure the safe use of users.

Excellent corrosion resistance:

AlN Heater can maintain stable performance in a variety of harsh environments and extend the service life of the equipment by using corrosion-resistant materials.

Technical Specifications

Material	Aluminum Nitride (AlN)
Maximum Operating Temperature	Up to 600°C
Thermal Expansion Coefficient	4.5×10⁻⁶/℃
Volume Resistivity	> 10¹³ Ω·cm
Thermal Conductivity	> 150 W/m·K
Available Sizes	10-50mm

Application field

Aluminum nitride heaters have a wide range of applications in many of industries.
Semiconductor manufacturing: With precise temperature control, AlN heater can meet requirement in the semiconductor manufacturing process.

Ceramic sintering: Ceramic materials are sintered at high temperatures, AlN heaters provide a stable high temperature environment.

Vacuum coating: AlN heater can provide rapid heating in the vacuum coating process.

Aluminum Nitride heaters perform very good heating in the heating technology. We provide engineering support including full internal thermal modeling, CFD, and CAD design services for your thermal management requirements. Any questions, pls contact with us.

Anti-static Ceramic Tweezers-Stainless Steel Handle With Ceramic Tips

Ceramic Tweezers: Ideal for Precision Operations
With its unique material properties and functional design, ceramic tweezers have become the new favorite precision tool in laboratory, electronic manufacturing, medical cosmetology and other fields.

Material Characteristics: Technology Enables Quality

Anti-static Ceramic tweezers are made of zirconia ceramics, wear-resistant and scratch-resistant, tweezers are easy to maneuver. The material is insulating and safe for use in electrically charged environments; it is also resistant to high temperatures, acid and alkali corrosion, and has stable performance in chemical environments, avoiding the risk of metal contamination.

Functional Advantage: Combination of Precision and Safety
Conventional metal tweezers are prone to conductivity/magnetization problems, while ceramic heat resistant tweezers are insulated and anti-static, safe for clamping precision electronic components (e.g. chips, wafers) and protecting sensitive devices from damage. The material is smooth and non-porous, not easy to adsorb samples, ideal for handling trace biological samples in the laboratory and optical lens cleaning to ensure data accuracy. The ceramic material is non-toxic and highly biocompatible, and is also suitable for holding sterile consumables in the medical aesthetic field.

Multiple Scenarios: Versatile Hand in Professional Field
From semiconductor testing to jewelry setting, from chemical experiments to DIY, ceramic tweezers have become efficient assistants for researchers, engineers, and craftsmen due to their corrosion-resistant, non-conductive, and high-temperature-resistant features. Its ultra-thin tip design can easily pick up tiny objects of 0.1mm, while the ergonomic handle relieves fatigue during long-time operation.

Innovacera Ceramic Tweezers Product detail:

Style	Straight tip Big elbow Elbow
Ceramic material	Zirconia
Ceramic color	White/ Black
Handle color	Stainless steel/ black
Length	100mm/130mm
Logo printing	Laser Printing
Features	Customizable, Interchangeable heads
Ceramic tweezers features	1. Tight clamping 2. Durable 3. Comfortable grip 4. Acid and alkali resistant
Applicable scenes	Acidic occasions, SMD, high temperature operation, clean room, precision machinery, etc.
Material advantages	Anti-rust, pressure and abrasion resistance, acid and alkali resistance, high elasticity, anti-static, non-sensitive, non-magnetic, antioxidant, high hardness, not easy to rust, not easy to deform, high temperature resistance of 1200 degrees Celsius
Production advantages	1. Carefully polished ceramic tweezers head, smooth surface after screw fastening, no burrs 2. Screws are fixed to the head, more solid and not easy to fall off.
Specific application:	1. Integrated circuit repair 2. Precision parts repair 3. Jewelry articulation process 4. Cell phone parts repair 5. Flying line and other electronic soldering

Ceramic Insulated tweezers samples are available, For more details and customization design welcome to contact with Innovacera.

Boron Nitride (BN) Ceramic for Metallurgy Applications

Aluminum, copper, magnesium, steel and its alloys, and nickel, cobalt, precious metals, and magnetic materials, require various refractory materials during casting, processing, and forming. Boron nitride is an ideal refractory material in the field of metallurgy due to its inertness, low wettability of molten metals, resistance to high temperatures over 2000°C, good thermal shock resistance to withstand extreme temperatures without significant deformation. This is why boron nitride has various applications in the field of metallurgy in various forms.

Sintered Boron Nitride Components in Contact with Molten Metal BMATS®.
Boron Nitride parts have high chemical resistance, long service life and reduce maintenance during production. Therefore, they are often used in the following applications:

Break rings in horizontal continuous casting of steel and its alloys:
In the horizontal casting process, the molten metal passes through different stages until it reaches the refractory rings in the solidification zone, at this point, the temperature changes drastically. Therefore, it is crucial to protect the integrity of the split rings or the broken rings, as failure at this point will result in the casting loss. Boron Nitride, together with different additives, has a high resistance to thermal shock and is non-sticky and has a low coefficient of friction.

Boron Nitride Nozzles for Molten Metal Atomizing:
Boron Nitride nozzles are widely used in the processing of metal powder. Molten metal atomization is a process used to fabricate metal powder from a melt. The metal falls into the spray chamber through a “nozzle” . The nozzle is one of the most important parts of the atomization process, a damaged or clogged nozzle can cause the metal flow to stop or the flow to increase dramatically – both of which can disrupt the powdering process. Under high vacuum, boron nitride can withstand high temperatures up to 1800°C. A gas atmosphere can push the temperature further up to 2100 °C. This means boron nitride will remain solid during the melting of most metals. Boron Nitride components are a cost-efficient solution, offering various grades based on the chemical composition of each alloy.

Boron Nitride Material Advantages:
-Non-wetting
-High electrical resistivity
-High thermal conductivity
-Excellent machinability
-Good chemical inertness
-High-temperature material
-High dielectric breakdown strength
-Excellent thermal shock resistance
-Excellent lubricating properties — low coefficient of friction

Packaging of Boron nitride
Given its fragile nature, BN is typically vacuum-sealed in plastic bags, cushioned with thick foam, and packed in cartons to prevent damage during transportation. Special packaging arrangements can be made upon request.

INNOVACERA provides a series of Boron Nitride materials, we provide our customers with a lot of solutions. If you’re looking for a boron nitride components for your application, please get in touch with us to learn more about our full range of products and how we can help you meet your needs.

Innovacera Innovative High-Power Ceramic Heating Elements with Thermocouples

Innovacera specializes in high-power ceramic heating elements integrated with thermocouples. With over a decade of expertise in ceramic heating solutions, we provide not only standard models but also provides customized heating elements.

Advanced MCH Alumina Ceramic Heating Technology

The process of MCH alumina ceramic heating elements is as below, Circuits are printed directly onto alumina green sheets, which undergo high-temperature co-firing at approximately 1600°C. This process results in a highly efficient heating element capable of reaching 800°C in just 30 seconds. So that it is Widely used for medical devices, automotive applications, and electronic tools, such as soldering irons, these heating elements operate silently and are free from hazardous materials, aligning with global environmental standards.

Key Features and Applications

Name	The thermocouple-equipped ceramic heating elements
Voltage	120V/230V
Working power	50W~200W
Model	An exists model or custom
Resistance	Per customized
Working temperature	525°F~896°F
Applications	Automotive Repairs: Quick DIY fixes for bumpers and other components. Plastic Welding: Versatile applications in kayaks, canoes, ATVs, plastic containers, outdoor furniture, and toys. Industrial Tools: Reliable performance in soldering stations and other high-precision equipment.

Blow is an example of temperature curve for MCH heater

Eco-Friendly and Cost-Effective Solutions

These heating elements not only enhance efficiency but also promote sustainability. By enabling easy repairs of plastic items, they help reduce landfill waste, supporting eco-conscious initiatives.

For industries seeking durable, high-performance heating solutions, Innovacera products stand out as a top choice.

Ceramic Hot Knife Tips: The Ultimate 510-Thread Dab Tool for Effortless Wax & Viscous Oil Slicing

Introduction: Solving Precision and Efficiency Challenges

Com-paired with traditional metal blades struggle with residue buildup, ceramic hot knife designed for precision, durability, and versatility. With its advanced ceramic heating technology and ergonomic design, this tool revolutionizes how users slice, carve, and handle high-viscosity Substances.

Why choose a ceramic Hot Knife Tip?

1.Good Ceramic Material for Superior Performance

-Heat resistance and thermal stability: Ceramic hot knives are made of alumina ceramics, and the tip can withstand temperatures up to 200 degrees Celsius without warping or oxidation, ensuring consistent performance over a long period of time.

-Non-adhesion surface: ceramic coating prevents material adhesion, reduces cleanup time and maintains a good cutting edge.

-Chemical inertness: Unlike metal tools, ceramic resists corrosion from acidic or oily substances, ideal for handling cannabis concentrates or industrial lubricants.

2.Precision Engineering for Versatile Applications

–510-Thread Compatibility: Designed to fit most standard 510-thread batteries (e.g. box mods or vape pens), this tool offers plug-and-play convenience for dabbers and DlYers.

–Adjustable Temperature Control: With a range of 60°c-200’c, users can tailor heat settings for different materials-soften CBD wax at lower temps or slice hardened resins effortlessly.

–Multi-Tool Functionality: Beyond dabbing, its sharp, heated edge doubles as a soldering aid plastic welder, or craft knife, making it indispensable for workshops and creative proiects.

3.Safety and energy saving

–Fast heating: The target temperature is reached in 3 seconds, reducing energy waste.

–Insulated handles: Ergonomic handles keep cool during operation and prevent accidental burns.

–Low Power Consumption: Compatible with eco-friendly 3.7V batteries, it reduces operation costs by 30% compared to conventional tools.

Below is one example of the ceramic hot knife application.

Specification as below:

Size:	1.270.610.61cm
Weight	32g
Operating temperature	70-150℃
Temperature speed	3 seconds to 200°C
Cutting material	Easily cut wax, honey and other sticky substances.
Connectors	Suitable for 510 connectors
Notice for use	It is recommended that you heat it at the beginning of use and turn it off after use. Always keep the temperature of the ceramic cutter head within the appropriate range to protect the ceramic cutter head.
Advantages:	– No waste – Clean – Suitable for any 510 pen battery

Note:
1.The black coating on the surface of the ceramic cutter head can resist temperature to 200°C, if temperature above 300°C, the coating will be easily falling off.
2. Products with power plugs are designed for use in the USA. Sockets and voltages vary by country, and this product may require an adapter or converter to work in your destination country. Please check compatibility before purchasing.

Temperature rising speed is as below:

Innovacera have been producing a wide range of rapid heating elements and their derivatives for more than a decade. Apart from existing heating elements, we also provide customized heating element solutions and services based on customer design’s or samples with the help of our own research and development team to meet the different requirement of our customers. If you have any request, pls contact with us.

What is TTV, Bow, Warp in Semiconductor Wafers

In wafer manufacturing, TTV, Bow, and Warp are essential parameters that determine wafer flatness and thickness uniformity, significantly impacting critical chip fabrication processes.

A.Definitions and Measurement Methods of TTV, Bow, and Warp

1.TTV (Total Thickness Variation)

Definition:
TTV refers to the difference between the maximum and minimum thickness across the diameter of a wafer, assessing thickness uniformity.

Measurement:
Measured in a non-clamped state, it calculates the deviation between the minimum and maximum distances from the wafer’s center surface to a reference plane, including both concave and convex variations.

Importance:
TTV ensures uniform thickness distribution during processing, preventing adverse effects on subsequent steps and final product performance.

2.Bow

Definition:
Bow indicates the curvature of a wafer, representing the vertical distance variation between the center and edges.

Measurement:
In a free-standing state, the wafer’s backside serves as a reference plane, and the deviation between the highest and lowest points on the wafer surface relative to this plane is measured.

Importance:
Bow is a key parameter for assessing wafer quality and reliability. . Lower Bow values typically indicate cleaner, flatter surfaces with fewer defects during processing.

3.Warp

Definition:
Warp refers to the overall distortion or irregular deformation of the wafer surface, not limited to localized curvature.

Measurement :
Using the surface with the smallest sum of intercepts of all points within the qualified quality area of the wafer surface as the reference plane, measure the deviation between the maximum and minimum distances of the surface from the reference plane.

Importance:
WARP is a key metric for measuring the overall flatness of wafers and is crucial for processes such as lithography and etching.

B.Differences Between TTV, Bow, and Warp

1.TTV: Focuses on thickness variation, independent of curvature or distortion.

2.Bow: Focuses on overall curvature, primarily considering the bending between the center and edges.

3.Warp: Encompasses both global curvature and distortion across the wafer surface.
While these parameters are related to the wafer’s geometric properties, they measure and describe different aspects, each impacting semiconductor processes and wafer handling uniquely.

C.Impact of TTV, Bow, and Warp on Semiconductor Processes

Impact on Lithography
Depth of Focus (DOF) Issues: TTV, Bow, and Warp can cause variations in focus depth during lithography, affecting pattern clarity.

Alignment issues: These parameters can cause misalignment of wafers, affecting the coverage accuracy between layers.

Effect on chemical mechanical polishing
Uneven polishing: During CMP, TTV, bow, and warping can cause
uneven polishing, resulting in surface roughness and residual stress.

Impact on Thin Film Deposition
Non-Uniform Deposition: Irregular wafer surfaces may cause uneven thin film deposition.

Impact on Wafer Handling
Handling Issues: Warped wafers may suffer damage during automated handling processes.

Aluminum Nitride Wafers
AlN wafers are ceramic substrates engineered for cutting-edge electronic and optoelectronic systems, in the semiconductor processes, the aluminum nitride wafers as a bearing substrate for thin film deposition (such as MOCVD), it supports the high-quality epitaxial growth of compound semiconductors such as GaN and AlGaN. Innovacera supplies standard aluminum nitride wafers such as 6” and 8”, if you need it, welcome to contact us at sales@innovacera.com.

A New Generation of Pellet Grill Igniter-Silicon Nitride Quartz Igniter

Silicon nitride ignition technology is a new technology commonly used in ignition devices. As new arrival of ceramic igniter also called Quartz Crystal Igniter is a very good solution in the pellet ignition market. Compared with traditional ceramic lighters, the ignition time is reduced to less than 60 seconds. It is based on the special properties of silicon nitride materials under high temperature and high pressure environments, and can provide high-energy and high-reliability ignition capabilities.It can speed up your cooking process and minimize the white smoke period before ignition.

Today, let’s take a look about the silicon nitride igniter.

Silicon nitride ceramics have the characteristics of high strength and high temperature resistance. It has the best comprehensive mechanical properties among ceramic materials, and has good thermal shock resistance, oxidation resistance, wear resistance and corrosion resistance. It is the third ceramic used in thermal engine parts. A candidate material. In traditional fields, silicon nitride ceramics are used as bearing balls, rollers, ball races, tools and molds, new ceramic cutting tools, pump plungers, spindle sealing materials, etc.

With the improvement of the preparation process, the thermal conductivity and dielectric properties of silicon nitride have been significantly improved. It can be used in electric heating, thermal conductive substrates and other fields. Used as a water heater heating element, its high thermal conductivity enables it to quickly transfer heat to the heated medium, and its good thermomechanical properties and insulation properties ensure its safety. Can be widely used in various types of instant heating, water storage and thermostats. It can also be used as an industrial heating source and a heating and insulation device for special liquids.

Product Introduction:

Silicon nitride ceramic igniter can heat up to 800~1000℃ in tens of seconds and ignite fuel by direct heat transfer or blast heat transfer. A temperature buffer area is set on the ignition rod to protect the terminal from damage. The insulation package at the wire joint can effectively prevent short circuits caused by conductive ash. With reasonable installation methods and ignition procedures, silicon nitride ceramic ignition rods can be used safely for several years.

Specification:

Rapid heating	Heating faster. up to 1000°c in 30 seconds
Range of temperature	1100~1200 °C
mall size / High watt density	High-watt density discharge allow high thermak efficiency
High insulation
Direct water and kerosene heating
Vacuum environment
Oxidation and chemical resistance
provides the best quality silicon nitride Igniter, ceramic igniter for biomass pellet stove, and BBQ grill applications.

Model

Material

Voltage/
Power

Size

Ceramic Socket

Wire

Ceramic

Metal kit

INC-H6

Silicon Nitride

230V 300W

90*10.8*3.9mm

OD17.5*32

–

300-500mm

Length and type can be

customized

Advantages of Silicon Nitride Igniter:

– When it contact with the ash or the pipe holder, it does not create a short circuit.
– Quartz Crystal igniters are 2 times more resistant to mechanical shocks than ceramic lighters.
– High resistance to burning pellets.
-The black quartz crystal igniter (candle, lighter) reaches over 1000 ° in 10 seconds, also called quartz igniter is the new generation for burning pellets and other biomass boilers.
-Maintenance is even simpler.

Application:

1. Ignition of biomass boilers, ignition of straw incinerators
2. Ignition of gas and oil (such as natural gas)
3. Treatment of automobile exhaust and industrial waste gas
4. Gas heating (air, working gas)
5. Fireworks generator
6. Brazing equipment
7. Corrosive environment heater
8. Laboratory special heating elements, heating system customization
9. Mold and tool heating
10. Barbecue charcoal igniter

Precautions when using 300W Black Quartz Crystal Ignition for Biomass Boiler

-This product is for industrial use only.
-Use a variable transformer to perform voltage control or use a temperature controller to implement temperature control.
-Use the heater under atmospheric pressure in the air.

-Do not apply excessive external forces (tension, bending, etc.) to the lead wire joint.
-Since the heater material is silicon nitride (ceramics), please handle carefully, as it may crack if you drop it or hit it.
-Please fix the insulator part for attaching the heater.　Also, please be careful as overtightening may cause damage.

Our advantage
1. Factory/manufacturer
2. More than 150 to 200 online employees
3. Welcome to customize
4. Monthly output of heater igniter: 550,000
5. Fast delivery time for existing models: 1-3 days

Embrace the cutting-edge rapid igniters, capable of starting a fire in your pellet grills in just 90 seconds. Welcome to contact with us for more information.

Zirconia Pad Printing Rings For High-Performance Printing Solution

In the contemporary industrial realm, pad printing technology finds extensive application across diverse surfaces, such as plastic, metal, glass, and ceramics. With the escalating demand for high-quality and durable prints, traditional pad printing rings frequently fail to fulfill the exacting printing requirements. Nevertheless, zirconia pad printing rings have emerged as the preeminent solution, presenting remarkable performance and durability.

What Are Zirconia Pad Printing Rings?

Zirconia represents an advanced ceramic material renowned for its extraordinary hardness, corrosion resistance, and wear resistance. Zirconia pad printing rings are fabricated using this robust material, thereby constituting essential components within pad printing systems that necessitate outstanding durability and precision.

Advantages of Zirconia Pad Printing Rings:

1.Superior Wear Resistance
The elevated hardness of zirconia confers significantly enhanced wear resistance in comparison to conventional metal or plastic materials. Even during prolonged and high-frequency printing operations, zirconia rings manifest minimal wear, leading to an extended service life and diminished maintenance requirements.

2.Outstanding Corrosion Resistance
In pad printing, exposure to various inks and chemicals can readily corrode standard materials. Zirconia’s exceptional chemical stability endows it with robust resistance to most corrosive substances, guaranteeing that the rings maintain consistent and reliable performance over time.

3.Precision Printing Capabilities
Zirconia pad printing rings possess a smooth and uniform surface finish, ensuring accurate and consistent print quality. This renders them particularly apt for applications demanding intricate details and high-quality outcomes, such as those in the electronics and medical device industries.

4.High-Temperature Stability
Zirconia retains its physical properties even under high temperatures, ensuring that printing quality remains unaffected by thermal fluctuations. This characteristic is of crucial importance for pad printing equipment that operates continuously over extended periods.

Zirconia pad printing rings Applications:

Zirconia pad printing rings are ideal for industrial printing operations that require high precision, efficiency, and durability. Key application areas include:

·Consumer Electronics: Precise marking and detailed pattern printing
·Medical Devices: Clear and durable labeling for instruments
·Automotive Industry: Long-lasting part marking and logos
·Luxury Packaging: High-end decorative prints and anti-counterfeiting features

Why Choose Zirconia Pad Printing Rings?

Opting for zirconia pad printing rings augments printing quality while considerably reducing long-term maintenance costs and minimizing downtime. Whether your aim is to enhance product quality or streamline production processes, investing in zirconia pad printing rings constitutes a strategic and cost-effective advancement.

Innovacera Zirconia Ring Type-SD/DD/SS/DS

Zirconia Ring Dimension（Accept customization）

SPECIFICATION
OD	ID	H	OD	ID	H	OD	ID	H
25 18 10			90 82 12			140 131 15
50	40	10	92	86	9.5	145	135	12
60 50 12			94 86 12			150 140 12
60	53	12	95	90	5.4	155	150	5.2

Zirconia pad printing rings are redefining industrial printing by offering unparalleled efficiency and quality.

Consult with Innovacera

If you want to know how zirconia pad printing rings can transform your operations or any questions, welcome to contact Innovacera at sales@innovacera.com.

MCH Heater Used For Oxygen Sensor

Today we are going to introduce another popular application of the MCH heater used for oxygen senor, also called lambda sensor(O2 SENSOR).

LAMBDA SENSOR (O2 SENSOR)

The lambda sensor, also called lambda probe, measures the level of oxygen in exhaust gases and it’s placed on the engine exhaust. By analyzing the waveforms of operation of the lambda sensor in different modes of engine operation, functioning of the sensor itself can be assessed as well as the functioning of the engine management system on the whole. Sign of a malfunctioning lambda sensor is increased fuel consumption, vehicle dynamics reduction, loss of engine power, erratic idling or incorrect idle speed.

What is an oxygen sensor and how it works

Petrol engines require an exact air-fuel mixture proportion for a proper operation. The proportion, in which the fuel burns completely and effectively, is called a stoichiometric and is exactly 14.7:1. This means that one part of fuel must be mixed with 14.7 parts of air. In practice, this air-fuel proportion varies depending on the engine operation mode and the mixture formation. Thus the engine is uneconomic.

The excess air coefficient – L (lambda) characterizes how far is the actual fuel-air mixture from the stoichiometric (14.7:1). This mixture is considered optimal and in this case L = 1. If L < 1, we have a lack of air and the mixture is enriched. When L = 0.85 – 0.95 engine power is increased. If L > 1, there is an excess of air and the mixture is leaned. Engine power drops down when L = 1.05 – 1.3, but the economy rises. At L > 1.3 mixture becomes impossible to ignite and engine misfire occurs. Petrol engines reach their maximum power when a lack of air 5-15% (L = 0.85 – 0.95) is present, and a minimum fuel consumption is achieved with an excess air of 10 – 20% (L = 1.1 – 1.2).

Thereby when the engine is working, the proportion L is constantly varying in the range 0.9 – 1.1 and this is the lambda regulation operating range. When the engine warms up to its operating temperature and it’s not loaded (i.e. idling), keeping the equality L = 1 is essential in order the catalytic converter to completely fulfill its purpose and reduce the vehicle’s emissions to a minimum.

Oxygen sensor is mounted on the exhaust manifold so that exhaust gases can be on the streamline of its working surface. In essence the oxygen sensor is a galvanic current source, which changes its output voltage according to the temperature and the environment oxygen content. Depending on the exhaust gases oxygen concentration, a different output signal appears. Shape of this signal depends on the type of material the sensor is made from. Thus the oxygen sensor reports the onboard controller the amount of oxygen in exhaust gases. Clock edge of the signal between its “high” and “low” state, is negligible and can be ignored. The onboard controller receives signal from the oxygen sensor, compares it with a value stored in its memory and if the signal differs from the optimal for the current mode, it adjusts the fuel injection duration in both directions. Thus, by the implementation of a feedback and a correct operation mode, a maximum fuel economy and minimum harmful gases, is achieved.

Types of oxygen sensors
According to the substance used in their sensitive element, are:
Zirconium (zirconium oxide)
Titanium (titanium oxide)
Wideband

According to their design:
Single-wire lambda sensor
Two-wire lambda sensor
Three-wire lambda sensor
Four-wire lambda sensor

Single-wire lambda sensor was used in the early injection systems with a feedback (lambda regulation). It has only one terminal, which is the signal terminal. Sensor ground is its housing and it connects to the engine ground through the exhaust pipes.

Two-wire lambda sensor has a separate grounding cable. It was used in the early injection systems with a feedback (lambda regulation) also.

Disadvantage of the single-wire and the two-wire sensors is that their operating temperature range starts at 300 ºC. Sensor will not work and will not produce a signal until this temperature is reached. It was necessary for the sensor to be mounted as close to the engine cylinders as possible in order to heat and wrap from the hottest exhaust gases stream. Process of heating the sensor slows down the regulation process of the onboard controller because of the feedback. In addition, using the exhaust pipe as a signal ground requires sensor’s thread to be coated with a special electrically conductive paste, which increases the possibility of a bad contact in the feedback circuit.

In the three-wire lambda sensors, is a special heating element inside which is constantly turned on when the engine is working and thus it’s reducing the heating time of the sensor to the working temperature. This allows installation of the sensor on the exhaust manifold, near the catalytic converter. Disadvantage is the need of electrically conductive grease.

In the four-wire oxygen sensors – two of the terminals are the heater terminals and the other two, the signal terminals.

The structure of the ceramic heater in the oxygen sensor

The picture of MCH ceramic heater for oxygen sensor

Why use MCH heater?
-Quick Heating
-Temperature Stability
-Energy Efficiency:
-Uniform Heating
-Compact Design

The properties of MCH heater

Item	Unit	Alumina Heater
Max.Working temperature	°C	1050
Working temperature	°C	850
Thermal conductivity	W/m.k	21
Specific Heat	J/kg.k	0.78X10³
Expansion	/°C(40-800°C)	0.78X10^-6
Hardness （load 500g）	Gpa	13.5
Flexural	Mpa	320

Blow is the Temperature curve and TCR value for MCH heater

More application for MCH heater
E-cig, 3D printer, soldering iron, smart bide/Instant water heating, new energy vehicle, small home appliances such as kettles, hair straighteners, curlers, hair dryer etc.

Conclusion
MCH heaters have great performance for the oxygen sensor by offering rapid heating, precise temperature control, and energy efficiency. These advanced heating elements enable oxygen sensor to work with greater accuracy and effectiveness.

If you have any question about the MCH heater, welcome to contact us at sales@innovacera.com.