Self-regulating heater employing reactive components

• US 4,849,611 A
• Filed: 12/16/1985
• Issued: 07/18/1989
• Est. Priority Date: 12/16/1985
• Status: Expired due to Term

• Current Assignee: Tyco Electronics Corporation (TE Connectivity Ltd. (United Kingdom))
• Original Assignee: Raychem Limited (TE Connectivity Limited)
• Inventors: Kennedy, Brian, Whitney, Wells, Sandberg, Chester
• Primary Examiner(s): Goldberg, E. A.
• Assistant Examiner(s): PRESTON, GERALD
• Application Number:
  US06/810,134
• Time in Patent Office: 1,310 Days
• Field of Search: 219/482, 219/505, 219/538, 219/543, 219/544, 219/545, 219/546, 219/457, 219/553, 338/308, 338/309, 427/49, 427/58, 427/96, 430/311
• US Class Current: 219/538
• CPC Class Codes: H05B 2203/019 Heaters using heating elements having a negative temperature coefficient
• CPC Class Codes: H05B 2203/02 Heaters using heating elements having a positive temperature coefficient
• CPC Class Codes: H05B 3/141 Conductive ceramics, e.g. metal oxides, metal carbides, barium titanate, ferrites, zirconia, vitrous compounds
• CPC Class Codes: H05B 3/16 the conductor being mounted on an insulating base
• CPC Class Codes: H05B 3/56 Heating cables

Abstract

Novel electrical heater which are self-regulating as a result of appropriate combination of a constant current or constant voltage power source with a resistive heating component and a temperature-sensitive component. Preferred heaters comprise a plurality of heating units, each of which heating units comprises a reactive component, a resistive heating component, and a temperature-responsive component. Self-regulation of the heater may be achieved in a number of different ways, including the use of employing a reactive component and a temperature-responsive component which form a combination exhibiting an impedance which changes with temperature. The temperature-responsive component can for example change in dielectric constant, or in permeability or in shape, or can effect changes in the frequencies inputted to the reactive component.

Claims

1. An electrical heater which comprises

(A) two connection means which are connectable to an AC power supply;

and

(B) a plurality of discrete, spaced-apart, heating units, each of said heater units comprising

(a) a reactive component;

(b) a resistive heating component which generates heat when the connection means are connected to a suitable AC power supply; and

(c) a temperature responsive component which has a property which varies with temperature so that, when the heater is connected to a suitable AC power supply, the heat generated by the heating unit decreases substantially as the temperature of the unit approaches an elevated temperature;

said reactive component, when it is an inductor and is the same as the temperature-responsive component, being connected to the connection means by discrete electrical conductors.

2. A heater according to claim 1 wherein the temperature-sensitive component is not in direct physical contact with the heating component.

3. A heater according to claim 1 which is suitable for connection to a constant voltage AC power supply, wherein the heating components are connected in parallel with each other between the connection means, and wherein, in each heating unit, the temperature-responsive component and the reactive component together form a combination which exhibits PTCZ behavior and which is connected in series with the heating component.

4. A heater according to claim 3 wherein the reactive component and the temperature-responsive component are combined in the form of a capacitor comprising a dielectric whose dielectric constant decreases with temperature.

5. A heater according to claim 4 wherein the capacitor has a dielectric whose dielectric constant at a first temperature T₁, T₁ being at least 0°

C., is at least 3 times the dielectric constant of the dielectric at a second temperature T₂ which is between T₁ and (T₁ +100)°

C.

6. A heater according to claim 5 wherein the dielectric is a ferroelectric ceramic having a Curie point of at least 40°

C.

7. A heater according to claim 4 wherein each of the heating units comprises an insulating base having a ZTCR resistor and a PTCZ capacitor secured thereto.

8. A heater according to claim 1 which is suitable for connection to a constant voltage AC power supply, wherein the heating components are connected in parallel with each other between the connection means, and wherein, in each heating unit, the temperature-responsive component and the reactive component together form a combination which exhibits NTCZ behavior and which is connected in parallel with the heating component.

9. A heater according to claim 8 wherein the reactive component and the temperature-responsive component are combined in the form of an inductor having a core whose permeability at a first temperature T₁, T₁ being at least 0°

C., is at least 3 times the permeability of the core at a second temperature T₂ which is between T₁ and (T₁ +100)°

C.

10. A heater according to claim 8 wherein the reactive component and the temperature-responsive component are combined in the form of an inductor comprising a ferromagnetic ceramic having a Curie point of at least 40°

C.

11. A heater according to claim 1 which is suitable for connection to a constant current AC power supply, wherein the heating components are connected in series with each other, and wherein, in each heating unit, the temperature-responsive component and the reactive component together form a combination which exhibits NTCZ behavior and which is connected in parallel with the heating component by means of discrete electrical conductors.

12. A heater according to claim 11 wherein the reactive and temperature-sensitive components are combined in the form of an inductor having a core whose permeability at a first temperature T₁, T₁ being at least 0°

C., is at least 3 times the permeability of the core at a second temperature T₂ which is between T₁ and (T₁ +100)°

C.

13. A heater according to claim 12 wherein the reactive and temperature-sensitive components are provided by a ZTCR conductor and a core composed of a material having a Curie point of at least 100°

C., and the resistive component is in the form of a resistive metal wire.

14. A heater according to claim 1 wherein the temperature-responsive component is a frequency-changing component which, when the heater is connected to a suitable AC power source, changes the frequency of the current passing through the reactive component in response to changes in temperature.

15. A heater according to claim 1 wherein the reactive component has both capacitance and inductance, at least one of the capacitance and the inductance varying with temperature so that the heating unit has a temperature-dependent resonant or anti-resonant frequency.

16. A heater according to claim 1 wherein the heating component comprises first and second resistors connected in parallel.

17. A heater according to claim 1 wherein the heating component is connected in series with the reactive component, and the reactive component comprises first and second reactive elements which are of opposite sign and are connected in parallel.

18. A heater according to claim 1 which comprises reactive components between adjacent heater units.

19. A heating circuit which consists essentially of

(A) an AC power supply, and

(B) a heating unit which comprises

(a) a reactive component;

(b) a resistive heating component which is connected to the reactive component by discrete electrical conductors; and

(c) a temperature-responsive component which is not in direct physical contact with the heating component and which has an electrical property which varies with temperature so that the heat generated by the heating unit decreases substantially as the temperature of the unit approaches an elevated temperature.

20. A self-regulating electrical heater which

(A) two connection means which are connectable to a power supply;

and

(B) a plurality of discrete, spaced-apart heating units, each of said heater units comprising

(a) an active circuit component;

(b) a resistive heating component which generates heat when the connection means are connected to a suitable power supply; and

(c) a temperature-responsive component which has an electrical property which varies with temperature so that, when the heater is connected to a suitable power supply, the heat generated by the heating unit decreases substantially as the temperature of the unit approaches an elevated temperature.

21. An electrical heater comprising:

(A) two elongate connection means which are connectable to the constant voltage power supply; and

(B) a plurality of discrete, spaced-apart heating units which are electrically connected in parallel with each other between the connection means and each of which comprises;

(a) a first resistive heating component having a positive temperature coefficient of resistance; and

(b) a second resistive heating component having a zero temperature coefficient of resistance and connected in parallel with the first resistive heating component.

22. A heating circuit which comprises

(A) a constant current AC power supply, and

(B) a heating unit which comprises

(a) an NTC inductive component;

and

(b) a resistive heating component which is connected in parallel with the reactive component by discrete electrical conductors;

whereby the heat generated by the heating unit decreases substantially as the temperature of the unit approaches an elevated temperature.

23. A method of heating liquid which comprises placing the liquid in thermal contact with a heating unit which is connected to an AC power supply and which comprises

(a) a reactive component;

(b) a resistive heating component which is connected to the reactive component by discrete electrical conductors; and

(c) a temperature-responsive component which is not in direct physical contact with the heating component and which has an electrical property which varies with temperature so that the heat generated by the heating unit decreases substantially as the temperature of the unit approaches an elevated temperature.