Resistive heaters and uses thereof

• US 6,919,543 B2
• Filed: 11/28/2001
• Issued: 07/19/2005
• Est. Priority Date: 11/29/2000
• Status: Expired due to Term

• Current Assignee: Regal Ware Incorporated
• Original Assignee: Thermoceramix, Inc. (ThermoCeramix Corp.)
• Inventors: Abbott, Richard C., Magnant, Gary P., Glenn, William A.
• Primary Examiner(s): Evans, Robin O.
• Assistant Examiner(s): Fastovsky, Leonid M
• Application Number:
  US09/996,183
• Publication Number:
  US 20020096512A1
• Time in Patent Office: 1,329 Days
• Field of Search: 219/541, 219/543, 219/544, 219/469, 219/270, 219/216, 219/465.1, 219/553, 219/471, 219/470, 428/446, 428/698, 428/699, 427/96, 338/306, 338/307, 338/308, 338/309, 296/11, 296/12, 296/13, 392/438, 392/439
• US Class Current: 219/543
• CPC Class Codes: B21B 2027/086 heating internally
• CPC Class Codes: B29C 45/73 of the mould B29C45/2642 and B29C45/2737 take precedence
• CPC Class Codes: C23C 4/02 Pretreatment of the material to be coated, e.g. for coating on selected surface areas
• CPC Class Codes: C23C 4/12 characterised by the method of spraying
• CPC Class Codes: C23C 4/123 Spraying molten metal
• CPC Class Codes: F27D 1/1636 Repairing linings by projecting or spraying refractory materials on the lining
• CPC Class Codes: H01L 21/67103 mainly by conduction
• CPC Class Codes: H05B 3/12 characterised by the composition or nature of the conductive material
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft
• CPC Class Codes: Y10T 29/49099 Coating resistive material on a base

Abstract

A metallic resistive heater and a method of production are described. The resistive heater has a metallic component that is electrically conductive (i.e. has low resistivity) and an oxide, nitride, carbide, and or boride derivative of the metallic component that is electrically insulating (i.e., has high resistivity). The resistivity is controlled by controlling the amount of oxide, nitride, carbide, and boride formation during the deposition of the metallic component and the derivative.

Claims

1. A method of making a resistive heater having a controlled resistivity, having a substrate, a resistive heating layer, and a power source, comprising the steps of:

determining a desired resistivity of said resistive heater layer;

selecting a solid metallic component and at least one reactant gas;

selecting a proportion of said solid metallic component and said at least one reactant gas, so that when combined said desired resistivity of said resistive heater layer results;

promoting reaction of at least a portion of said solid metallic component and said reactant gas by melting said at least a portion of said solid metallic component resulting in a stream of molten droplets, and providing controlled introduction of said reactant as to said molten droplets, thereby combining said molten droplets and said reactant gas, resulting in a free metal and reaction product;

depositing said combined free metal and reaction product on said substrate to form said resistive heater layer having said desired resistivity; and

providing power to said resistive heater layer.

2. The method of claim 1, wherein said reaction product is one or more oxide, nitride, carbide, and/or boride derivatives of said metallic component.

3. The method of claim 1, wherein said reactant gas that is controlled in introduction to said molten droplets during said step of promoting reaction of at least a portion of said solid metallic component, comprises one or more of oxygen, nitrogen, carbon, and boron.

4. The method of claim 1, further comprising the step of providing an electrically insulating layer between said substrate and said resistive layer.

5. The method of claim 4, further comprising the step of providing an adhesion layer between said insulating layer and said substrate.

6. The method of claim 5, wherein said adhesion layer comprises nickel-chrome alloy or nickel-chrome-aluminum-yttrium alloy.

7. The method of claim 1, further comprising the step of providing a heat reflective layer between said resistive heater layer and said substrate.

8. The method of claim 7, wherein said heat reflective layer comprises zirconium oxide.

9. The method of claim 1, further comprising the step of providing a ceramic layer superficial to said resistive heater layer.

10. The method of claim 9, wherein said ceramic layer comprises aluminum oxide.

11. The method of claim 1, further comprising the step of providing a metallic layer superficial to said resistive heating layer.

12. The method of claim 11, wherein said metallic layer comprises molybdenum or tungsten.

13. The method of claim 1, wherein said metallic component is titanium (Ti), silicon (Si), aluminum (Al), zirconium (Zr), cobalt (Co), nickel (Ni), iron (Fe), or alloys thereof.

14. The method of claim 1, wherein said reaction product is one or more nitride, carbide, and/or boride derivatives of said metallic component.

15. The method of claim 1, wherein said reaction product is two or more oxide, nitride, carbide, and/or boride derivatives of said metallic component.

16. The method of claim 1, wherein said solid metallic component is not oxidized prior to said step of promoting reaction.

17. The method of claim 1, wherein said solid metallic component is a solid metallic wire.

18. The method of claim 1, wherein there is no reaction of said solid metallic component with said reactant gas prior to said step of promoting reaction.