Two-wire layered heater system
First Claim
Patent Images
1. A heater system comprising:
- a thick film heater defining;
a substrate;
a dielectric layer disposed on the substrate;
a resistive layer disposed on the dielectric layer, the resistive layer having sufficient temperature coefficient of resistance characteristics such that the resistive layer is a heater element and a temperature sensor; and
a protective layer disposed over the resistive layer; and
a two-wire controller in communication with the thick film heater, wherein the two-wire controller determines temperature of the thick film heater using the resistance of the resistive layer and controls heater temperature accordingly.
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Abstract
A heater system is provided that comprises a layered heater in communication with a two-wire controller, wherein a resistive layer of the layered heater is both a heater element and a temperature sensor. The two-wire controller thus determines temperature of the layered heater using the resistance of the resistive layer and controls heater temperature through a power source. Furthermore, a heater system using a layered heater in communication with a two-wire controller for a specific application of a hot runner nozzle in an injection molding system is provided by the present invention.
59 Citations
24 Claims
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1. A heater system comprising:
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a thick film heater defining;
a substrate;
a dielectric layer disposed on the substrate;
a resistive layer disposed on the dielectric layer, the resistive layer having sufficient temperature coefficient of resistance characteristics such that the resistive layer is a heater element and a temperature sensor; and
a protective layer disposed over the resistive layer; and
a two-wire controller in communication with the thick film heater, wherein the two-wire controller determines temperature of the thick film heater using the resistance of the resistive layer and controls heater temperature accordingly.
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2. A heater system comprising:
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a thick film heater comprising at least one resistive layer, the resistive layer having sufficient temperature coefficient of resistance characteristics such that the resistive layer is a heater element and a temperature sensor; and
a two-wire controller connected to the resistive layer, wherein the two-wire controller determines temperature of the thick film heater using the resistance of the resistive layer and controls heater temperature accordingly.
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3. A heater system comprising:
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a thin film heater comprising at least one resistive layer, the resistive layer having sufficient temperature coefficient of resistance characteristics such that the resistive layer is a heater element and a temperature sensor; and
a two-wire controller connected to the resistive layer, wherein the two-wire controller determines temperature of the thin film heater using the resistance of the resistive layer and controls heater temperature accordingly.
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4. A heater system comprising:
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a thermally sprayed heater comprising at least one resistive layer, the resistive layer having sufficient temperature coefficient of resistance characteristics such that the resistive layer is a heater element and a temperature sensor; and
a two-wire controller connected to the resistive layer, wherein the two-wire controller determines temperature of the thermally sprayed heater using the resistance of the resistive layer and controls heater temperature accordingly.
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5. A heater system comprising:
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a sol-gel heater comprising at least one resistive layer, the resistive layer having sufficient temperature coefficient of resistance characteristics such that the resistive layer is a heater element and a temperature sensor; and
a two-wire controller connected to the resistive layer, wherein the two-wire controller determines temperature of the sol-gel heater using the resistance of the resistive layer and controls heater temperature accordingly.
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6. A heater system comprising:
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a layered heater comprising at least one resistive layer, the resistive layer having sufficient temperature coefficient of resistance characteristics such that the resistive layer is a heater element and a temperature sensor; and
a two-wire controller connected to the resistive layer, wherein the two-wire controller determines temperature of the layered heater using the resistance of the resistive layer and controls heater temperature accordingly. - View Dependent Claims (7, 8, 9, 10, 11, 12, 13)
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14. A heater system comprising:
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a thick film heater defining;
a dielectric layer;
a resistive layer disposed on the dielectric layer, the resistive layer having sufficient temperature coefficient of resistance characteristics such that the resistive layer is a heater element and a temperature sensor; and
a protective layer disposed over the resistive layer; and
a two-wire controller in communication with the thick film heater, wherein the two-wire controller determines temperature of the thick film heater using the resistance of the resistive layer and controls heater temperature accordingly.
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15. A hot runner nozzle heater system comprising:
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at least one hot runner nozzle;
a substrate disposed proximate the hot runner nozzle;
a dielectric layer disposed on the substrate;
a resistive layer disposed on the dielectric layer, the resistive layer having sufficient temperature coefficient of resistance characteristics such that the resistive layer is a heater element and a temperature sensor;
a protective layer disposed over the resistive layer; and
a two-wire controller connected to the resistive layer, wherein the two-wire controller determines temperature of the heater system using the resistance of the resistive layer and controls heater system temperature accordingly.
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16. A hot runner nozzle heater system comprising:
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at least one hot runner nozzle; and
at least one resistive layer disposed proximate the runner nozzle, the resistive layer having sufficient temperature coefficient of resistance characteristics such that the resistive layer is a heater element and a temperature sensor; and
a two-wire controller connected to the resistive layer, wherein the two-wire controller determines temperature of the heater system using the resistance of the resistive layer and controls heater system temperature accordingly.
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17. A heater system for use with an existing temperature controller having at least one temperature sensor input and a power output, the improvement comprising:
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at least one layered heater, the layered heater comprising at least one resistive layer, the resistive layer having sufficient temperature coefficient of resistance characteristics such that the resistive layer is a heater element and a temperature sensor; and
at least one two-wire module connected to the layered heater and to the temperature controller, wherein the two-wire module determines temperature of the layered heater using the resistance of the resistive layer and transmits the temperature of the layered heater to the temperature controller input, and the temperature controller transmits the power output to the two-wire module.
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18. A heater system comprising:
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a layered heater comprising at least one resistive layer, the resistive layer having sufficient temperature coefficient of resistance characteristics such that the resistive layer is a heater element and a temperature sensor;
an electrical lead connected to the resistive layer;
a controller connected to the resistive layer through the electrical lead, wherein the controller determines temperature of the layered heater using the resistance of the resistive layer and controls heater temperature accordingly;
a common return device connected to the layered heater; and
a power source connected to the controller, wherein the common return device provides an electrical return to the controller from the layered heater.
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19. A method of operating a layered heater comprising the steps of:
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supplying power to the layered heater through a set of electrical leads to a resistive layer of the layered heater; and
calculating the temperature of the resistive layer using a two-wire controller connected to the layered heater through the set of electrical leads, wherein the resistive layer is a heater element and a temperature sensor. - View Dependent Claims (20, 21, 22, 23)
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24. A method of operating a layered heater in conjunction with a hot runner nozzle system comprising the steps of:
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supplying power to the layered heater through a set of electrical leads to a resistive layer of the layered heater; and
calculating the temperature of the resistive layer using a two-wire controller connected to the layered heater through the set of electrical leads, wherein the resistive layer is a heater element and a temperature sensor.
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Specification