Abstract: An apparatus (10) for splicing a heatable section (20) of a tubular heater (12) to a cold section, (22) the heatable section (20) includes an outer sheath (78), which has a heating element (84) therein. The cold section (22) includes an outer sheath (88) which has a cold pin (94) therein. The apparatus (10) comprises an enclosure (12) defining a chamber (62) which further defines opposed openings in communication with the chamber (62). A welding tip (30) extends into the chamber (62) and is capable of melting the cold pin (94) and welding the ends (80,90) of the heatable and cold sections (20,22) together.

Abstract: A multicell heater is shown with typically round outer tubing, containing a plurality of resistive heating elements having a common inner sheath. The inner sheath has a preferably non-circular cross-section and is given a hairpin bend to form a “U” shape. The resulting configuration, which is much less expensive than conventional multicell heaters, provides efficient heating at the toe end—a usually unheated (“cold”) zone in conventional multicell heaters.

Abstract: A metallic overcoat is shown for use on the termination of a thick film heater. The invention is specifically useful for reducing overall wall thickness on thick film heaters used in the injection molding industry. The overcoat is placed over at least the termination point of the heating element with access holes for the termination. Thereafter, holes are drilled parallel to the heater axis for the insertion of power leads. The overcoat further provides insulation for better efficiency and mechanical protection for the heating element.

Abstract: A branch assembly for a communication bus is shown that allows easy connection and removal of devices from the bus. A switch is located within each assembly to direct the bus either from one bus interface directly to a second bus interface or from one bus interface through a branch interface to the second bus interface, as appropriate depending on the presence of device at the branch interface. The switch is integrated into the assembly and is mechanically actuated by the presence or absence of a connector at the branch interface.

Abstract: Various components of thermal systems are shown molded within a polymer composite sheath, including heaters, sensors, and control circuits. The use of transfer and compression molding allows for the use of thermoset polymers containing very high levels of reinforcement fillers. These improved materials, in turn, create a component with superior thermophysical properties, including high heat flux levels, thermal conductivity, impact resistance, corrosion resistance, and maintenance of mechanical properties at high temperatures (>300° F.). The present invention also allows for wide variety of geometric configurations and the possibility to insert temperature sensors directly in hot zones of heaters.

Abstract: A method is shown of predicting failure of resistive element heaters using a compiled database of measured ratiometric factors affecting heater life. The method can either be carried out actively, by continuously measuring known factors affecting heater life and decrementing a count of the remaining heater life, or the method may be carried out passively by estimating the operating profile and the averages within each segment of the profile, of the factors affecting heater life.

Abstract: A molded polymer composite heater is shown. The use of transfer molding and compression molding allows for the use of thermoset polymers containing very high levels of reinforcement fillers. These improved materials, in turn create a heater with thermophysical properties superior to the prior art, including higher heat flux levels, thermal conductivity, impact resistance, and maintenance of mechanical properties at high temperatures (˜>300° F.). The present invention also allows for wide variety of geometric configurations and the possibility to insert temperature sensors directly in hot zones of the heater.

Abstract: A thermocouple with a tubular metallic sheath extending longitudinally about a sheath centerline; a first wire of a first material within the sheath and coiled about a first centerline lying parallel to the sheath centerline; a second wire of a second material within the sheath and coiled about a second centerline lying parallel to the sheath centerline; a hot junction within the sheath connecting the wires; and a layer of insulation separating the wires from each other and from the sheath.

Abstract: Hot runner injection molding systems with externally heated injection runner nozzles for such systems. The heater is preferably a tubular heater with the resistive element applied to the exterior surface by fine film printing. The heater is adapted to externally heat a hot runner injection mold runner nozzle.

Abstract: A selectively lockable button structure allows for simple and easy mechanical button deactivation and reactivation. The button structure is especially adapted for interface panels of various types of electrical equipment wherein there may be a need for button lockout once the equipment is installed. The button structure includes a button and button retention/housing portion. The button has a head and body with the body terminating in radially outwardly extending flanges that allows easy button installation into the button retention portion of the interface panel but inhibits button removal therefrom. The button retention portion includes angled, diametrically opposed shelves, each shelf of which has a pair of positive lock interference tabs. The button head and the shelves/tabs co-act such that in one rotational position the button is depressible (unlocked) while in another rotational position, the button is not depressible (locked).

Abstract: Various methods are described for assembling and/or coupling heater sections together for assemblage of heaters. The heater sections may be hot or cold heater sections having various geometries, dimensions, and specific electrical resistances. In one method, a cold heater section is assembled onto a pre-fabricated hot heater section with an oversized tube and pre-fabricated insulating cores. In another method, a pre-fabricated cold section is spliced onto a pre-fabricated hot section utilizing pre-fabricated semi-annular insulating cores and an oversized sleeve. In a further method, a first pre-fabricated hot section is spliced onto a second pre-fabricated hot section via an electrically conductive core and an oversized sleeve. These methods allow for the manufacture of stock lengths of hot and cold heater sections, that are then cut to length and coupled together. According to one aspect, the methods reduce tolerance errors in heater length.

Abstract: An interface for graphically programming a ramping controller coupled to and controlling an electric heater is implemented with a microcomputer. The interface presents to the user via a display device, a cartesian coordinate graph of temperature versus time onto which is plotted a desired temperature versus time (tvt) profile via an input device. The microcomputer translates the plotted tvt profile into controller logic to create a controller logic data file that is then uploaded into the ramping controller. The controller logic data file may be stored in memory. In addition to temperature, other functions or events may be plotted on the graph which are also translated into controller logic and uploaded to the ramping controller. Other features include data logging of heater parameters that may displayed in real time. The present invention eliminates cumbersome front panel entry of the data into the controller.

Abstract: A hybrid power switching device for eliminating mechanical relay arcing. The device reduces mechanical relay contact damage due to arcing and substantially reduces power dissipation by placing a solid state relay in parallel with a mechanical relay. The solid state relay is preferably a semiconductor triac optically coupled to a light emitting diode. The device takes advantage of the inherent lag time (operating time) when a mechanical relay contact switch closes. The device uses only analog components and controls the triac by means of a Schmitt trigger pulse stretcher. The advantages to the present Schmitt trigger include discrete turn off and a narrow hysteresis. A low level control voltage signal operates the mechanical relay and the Schmitt trigger, or optionally a high level control voltage signal in conjunction with a signal inverter.

Abstract: A self-erasing writing system includes a writing surface structure, a writing instrument, and an erasing structure. The writing surface is preferably a laminate structure having a layer of a thermochromic material. The thermochromic material is of one color when within a certain temperature range (e.g. room temperature), but changes to a second color when the material is brought into a second temperature range (e.g. a lower temperature). The writing instrument is a temperature controlled cooled tip device that lowers the thermochromic material to within the second temperature range at the point of contact such that the points of contact become the second color. The thermochromic material has a "memory" that retains the second color until the temperature is raised to within a third temperature range at which time the thermochromic material changes back to its first color.

Abstract: An expandable band heater having multiple heater segments wherein a jumper type arrangement is utilized between heater segments to reduce the number of sets of lead wires or other termination configuration for providing power to each of the heater segments.

Abstract: A power control system in a DIN rail mount assembly for switching power in a low cost, compact, and solid state for controlling electric heaters. The system can be used for single phase, three phase-two leg, and three phase-three leg. Current switching capabilities range from 30A to 50A. Variable time base, 4-20 mA process control or VAC/DC input contactor configurations can be utilized. The DIN Rail back plate includes a sliding mechanical configuration. A potting fence provides for potting of the electrical substrate and also provides a heat sink. A large cover covers finger palm safer terminals. The DIN rail assembly can also be used for supporting electrical, electromechanical, optical or other types of assemblies.

Abstract: A band and/or strip heater assembly which enables the terminal end portions of the electrical heating element to be readily exposed so as to be easily accessible for later connection to any one of a wide variety of lead/terminal connections. The assembly comprising a heater element having a plurality of end portions associated therewith, electrical insulation material positioned in surrounding relationship on at least two sides of the heater element, a housing member enclosing the heater element and insulation material, an opening extending through at least a portion of the insulating material located adjacent one side of the heater element and through at least a portion of the housing member, the heater element end portions extending through such openings so as to be readily exposed exterior of the housing member. This construction enables the basic heater unit to be fully fabricated and assembled without attaching a particular style of lead/terminal connection thereto.

Abstract: An electrical heater comprising a heating element, a tubular metal sheath surrounding the heating element and spaced therefrom, insulation inside the sheath for electrically insulating the heating element from the sheath, and a closure closing one end of the sheath. A passaging extends through the closure in a direction generally lengthwise of the sheath. At least one power lead adapted for connection to a source of electrical energy extends through the passaging for conducting electrical energy to the heating element. The power lead includes an electrical conductor, a metallic sleeve surrounding the conductor, and insulation for electrically insulating the conductor from the sleeve. The conductor has a terminal portion electrically connected to the heating element. A seal between the closure and the sheath around the one end of the sheath seals against the passage of contaminants between the closure and the sheath.

Abstract: An electric heater comprising a metal casting having an electric heating element of sinuate shape cast therein. The casting has a plurality of ventilation openings therethrough located between the sinuations of the heating element for permitting air to flow directly to the surface on which the heater is mounted for ventilating and cooling it.