Patents Assigned to Watlow Electric Manufacturing
  • ISOLATED POWER CONVERTER FOR A THERMAL SYSTEM
    Publication number: 20200266715
    Abstract: A power converter system provides adjustable power to a heater and includes an input rectifier and a full-bridge isolating converter. The input rectifier is configured to rectify a line power having a line energy. The full-bridge isolating converter configured to generate an isolated output voltage based on the rectified line power. The isolated output voltage is electrically isolated from the line energy.
    Type: Application
    Filed: May 6, 2020
    Publication date: August 20, 2020
    Applicant: WATLOW ELECTRIC MANUFACTURING COMPANY
    Inventors: Keith NESS, Geoffrey ROZEK, Stanton H. BREITLOW, James HENTGES, John LEMKE, William BOHLINGER, Matthew YENDER
  • POWER CONVERTER FOR A THERMAL SYSTEM
    Publication number: 20200264216
    Abstract: The present disclosure generally describes a method and system for converting power to operate a load being supplied by line power having a line energy. The method includes rectifying the line power, bucking the rectified line power to generate a desired voltage output such that current is drawn from the line power in phase with the desired voltage output, and bypassing switching energy created during the bucking of the rectified line power.
    Type: Application
    Filed: May 6, 2020
    Publication date: August 20, 2020
    Applicant: WATLOW ELECTRIC MANUFACTURING COMPANY
    Inventors: Stanton H. BREITLOW, John LEMKE, James HENTGES, Keith Ness, Eric ELLIS, William BOHLINGER, Matthew YENDER, Dean R. MCCLUSKEY
  • POWER CONVERTER FOR A THERMAL SYSTEM
    Publication number: 20200256899
    Abstract: A control system includes a power converter being a step-down voltage converter and including a power switch. The power converter is operable to generate an adjustable output voltage and includes a sensor circuit configured to measure at least one of a voltage and an electric current of the heater. The control system includes a controller connected to the power converter and the sensor circuit. The controller is configured to determine an input parameter based on the at least one of the voltage and the electric current. The input parameter is indicative of a temperature of the heater. The controller is configured to set the output voltage applied for the heater based on the input parameter and a desired setpoint. The desired setpoint is based on an operational state of the heater. The controller is configured to operate the power switch of the power converter to generate the output voltage.
    Type: Application
    Filed: April 29, 2020
    Publication date: August 13, 2020
    Applicant: Watlow Electric Manufacturing Company
    Inventors: Stanton H. BREITLOW, John F. LEMKE, James HENTGES, Keith Douglas NESS, Eric ELLIS, William BOHLINGER, Matthew YENDER, Dean R. MCCLUSKEY
  • Compact modular wireless sensor
    Patent number: 10743088
    Abstract: A wireless sensor assembly includes a housing, a wireless power source, and electronics. The housing defines an interior space and at least one aperture sized to receive at least one external sensor. The wireless power source is mounted within the housing. The electronics are mounted within the housing and are configured to receive power from the wireless power source and to be in electrical communication with the external sensor. The electronics include a wireless communications component, and firmware configured to manage a rate of data transmittal from the wireless communications component to an external device such that the wireless communications component has a power consumption less than about 0.5 mW. The electronics are powered exclusively by the wireless power source and the wireless sensor assembly defines a volume less than about 2 in3.
    Type: Grant
    Filed: February 16, 2018
    Date of Patent: August 11, 2020
    Assignee: Watlow Electric Manufacturing Company
    Inventors: James Phillips, Don Recupido, Nathan Frost, Randy Scott Brown
  • High definition heater and method of operation
    Patent number: 10734256
    Abstract: A heater system is provided that includes a base functional layer having at least one functional zone. A substrate is secured to the functional member, and a tuning layer is secured to the substrate opposite the base functional layer. The tuning layer includes a plurality of zones that is greater in number than the zones of the base functional layer, and the tuning layer provides lower power than the base functional layer. A component is secured to the tuning layer opposite the substrate, and the substrate defines a thermal conductivity to absorb and dissipate a requisite amount of power from the base functional layer. A control system is also provided that has a plurality of addressable control elements in electrical communication with power lines and with the tuning layer, the control elements providing selective control of the tuning layer zones.
    Type: Grant
    Filed: January 7, 2016
    Date of Patent: August 4, 2020
    Assignee: Watlow Electric Manufacturing Company
    Inventors: Kevin Ptasienski, Kevin Robert Smith, Cal Thomas Swanson, Philip Steven Schmidt, Mohammad Nosrati, Jacob Lindley, Allen Norman Boldt, Sanhong Zhang, Louis P. Steinhauser, Dennis Stanley Grimard
  • Dual-purpose heater and fluid flow measurement system
    Patent number: 10724417
    Abstract: A control system for use in a fluid flow application is provided. The control system includes a heater having at least one resistive heating element. The heater is adapted to heat the fluid flow. The control system further includes a control device that uses heat loss from at least one resistive heating element to determine flow characteristics of the fluid flow.
    Type: Grant
    Filed: March 2, 2017
    Date of Patent: July 28, 2020
    Assignee: WATLOW ELECTRIC MANUFACTURING COMPANY
    Inventors: Cal Swanson, Mark D. Everly, David P. Culbertson, James N. Pradun, Jeremy J. Quandt, Mark L. G. Hoven, Jeremy Ohse, Sanhong Zhang
  • Resistive heater with temperature sensing power pins
    Patent number: 10728956
    Abstract: A heater is provided that includes a first power pin made of a first conductive material, a second power pin made of a second conductive material that is dissimilar from the first conductive material of the first power pin, and a resistive heating element having two ends and made of a material that is different from the first and second conductive materials of the first and second power pins. The resistive heating element forms a first junction at one end with the first power pin and a second junction at its other end with the second power pin, and changes in voltage at the first and second junctions are detected to determine an average temperature of the heater.
    Type: Grant
    Filed: May 29, 2015
    Date of Patent: July 28, 2020
    Assignee: Watlow Electric Manufacturing Company
    Inventors: Jack Reynolds, Louis P. Steinhauser, Jake Spooler, William Bohlinger
  • CERAMIC-ALUMINUM ASSEMBLY WITH BONDING TRENCHES
    Publication number: 20200230728
    Abstract: A method of joining is provided. the method includes preparing a first member, preparing a second member, and forming at least one trench in at least one of the first member and the second member. The method further includes placing a strip of solid aluminum material between the first member and the second member across the trench, bringing the first member and the second member together to contact the solid aluminum material and to form an assembly, and applying a force and heat to the assembly above a melting point of the solid aluminum material such that the solid aluminum material flows into the trench. Additionally, the method further includes applying additional heat to the assembly at or above a wetting temperature of the member in which the trench is formed to bond the first member to the second member along adjacent faces and cooling the assembly.
    Type: Application
    Filed: March 2, 2020
    Publication date: July 23, 2020
    Applicant: Watlow Electric Manufacturing Company
    Inventors: Patrick Margavio, Kurt English, Jacob Wilson, Miranda Pizzella, Todd Brooke
  • HEATER BUNDLE FOR ADAPTIVE CONTROL AND METHOD OF REDUCING CURRENT LEAKAGE
    Publication number: 20200232677
    Abstract: A heater system includes a heater bundle. The heater bundle includes a plurality of heater assemblies. Each heater assembly includes a plurality of heater units and an insulating material, and each heater unit defines at least one independently controlled heating zone. The heater bundle includes power conductors electrically connected to each of the independently controlled heating zones in each of the heater units. The heater bundle includes a power supply device configured to modulate power to each of the independently controlled heater zones of the heater units through the power conductors. A voltage is selectively supplied to each of the independently controlled heating zones such that a reduced number of independently controlled heating zones receives the voltage at a time or at least a subset of the independently controlled heating zones receive a reduced voltage at all times.
    Type: Application
    Filed: April 6, 2020
    Publication date: July 23, 2020
    Applicant: Watlow Electric Manufacturing Company
    Inventors: Mark D. EVERLY, Michael W. RUHR, Louis P. STEINHAUSER, Mark L. G. HOVEN, Richard T. WILLIAMS
  • MODULAR HEATER ASSEMBLY WITH INTERCHANGEABLE AUXILIARY SENSING JUNCTIONS
    Publication number: 20200236739
    Abstract: A heater system is provided, which includes a plurality of heaters, a controller for supplying power to the plurality of heaters, a plurality sets of auxiliary wires extending from the plurality of heaters, and a wire harness for connecting the plurality sets of auxiliary wires to the controller. Each set of auxiliary wires includes three wires, two of the three wires being made of different materials and being joined to form a thermocouple junction, such that each of the plurality of heaters is operable to function as both a heater and a temperature sensor.
    Type: Application
    Filed: April 6, 2020
    Publication date: July 23, 2020
    Applicant: Watlow Electric Manufacturing Company
    Inventors: Jeremy OHSE, Douglas SCHAEFER, Eric ELLIS
  • Process controller with an integrated optical detector
    Patent number: 10712757
    Abstract: A process controller is provided and includes at least one optical sensor. The optical sensor includes an optical source is configured to emit an electronic signal toward an object. The process controller further includes a control unit in communication with the at least one optical sensor, wherein the control unit controls a controlled device based on the electronic signal received by the at least one optical sensor. In another form, the optical sensor further includes an optical detector configured to receive the return electronic signal reflected by the object. A system for process control in an elevated radio frequency (RF) environment is also provided and includes a process controller having at least one optical sensor and a control unit in communication with the optical sensor. The optical sensor is disposed within the elevated RF environment and includes an optical detector.
    Type: Grant
    Filed: March 21, 2017
    Date of Patent: July 14, 2020
    Assignee: Watlow Electric Manufacturing Company
    Inventors: William Bohlinger, John P. Bergen, Stanton Hopkins-Breitlow, James Hentges, Jason Houzenga, Gil Ramos, Kurt Peterson, Larry Walters, Daryl G. James
  • HIGH POWER DENSITY INSULATED EXHAUST HEATING SYSTEM
    Publication number: 20200200060
    Abstract: A heating apparatus for a fluid flow system having a fluid conduit includes at least one heater element and a support member within the conduit. The at least one heater element includes a resistance wire, a sheath, and an electrically insulating material. The sheath has a closed profile shape that extends along a tortuous path through the container body and surrounds the resistance wire along the tortuous path. The insulating material is disposed about the wire between the wire and the sheath. The support member restricts movement of the at least one heater element relative to the fluid conduit. The support member defines a corrugated geometry that follows the tortuous path while contacting the sheath along a majority of a length of the sheath. The support member increases heat transfer from the at least one heater element to a fluid flowing through the fluid conduit.
    Type: Application
    Filed: March 2, 2020
    Publication date: June 25, 2020
    Applicant: WATLOW ELECTRIC MANUFACTURING COMPANY
    Inventors: Mark D. Everly, Jeremy Ohse, David P. Culbertson, Richard T. Williams, George Jambor, Jacob Wilson
  • Power converter for a thermal system
    Patent number: 10690705
    Abstract: The present disclosure generally describes a system that includes a heater, a power converter including a power switch, and a controller. The power converter is in communication with the heater and is operable to apply an adjustable voltage to the heater. The controller is in communication with the power switch to control the voltage output of the power converter based on at least one of a load current and a detected voltage at the heater. The controller operates the power switch to adjust the voltage output of the power converter.
    Type: Grant
    Filed: June 15, 2017
    Date of Patent: June 23, 2020
    Assignee: Watlow Electric Manufacturing Company
    Inventors: Stanton H. Breitlow, John Lemke, James Hentges, Keith Ness, Eric Ellis, William Bohlinger, Matthew Yender, Dean R. McCluskey
  • Integrated heater and method of manufacture
    Patent number: 10681778
    Abstract: A method of constructing a heater includes providing a substrate, forming at least one trench into the substrate, depositing a functional material onto the substrate and into the at least one trench to form a functional element, and providing an electrical termination in contact with the functional element.
    Type: Grant
    Filed: November 21, 2017
    Date of Patent: June 9, 2020
    Assignee: Watlow Electric Manufacturing Company
    Inventors: Mohammad Nosrati, Kurt English, Patrick Margavio, Kevin Smith
  • SMART HEATER SYSTEM
    Publication number: 20200174505
    Abstract: A heating system includes a plurality of heater elements, a plurality of switches connected to the plurality of heater elements, a set of predetermined performance information including heater information specific for each heater element, at least one temperature sensor measuring temperature of at least one heater element from among the plurality of heater elements, and a heater control unit in communication with the temperature sensor(s). The heater control unit controls the heater elements differently, via the switches, based on the heater information and the measured temperature from the temperature sensor(s).
    Type: Application
    Filed: February 10, 2020
    Publication date: June 4, 2020
    Applicant: Watlow Electric Manufacturing Company
    Inventors: David P. CULBERTSON, Magdi KHAIR, Julian TAN, Mark EVERLY
  • Electric heating assisted passive and active regeneration for efficient emission controls of diesel engines
    Patent number: 10669907
    Abstract: A heater control module of the present disclosure controls exhaust temperature in an exhaust after treatment system. The heater control module includes a heating mode determination module and a heater operating module. The heating mode determination module is configured to select a desired heating mode from a plurality of heating modes based on an engine load and a status of a component of the exhaust aftertreatment system. The heater operating module is configured to operate an electric heater based on the desired heating mode. The plurality of modes includes at least a passive regeneration heating mode and an active regeneration heating mode. The electric heater is operated in the passive regeneration heating mode to heat an exhaust gas to a predetermined temperature to increase NO2 generation when an engine load is less than or equal to approximately 25%.
    Type: Grant
    Filed: July 2, 2018
    Date of Patent: June 2, 2020
    Assignee: WATLOW ELECTRIC MANUFACTURING COMPANY
    Inventors: Wenzhong Zhang, Mike Bange, Scott Boehmer, Magdi Khair, Julian Tan
  • Method of forming a composite substrate for layered heaters
    Patent number: 10658206
    Abstract: A method of forming a heater assembly for use in semiconductor processing includes thermally securing a heater substrate to an application substrate; and applying a layered heater having at least one functional layer to the heater substrate after the heater substrate is secured to the application substrate. The heater substrate defines a material having a coefficient of thermal expansion that is matched to a coefficient of thermal expansion of the functional layer. The material of the functional layer is not capable of withstanding the elevated temperature of the thermal securing step.
    Type: Grant
    Filed: October 6, 2015
    Date of Patent: May 19, 2020
    Assignee: Watlow Electric Manufacturing Company
    Inventors: Jacob R. Lindley, Dean J. Meyer, Alexander D. Glew
  • RAPID RESPONSE SENSOR HOUSING
    Publication number: 20200149977
    Abstract: A sensor assembly includes a housing having a body having a distal end portion defining an internal cavity and a proximal end portion defining a plurality of internal passageways. A micro-sensor is disposed within the internal cavity and exposed to the outside environment and an internal wall separates the internal cavity from the plurality of internal passageways. The micro-sensor abuts the internal wall.
    Type: Application
    Filed: January 17, 2020
    Publication date: May 14, 2020
    Applicant: Watlow Electric Manufacturing Company
    Inventors: Jeremy OHSE, Graham FISCHER, Ryan AFFARA
  • System and method for axial zoning of heating power
    Patent number: 10648390
    Abstract: A heater system for an exhaust system is provided. The heater system includes a heater disposed in an exhaust conduit. The heater includes a plurality of heating elements disposed in the exhaust conduit. A heating control module controls the plurality of heating elements differently according to operating conditions specific to each heating element. In other forms, the heater system for an exhaust system has a plurality of heating zones, instead of a plurality of heating elements. The heating control module controls the plurality of heating zones differently according to operating conditions specific to each heating zone.
    Type: Grant
    Filed: March 2, 2017
    Date of Patent: May 12, 2020
    Assignee: WATLOW ELECTRIC MANUFACTURING COMPANY
    Inventors: Mark D. Everly, James Pradun, Sanhong Zhang
  • MODULAR HEATER SYSTEMS
    Publication number: 20200132235
    Abstract: A modular unit includes a carrier member defining a receiving space for receiving a fluid conduit, a heating element disposed on a surface of the carrier member, and a thermal insulation jacket surrounding the carrier member. The thermal insulation jacket includes an upper portion and a lower portion. The upper and lower portions of the thermal insulation jacket have mating features for securing the upper and lower portions together.
    Type: Application
    Filed: December 24, 2019
    Publication date: April 30, 2020
    Applicant: Watlow Electric Manufacturing Company
    Inventors: John LILLELAND, Terry MADSON, Eric ELLIS, Cristian PORTILLO