Patents by Inventor David P. Culbertson
David P. Culbertson has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20240328342Abstract: A control system for use in a fluid flow application includes a heater and a control device. The heater includes at least one resistive heating element having a relationship between resistance and temperature defining a non-monotonic curve. The heater is to heat fluid flow. The control device is to determine a flow characteristic of the fluid flow and a temperature of the at least one resistive heating element along the non-monotonic curve between resistance and temperature based on a change in resistance of the at least one resistive heating element.Type: ApplicationFiled: June 14, 2024Publication date: October 3, 2024Applicant: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: Cal SWANSON, Mark D. EVERLY, David P. CULBERTSON, James N. PRADUN, Jeremy J. QUANDT, Mark L.G. HOVEN, Jeremy OHSE, Sanhong ZHANG
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Publication number: 20240319020Abstract: A method of calibrating temperature of a resistive element includes: generating a standard resistance-temperature (R-T) curve for the resistive element in an isothermal condition, wherein the resistive element comprises a material with a Curie temperature; generating an operational R-T curve for the resistive element during a normal operation of the resistive element; shifting the operational R-T curve toward the standard R-T curve at the Curie temperature to generate an adjusted operational R-T curve; and adjusting a measured temperature of the resistive element based on a resistance of the resistive element and the adjusted operational R-T curve.Type: ApplicationFiled: June 5, 2024Publication date: September 26, 2024Applicant: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: David P. CULBERTSON, Steven T. JYSTAD, Roger BRUMMELL, Sanhong ZHANG, Jeremy OHSE, Peter KOSS, Austin JOHANNES
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Publication number: 20240280042Abstract: Methods and systems for predicting at least one temperature along a fluid flow path of a fluid flow system having a heater disposed in the fluid flow path are provided. In one example, a method includes: obtaining at least one input, wherein the at least one input includes a setpoint, a mass flow rate, an inlet temperature, or a combination thereof; calculating a temperature associated with the heater based on a predefined model and the at least one input; and setting a value of the at least one temperature along the fluid flow path to the temperature of the heater.Type: ApplicationFiled: April 29, 2024Publication date: August 22, 2024Applicant: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: James N. PRADUN, Sanhong ZHANG, Jeremy J. QUANDT, David P. CULBERTSON, Magdi KHAIR
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Patent number: 12037933Abstract: A control system for use in a fluid flow application includes a heater and a control device. The heater has at least one resistive heating element and the heater is operable to heat fluid. The control device determines at least one flow characteristic of a fluid flow based on a heat loss of the at least one resistive heating element and determines a mass flow rate of the fluid based on the at least one flow characteristic and a property of the at least one resistive heating element. And the property of the at least one resistive heating element includes a change in resistance of the at least one resistive heating element under a given heat flux density.Type: GrantFiled: May 27, 2020Date of Patent: July 16, 2024Assignee: Watlow Electric Manufacturing CompanyInventors: Cal Swanson, Mark D. Everly, David P. Culbertson, James N. Pradun, Jeremy J. Quandt, Mark L. G. Hoven, Jeremy Ohse, Sanhong Zhang
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Patent number: 12031875Abstract: A method of calibrating temperature of a resistive element having a material with a Curie temperature includes generating a standard resistance-temperature (R-T) curve for the resistive element in isothermal conditions to identify values of the R-T curve and an inflection point at the Curie temperature, generating operational R-T curves for the resistive element over an operational time period, comparing the standard R-T curve to the operational R-T curves, and adjusting the operational curves to the standard R-T curve at the Curie temperature to calibrate temperature of the resistive element.Type: GrantFiled: April 8, 2021Date of Patent: July 9, 2024Assignee: Watlow Electric Manufacturing CompanyInventors: David P. Culbertson, Steven T. Jystad, Roger Brummell, Sanhong Zhang, Jeremy Ohse, Pete Koss, Austin Johannes
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Publication number: 20240151173Abstract: An exhaust gas heater system for an exhaust system of an internal combustion engine includes a housing and a heating element. The housing includes an outer peripheral wall disposed about a central axis and defining an interior hollow space configured to receive exhaust gas from an exhaust pipe of the exhaust system such that the exhaust gas flows through the interior hollow space. The heating element is positioned within the hollow space and including a first end and a second end. The heating element forms a zig-zag shape extending in a radial direction relative to the central axis.Type: ApplicationFiled: January 19, 2024Publication date: May 9, 2024Applicant: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: Mark D. EVERLY, Jeremy OHSE, David P. CULBERTSON, Richard T. WILLIAMS, George JAMBOR, Jacob WILSON
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Patent number: 11970964Abstract: A method of predicting temperature of at least one location in a fluid flow system that has a heating system for heating fluid. The method includes obtaining a mass flow rate of fluid flow of the fluid flow system, obtaining at least one of a fluid outlet temperature and a fluid inlet temperature of a heater of the heating system, obtaining power provided to the heater, and calculating temperature at the at least one location based on a model of the fluid flow system and the obtained mass flow rate, fluid outlet temperature, and fluid inlet temperature.Type: GrantFiled: December 11, 2019Date of Patent: April 30, 2024Assignee: Watlow Electric Manufacturing CompanyInventors: James N. Pradun, Sanhong Zhang, Jeremy J. Quandt, David P. Culbertson, Magdi Khair
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Patent number: 11913365Abstract: An exhaust gas heater system for an exhaust system of an internal combustion engine includes a housing and a heating element. The housing includes an outer peripheral wall disposed about a central axis and defining an interior hollow space configured to receive exhaust gas from an exhaust pipe of the exhaust system such that the exhaust gas flows through the interior hollow space. The heating element is positioned within the hollow space and including a first end and a second end. The heating element forms a zig-zag shape extending in a radial direction relative to the central axis.Type: GrantFiled: July 26, 2022Date of Patent: February 27, 2024Assignee: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: Mark D. Everly, Jeremy Ohse, David P. Culbertson, Richard T. Williams, George Jambor, Jacob Wilson
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Patent number: 11795857Abstract: A heating system includes at least one electric heater disposed within a fluid flow system and a control device that is configured to determine a temperature of the at least one electric heater based on a model, at least one fluid flow system input, and at least one heater input. The at least one heater input includes at least one physical characteristic of the heating system, the at least one physical characteristic includes at least one of a resistance wire diameter, a heater insulation thickness, a heater sheath thickness, a conductivity, a specific heat and density of the material of the heater, an emissivity of the heater and the fluid flow pathway, and combinations thereof. The control device is configured to provide power to the at least one electric heater based on the temperature of the at least one electric heater.Type: GrantFiled: September 2, 2022Date of Patent: October 24, 2023Assignee: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: James N. Pradun, Sanhong Zhang, Jeremy J. Quandt, David P. Culbertson, Magdi Khair
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Patent number: 11686232Abstract: An exhaust gas heating unit for an engine includes a housing and a heating element. The housing includes a tubular peripheral wall and has an interior hollow space. The heating element has first and second ends and extends longitudinally therebetween to form a spiral shape within the interior hollow space. The heating element includes a thermally conductive sheath, an electrically conductive resistance element that extends longitudinally within the external sheath, and an electrically insulating material disposed about the resistance element between the resistance element and the sheath. A heat transfer member is positioned within the interior hollow space and is formed from one or more strips of thermally conductive material. The strips contact the external sheath at a plurality of locations between the first end and the second end. The heat transfer member has a corrugated shape that follows the spiral shape of the heating element.Type: GrantFiled: July 26, 2022Date of Patent: June 27, 2023Assignee: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: Mark D. Everly, Jeremy Ohse, David P. Culbertson, Richard T. Williams, George Jambor, Jacob Wilson
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Patent number: 11585252Abstract: A heating apparatus for a fluid flow system having a container body includes a heater element and a strip. The heater element is within the container body and includes an electrical resistance element, a sheath, and an insulating material. The sheath extends along a predefined path through the container body and surrounds the electrical resistance element along the predefined path. The insulating material is disposed about the electrical resistance element between the electrical resistance element and the sheath. The insulating material electrically insulates the electrical resistance element from the sheath. The strip is disposed inside the container body and defines a tortuous geometry that follows the predefined path. The strip defines a plurality of openings at discrete locations along the strip. The heater element extends through the plurality of openings and is configured to contact the strip at the discrete locations.Type: GrantFiled: November 24, 2021Date of Patent: February 21, 2023Assignee: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: Mark D. Everly, Jeremy Ohse, David P. Culbertson, Richard T. Williams, George Jambor, Jacob Wilson
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Patent number: 11550346Abstract: 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: GrantFiled: February 10, 2020Date of Patent: January 10, 2023Assignee: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: David P. Culbertson, Magdi Khair, Julian Tan, Mark Everly
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Publication number: 20230003161Abstract: A heating system includes at least one electric heater disposed within a fluid flow system and a control device that is configured to determine a temperature of the at least one electric heater based on a model, at least one fluid flow system input, and at least one heater input. The at least one heater input includes at least one physical characteristic of the heating system, the at least one physical characteristic includes at least one of a resistance wire diameter, a heater insulation thickness, a heater sheath thickness, a conductivity, a specific heat and density of the material of the heater, an emissivity of the heater and the fluid flow pathway, and combinations thereof. The control device is configured to provide power to the at least one electric heater based on the temperature of the at least one electric heater.Type: ApplicationFiled: September 2, 2022Publication date: January 5, 2023Applicant: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: James N. PRADUN, Sanhong ZHANG, Jeremy J. QUANDT, David P. CULBERTSON, Magdi KHAIR
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Publication number: 20220356829Abstract: An exhaust gas heater system for an exhaust system of an internal combustion engine includes a housing and a heating element. The housing includes an outer peripheral wall disposed about a central axis and defining an interior hollow space configured to receive exhaust gas from an exhaust pipe of the exhaust system such that the exhaust gas flows through the interior hollow space. The heating element is positioned within the hollow space and including a first end and a second end. The heating element forms a zig-zag shape extending in a radial direction relative to the central axis.Type: ApplicationFiled: July 26, 2022Publication date: November 10, 2022Applicant: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: Mark D. EVERLY, Jeremy OHSE, David P. CULBERTSON, Richard T. WILLIAMS, George JAMBOR, Jacob WILSON
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Publication number: 20220356828Abstract: An exhaust gas heating unit for an engine includes a housing and a heating element. The housing includes a tubular peripheral wall and has an interior hollow space. The heating element has first and second ends and extends longitudinally therebetween to form a spiral shape within the interior hollow space. The heating element includes a thermally conductive sheath, an electrically conductive resistance element that extends longitudinally within the external sheath, and an electrically insulating material disposed about the resistance element between the resistance element and the sheath. A heat transfer member is positioned within the interior hollow space and is formed from one or more strips of thermally conductive material. The strips contact the external sheath at a plurality of locations between the first end and the second end. The heat transfer member has a corrugated shape that follows the spiral shape of the heating element.Type: ApplicationFiled: July 26, 2022Publication date: November 10, 2022Applicant: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: Mark D. EVERLY, Jeremy OHSE, David P. CULBERTSON, Richard T. WILLIAMS, George JAMBOR, Jacob WILSON
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Patent number: 11486291Abstract: A heating system includes at least one electric heater disposed within the fluid flow system. A control device includes a microprocessor and is configured to determine a temperature of the at least one electric heater based on a model and at least one input from the fluid flow system. The control device is configured to provide power to the at least one electric heater based on the temperature of the at least one electric heater.Type: GrantFiled: August 10, 2020Date of Patent: November 1, 2022Assignee: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: James N. Pradun, Sanhong Zhang, Jeremy J. Quandt, David P. Culbertson, Magdi Khair
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Patent number: 11408314Abstract: A heating apparatus for heating fluid includes a container body, a plurality of electric heater elements, and a support structure. The container body defines a perimeter of a flow path for a fluid flowing through the container body. The plurality heater elements are exposed to the flow path. Each heater element includes a resistance element, sheath, and insulating material disposed about the resistance element between the resistance element and the sheath. The support structure includes a plurality of support sheets. The heater elements extend transversely through each support sheet and contact each support sheet to restrict movement of the heater elements and support the heater elements in the container body. The support sheets contact the sheaths of the electric heater elements to increase heat transfer to the fluid flowing through the flow path. Opposite ends of each support sheet are connected to the container body.Type: GrantFiled: August 25, 2021Date of Patent: August 9, 2022Assignee: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: Mark D. Everly, Jeremy Ohse, David P. Culbertson, Richard T. Williams, George Jambor, Jacob Wilson
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Publication number: 20220082043Abstract: A heating apparatus for a fluid flow system having a container body includes a heater element and a strip. The heater element is within the container body and includes an electrical resistance element, a sheath, and an insulating material. The sheath extends along a predefined path through the container body and surrounds the electrical resistance element along the predefined path. The insulating material is disposed about the electrical resistance element between the electrical resistance element and the sheath. The insulating material electrically insulates the electrical resistance element from the sheath. The strip is disposed inside the container body and defines a tortuous geometry that follows the predefined path. The strip defines a plurality of openings at discrete locations along the strip. The heater element extends through the plurality of openings and is configured to contact the strip at the discrete locations.Type: ApplicationFiled: November 24, 2021Publication date: March 17, 2022Applicant: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: Mark D. EVERLY, Jeremy OHSE, David P. CULBERTSON, Richard T. WILLIAMS, George JAMBOR, Jacob WILSON
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Patent number: 11255244Abstract: A control system includes an electric heater disposed within an exhaust fluid flow pathway, and a control device for receiving at least one input selected from the group consisting of temperature readings along the exhaust fluid flow pathway, alternator power/current/voltage, battery power/current/voltage/state of charge, IAT and EAT profiles, mass flow rate of an exhaust fluid flow, NH3 slip, TCR characteristics of the heater, alternator speed, engine speed, state of aging of an aftertreatment component, state of aging of engine, aging degradation characteristics, a dosing rate and a temperature of DEF, NH3 storage condition of aftertreatment system, an ambient temperature, and combinations thereof. The control device modulates power to the heater based on the at least one input such that the heater provides different power output as a function of the at least one input and a continuously variable power output during operation of the exhaust system.Type: GrantFiled: January 29, 2019Date of Patent: February 22, 2022Assignee: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: David P. Culbertson, Magdi Khair, Mark Hoven, James Pradun
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Publication number: 20210381417Abstract: A heating apparatus for heating fluid includes a container body, a plurality of electric heater elements, and a support structure. The container body defines a perimeter of a flow path for a fluid flowing through the container body. The plurality heater elements are exposed to the flow path. Each heater element includes a resistance element, sheath, and insulating material disposed about the resistance element between the resistance element and the sheath. The support structure includes a plurality of support sheets. The heater elements extend transversely through each support sheet and contact each support sheet to restrict movement of the heater elements and support the heater elements in the container body. The support sheets contact the sheaths of the electric heater elements to increase heat transfer to the fluid flowing through the flow path. Opposite ends of each support sheet are connected to the container body.Type: ApplicationFiled: August 25, 2021Publication date: December 9, 2021Applicant: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: Mark D. EVERLY, Jeremy OHSE, David P. CULBERTSON, Richard T. WILLIAMS, George JAMBOR, Jacob WILSON