Patents by Inventor Elias Russegger
Elias Russegger 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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Patent number: 11304265Abstract: A method of manufacturing a layered heater includes: applying a dielectric material on a substrate to form a dielectric layer; thermal-spraying a resistive material on the dielectric layer to form a resistive layer on the dielectric layer; forming a plurality of conductive overlays at predetermined locations on the substrate; and forming a plurality of cuts into the resistive layer by laser cutting to form a resistive circuit pattern that overlaps the conductive overlays.Type: GrantFiled: October 11, 2018Date of Patent: April 12, 2022Assignee: Watlow Electric Manufacturing CompanyInventors: Elias Russegger, Gerhard Schefbanker, Martin Wallinger, Kevin Ptasienski
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Patent number: 11191129Abstract: A layered heater includes a resistive layer formed from a conductive material and separated into an intermediate area and a resistive circuit pattern by a plurality of cuts that extend all the way through the resistive layer. The resistive circuit pattern includes termination pads electrically connected to the resistive circuit pattern with the intermediate area being electrically inactive. A conductive overlay is disposed over a continuous portion of the resistive circuit pattern. The plurality of cuts extend longitudinally into the conductive overlay such that no portion of the resistive pattern is present outside the conductive overlay.Type: GrantFiled: February 7, 2019Date of Patent: November 30, 2021Assignee: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: Elias Russegger, Gerhard Schefbanker, Martin Wallinger, Kevin Ptasienski
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Patent number: 10361019Abstract: A method of forming a layered heater assembly includes: forming a plurality of layers onto a substrate, the plurality of layers including a resistive element layer; forming electrical terminations in contact with the resistive element layer; securing a protective cover over the layers using a laser welding process, wherein edges of the protective cover are welded circumferentially around raised end portions of the substrate and welded longitudinally along a slotted portion of the substrate; securing a pair of lead wires to the electrical terminations; and securing a lead cap assembly around the pair of lead wires and to the protective cover using a laser welding process.Type: GrantFiled: June 2, 2015Date of Patent: July 23, 2019Assignee: Watlow Electric Manufacturing CompanyInventors: Elias Russegger, Gerhard Schefbanker, Gernot Antosch, Wolfgang Poeschl, Martin Wallinger, Kevin Ptasienski, Matt Kenchel, Kenneth Fennewald, Allen Boldt
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Publication number: 20190174579Abstract: A layered heater includes a resistive layer formed from a conductive material and separated into an intermediate area and a resistive circuit pattern by a plurality of cuts that extend all the way through the resistive layer. The resistive circuit pattern includes termination pads electrically connected to the resistive circuit pattern with the intermediate area being electrically inactive. A conductive overlay is disposed over a continuous portion of the resistive circuit pattern. The plurality of cuts extend longitudinally into the conductive overlay such that no portion of the resistive pattern is present outside the conductive overlay.Type: ApplicationFiled: February 7, 2019Publication date: June 6, 2019Applicant: Watlow Electric Manufacturing CompanyInventors: Elias Russegger, Gerhard Schefbanker, Martin Wallinger, Kevin Ptasienski
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Patent number: 10314113Abstract: A layered heater includes a resistive layer defining a resistive circuit pattern having at least one bend portion. A conductive overlay is provided on at least one of a top surface and a bottom surface of the bend portion to alleviate the current crowding effect, thereby protecting the electric circuit from premature failure. Methods of manufacturing the layered heater are also disclosed. The overlay may be formed on the bend portion after the resistive layer is formed. The overlay may also be formed on a substrate or a dielectric layer that supports the resistive layer before the resistive layer is formed.Type: GrantFiled: May 18, 2015Date of Patent: June 4, 2019Assignee: Watlow Electric Manufacturing CompanyInventors: Elias Russegger, Gerhard Schefbanker, Martin Wallinger, Kevin Ptasienski
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Patent number: 10236103Abstract: A heater assembly is provided that includes a substrate having opposed end portions defining raised flanges, a slot extending between the opposed end portions, and opposed chamfered surfaces extending along the slot and across the raised flanges. A plurality of layers are disposed onto the substrate, along with a pair of terminal pads. A protective cover defining at least one aperture is disposed over the layers and is secured to the raised flanges and the opposed chamfered surfaces of the substrate, and the aperture is disposed proximate the terminal pads. A pair of lead wires is secured to the pair of terminal pads, and a lead cap assembly is disposed around the pair of lead wires and is secured to the protective cover.Type: GrantFiled: February 8, 2013Date of Patent: March 19, 2019Assignee: WATLOW ELECTRIC MANUFACTURING COMPANYInventors: Elias Russegger, Gerhard Schefbanker, Gernot Antosch, Wolfgang Poeschl, Martin Wallinger, Kevin Ptasienski, Matt Kenchel, Kenneth Fennewald, Allen Boldt
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Publication number: 20190045584Abstract: A method of manufacturing a layered heater includes: applying a dielectric material on a substrate to form a dielectric layer; thermal-spraying a resistive material on the dielectric layer to form a resistive layer on the dielectric layer; forming a plurality of conductive overlays at predetermined locations on the substrate; and forming a plurality of cuts into the resistive layer by laser cutting to form a resistive circuit pattern that overlaps the conductive overlays.Type: ApplicationFiled: October 11, 2018Publication date: February 7, 2019Applicant: Watlow Electric Manufacturing CompanyInventors: Elias Russegger, Gerhard Schefbanker, Martin Wallinger, Kevin Ptasienski
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Patent number: 9758854Abstract: An electrically conductive resistive layer is produced by thermally spraying an electrically conductive material onto the surface of a non-conductive substrate. Initially, the material layer arising therefrom has no desired shape. The material layer is then removed in certain areas so that an electrically conductive resistive layer having said desired shape is produced.Type: GrantFiled: March 26, 2015Date of Patent: September 12, 2017Assignee: WATLOW ELECTRIC MANUFACTURING COMPANYInventor: Elias Russegger
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Publication number: 20150267288Abstract: An electrically conductive resistive layer is produced by thermally spraying an electrically conductive material onto the surface of a non-conductive substrate. Initially, the material layer arising therefrom has no desired shape. The material layer is then removed in certain areas so that an electrically conductive resistive layer having said desired shape is produced.Type: ApplicationFiled: March 26, 2015Publication date: September 24, 2015Inventor: Elias Russegger
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Publication number: 20150262739Abstract: A method of forming a layered heater assembly includes: forming a plurality of layers onto a substrate, the plurality of layers including a resistive element layer; forming electrical terminations in contact with the resistive element layer; securing a protective cover over the layers using a laser welding process, wherein edges of the protective cover are welded circumferentially around raised end portions of the substrate and welded longitudinally along a slotted portion of the substrate; securing a pair of lead wires to the electrical terminations; and securing a lead cap assembly around the pair of lead wires and to the protective cover using a laser welding process.Type: ApplicationFiled: June 2, 2015Publication date: September 17, 2015Inventors: Elias Russegger, Gerhard SCHEFBANKER, Gernot ANTOSCH, Wolfgang POESCHL, Martin WALLINGER, Kevin PTASIENSKI, Matt KENCHEL, Kenneth FENNEWALD, Allen BOLDT
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Publication number: 20150250026Abstract: A layered heater includes a resistive layer defining a resistive circuit pattern having at least one bend portion. A conductive overlay is provided on at least one of a top surface and a bottom surface of the bend portion to alleviate the current crowding effect, thereby protecting the electric circuit from premature failure. Methods of manufacturing the layered heater are also disclosed. The overlay may be formed on the bend portion after the resistive layer is formed. The overlay may also be formed on a substrate or a dielectric layer that supports the resistive layer before the resistive layer is formed.Type: ApplicationFiled: May 18, 2015Publication date: September 3, 2015Inventors: Elias Russegger, Gerhard Schefbanker, Martin Wallinger, Kevin Ptasienski
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Patent number: 9029742Abstract: An electrically conductive resistive layer is produced by thermally spraying an electrically conductive material onto the surface of a non-conductive substrate. Initially, the material layer arising therefrom has no desired shape. The material layer is then removed in certain areas so that an electrically conductive resistive layer having said desired shape is produced.Type: GrantFiled: May 28, 2013Date of Patent: May 12, 2015Assignee: Watlow Electric Manufacturing CompanyInventor: Elias Russegger
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Publication number: 20130260048Abstract: An electrically conductive resistive layer is produced by thermally spraying an electrically conductive material onto the surface of a non-conductive substrate. Initially, the material layer arising therefrom has no desired shape. The material layer is then removed in certain areas so that an electrically conductive resistive layer having said desired shape is produced.Type: ApplicationFiled: May 28, 2013Publication date: October 3, 2013Applicant: Watlow Electric Manufacturing CompanyInventor: Elias Russegger
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Patent number: 8395092Abstract: A heater assembly is provided that includes a substrate having opposed end portions defining raised flanges, a slot extending between the opposed end portions, and opposed chamfered surfaces extending along the slot and across the raised flanges. In one form, a plurality of layers are disposed onto the substrate, along with a pair of terminal pads. A protective cover defining at least one aperture is disposed over the layers and is secured to the raised flanges and the opposed chamfered surfaces of the substrate, and the aperture is disposed proximate the terminal pads. A pair of lead wires is secured to the pair of terminal pads, and a lead cap assembly is disposed around the pair of lead wires and is secured to the protective cover. Methods of manufacturing the heater assembly are also provided in accordance with the present disclosure.Type: GrantFiled: November 13, 2008Date of Patent: March 12, 2013Assignee: Watlow Electric Manufacturing CompanyInventors: Elias Russegger, Gerhard Schefbanker, Gernot Antosch, Wolfgang Poeschl, Martin Wallinger, Kevin Ptasienski, Matt Kenchel, Kenneth F. Fennewald, Allen Boldt
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Patent number: 8175446Abstract: An instrumented heater sleeve is provided that has a plurality of zones, a dielectric layer disposed over an outer surface of the sleeve, a resistive element layer disposed over the first dielectric layer, and a plurality of pairs of lead wires secured to a portion of the resistive element layer. Each pair of lead wires is connected to and corresponds with each of the zones and a protective layer is disposed over the dielectric layer. An amount of power is supplied to each of the zones and adjusted during a test run, or multiple test runs, to achieve a desired temperature profile along a heating target such as a hot runner nozzle. Methods of designing a hot runner nozzle heater using the instrumented heater sleeve are also provided.Type: GrantFiled: September 5, 2007Date of Patent: May 8, 2012Assignee: Wallow Electric Manufacturing CompanyInventors: Elias Russegger, Gerhard Schefbänker, Gernot Antosch, Wolfgang Pöschl, Christopher C. Lanham, James McMillin, William A. McDowell, III, Kenneth F. Fennewald, Allen Boldt, Frederic Zimmermann, Reinhardt Lehnert, Kevin Ptasienski
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Publication number: 20110265315Abstract: A method of forming a layered heater includes forming a continuous resistive layer over a substrate, forming conductive overlays in predetermined areas of the resistive layer, and removing portions of the continuous resistive layer between the conductive overlays to form a plurality of single cuts extending between the conductive overlays. The single cuts extend through the continuous resistive layer between the conductive overlays and longitudinally into a portion of the corresponding conductive overlays. Preferably, the single cuts are formed using a laser.Type: ApplicationFiled: July 5, 2011Publication date: November 3, 2011Applicant: Watlow Electric Manufacturing CompanyInventors: Elias Russegger, Gerhard Schefbanker, Martin Wallinger, Kevin Ptasienski
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Patent number: 7964825Abstract: An apparatus and methods for attaching electrical leads (22, 24) to a heating layer (16) of a heater are provided. An attachment material (50) is thermally sprayed over cords (32) of the electrical leads (22, 24), which are in contact with the heating layer (16) over a contact area (20). The attachment material (50) and the heating layer 16 are further thermally sprayed with a layer (52), which is an isolating material. The thermal sprayed connection between the electrical leads (22, 24) and the heating layer (16) thus provides more intimate contact and an improved electrical connection.Type: GrantFiled: November 24, 2004Date of Patent: June 21, 2011Assignee: Watlow Electric Manufacturing CompanyInventors: Elias Russegger, Reinhardt W. Lehnert
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Publication number: 20090127244Abstract: A heater assembly is provided that includes a substrate having opposed end portions defining raised flanges, a slot extending between the opposed end portions, and opposed chamfered surfaces extending along the slot and across the raised flanges. In one form, a plurality of layers are disposed onto the substrate, along with a pair of terminal pads. A protective cover defining at least one aperture is disposed over the layers and is secured to the raised flanges and the opposed chamfered surfaces of the substrate, and the aperture is disposed proximate the terminal pads. A pair of lead wires is secured to the pair of terminal pads, and a lead cap assembly is disposed around the pair of lead wires and is secured to the protective cover. Methods of manufacturing the heater assembly are also provided in accordance with the present disclosure.Type: ApplicationFiled: November 13, 2008Publication date: May 21, 2009Applicant: Watlow Electric Manufacturing CompanyInventors: Elias Russegger, Gerhard Schefbanker, Gernot Antosch, Wolfgang Poeschl, Martin Wallinger, Kevin Ptasienski, Matt Kenchel, Kenneth Fennewald, Allen Boldt
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Publication number: 20080138053Abstract: An instrumented heater sleeve is provided that has a plurality of zones, a dielectric layer disposed over an outer surface of the sleeve, a resistive element layer disposed over the first dielectric layer, and a plurality of pairs of lead wires secured to a portion of the resistive element layer. Each pair of lead wires is connected to and corresponds with each of the zones and a protective layer is disposed over the dielectric layer. An amount of power is supplied to each of the zones and adjusted during a test run, or multiple test runs, to achieve a desired temperature profile along a heating target such as a hot runner nozzle. Methods of designing a hot runner nozzle heater using the instrumented heater sleeve are also provided.Type: ApplicationFiled: September 5, 2007Publication date: June 12, 2008Applicant: Watlow Electric Manufacturing CompanyInventors: ELIAS RUSSEGGER, Gerhard Schefbanker, Gernot Antosch, Wolfgang Poschl, Christopher C. Lanham, James McMillin, William A. McDowell, Kenneth F. Fennewald, Allen Boldt, Frederic Zimmermann, Reinhardt Lehnert, Kevin Ptasienski
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Patent number: 7361869Abstract: An electrically conductive resistive layer (26) is produced by thermally spraying an electrically conductive material (18) onto the surface of a non-conductive substrate (12). Initially, the material layer (14) arising therefrom has no desired shape. The material layer (14) is then removed (24) in certain areas so that an electrically conductive resistive layer (26) having said desired shape is produced.Type: GrantFiled: June 21, 2004Date of Patent: April 22, 2008Assignee: Watlow Electric Manufacturing CompanyInventor: Elias Russegger