Abstract: A heater includes a first conducting pin, a second conducting pin, and a plurality of resistance coils. Each resistance coil includes a first end connected to the first conducting pin and a second end connected to the second conducting pin. At least one resistance coil among the plurality of resistance coils has a continuously variable pitch. In one form, the plurality of resistance coils are connected in a parallel circuit with the first and second conducting pin. A first resistance coil among the plurality of resistance coils may have a diameter that is different than a second resistance coil among the plurality of resistance coils.

Abstract: A resistance element includes a resistance coil having a first end and a second end opposite the first end. The resistance coil defines a plurality of first portions defining a first constant diameter and a plurality of second portions defining a second constant diameter smaller than the first diameter. At least one of the first portions and the second portions has a continuously variable pitch. The resistance coil may also further define two third portions, each third portion being disposed adjacent to a corresponding first or second end. The resistance element may be disposed between first and second conducting pins in a heater.

Abstract: A heater includes a resistance coil, a first conducting pin and a second conducting pin. The resistance coil includes a first end connected to the first conducting pin, and a second end connected to the second conducting pin. The resistance coil defines a first portion adjacent the first end, a second portion adjacent the second end, and a third portion disposed between the first portion and the second portion. At least one of the first, second, and third portions has a continuously variable pitch along its length.

Abstract: A resistance element includes a resistance coil having a first end and a second end opposite the first end. The resistance coil defines a plurality of first portions defining a first constant diameter and a plurality of second portions defining a second constant diameter smaller than the first diameter. At least one of the first portions and the second portions has a continuously variable pitch. The resistance coil may also further define two third portions, each third portion being disposed adjacent to a corresponding first or second end. The resistance element may be disposed between first and second conducting pins in a heater.

Abstract: A heater includes a first conducting pin, a second conducting pin, and a plurality of resistance coils. Each resistance coil includes a first end connected to the first conducting pin and a second end connected to the second conducting pin. At least one resistance coil among the plurality of resistance coils has a continuously variable pitch. In one form, the plurality of resistance coils are connected in a parallel circuit with the first and second conducting pin. A first resistance coil among the plurality of resistance coils may have a diameter that is different than a second resistance coil among the plurality of resistance coils.

Abstract: A heater includes a resistance coil, a first conducting pin and a second conducting pin. The resistance coil includes a first end connected to the first conducting pin, and a second end connected to the second conducting pin. The resistance coil defines a first portion adjacent the first end, a second portion adjacent the second end, and a third portion disposed between the first portion and the second portion. At least one of the first, second, and third portions has a continuously variable pitch along its length.

Abstract: A heater is provided that includes a resistance coil assembly defining a first end portion having a first conducting pin and a second end portion having a second conducting pin, and a resistance coil disposed between the first end portion and the second end portion, and a first zone adjacent the first end portion with a constant pitch. The resistance coil further defines a continuously variable pitch extending along a length of the resistance coil from the first zone to the second end portion. The continuously variable pitch provides a variable watt density such that a predetermined temperature profile is provided along the sheath.

Abstract: A heater is provided that includes a resistance coil assembly defining a first end portion having a first conducting pin and a second end portion having a second conducting pin, and a resistance coil disposed between the first end portion and the second end portion, and a first zone adjacent the first end portion with a constant pitch. The resistance coil further defines a continuously variable pitch extending along a length of the resistance coil from the first zone to the second end portion. The continuously variable pitch provides a variable watt density such that a predetermined temperature profile is provided along the sheath.

Abstract: A heater is provided that includes a resistance coil assembly defining a first end portion having a first conducting pin and a second end portion having a second conducting pin, and a resistance coil disposed between the first end portion and the second end portion, the resistance coil defining a plurality of different pitches between the first end portion and the second end portion. An insulating material surrounds the resistance coil assembly, and a sheath surrounds the insulating material. The plurality of different pitches provide a variable watt density such that a predetermined temperature profile is provided along the sheath.

Abstract: A layered heater is provided that includes at least one resistive layer having a resistive circuit pattern, the resistive circuit pattern defining a length, a width, and a thickness, wherein the thickness varies along the length of the resistive circuit pattern and/or the width of the resistive circuit pattern for a variable watt density. The present disclosure also provides layered heaters having a resistive circuit pattern with a variable thickness along with a variable width and/or spacing of the resistive circuit pattern in order to produce a variable watt density.

Abstract: A layered heater is provided that comprises at least one resistive layer defining a circuit configuration, the circuit configuration comprising at least one resistive trace oriented relative to a heating target and comprising a material having temperature coefficient characteristics such that the resistive trace provides power commensurate with demands of the heating target In one form, resistive traces of the resistive layer are an NTC material having a relatively high BETA coefficient and are oriented approximately parallel to a primary heating direction.

Abstract: A layered heater is provided that comprises at least one resistive layer defining a circuit configuration, the circuit configuration comprising at least one resistive trace oriented relative to a heating target and comprising a material having temperature coefficient characteristics such that the resistive trace provides power commensurate with demands of the heating target In one form, resistive traces of the resistive layer are an NTC material having a relatively high BETA coefficient and are oriented approximately parallel to a primary heating direction.

Abstract: A heater is provided that includes a resistance coil assembly defining a first end portion having a first conducting pin and a second end portion having a second conducting pin, and a resistance coil disposed between the first end portion and the second end portion, the resistance coil defining a plurality of different pitches between the first end portion and the second end portion. An insulating material surrounds the resistance coil assembly, and a sheath surrounds the insulating material. The plurality of different pitches provide a variable watt density such that a predetermined temperature profile is provided along the sheath.

Abstract: A layered heater is provided that comprises at least one resistive layer defining a circuit configuration, the circuit configuration comprising at least one resistive trace oriented relative to a heating target and comprising a material having temperature coefficient characteristics such that the resistive trace provides power commensurate with demands of the heating target. In one form, resistive traces of the resistive layer are a PTC material having a relatively high TCR and are oriented approximately perpendicular to a primary heating direction. In another form, resistive traces of the resistive layer are an NTC material having a relatively high BETA coefficient and are oriented approximately parallel to a primary heating direction.

Abstract: Methods of forming a layered heater are provided that comprise at least one resistive layer comprising a resistive circuit pattern, the resistive circuit pattern defining a length, a thickness, and a spacing, wherein the thickness varies along the length of the trace of the resistive circuit pattern for a variable watt density. The methods include achieving the variable thickness by varying a dispensing rate of a conductive ink used to form the resistive circuit pattern, varying the feed rate of a target surface relative to the dispensing of the ink, and overwriting a volume of conductive ink on top of a previously formed trace of the resistive circuit pattern.

Abstract: A layered heater is provided with a resistive layer having a resistive circuit pattern, the resistive circuit pattern defining a length and a thickness, wherein the thickness varies along the length of the resistive circuit pattern for a variable watt density. The present invention also provides layered heaters having a resistive circuit pattern with a variable thickness along with a variable width and/or spacing of the resistive circuit pattern in order to produce a variable watt density. Methods are also provided wherein the variable thickness is achieved by varying a dispensing rate of a conductive ink used to form the resistive circuit pattern, varying the feed rate of a target surface relative to the dispensing of the ink, and overwriting a volume of conductive ink on top of a previously formed trace of the resistive circuit pattern.

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 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 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 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.