Abstract: A heater that may be applied to a substrate. The heater may include a graduating material deposited on at least a portion of a substrate, a resistive material and a thermal barrier dielectric coating. The resistive material may include at least two resistive compositions, wherein the resistivity of the material may be altered by varying the composition in given areas.

Abstract: Apparatus and method for inductive heating of a material located in a channel, to modify the state of the material between flowable and nonflowable states. An internal inductive heating assembly is disposed in the material in the channel, and a signal is supplied to the assembly to generate a magnetic flux in at least one of the assembly and the material, the magnetic flux generating inductive heating of the assembly and/or the material. The signal is adjusted to produce a desired rate of temperature cycling of the material in the channel which includes modifying the state of the material between flowable and nonflowable states. In one embodiment, the heating assembly includes an interior coil, an exterior sheath inductively coupled to the coil, a dielectric material disposed between the coil and sheath, a flux concentrator, and a conductor for supplying a signal to the coil to generate the magnetic flux.

Abstract: Apparatus and method for inductive heating of a material located in a channel. In one embodiment, the heating assembly comprises an interior coil, an exterior sheath inductively coupled to the coil, a dielectric material disposed between the coil and sheath, and a conductor for supplying a signal to the coil to generate the magnetic flux for inductive heating of the sheath. The heating assembly is disposed in the material in the channel, and the magnetic flux generated by the coil may also inductively couple to the material in the channel. The material may be heated from a nonflowable to a flowable state, such as heating a metal or polymer plug formed in a melt channel of a molding apparatus.

Abstract: A composite inductive heating assembly capable of providing in various embodiments, one or more of a variable or higher power density, tighter temperature control, reduced power consumption, longer operating life, and lower manufacturing costs, particularly in a compact design. A composite inductive heating assembly includes an inner layer of dielectric material, a multi-turn coil disposed over the inner layer, and an outer self-supporting body of moldable flux concentrator material rendering the inner layer, coil and flux concentrator into a self-supporting assembly. Select embodiments of the composite heating assembly include a nozzle heater and a manifold heater. A method of manufacturing the composite heater in a mold, with application of heat and pressure, is described.

Abstract: Method for inductive heating of a material located in a channel, the material having a melting range between a solidus temperature and a liquidus temperature. The method includes providing an internal inductive heating assembly in the material in the channel, and supplying a signal to the assembly to generate a magnetic flux in at least one of the assembly and material. The magnetic flux generates inductive heating of the assembly and/or the material and a physical agitation which lowers the solidus temperature of the material to a reduced solidus temperature.

Abstract: Apparatus and method for inductive heating wherein an internal inductive heating assembly is provided within a bore of a solid article. The heating assembly includes an interior coil inductively coupled to a portion of the article adjacent the bore to inductively heat the article. The heating assembly lacks an internal cooling mechanism and the coil thermally coupled to the adjacent article portion for transmission of heat from the coil to the article.

Abstract: The present disclosure relates to a heater that may be applied to a substrate. The heater may include a graduating material deposited on at least a portion of a substrate, a resistive material and a thermal barrier dielectric coating. The resistive material may include at least two resistive compositions, wherein the resistivity of the material may be altered by varying the composition in given areas.

Abstract: Apparatus and method for inductive heating wherein an internal inductive heating assembly is provided within a bore of a solid article. The heating assembly includes an interior coil inductively coupled to a portion of the article adjacent the bore to inductively heat the article. The heating assembly lacks an internal cooling mechanism and the coil thermally coupled to the adjacent article portion for transmission of heat from the coil to the article. A signal is provided to the coil to generate a magnetic flux for inductive heating of the adjacent article portion.

Abstract: Apparatus and method for inductive heating of a material located in a channel. In one embodiment, the heating assembly comprises an interior coil, an exterior sheath inductively coupled to the coil, a dielectric material disposed between the coil and sheath, and a conductor for supplying a signal to the coil to generate the magnetic flux for inductive heating of the sheath. The heating assembly is disposed in the material in the channel, and the magnetic flux generated by the coil may also inductively couple to the material in the channel. The material may be heated from a nonflowable to a flowable state, such as heating a metal or polymer plug formed in a melt channel of a molding apparatus.

Abstract: Apparatus and method for inductive heating wherein an internal inductive heating assembly is provided within a bore of a solid article. The heating assembly includes an interior coil inductively coupled to a portion of the article adjacent the bore to inductively heat the article. The heating assembly lacks an internal cooling mechanism and the coil thermally coupled to the adjacent article portion for transmission of heat from the coil to the article.

Abstract: Apparatus and method for inductive heating of a material located in a channel, to modify the state of the material between flowable and nonflowable states. An internal inductive heating assembly is disposed in the material in the channel, and a signal is supplied to the assembly to generate a magnetic flux in at least one of the assembly and the material, the magnetic flux generating inductive heating of the assembly and/or the material. The signal is adjusted to produce a desired rate of temperature cycling of the material in the channel which includes modifying the state of the material between flowable and nonflowble states. In one embodiment, the heating assembly includes an interior coil, an exterior sheath inductively coupled to the coil, a dielectric material disposed between the coil and sheath, a flux concentrator, and a conductor for supplying a signal to the coil to generate the magnetic flux.

Abstract: Method for inductive heating of a material located in a channel, the material having a melting range between a solidus temperature and a liquidus temperature. The method includes providing an internal inductive heating assembly in the material in the channel, and supplying a signal to the assembly to generate a magnetic flux in at least one of the assembly and material. The magnetic flux generates inductive heating of the assembly and/or the material and a physical agitation which lowers the solidus temperature of the material to a reduced solidus temperature.

Abstract: An apparatus for heating a flowable material comprises a core having a passageway formed therein for the communication of the flowable material, and an electric element coiled in multiple turns against the core in a helical pattern. The electric element, in use, heats the core both resistively and inductively. The electric element has no auxiliary cooling capacity. The electric element may be installed against the outside of the core, with an optional ferromagnetic yoke installed over it, or it may be installed against the inside of the core, embedded in a wear-resistant liner. The yoke and liner may be metallic material deposited such as by hot-spray technology and finished smooth.

Abstract: An apparatus for retaining a heater on an injection molding nozzle comprises a retaining body configured to fit around the injection molding nozzle. The retaining body has two flanges extending inward. One is configured to be received in a groove in the injection molding nozzle; the other is configured to be received in a groove in the heater. An axial slot allows the retaining body to elastically spread outward. The retaining body also has at least one aperture that receives a thermocouple. The aperture is preferably an elongated hole having an axis parallel to a longitudinal axis of the retaining body. Preferably the heater is a thick-film heater and the thermocouple is installed adjacent one on the resistive elements of the thick-film heater. When the resistive elements produce different heat levels, the thermocouple is preferably installed adjacent the resistive element that produces the greatest heat.

Abstract: An apparatus for heating a flowable material comprises a core having a passageway formed therein for the communication of the flowable material, and an electric element coiled in multiple turns against the core in a helical pattern. The electric element, in use, heats the core both resistively and inductively. The electric element has no auxiliary cooling capacity. The electric element may be installed against the outside of the core, with an optional ferromagnetic yoke installed over it, or it may be installed against the inside of the core, embedded in a wear-resistant liner. The yoke and liner may be metallic material deposited such as by hot-spray technology and finished smooth.

Abstract: A method and apparatus for temperature control of an article is provided that utilizes both the resistive heat and inductive heat generation from a heater coil.

Abstract: An apparatus for retaining a heater on an injection molding nozzle comprises a retaining body configured to fit around the injection molding nozzle. The retaining body has two flanges extending inward. One is configured to be received in a groove in the injection molding nozzle; the other is configured to be received in a groove in the heater. An axial slot allows the retaining body to elastically spread outward. The retaining body also has at least one aperture that receives a thermocouple. The aperture is preferably an elongated hole having an axis parallel to a longitudinal axis of the retaining body. Preferably the heater is a thick-film heater and the thermocouple is installed adjacent one on the resistive elements of the thick-film heater. When the resistive elements produce different heat levels, the thermocouple is preferably installed adjacent the resistive element that produces the greatest heat.

Abstract: An apparatus for heating a flowable material comprises a core having a passageway formed therein for the communication of the flowable material, and an electric element coiled in multiple turns against the core in a helical pattern. The electric element, in use, heats the core both resistively and inductively. The electric element has no auxiliary cooling capacity. The electric element may be installed against the outside of the core, with an optional ferromagnetic yoke installed over it, or it may be installed against the inside of the core, embedded in a wear-resistant liner. The yoke and liner may be metallic material deposited such as by hot-spray technology and finished smooth.

Abstract: An apparatus for heating a flowable material comprises a core having a passageway formed therein for the communication of the flowable material, and an electric element coiled in multiple turns against the core in a helical pattern. The electric element, in use, heats the core both resistively and inductively. The electric element has no auxiliary cooling capacity. The electric element may be installed against the outside of the core, with an optional ferromagnetic yoke installed over it, or it may be installed against the inside of the core, embedded in a wear-resistant liner. The yoke and liner may be metallic material deposited such as by hot-spray technology and finished smooth.

Abstract: A method and apparatus for temperature control of an article is provided that utilizes both the resistive heat and inductive heat generation from a heater coil.