Watlow Electric Manufacturing Company

Pges Gmbh

Russegger, Elias

Elias Russegger

Kevin Ptasienski

Martin Wallinger

Gerhard Schefbanker

Allen Norman Boldt

Kenneth F Fennewald

Gernot Antosch

Reinhardt W Lehnert

Wolfgang Poeschl

Matt Kenchel

James McMillin

Christopher C Lanham

Wolfgang Pöschl

Gerhard Schefbänker

Frederic Zimmermann

William A McDowell, Iii

Reinhardt Lehnert

Allen Boldt

Kenneth Fennewald

Andreas Herdin

Clemens Frank

Josef SCHNÖLL

Wolfgang Poschl

William A Mcdowell

James Mcmillin

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.

Layered heater system having conductive overlays

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.

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.

Moisture resistant layered sleeve heater and method of manufacture thereof

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.

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.

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.

Method for the production of an electrically conductive resistive layer and heating and/or cooling device

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.

Moisture resistant layered sleeve heater and method of manufacturing thereof

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.

Hot runner nozzle heater and methods of manufacture thereof

An apparatus and methods for attaching electrical leads () to a heating layer () of a heater are provided. An attachment material () is thermally sprayed over cords () of the electrical leads (), which are in contact with the heating layer () over a contact area (). The attachment material () and the heating layerare further thermally sprayed with a layer (), which is an isolating material. The thermal sprayed connection between the electrical leads () and the heating layer () thus provides more intimate contact and an improved electrical connection.

Method for the attachment of an electrical lead wire on a surface element, as well as a heating element, especially for a plastic-spraying device

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.

A hot runner nozzle heater is provided that includes a sleeve defining a slot extending along a length of the sleeve. A first dielectric layer is disposed over an outer surface of the sleeve, and a resistive element layer is disposed over the first dielectric layer, wherein the resistive element layer defines a resistive circuit pattern that is preferably formed by a laser trimming process. A pair of terminal leads are secured to a portion of the resistive element layer thus defining a termination area, and the termination area is positioned proximate the slot and away from the proximal end and the distal end of the sleeve. A second dielectric layer is disposed over the resistive element layer but not over the termination area, a third dielectric layer is disposed over the termination area, and a protective layer disposed over the second dielectric layer and the third dielectric layer.

An electric heating device especially for fluids, such as liquid fuel, includes a heat element with an electrical resistance. The heat element can be connected to an electrical power source and also includes a carrier element to which en electrically conductive heat layer of a PTC material with positive temperature resistance co-efficient is applied. The heat layer can, at least in two interspaced positions, be connected to the electrical power source.

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Golling, Austria

Elias Russegger