TW201946491A - Resistive heater with temperature sensing power pins and auxiliary sensing junction - Google Patents

Abstract

The present disclosure is directed toward a heater that includes a resistive heating element, a first power pin, and a second power pin. The first power pin forms a first junction with a first end of the resistive heating element, and the second power pin forms a second junction with the second end of the resistive heating element. The second power pin includes a first lead wire and a second lead wire. The first lead wire forms the second junction with the second end of the resistive heating element and defines a first conductive material. The second lead wire forms a primary sensing junction with the first lead wire at a first reference area, and defines a second conductive material different from the first conductive material to measure a temperature at the first reference area based on a voltage change created by the primary sensing junction.

Description

Resistance heater with temperature-sensing power pin and auxiliary sensing joint

The present application was filed on May 29, 2015 and is a part of US Application No. 14 / 725,537 entitled "Resistant Heater with Temperature-Sensing Power Supply Pins". The entire content of this US application is consolidated For reference herein.

The present disclosure relates to resistance heaters and temperature sensing devices such as thermocouples.

The narratives in this section only provide background information about the disclosures in this case and may not constitute conventional technology.

Resistive heaters are used in a variety of applications to provide thermal energy to a target and / or environment. One type of resistance heater in the conventional technology is a cassette heater, which is basically composed of a resistance wire heating element wound on a ceramic core. A typical ceramic core defines two longitudinal holes, and power / terminal pins are placed in them. A first end of the resistance line is electrically connected to a power pin, and the other end of the resistance line is electrically connected to another power pin. This assembly is then inserted into a larger-diameter tubular metal sleeve with an open end and a closed end or two open ends, so between the sleeve and the resistance wire / core assembly Generate an annular space. An insulating material, such as magnesium oxide (MgO) or the like, fills the open end of the casing to fill the annular space between the resistance wire and the inner surface of the casing.

The open end of the sleeve is sealed, for example, by using a potting compound and / or a separate sealing member. The entire assembly is then compacted or compressed as if by swaging or other suitable procedure to reduce the diameter of the casing, and thus compact or compress MgO, and at least partially crush the ceramic core to surround the core. The pins collapse to ensure good electrical contact and thermal transfer. The compacted MgO provides a fairly good heat transfer path between the heating element and the casing, and MgO also electrically insulates the casing from the heating element.

To determine the proper temperature at which the heater should operate, for example, a discrete temperature sensor for a thermocouple is placed on or near the heater. Adding a discrete temperature sensor to the heater and its environment is costly and complicated for the entire heater system.

This section provides a general summary of the disclosure, rather than a comprehensive disclosure of its full scope or all of its features.

In one aspect, the disclosure in this case is directed to a heater, which includes a resistive heating element, a first power pin, and a second power pin. The first power pin forms a first joint with the first end of the resistive heating element. The second power pin includes a first lead and a second lead. The first lead and the second end of the resistive heating element form a second joint portion and define a first conductive material. The second lead and the first lead form a main sensing joint at a first reference area. The second lead defines a second conductive material different from the first conductive material to measure a temperature at the first reference region based on a voltage change generated by the main sensing joint.

In another aspect, the first power pin, the first lead of the second power pin, and the resistive heating element are made of the same material.

In yet another aspect, the first and second leads are different nickel alloys.

In one aspect, the first lead of the first power pin and the second lead of the second power pin are made of the same material.

In another aspect, the heater further includes a controller in communication with the first power pin and the second power pin. The controller is configured to switch between a heating mode and a measurement mode for directing power to a resistive heating element, and the measurement mode is used to measure a voltage change generated by a main sensing joint To determine the temperature at the first reference area.

In yet another aspect, the heater further includes a controller in communication with the first and second power pins, and is configured to measure the voltage change at the first and second joints without interrupting the resistance heating Components of electricity.

In one aspect, the Seebeck coefficients of the first power pin, the first lead of the second power pin, and the resistive heating element are substantially the same.

In another aspect, the main sensing joint is disposed between the first end and the second end of the resistance heating element along the resistance heating element.

In yet another aspect, the main sensing joint is disposed outside the heater.

In one aspect, the first power pin includes a third lead and a fourth lead. The third lead is connected to the first end of the resistive heating element to form a first bonding portion, and defines a first conductive material. The fourth lead and the third lead form a second main sensing joint at a second reference area, and the second reference area is adjacent to and close to the first reference area. The fourth lead defines a third conductive material different from the first conductive material and the second conductive material as a thermocouple, and is used with the main sensing joint to determine the temperature between the first and second reference regions.

In one aspect, the first lead of the second power pin, the third lead of the first power pin, and the Shebeck coefficient of the resistive heating element are substantially the same.

In another aspect, the heater further includes a heating diffuser disposed around the main sensing joint.

In yet another aspect, the heater further includes a non-conductive portion, a sheath, and a sealing member. The non-conductive portion defines a proximal end and a distal end. The non-conductive portion has a first hole and a second hole extending through at least the proximal end. The first and second power pins are disposed in the first and second holes, and the resistive heating element is surrounded around the non-conductive portion. The sheath surrounds the non-conductive portion, and the sealing member is disposed at a proximal portion of the non-conductive portion and extends at least partially into the sheath.

In one aspect, the disclosure of this case is related to a heater, which includes a resistance heating element, a first power pin, and a second power pin. The resistive heating element can operate in a heating mode and a measurement mode. In the measurement mode, the resistance heating element senses a temperature at a first reference area along the resistance heating element. The first power pin forms a first joint with the first end of the resistive heating element. The second power pin includes a first lead and a second lead. The first lead forms a second joint with the second end of the resistive heating element, and defines a first conductive material. The second lead and the first lead form a main sensing joint at a second reference area. The second lead defines a second conductive material different from the first conductive material to measure a temperature at the second reference region based on a voltage change generated by the main sensing joint.

In another aspect, the heater further includes a controller in communication with the first power pin and the second power pin. The controller is configured to switch between a heating mode and a measurement mode. The heating mode is used to direct power to a resistance heating element. The measurement mode is used to measure the resistance of the resistance heating element to determine whether A temperature at a reference area and a voltage change generated by the main sensing joint to measure a temperature at the second reference area. The controller is configured to calculate a temperature at a third reference area based on the temperature at the first reference area, the temperature at the second reference area, a heater geometry, and the power delivered to the heating element.

In one aspect, the controller is configured to use the temperature measured by the primary sensing joint to calibrate the heating element.

In yet another aspect, the main sensing joint is formed along a plane different from the plane of the heating element.

In one aspect, the first power pin, the first lead of the second power pin, and the resistive heating element define one or more conductive materials having substantially the same Seebeck coefficient.

In one aspect, the present disclosure is about a heater having a resistive heating element, a first power pin, and a second power pin. The first power pin forms a first joint with the first end of the resistive heating element. The second power pin includes a first lead and a second lead. The first lead and the second end of the resistive heating element form a second joint portion. The second lead and the first lead form a main sensing joint at a reference area. The resistive heating element, the first power pin, and the first lead are made of a first conductive material. The second lead is made of a second conductive material having a Shebeck coefficient different from the first conductive material to measure the voltage at the reference area based on a voltage change generated by the main sensing junction. temperature.

In another aspect, the main sensing joint is disposed between the first end and the second end of the resistance heating element along the resistance heating element.

In yet another aspect, the main sensing joint is disposed outside the heater.

Further areas of application will be apparent from the description provided herein. It should be understood that the narrative and specific examples are intended for illustrative purposes only and are not intended to limit the scope of the disclosure in this case.

The content of the following description is merely exemplary in nature and is not intended to limit the content, application, or use of the disclosure in this case. It should be understood that corresponding reference numerals in all drawings represent similar or corresponding parts and features.

Referring to FIG. 1, a heater constructed according to the teachings disclosed in this case is shown, and is generally denoted by reference numeral 20. This type of heater 20 is a cassette heater. However, it should be understood that the teachings disclosed in this case can be applied to other types of heaters described in more detail below, and still remain in the contents disclosed in this case. In scope. As shown in the figure, the heater 20 includes a resistive heating element 22 having two end portions 24 and 26, and the resistive heating element 22 is in the form of a metal wire, such as a nickel-chromium alloy material as an example. The resistive heating element 22 is arranged around or around a non-conductive portion (or core in this form) 28. The core 28 defines a proximal end 30 and a distal end 32, and further defines a first hole 34 and a second hole 36 extending through at least the proximal end 30.

The heater 20 further includes a first power pin 40 made of a first conductive material and a second power pin 42 made of a second conductive material. The second conductive material and the first conductive material of the first power pin 40 Different. In addition, the resistance heating element 22 is made of a material different from the first and second conductive materials of the first power supply pin 40 and the second power supply pin 42, and the end portion 24 and the first power supply pin 40 form a first material. A joint portion 50 is formed, and a second joint portion 52 is formed at the other end portion 26 and the second power pin 42. Since the material of the resistance heating element 22 is different from the material of the first power pin 40 at the joint 50 and the material of the second power pin 42 at the joint 52, a thermocouple joint can be effectively formed, and thus Without the use of an independent / discrete temperature sensor, voltage changes at the first joint 50 and the second joint 52 can be detected (described in more detail below) to determine an average of the heater 20 temperature.

In one aspect, the resistive heating element 22 is a nickel-chromium-based alloy, a first power supply pin 40 is based Chromel ^® nickel alloy, and the second power pin 42 is based Alumel ^® nickel alloy. Alternatively, the first power supply pin 40 may be iron, and the second power supply pin 42 may be a copper-nickel alloy. Those skilled in the art should understand that any number of different materials and combinations thereof can be used for the resistive heating element 22, the first power pin 40, and the second power pin 42, as long as the three materials are different and are joining The sections 50 and 52 can effectively form a thermocouple junction. The materials described herein are for illustration purposes only, and should therefore not be construed as limiting the scope of the disclosure in this case.

In one application, the average temperature of the heater 20 can be used to detect the presence of moisture. If water vapor is detected, the water gas management control deduction rule can then be implemented by a controller (described in more detail below) to remove water vapor and a method by using a controlled method instead of continuously operating the heater 20 Possible early failure.

As further shown in the figure, the heater 20 includes a sheath 60 surrounding the non-conductive portion 28 and a proximal end 30 disposed on the non-conductive portion 28 and extending at least partially into the sheath 60 to complete the heater assembly.一 Sealing member 62. In addition, a dielectric filling material 64 is disposed between the resistance heating element 22 and the sheath 60. The various constructions and further structural and electrical details of the cassette heater are described in more detail in U.S. Patent Nos. 2,831,951 and 3,970,822. These patents are co-assigned with this application, and the entire contents thereof are by reference Incorporated herein. Therefore, it should be understood that the aspects described in this article are only examples and should not be construed as limiting the scope of the disclosure in this case.

Referring now to FIG. 2, the disclosure of the present case further includes a controller 70 that communicates with the power pins 40 and 42 and is configured to measure the voltage change at the first joint 50 and the second joint 52. More specifically, the controller 70 measures millivolt (mV) changes in the joints 50, 52, and then uses these voltage changes to calculate an average temperature of the heater 20. In one aspect, the controller 70 measures the voltage change of the joints 50 and 52 without interrupting the power to the resistive heating element 22. This can be done, for example, by taking a reading at the zero crossing of the AC input power signal. In another aspect, the power is interrupted and the controller 70 switches from a heating mode to a measurement mode to measure a voltage change. Once the average temperature is determined, the controller 70 switches back to the heating mode, which will be described in more detail below. More specifically, in one aspect, a triac AC switch is used to switch AC power to the heater 20, and temperature information is collected at or near the zero crossing point of the power signal. Other forms of AC switching devices can be used while remaining within the scope of the disclosure in this case, and therefore the use of triode AC switches is for illustration only and should not be construed as limiting the scope of the disclosure in this case.

Alternatively, as shown in FIG. 3, a FET 72 is a component that is used as a switching device and is used to measure a voltage during an FET off period with a DC power supply. In one aspect, three relatively large resistors 73, 74, and 75 are used to form a protection circuit for the measurement circuit 76. It should be understood that this switching and measurement circuit is merely an example and should not be construed as limiting the scope of the disclosure in this case.

Referring back to FIG. 2, a pair of leads 80 are connected to the first power pin 40 and the second power pin 42. In one aspect, the leads 80 are all the same material, such as copper as an example. In the case where another joint is introduced due to different materials at the joints 82 and 84, the lead wire 80 is provided to reduce the length of the power supply pin required to reach the controller 70. In this state, in order for the controller 70 to decide which joint to measure the voltage change, the signal lines 86 and 88 can be used to make the controller 70 switch between the signal lines 86 and 88 to identify the measured joint. unit. Alternatively, the signal lines 86 and 88 may be eliminated, and the voltage change across the wire bonding portions 82 and 84 may be skipped or compensated by software in the controller 70.

Referring now to FIG. 4, the teachings of the present disclosure can also be applied to a heater 20 'having multiple locations 90, 92, and 94. Each zone includes its individual set of power pins 40 ', 42' and resistive heating elements 22 'as previously described (drawn for simplicity in only one zone 90). In this aspect of the multiple-zone heater 20 ', the controller 70 (not shown in the figure) can communicate with the end portions 96, 98, and 100 of each zone to detect the voltage change and thus decide for that specific zone An average temperature. Alternatively, the controller 70 may be in communication with only the end portion 96 to determine the average temperature of the heater 20 'and determine whether there is water vapor as mentioned previously. Although three locations are shown, it should be understood that any number of locations can be used while remaining within the scope of the disclosure in this case.

Turning now to FIG. 5, the teachings disclosed in this case can also be applied to multiple separate heaters 100, 102, 104, 106, and 108, which can be cassette heaters and connected sequentially as shown in the figure. Each heater includes first and second joints of distinct power pins connected to a resistive heating element as shown, and therefore the average temperature of each heater 100, 102, 104, 106, and 108 can be as previously mentioned It is determined by the controller 70. In another aspect, the heaters 100, 102, 104, 106, and 108 each have their own power supply pins, and a single power return pin is connected to all heaters to reduce such multiple heater implementations. Case complexity. In this aspect having a cassette heater, each core may include a channel for receiving a power supply pin for each continuous heater.

Referring now to FIGS. 6 and 7, the pitch of the resistive heating element 110 may be changed according to another aspect of the disclosure of the present case to provide an adapted heating profile along the heater 120. In one aspect (FIG. 5), the resistive heating element 110 defines a continuously variable pitch along its length. More specifically, the resistive heating element 110 has a continuously variable pitch, and can tolerate an increased or decreased pitch P ₄ -P ₉ on the next next 360-degree loop. The continuously variable pitch of the resistive heating element 110 provides a gradual change in flux density of the heater surface (ie, the surface of the sheath 112). Although the principle of this continuously variable pitch is shown to be applied to a tubular heater with a filled insulator 114, this principle can also be applied to any type of heater, including but not limited to the previously mentioned cassette heating Device. In addition, as mentioned above, the first power supply pin 122 is made of a first conductive material, and the second power supply pin 124 is made of a second conductive material different from the first conductive material of the first power supply pin 122. The heating element 110 is made of a material different from the first conductive material of the first power pin 122 and the second conductive material of the second power pin 124, so that the voltage at the first joint 126 and the second joint 128 The change is detected to determine an average temperature of one of the heaters 120.

In another aspect (FIG. 7), the resistive heating element 130 has pitches P ₁ , P ₂ , and P ₃ at locations A, B, and C, respectively. P _{3 is} greater than P ₁ , and P _{1 is} greater than P ₂ . The resistive heating element 130 has a fixed pitch along the length of each zone as shown. Similarly, the first power pin 132 is made of a first conductive material, and the second power pin 134 is made of a second conductive material different from the first conductive material of the first power pin 132, and the resistance heating element 130 is made of a material different from the first conductive material of the first power supply pin 132 and the second conductive material of the second power supply pin 134, so that the voltage variation at the first joint portion 136 and the second joint portion 138 is changed. Check to determine the average temperature of one of the heaters 120.

Referring to FIG. 8, the heater and dual purpose power pins described herein have several applications, including, for example, a heat exchanger 140. The heat exchanger 140 may include one or more heating elements 142, and each of the heating elements 142 may further include a plurality of zones or variable pitch resistive heating elements, as previously described in the context of keeping the scope of the disclosure of this case. Description and narrator. It should be understood that the application of heat exchangers is only an example, and the teachings disclosed in this case can be applied to any application that provides heat and also requires temperature measurement, whether the temperature is absolute or used such as previously mentioned There is another environmental condition of water vapor.

As shown in FIG. 9, the teachings of this disclosure can also be applied to other types of heaters, such as the layered heater 150. Generally, the layered heater 150 includes a dielectric layer 152 applied to the substrate 154, a resistive heating layer 156 applied to the dielectric layer 152, and a protection applied over the resistive heating layer 156. Layer 158. A joint 160 is formed between one end of the trace of the resistive layer 158 and the first lead 162 (only one end is shown briefly), and similarly, a second joint is formed on the other end and follows the previously mentioned The principle of this disclosure is that the voltage change at these joints is detected to determine the average temperature of the heater 150. These layered heaters are described and described in more detail in US Patent No. 8,680,443, which is co-assigned with this application and its contents are incorporated herein by reference in its entirety.

Other types of heaters that are different from or previously added to the cassette-type, tubular, and layered heaters mentioned above can also be used according to the teachings disclosed in this case. These additional types of heaters may include, for example, polymer heaters, flexible heaters, thermal traces, and ceramic heaters. It should be understood that these types of heaters are merely examples and should not be construed as limiting the scope of the disclosure in this case.

Referring now to FIG. 10, a method of controlling at least one heater constructed in accordance with the teachings of the present disclosure is shown. This method includes the following steps:

(A) Activate a heating mode for supplying power to a power supply pin and returning power through a power return pin. The power supply pin is made of a first conductive material, and the power return pin is made of a first conductive material. Made of a different conductive material;

(B) Supply power to the power supply pin, to a resistance heating element having two ends and made of a material different from the first and second conductive materials of the power supply pin and the power return pin. This resistance heating The component forms a first joint portion with the power supply pin at one end and a second joint portion with the power return pin at the other end; and further provides power through the power return pin;

(C) Measure the voltage change between the first joint and the second joint to determine an average temperature of the heater;

(D) adjusting the power supplied to the heater as needed based on the average temperature determined in step (C); and

(E) Repeat steps (A) to (D).

In another aspect of this method, as shown by the dotted line in the figure, step (B) is interrupted to measure the voltage change when the controller switches to a measurement mode, and then the controller is switched back to heating mode.

Another aspect of the content disclosed in this case is shown in FIG. 11 to FIG. 13, wherein a heater for fluid immersion heating is shown and is generally denoted by reference numeral 200. The heater 200 includes a heating portion 202 configured to be immersed in a fluid. The heating portion 202 includes a plurality of resistive heating elements 204 and at least two non-heating portions 206 and 208 connected to the heating portion 202 (FIG. 12 Only one non-heated portion is shown in 206). Each non-heating portion 206, 208 defines a length and includes a corresponding plurality of sets of power pins electrically connected to a plurality of heating elements 204. More specifically, each set of power pins includes a first power pin 212 made of a first conductive material, and a first power pin made of a second conductive material different from the first conductive material of the first power pin 212. Two power pins 214. The first power pin 212 is electrically connected to the second power pin 214 in the non-heating portions 206 and 208 to form the joints 220, 230 and 240. As further shown in the figure, the second power pin 214 extends into the heating portion 202 and is electrically connected to the corresponding resistive heating element 204. In addition, the second power supply pin 214 defines a cross-sectional area larger than one of the corresponding resistive heating elements 204 without establishing another joint or measurable portion at the connection between the second power supply pin 214 and the resistance heating element 204 Heat.

As further shown in the figure, the one-end connection portion 250 is connected to the non-heating portion 206, and the plurality of first power pins 212 leave the non-heating portion 206 and extend into the termination portion 250 for electrical connection to a plurality of leads and one Controller (not shown). Similar to the previous description, the resistance heating elements 204 are each made of a material different from the first conductive material of the first power pin 212 and the second conductive material of the second power pin 214, and the first power pin 212 The joint portions 220, 230, and 240 of the second power supply pin 214 are respectively disposed at different positions along the length of the non-heating portions 206, 208. More specifically, for example, the joint 220 is at a distance L ₁ , the joint 230 is at a distance L ₂ , and the joint 240 is at a distance L ₃ .

As shown in FIG. 13, under the relationship shown in the temperature versus time “t” of the joints 220, 230, and 240, the joint 220 is immersed in the fluid F, and the joint 230 is immersed in the fluid F but not deep. , And the joint 240 is not immersed. Therefore, detecting a change in voltage at each of the joints 220, 230, and 240 can provide an indication of the fluid level relative to the heating portion 202. Especially when the fluid is oil in a cooking / frying application, it is desirable that the heating portion 202 is not exposed to the air during operation and does not cause a fire. Using the joints 220, 230, and 240 constituted by the teachings disclosed in this case, a controller can determine whether the fluid level is too close to the heating portion 202, thereby interrupting the power of the heater 200.

Although only three joints 220, 230, and 240 are shown in this example, it should be understood that any number of joints can be used while remaining within the scope of the disclosure in this case, as long as those joints are not Heating section 202.

Referring now to FIG. 14, another aspect of the disclosure of the present case includes a plurality of heater cores 300 arranged in zones in the heater system 270 as shown. The heater core 300 in this example aspect is a cassette heater as described above, however, it should be understood that other types of heaters as mentioned herein may also be used. Therefore, the cassette heater structure in this aspect of the disclosure in this case should not be interpreted as limiting the scope of the disclosure in this case.

Each heater core 300 includes a plurality of power pins 301, 302, 303, 304, and 305 as shown. Similar to the aforementioned aspects, the power pins are made of different conductive materials, and more specifically, the power pins 301, 304, and 305 are made of a first conductive material, and the power pins 302, 303, and 306 are made of The second conductive material is different from the first conductive material. As further shown in the figure, at least one jumper 320 is connected between different power pins, and in this example, it is connected between power pin 301 and power pin 303 to get close to jumper 320 A temperature reading of the position. This jumper 320 may be, for example, a lead or other conductive member sufficient to obtain a millivolt signal indicating the temperature near the position of the jumper 320, which is also in communication with the controller 70 as previously explained and described. Any number of jumpers 320 can be used across different power pins, and another position is shown in the figure as a jumper 322 connected between the power pin 303 and the power pin 305, which is located between the positions 3 and 4 between.

In this example aspect, the power pins 301, 303, and 305 are neutral pins in the heater circuit between adjacent power pins 302, 304, and 306, respectively. More specifically, a heater circuit in location 1 may be between the power pins 301 and 302, and a resistive heating element (such as element 22 shown in FIG. 1) is located between these power pins. A heater circuit in location 2 may be between the power pins 303 and 304, and a resistive heating element is located between the two power pins. Similarly, a heater circuit in location 3 may be between power pins 305 and 306, and a resistive heating element is located between these two power pins. It should be understood that these heater circuits are merely examples, and are explained in accordance with the teachings of the cassette heater described previously and with reference to FIG. 1.

Referring now to FIG. 15, in one aspect, the heater 400 is configured to include a primary sensing joint that can be disposed inside or outside the heater 400 to measure temperature. The heater 400 includes a resistive heating element 402, a first power pin 404 and a second power pin 406. The resistive heating element 402 has a first end and a second end. The first power pin 404 is connected to the first end of the resistance heating element 402 to form a first joint, and the second power pin 406 is connected to the second end of the resistance heating element 402 to form a second Junction. The first power pin 404 and the second power pin 406 are operable to supply power to the heating element 402 via a controller.

The second power pin 406 includes a first lead 412 and a second lead 414. The first lead 412 is connected to the second end of the resistive heating element 402 to form a second joint 410, and the second lead 414 is connected to the first lead 412 to form a main sensing joint in a first reference area. 416. The second lead 414 is assembled to connect the resistive heating element 402 to the controller via the first lead 412.

In one aspect, the first leads 412 and the second leads 414 are made of dissimilar conductive materials, or more specifically, materials having different Seebeck coefficients. For example, using various combinations of nickel, iron, copper-nickel alloy, Alumel ^® or the like. The material differences between the first lead 412 and the second lead 414 are shown in FIG. 15 by lines of different patterns (for example, a dashed line for the second lead 414 and a dotted line for the first lead 412). Because the materials are different, the main sensing joint 416 can effectively act as a thermocouple to generate a voltage change that is measured to determine the temperature at the first reference region. Therefore, in this aspect, the joints 408 and 410 for connecting to the resistance heating element 402 are separated from a sensing position. Therefore, the heater 400 is not limited to detecting the temperature at the end of the heating element 402, and the temperature measurement value can be detected at a plurality of positions in the heater 400. Furthermore, in one aspect, the first lead 412 and the second lead 414 are assembled to have a main sensing joint 416 outside the heater 400.

As discussed in relation to FIG. 2, the controller (not shown in FIG. 15) is in communication with the first power pin 404 and the second power pin 406 and is configured to supply power to the resistive heating element 402 via the power pins 404 and 406. . The controller is also configured to calculate a temperature in the first reference region based on a voltage change generated by the sensing junction 416 using a material's Shebeck coefficient.

In one aspect, the resistive heating element 402, the first power pin 404, and the first lead 412 of the second power pin 406 are made of the same conductive material or have similar Seebeck characteristics (i.e., substantially the same Seebeck coefficient). Therefore, the voltage change generated by the first bonding portion 408 and the second bonding portion 410 is substantially zero, and the temperature measurement determined by the controller is based on the voltage change generated by the main sensing bonding portion 416.

In another aspect, the resistive heating element 402, the first power pin 404, and / or the first lead 412 of the second power pin 406 are made of different conductive materials. With such a configuration, the material of the second lead 414 is selected such that the Seebeck coefficient of the second lead 414 and the resistance of the resistive heating element 402, the first power pin 404, and the first lead 412 of the second power pin 406 The Baker coefficients are the most different. Therefore, the main sensing joint 416 is provided as the largest enabler of the overall temperature measurement, and any temperature measurement from the first joint 408 and the second joint 410 is minimized.

As previously discussed, temperature can be detected at the zero crossing point of the power signal. In addition, the controller is configured to switch between a heating mode and a measurement mode for directing power to a resistance heating element, and the measurement mode is used to measure the main sensing joint 416. The voltage changes to determine the temperature at the reference area.

Referring to FIG. 16, in one aspect, a heater 420 includes two sensing joints close to each other to detect a temperature of an effective point between the two sensing joints. Here, the heater 420 includes a resistive heating element 422, a second power pin 424 and a first power pin 426. The resistive heating element 422 includes a first end and a second end. The first power pin 426 and the first end of the heating element 422 form a first joint portion 428, and the second power pin 424 and the second end of the heating element 422 form a second joint portion 430. The second power pin 424 is assembled in a similar manner as the second power pin 406 of FIG. 15, and thus the second power pin 424 includes a first lead 432 and a second lead 434, and the first lead 432 is connected to the resistor The heating element 422 is used to form the second bonding portion 430, and the second lead 434 is connected to the first lead 432 to form a first main sensing bonding portion 440 at a first reference area in the heater 420.

In this aspect, the first power pin 426 is assembled in a similar manner to the second power pin 424, and the first power pin 426 includes two leads (ie, the third lead 436 and the fourth lead 438) to form A sensing joint. More specifically, the third lead 436 is connected to the first end of the resistive heating element 422 to form a first bonding portion 428, and the fourth lead 438 and the third lead 436 form a second main portion in a second reference area. Sense joint 442. The second main sensing joint 442 is disposed at a second reference region of the heater 420, and the second reference region is adjacent to and close to the first reference region having the first main sensing joint 440. Although the sensing joints 440 and 442 are disposed inside the heater 420, the sensing joints 440 and 442 may be disposed outside the heater 420.

Similar to the second power pin 424, the third lead 436 is made of a different conductive material than the fourth lead 438, and has a different conductive material than the second lead 434 of the second power pin 424. Therefore, the second main sensing joint 424 can effectively be a thermocouple, which is used to engage the first sensing joint to determine the temperature between the first and second reference regions. Furthermore, the resistive heating element 422, the first lead 432 of the second power pin 424, and the third lead 436 of the first power pin 426 are made of the same conductive material or a material with a similar Seebeck coefficient such that The voltage changes generated by the first bonding portion 428 and the second bonding portion 430 are substantially zero, and the temperature measurement result determined by the controller is based on the voltage changes at the sensing bonding portions 440 and 442.

The aforementioned controller (not shown in FIG. 16) is configured to supply power to the heating element 422 via the first power supply pin 426 and the second power supply pin 424, and is measured in two based on the voltage change generated by the joints 440 and 442. A temperature of an effective point between the joints 440 and 442 is sensed. In one aspect, the temperatures at the first and second reference regions are assumed to be substantially the same, and therefore the temperature detected by the controller is associated with a valid point between the first and second reference regions.

Referring to FIGS. 17A and 17, in one aspect, the main sensing joint is disposed in a cassette heater to measure a temperature of an effective point outside the heater or a temperature in the heater. Reference zone temperature. FIG. 17A illustrates a cassette heater 450 including a resistive heating element 452 in the form of a metal wire, a first power pin 454, and a second power pin 456. The cassette heater 450 is assembled to include two sensing joints disposed outside the heater 450 to measure a temperature of an effective point between the two sensing joints.

More specifically, in one aspect, the resistive heating element 452 is wound or disposed around a non-conductive portion (or core in this form) as discussed with respect to FIG. 1. The first power pin 454 includes a first lead 458 and a second lead 460. The first lead 458 is connected to the first end of the resistive heating element 452 to form a first joint portion 462, and the second lead 460 and the first lead 458 at a first reference area outside the heater 450 form a The first main sensing joint 464. The second power pin 456 includes a third lead 466 and a fourth lead 468. The third lead 466 is connected to the resistive heating element 452 to form a second joint 470. The fourth lead 468 is connected to the third lead 466 to form a second main sensing joint 472 at a second reference area outside the heater 450. The first main sensing joint 464 and the second main sensing joint 472 are disposed adjacent to and close to each other.

In one aspect, the resistive heating element 452, the first lead 458 of the first power pin 454, and the third lead 466 of the second power pin 456 are made of the same material or a material with similar Seebeck characteristics And is made of a material different from the second lead 460 of the first power pin 454 and the fourth lead 468 of the second power pin 456. In addition, the material of the second lead 460 of the first power pin 454 is different from that of the fourth lead 468 of the second power pin 456. Therefore, the first main joint 464 and the second main joint 472 serve as thermocouples to detect the temperature at the effective point between the two joints 464 and 472.

FIG. 17B illustrates a cassette heater 480 having a main sensing joint in the heater. The cassette heater 480 includes a resistive heating element 482 having two ends, a first power pin 484, and a second power pin 486. The first power pin 484 and the first end of the heating element 482 form a first joint portion 488, and the second power pin 486 and the second end of the heating element 482 form a second joint portion 490. Similar to the heater in FIG. 15, the second power pin 486 includes a first lead 492 and a second lead 494. These leads are made of different materials (that is, have different Shebeck coefficients). The first lead 492 is connected to the second end of the resistive heating element 482 to form a second bonding portion 490, and the second lead 494 is connected to the first lead 492 to form a first reference area in the heater 480. The joint 496 is mainly sensed. Therefore, the main sensing joint 496 can be used as a thermocouple to measure the temperature at the first reference region.

In one aspect, the first lead 492 of the resistive heating element 482, the first power pin 484, and the second power pin 486 are made of the same conductive material or a material with similar Schiebeck characteristics. Therefore, the voltage change generated by the first joint portion 488 and the second joint portion 490 is substantially zero, and the temperature measurement result determined by the controller is based on the voltage change caused by the main sensing joint portion 496.

Referring to FIG. 18, the main sensing joints disclosed in this case can also be used as a part of a heat flow sensor to estimate the temperature between the inner surface and the outer surface of a heater. More specifically, in one aspect, a heater 500 is operable to heat a fluid (such as a gas) flowing through a tube, and the heater 500 includes a resistive heating (ie, thermal) element 502 ( (Shown with imaginary lines), a first power pin 504 and a second power pin 506. Although not fully illustrated in FIG. 18, the resistive heating element 502 is configured to extend through the heater 500 and is protected by a cover. The first power pin 504 and the second power pin 506 extend into the cover of the heater 500 to form a first joint portion with the first end of the heating element 502 and a second joint with the second end of the heating element 502, respectively. unit.

The resistance heating element 502 is a two-wire heating element, so that it has the functions of a heater and a temperature sensor. This two-wire performance is disclosed, for example, in US Patent No. 7,196,295, which is co-assigned with this application and is incorporated herein by reference in its entirety. Generally, for a two-wire system, the heating element 502 is made of a high resistance temperature coefficient (TCR) material. A controller (not shown in FIG. 18) is in communication with the first power pin 504 and the second power pin 506, and is configured to measure a change in voltage (ie, mV) across the power pins 504 and 506. Using this voltage change, the controller calculates the average temperature of the resistive heating element 502 (for example, regarding R1).

The first power pin 504 includes a first lead 508 and a second lead 510. These leads are made of different materials (that is, have different Shebeck coefficients). The first lead 508 and the heating element 502 form a second joint portion, and the second lead 510 and the first lead 508 form a main sensing joint 512 at a second reference area, the second reference area is along the heater The outer surface of 500 (ie, R2) (ie, along a plane different from the plane of heating element 502). Therefore, the main sensing joint 512 can operate as a thermocouple to measure the temperature at the second reference region based on the voltage change generated by the sensing joint 512. The resistive heating element 502, the second power supply pin 506, and the first lead 508 of the first power supply pin 504 are made of the same material or a material with similar Seebeck characteristics.

In one aspect, the controller is configured to estimate the heater 500 based on the temperature measurement of the heating element 502, the temperature at the main sensing joint 512, and the power transmitted from the controller to the heater 500. The temperature of the effective point between the inner surface (ie the first reference area) and the outer surface (ie the second reference area). More specifically, the controller uses the voltage change across the power pins 506 and 504 to determine the average temperature of the heating element at the first reference area, as described above for the two-wire system. The controller further determines the temperature at the second reference region based on the voltage change generated by the main sensing joint 512 and the Seebeck coefficients of the first lead 508 and the second lead 510. Using two measurements, the power provided and the geometry of the heater, the controller can calculate the temperature at a third reference area at a desired location (eg, any location within the heater) in the heater 500. In addition, if the geometry of the heater 500 is known, the controller can also be configured to determine a heat flux between the inner surface and the outer surface of the heater 500. This heat flow can be used, for example, to detect the entry area of the cold fluid, adjust the temperature set point, and / or other suitable system control methods. Although the heater 500 is shown as a tube, the heater can be assembled into other suitable shapes (such as a flat plate), and still falls within the scope of the disclosure of this case.

Furthermore, in one aspect, before the heater 500 is powered on, the heater 500 is substantially at room temperature, so that the main sensing joint 512 is at the same or a high TCR element line (that is, the heating element 502). Roughly the same temperature. The controller is configured to measure the temperature using the main sensing joint 512, and further measure the resistance of the heating element 502. The controller correlates the resistance of the heater 500 with the temperature measured by the main sensing joint 512, and uses this reference value to convert other resistance values into temperature, thereby correcting the heating element 502.

Referring to FIG. 19, a main sensing joint can be configured in a variety of suitable ways to improve temperature measurement along a surface. For example, in one aspect, a main sensing joint 550 is formed of a first lead 552 and a second lead 554 made of different materials. The sensing joint 550 has a planar shape (that is, flat) and is surrounded by a heating diffuser 556, which is a thermally conductive material (such as copper) for improving thermal contact with the surface and for The thermal energy from the heating element is diffused.

The main sensing joints disclosed in this case serve as thermocouples to enable temperature measurement to be performed at different locations inside and even outside the heater. Therefore, the temperature measurement is not limited to the end of the heating element. In addition, the heater eliminates the need for a separate temperature sensor, thereby reducing the complexity of the heater.

It should be noted that the disclosure is not limited to the embodiments described and illustrated as examples. Many types of modifications have been described in this article, and more are part of the knowledge of those skilled in the art. Any alternatives of these and further modifications and technical equivalents can be added to the description and drawings without departing from the scope of the disclosure and the protection of the present case.

20, 20 ’, 100-108, 120, 150, 200, 400, 420, 500‧‧‧ heaters

22‧‧‧ (resistive heating) element

22 ’, 110, 130, 204, 402, 452‧‧‧ resistance heating elements

24, 26‧‧‧ tip (minutes)

28‧‧‧ core / non-conductive part

30‧‧‧ proximal

32‧‧‧ distal

34‧‧‧ first hole

36‧‧‧Second Hole

40, 504‧‧‧ (first) power pin

40 ’, 42’, 301 ~ 305‧‧‧ power pins

42, 506‧‧‧ (second) power pin

50‧‧‧ (first) joint

52‧‧‧ (second) joint

60、112‧‧‧Sheath

62‧‧‧sealing member

64‧‧‧ Dielectric Filler

70‧‧‧controller

72‧‧‧FET

73 ~ 75‧‧‧ resistor

76‧‧‧Measurement circuit

80‧‧‧ Lead

82, 84‧‧‧ (lead) junction

86、88‧‧‧Signal cable

Locations 90, 92, 94, A ~ C‧‧‧

96, 98, 100‧‧‧ end

114‧‧‧filled insulator

122, 132, 212, 404, 426, 454, 484‧‧‧ First power pin

124, 134, 214, 406, 424, 456, 486‧‧‧ second power pin

126, 136, 408, 428, 462, 488‧‧‧ first joint

128, 138, 410, 430, 470, 490‧‧‧ second joint

140‧‧‧ heat exchanger

142‧‧‧Heating element

150‧‧‧ (Layered) heater

152‧‧‧Dielectric layer

154‧‧‧Matrix

156‧‧‧ resistance heating layer

158‧‧‧protective layer

160, 220 ~ 240‧‧‧ Junction

162, 412, 432, 458, 492, 508, 552‧‧‧ first lead

202‧‧‧Heating section

206, 208‧‧‧ non-heated part

250‧‧‧ Termination section

270‧‧‧heater system

300‧‧‧ heater core

320, 322‧‧‧ Jumper

414, 434, 460, 494, 510, 554‧‧‧ second lead

416, 512, 550‧‧‧ (main) sensing junction

422, 482, 502‧‧‧ (resistive) heating elements

436, 466‧‧‧ Third Lead

438, 468‧‧‧ Fourth lead

440‧‧‧The first major sensing joint / sensing joint / joint

442‧‧‧Second main sensing joint / sensing joint / junction

450, 480‧‧‧ (cassette type) heater

464‧‧‧First major sensing joint / first major joint / joint

472‧‧‧Second major sensing joint / Second major joint / Joint

496‧‧‧Main sensing joint

556‧‧‧heated diffuser

F‧‧‧ fluid

L ₁ ~ L ₃ ‧‧‧Distance

P ₁ ~ P ₉ ‧‧‧ pitch

In order to make this disclosure better understandable, multiple forms provided by way of example will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a side cross-sectional view of one of a resistance heater having a dual purpose power pin constructed according to the teachings disclosed in this case;

FIG. 2 is a perspective view of the resistance heater of FIG. 1 and a controller with leads constructed according to the teachings disclosed in this case;

FIG. 3 is a circuit diagram showing a switching circuit and a measuring circuit constructed according to a form disclosed in the present case; FIG.

4 is a side cross-sectional view of one of the alternative forms of heaters having multiple heating zones and constructed in accordance with the teachings disclosed in the present case;

5 is a side elevation view of an alternative form of the disclosure of the present case, which illustrates a plurality of heaters successively connected and constructed according to the teachings of the disclosure of the present case;

6 is a side cross-sectional view of another aspect of a heater constructed with a resistive element having a continuously variable pitch and constructed in accordance with the teachings disclosed in this case;

7 is a side cross-sectional view of another aspect of a heater constructed with resistive elements having different pitches in a plurality of heating zones and constructed in accordance with the teachings disclosed in this case;

8 is a side cross-sectional view of a heat exchanger constructed using a heater and according to the teachings disclosed in the present case;

9 is a side cross-sectional view showing a layered heater constructed using dual purpose power pins and constructed according to the teachings disclosed in this case;

FIG. 10 is a flowchart illustrating a method formed by the teachings disclosed in this case;

11 is a perspective view of a heater constructed for fluid immersion heating according to the teachings disclosed in the present case;

FIG. 12 is a side cross-sectional view of a portion of the heater of FIG. 11 constructed according to the teachings of the present disclosure;

FIG. 13 is a graph showing an exemplary temperature difference at a plurality of joints of the heater of FIG. 10 constructed according to the teachings of the disclosure of the present case; FIG.

14 is a perspective view of another form of the disclosure of the present invention having a plurality of heater cores in the area and according to the teaching of the disclosure of the present disclosure;

FIG. 15 illustrates a heater having a main sensing joint formed according to the teachings disclosed in this case;

FIG. 16 illustrates a heater having one of two main sensing joints constructed according to the teachings disclosed in this case;

17A and 17B are external views of a cassette heater having a main sensing joint formed according to the teachings disclosed in this case;

FIG. 18 is a perspective view of a tubular heater having a main sensing joint and a two-wire heating element constructed according to the teachings disclosed in this case; and

FIG. 19 illustrates one of the main sensing joints with enhanced temperature measurement features constructed according to the teachings disclosed in this case.

The drawings herein are for illustration only and are not intended to limit the scope of the disclosure in this case in any way.

Claims (15)

A heater comprising: A resistance heating element; A first power pin forming a first joint with a first end of the resistive heating element; and, A second power pin, including: A first lead, forming a second joint with a second end of the resistive heating element, and defining a first conductive material; and A second lead, forming a main sensing joint with the first lead at a first reference area, wherein the second lead defines a second conductive material different from the first conductive material, based on A voltage change generated by the joint is sensed to measure a temperature at the first reference region. The heater of claim 1, wherein the first power pin, the first lead of the second power pin, and the resistive heating element are made of the same material. The heater of claim 1, wherein the first lead of the first power pin and the first lead of the second power pin are made of the same material. For example, the heater of claim 1, further comprising a controller in communication with the first power pin and the second power pin, wherein the controller is configured to switch between a heating mode and a measurement mode, the The heating mode is used to direct power to the resistive heating element, and the measurement mode is used to measure a voltage change generated by the main sensing joint to determine a temperature at the first reference region. The heater of claim 4, wherein the controller is configured to calibrate the resistive heating element using a temperature measured by the main sensing joint. The heater of claim 4, wherein the resistive heating element is operable to sense a temperature at a second reference area along the resistive heating element, and the controller measures the resistance of the resistive heating element To determine the temperature at the second reference area. The heater of claim 6, wherein the controller is configured to calculate based on the temperature at the first reference area, the temperature at the second reference area, the geometry of the heater, and the power delivered to the heater element. Temperature at a third reference zone. For example, the heater of claim 1 further includes a controller in communication with the first power pin and the second power pin, which is configured to measure a voltage change at the first joint portion and the second joint portion. Without interrupting the power supplied to the resistive heating element. The heater of claim 1, wherein the Seebeck coefficient of the first power pin, the first lead of the second power pin, and one of the resistive heating elements is substantially the same. The heater as claimed in claim 1, wherein the main sensing joint is disposed between the first end and the second end of the resistance heating element along the resistance heating element. The heater as claimed in claim 1, wherein the main sensing joint is disposed outside the heater. The heater of claim 1, wherein the first power pin includes: A third lead connected to a first end of the resistive heating element to form the first joint, and the third lead defines the first conductive material, and A fourth lead that forms a second main sensing joint with the third lead in a second reference area, the second reference area is adjacent to and close to the first reference area, and the fourth lead defines and the A third conductive material different from the first conductive material and the second conductive material is used as a thermocouple, and is used in conjunction with the main sensing joint to determine the temperature between the first and second reference regions. The heater as claimed in claim 9, wherein the first lead of the second power pin, the third lead of the first power pin, and the Seebeck coefficient of the resistive heating element are substantially the same. The heater as claimed in claim 1, further comprising a heat spreader arranged around the main sensing joint. If the heater of claim 1 further includes: A non-conductive portion defining a proximal end and a distal end, the non-conductive portion having a first hole and a second hole extending through at least the proximal end, wherein the first and second power pins are disposed on the Inside the first and second holes, and the resistive heating element is disposed around the non-conductive portion; A sheath surrounding the non-conductive portion; and A sealing member is disposed on a proximal portion of the non-conductive portion and extends at least partially into the sheath.