One aspect of the invention provides a gas heater including: a structure that defines a gas flow path having an upstream portion and a downstream portion; a first heating element positioned at least partially in the upstream portion of the flow path and having a first heating element maximum temperature capability; and a second heating element positioned downstream of the first heating element in the downstream portion of the flow path. The second heating element has a resistance that varies with temperature according to a second-heating-element-temperature-dependent resistivity rate.
One aspect of the invention provides an electric heater including: a resistive heating element; a current transformer positioned around a portion of the resistive heating element or a lead thereto, the current transformer adapted and configured to produce a secondary induced current proportional to a primary current flowing through the resistive heating element; and a controller communicatively coupled to the resistive heating element and the current transformer. The controller is programmed to either: (i): detect a deviation between the secondary induced current and a reference value; and in response to the deviation, generate an alert; or (ii) communicate to a remote server programmed to detect a deviation between the secondary induced current and a reference value.
A heating element includes first and second terminals and one or more heating element segments extending between the first and second terminals. The one or more heating element segments have a circuit trace that includes at least first and second portions, the at least first and second portions configured so that a surface temperature difference exists between the at least first and second portions when a voltage is applied between the at least first and second terminals. The heating element can also be made with a three dimensional shape, including one that is generated by fastening of the heating element to one or more support plates. The heating element can also have a cylindrical shape and be disposed in an insulating medium in a tubular member to provide varied heating capability along the tubular member length.
H05B 3/36 - Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs heating conductor embedded in insulating material
4.
ONE PIECE HEATER RACK, HEATER ASSEMBLY USING THE HEATER RACK, AND METHOD OF USE
A one-piece heater rack includes a number of arrays of attachment nodes and a surrounding peripheral structure. The attachment nodes are configured to allow the attachment of ceramic supports, the ceramic supports designed to hold open type coil electrical resistance heating elements that make up of a heater assembly using the heater rack. The attachment nodes allow attachment of the ceramic supports from above and below the heater rack for ease of installation. The heater rack also includes other features that providing mounting support for other heater assembly elements like terminals, thermostats, temperature limit switches, and air flow control over and through the heater using the peripheral structure, the arrays of attachment nodes or combinations thereof.
H05B 3/26 - Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base
H05B 3/16 - Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor the conductor being mounted on an insulating base
5.
Support insulators for open coil electric heaters and method of use
A support insulator for an open coil electric heater includes an insulator body having at least one coil support portion and plate attachment slots. The support insulator has an arm extending from the insulator body, the arm having a slot on an end thereof. Depending on the mounting of the support insulator, the slot can receive a resistance wire as a portion of a coil break-turn, a wire as part of a coil section, a part of a lead wire, or a part of a run of resistance wire that is not a coil break-turn or coil section.
H05B 3/06 - Heater elements structurally combined with coupling elements or with holders
H05B 3/32 - Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulators on a metallic frame
H05B 3/16 - Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor the conductor being mounted on an insulating base
6.
Heater with an optical sensor for over-temperature protection
A heater with an optical sensor for over-temperature protection. The heater includes a heating element and a sensor assembly including a coupler and an optical sensor. Wavelengths emanating from the heating element passes directly through the coupler to the optical sensor. The optical sensor provides an over-temperature feedback signal for limiting power to the heating element to avoid an over-temperature condition for the heating element.
An electric belly band heater is configured with only one end of the heater cable assembly thereof having lead wires extending therefrom. A single housing box is positioned at the end of the heater cable assembly where the lead wires exit to encompass the lead wires and includes an opening to receive a conduit to provide further protection to the lead wires exiting the housing box and being connected to a power source.
H05B 3/06 - Heater elements structurally combined with coupling elements or with holders
H05B 3/34 - Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs
H05B 3/36 - Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs heating conductor embedded in insulating material
A silicone band heater assembly includes a silicone heater cable, lead wires, and a zip tie connection. The heater cable consists of a resistance heater wire that is optionally surrounded by a fiberglass braid, which in turn is encased in a silicone insulator. Each end of the heater cable includes an overmolded zip tie segment, which includes the splice connection between the lead wire and resistance wire, and the ability to link the ends of the heater cable assembly together when being clamped to a desired structure.
H05B 3/08 - Heater elements structurally combined with coupling elements or with holders having electric connections specially adapted for high temperatures
A duct heater has a unique and symmetric arrangement of an auto limit and a pair of back up limits to permit the duct heater to be mounted in a duct in a number of different orientations. The duct heater can include a diffuser screen and have a particular size with respect to an upstream piece of equipment such as a single duct variable air volume damper box so that it can be used in these types of applications as well as stand alone applications in a duct.
H05B 3/16 - Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor the conductor being mounted on an insulating base
F24H 3/04 - Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element
F24H 9/20 - Arrangement or mounting of control or safety devices
10.
Insulator for open coil electrical resistance heater, heater using same, and method of use
An open coil electrical resistance heater employs an insulator having a coil convolution engaging portion that is adapted to engage heater coils with small diameters, small wire diameters, and/or small pitches without distorting the coil and compromising heater performance.
H05B 3/06 - Heater elements structurally combined with coupling elements or with holders
H05B 3/32 - Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulators on a metallic frame
H05B 3/16 - Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor the conductor being mounted on an insulating base
11.
Multiple stage open coil electric resistance heater with balanced coil power arrangement and method of use
An open coil electrical resistance heater subassembly for use in a heater has a support plate dividing the heater into at least two portions. At least two resistance wire coils are supported on the support plate using a plurality of insulators. Each insulator is configured to provide support to a portion of the resistance wire coil. The at least two resistance wire coils are arranged with respect to the support plate so that the coil power for each coil is distributed generally evenly between the top and bottom of the support plate and across the width of the support plate.
H05B 3/06 - Heater elements structurally combined with coupling elements or with holders
H05B 1/00 - ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL - Details of electric heating devices
F24H 3/04 - Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element
H05B 3/32 - Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulators on a metallic frame
F24H 9/18 - Arrangement or mounting of grates or heating means
12.
Electrical resistance heater assembly and method of use
An electrical resistance heating assembly comprises a heater ribbon woven through a first mica board. The heater ribbon extends upwardly from a top surface of the first mica board to provide heat to a fluid passing over the upwardly extending heater ribbon. The heat ribbon on an underside of the first mica board is electrically isolated by a second mica board positioned adjacent the first mica board. The first and second mica boards are held together with by a clamp-containing metal place positioned adjacent the second mica board with the clamps bent over the first mica board to keep the mica boards together.
H05B 3/78 - Heating arrangements specially adapted for immersion heating
H05B 3/16 - Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor the conductor being mounted on an insulating base
H05B 3/06 - Heater elements structurally combined with coupling elements or with holders
13.
Two level electric resistance heater and method of use
An electrical resistance heater assembly includes a heater housing forming a channel having a longitudinal axis for a fluid such as air to pass through and a heater support plate forming first and second levels in the heater housing. A first mica board assembly supporting a ribbon heater is mounted to the heater support plate at the first level and a second mica board assembly supporting a ribbon heater is mounted to the heater support plate at the second level. The first level is positioned adjacent an inlet of the heater housing and the second level is positioned adjacent an outlet of the heater housing. The first level and a side of the heater housing form a passageway for air to enter the heater housing and be directed to the ribbons of the second level, thereby allowing air to bypass the heater ribbons of the first level.
D06F 58/26 - Heating arrangements, e.g. gas heating equipment
F24H 9/18 - Arrangement or mounting of grates or heating means
F24H 3/04 - Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element
H05B 3/36 - Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs heating conductor embedded in insulating material
14.
Foldable electric resistance heater and method of use
A foldable electric resistance heater comprises at least a pair of insulator plates with a resistance wire threaded through openings in the insulator plates. In one mode, the insulator plates are folded with respect to each other and fastened together using one or more fasteners. In another mode, the plates can have other angled configurations with respect to each other. One or more insulators is positioned between the folded plates or adjacent the plates to isolate the resistance wire. The folded plate configuration and resistance wire provide significant advantages in manufacturing costs while forming a more robust heater configuration.
H05B 3/26 - Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base
15.
Close quarter electric resistance heater and method of use
A close quarter electric resistance heater comprises a ribbon heater element that is woven between ribbon support segments and within a heater shell. The ribbon support segments form an annulus on each end of the heater and are linked to each other using connectors. The connectors space the ribbon support segments apart from each other to facilitate the weaving of the ribbon element along the inside of the heater shell for heating purposes. The connectors also link the ribbon support segments to the shell. The ribbon heater element has faces that are wider than its edges and the ribbon heater element is woven on the support segments such that the edges face the heater shell. This configuration minimizes the migration of the ribbon heater element towards the shell and possible short circuiting of the heater.
H05B 3/46 - Heating elements having the shape of rods or tubes non-flexible heating conductor mounted on insulating base
H05B 3/16 - Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor the conductor being mounted on an insulating base
16.
Mica board electric resistance wire heater and method of use
A mica board heater has a mica board support plate assembly that isolates the mica boards from the frame of the heater. The mica board support plate assembly includes a mica board with openings sized to receive ends of the mica boards that support the resistance wires. The mica board with the specially sized openings is supported by a frame that is attached to the heater frame. By using the mica board support plate assembly, the mica boards are electrically isolated from the frame and without compromising the structural soundness of the frame.
A multiple stage open coil electrical resistance heater uses a unique coil configuration on either side of a dividing support plate so that the air passing through the heater is heated uniformly when one or more stages of the heater are energized. The coil configuration also creates a termination zone on one side of the heater so that the terminations of the coils can be situated on the cool side of the heater. The heater coils also includes specially configured terminals to facilitate connection to power using an elongated member such as a stud or bolt.
H05B 3/06 - Heater elements structurally combined with coupling elements or with holders
H01C 3/14 - Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven, or formed as grids the resistive element being formed in two or more coils or loops continuously wound as a spiral, helical, or toroidal winding
18.
Open coil electric resistance heater with offset coil support and method of use
An open coil electrical resistance heater uses a number of offset insulators to support the coil of the heater. The offset insulators configure the run of coil in a sinusoidal shape to hold the insulators in a more secure manner and reduce vibration and noise generation during heat operation. The sinusoidal configuration of the coil also reduces the problem of shadowing of portions of the resistance wire coil.
H05B 3/06 - Heater elements structurally combined with coupling elements or with holders
H01C 3/14 - Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven, or formed as grids the resistive element being formed in two or more coils or loops continuously wound as a spiral, helical, or toroidal winding
19.
Metal sheathed heater with solid state control device
A metal sheathed heater includes a solid state control device that allows the metal sheathed heater to be more efficiently operated. The control device supplies or terminates power to the heater according to certain conditions. Further, the control device uses predetermined time periods to control power to the heater. Thus, the heater is not kept on unnecessarily.
A metal sheathed heater includes a thermostat, a means for mounting the thermostat in a secure location, and a joint interconnecting the thermostat with a source of power and a lead wire of the metal sheathed heater. The joint is a type that is moisture and abrasion resistant, mechanically strong, and electrically insulating.
H05B 3/08 - Heater elements structurally combined with coupling elements or with holders having electric connections specially adapted for high temperatures
H05B 3/16 - Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor the conductor being mounted on an insulating base
21.
Method of using open coil resistance heater in appliances with right and left hand installation capability
An open coil resistance heater assembly is made for universal mounting between left and right hand installations in an appliance or other equipment. The heater assembly has its coils arranged symmetrically about a bisecting plane of the heater assembly and/or a center line of its terminal assembly aligned with the bisecting plane. The symmetrical coil arrangement and/or bisected terminal assembly allow the heater to be used in right hand or left hand installations.
H05B 3/06 - Heater elements structurally combined with coupling elements or with holders
H05B 3/08 - Heater elements structurally combined with coupling elements or with holders having electric connections specially adapted for high temperatures
H05B 3/16 - Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor the conductor being mounted on an insulating base
F24D 5/10 - Hot-air central heating systems; Exhaust-gas central heating systems operating without discharge of hot air into the space or area to be heated with hot air led through heat-exchange ducts in the walls, floor, or ceiling
A heater is provided that has a temperature sensing control system which can be used for both temperature control and over-temperature protection against element burnout. The temperature control system is comprised of an inlet temperature sensing assembly positioned at the inlet to the heater element and an exit thermocouple positioned in the exit end of the heater element. The exit thermocouple may be used for control the heater temperature and provide over-temperature protection. The inlet temperature sensing assembly is used to detect low or no air flow conditions which could lead to heater element failure.
H01H 37/12 - Means for adjustment of "on" or "off" operating temperature
G01K 7/02 - Measuring temperature based on the use of electric or magnetic elements directly sensitive to heat using thermoelectric elements, e.g. thermocouples
23.
Standoff for use with uncoiled bare wire and insulated runs of an open coil electric resistance heater, method of use, and an open coil resistance heater using the standoff
An open coil resistance heater uses one or more standoffs to engage and support the generally straight or uncoiled run of bare or insulated wire that is part of the resistance wire of the heater. The standoff has slots, which are sized to engage the bare or insulated wires for support purposes, and is removably mountable to the heater frame for supporting the run of uncoiled wire.
patents
