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US 11,240,881 B2Granted
Method of manufacturing and adjusting a resistive heater
AssigneeWatlow Electric Manufacturing Company
InventorsMartin Wallinger, Sanhong Zhang
Life of this patent
Estimating the term…
Abstract
A method of adjusting a watt density distribution of a resistive heater includes designing a baseline heater circuit. A detection circuit is designed having a constant trace watt density and the detection circuit overlaps the baseline heater circuit. The detection circuit is manufactured, and its baseline thermal map is obtained. The baseline heater circuit is manufactured, and a nominal thermal map is obtained. A subsequent detection circuit is manufactured, and an actual thermal map is obtained. A subtraction thermal image is created by subtracting the baseline thermal map from the actual thermal map, and a subsequent baseline heater circuit is modified according to the subtraction thermal image.
Claims20
A method of manufacturing and adjusting a resistive heater comprising:
- (a) designing a baseline heater circuit to be manufactured, the baseline heater circuit having a desired temperature profile;
- (b) designing a detection circuit to be manufactured, the detection circuit having a constant trace watt density, the detection circuit being larger than the baseline heater circuit to allow a margin to be present between the detection circuit and the baseline heater circuit;
- (c) manufacturing the detection circuit;
- (d) applying power to the detection circuit and obtaining a baseline thermal map;
- (e) removing a conductive material of the detection circuit by a selective removal process to form the baseline heater circuit;
- (f) applying power to the baseline heater circuit and obtaining a nominal thermal map representing a temperature profile of the baseline heater circuit being manufactured;
- (g) assembling the baseline heater circuit to a thermal device;
- (h) applying power to the baseline heater circuit and obtaining a thermal map of a target surface;
- repeating steps (a) through (h) until the thermal map of the target surface represents the desired temperature profile of the baseline heater circuit;
- (i) manufacturing a subsequent detection circuit;
- (j) applying power to the subsequent detection circuit and obtaining an actual thermal map;
- (k) creating a subtraction thermal image which represents a temperature profile based on a temperature difference between the nominal thermal map and the actual thermal map;
- and
- (l) modifying a subsequent baseline heater circuit according to the subtraction thermal image.
11 more elements
A method of manufacturing and adjusting a resistive heater comprising:
- (a) designing a baseline heater circuit to be manufactured, the baseline heater circuit having a desired temperature profile;
- (b) designing a detection circuit to be manufactured, the detection circuit having a constant trace watt density, the detection circuit being larger than the baseline heater circuit to allow a margin to be present between the detection circuit and the baseline heater circuit;
- (c) manufacturing the detection circuit;
- (d) applying power to the detection circuit and obtaining a baseline thermal map representing a temperature profile of the detection circuit;
- (e) removing a conductive material of the detection circuit to form the baseline heater circuit;
- (f) applying power to the baseline heater circuit and obtaining a nominal thermal map representing a temperature profile of the baseline heater circuit;
- (g) assembling the baseline heater circuit to a thermal device;
- (h) applying power to the baseline heater circuit and obtaining a thermal map of a target surface;
- repeating steps (a) through (h) until the thermal map of the target surface represents the desired temperature profile of the baseline heater circuit;
- (i) manufacturing a subsequent detection circuit;
- (j) applying power to the subsequent detection circuit and obtaining an actual thermal map;
- (k) creating a subtraction thermal image which represents a temperature profile based on a temperature difference between the nominal thermal map and the actual thermal map;
- and
- (l) modifying a subsequent baseline heater circuit according to the subtraction thermal image.
11 more elements
A method of manufacturing and adjusting a resistive heater comprising:
- (a) manufacturing a detection circuit;
- (b) applying power to the detection circuit and obtaining a baseline thermal map;
- (c) removing a conductive material of the detection circuit to form a baseline heater circuit;
- (d) applying power to the baseline heater circuit and obtaining a nominal thermal map representing a temperature profile of the baseline heater circuit being manufactured;
- (e) assembling the baseline heater circuit to a thermal device;
- (f) applying power to the baseline heater circuit and obtaining a thermal map of a target surface;
- repeating steps (a) through (f) until the thermal map of the target surface represents a desired temperature profile of the baseline heater circuit;
- (g) manufacturing a subsequent detection circuit;
- (h) applying power to the subsequent detection circuit and obtaining an actual thermal map;
- (i) creating a subtraction thermal image which represents a temperature profile based on a temperature difference between the nominal thermal map and the actual thermal map;
- and
- (j) modifying a subsequent baseline heater circuit according to the subtraction thermal image.
9 more elements
Dependencies are inferred from the claim text.