Electrical components molded within a polymer composite
AssigneeWatlow Electric Manufacturing Company
InventorsTheodore T. Von Arx, Louis P. Steinhauser, A. Konrad Juethner
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Abstract
Various components of thermal systems are shown molded within a polymer composite sheath, including heaters, sensors, and control circuits. The use of transfer and compression molding allows for the use of thermoset polymers containing very high levels of reinforcement fillers. These improved materials, in turn, create a component with superior thermophysical properties, including high heat flux levels, thermal conductivity, impact resistance, corrosion resistance, and maintenance of mechanical properties at high temperatures (>300.degree. F.). The present invention also allows for wide variety of geometric configurations and the possibility to insert temperature sensors directly in hot zones of heaters.
Claims17
An integrated sensor unit comprising:
- a sheath comprising a transfer moldable polymer composite;
- an electrical sensor encased within said sheath:
- one or more leads operatively coupled to said sensor and extending therefrom to a point outside said sheath;
- and
- wherein said sensor is capable of measuring a physical variable and providing an electrical signal through said leads indicative of the variable;
- wherein said transfer moldable polymer composite is a first transfer moldable polymer composite and further comprising:
- a core comprising a second transfer moldable polymer composite;
- and an electrically conductive heating element disposed about said core, said heating element having two ends adapted to receive an electric current.
An integrated heating system comprising:
- a core comprising a first transfer moldable polymer composite;
- an electrically conductive heating element disposed about said core, said heating element having two ends adapted to receive an electric current;
- a sheath surrounding said heating element, said sheath comprising a second transfer moldable polymer composite;
- an electrical sensor disposed within said sheath, wherein said sensor is capable of measuring a physical variable and providing an electrical signal through one or more leads indicative of the variable;
- and
- control means disposed within said sheath, said control means adapted to receive the electrical signal from said sensor and accordingly regulating an electric current to the ends of said heating element.
Dependencies are inferred from the claim text.