U.S. patent number 3,619,560 [Application Number 04/888,189] was granted by the patent office on 1971-11-09 for self-regulating thermal apparatus and method.
This patent grant is currently assigned to Texas Instruments Incorporated. Invention is credited to Francis P. Buiting, Joseph W. Waseleski, Jr..
United States Patent |
3,619,560 |
Buiting , et al. |
November 9, 1971 |
SELF-REGULATING THERMAL APPARATUS AND METHOD
Abstract
Electrical heating devices and methods of making same employing
polymeric materials which display a steep-sloped positive
temperature resistivity coefficient (PTC) which serves to
self-regulate the amount of heat produced. The materials are
ductile and can be molded, extruded, machined and formed in complex
shapes including the following embodiments: A utensil formed of a
PTC heater element defining a cavity therein; the heating element
encapsulated in an electrical insulating jacket preferably formed
of material having the same thermal coefficient of expansion and
also serving as thermal insulation where desired. Another
embodiment employs a plurality of PTC elements having different
anomaly temperatures to provide a choice in temperature selection.
Yet another embodiment shows either open or closed ended passages
formed in a PTC heating element.
Inventors: |
Buiting; Francis P.
(Plainville, MA), Waseleski, Jr.; Joseph W. (Mansfield,
MA) |
Assignee: |
Texas Instruments Incorporated
(Dallas, TX)
|
Family
ID: |
25392700 |
Appl.
No.: |
04/888,189 |
Filed: |
December 5, 1969 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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732717 |
May 28, 1968 |
3501619 |
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Current U.S.
Class: |
392/480; 219/386;
219/441; 219/210; 219/407; 219/438; 219/505; 219/521; 392/472;
392/502 |
Current CPC
Class: |
H01C
7/027 (20130101) |
Current International
Class: |
H01C
7/02 (20060101); H05b 001/02 (); H05b 003/12 () |
Field of
Search: |
;219/300,301,504,505,10.51,210,520,521 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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609,391 |
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Sep 1948 |
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GB |
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756,945 |
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Sep 1956 |
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GB |
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932,558 |
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Jul 1963 |
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GB |
|
Primary Examiner: Bartis; A.
Parent Case Text
This is a division of application Ser. No. 732,717, filed May 28,
1968, now U.S. Pat. No. 3,501,619 which in turn is a division of
application Ser. No. 472,108, filed July 15, 1965, now U.S. Pat.
No. 3,413,442.
Claims
We claim:
1. An electric heating device comprising:
a. an elongated extrudable steep-sloped PTC element having a
longitudinal axis and at least one bore therein; and
b. means to apply a voltage across the element including a pair of
spaced terminals substantially coextensive in length with the PTC
element, one of which is embedded in and in electrical contact
substantially throughout its length with the PTC element and
extends parallel to the longitudinal axis, another of the spaced
terminals is generally helical in configuration surrounding the PTC
element and an electrical contact with the outer surface thereof,
whereby application of the voltage will cause electrical current
flow causing the element to heat up until an electrical, thermal
equilibrium is reached limiting the temperature of the element.
2. An electric heating device according to claim 1 in which a
plurality of bores are provided in the element.
3. An electric heating device according to claim 2 in which,
c. a lining of electrical insulation is located in each of the
bores.
4. An electric heating device according to claim 3 in which,
d. each bore has an end closed with electric insulation.
5. An electric heating device according to claim 2 wherein the
bores extend generally parallel to the longitudinal axis of the
element.
6. An electric heating device comprising:
a. an elongated extrudable steep-sloped PTC element having therein
at least one bore extending generally parallel to an axis of the
element; and
b. means to apply a voltage across the element including a pair of
terminals substantially coextensive in length with the PTC element
to cause an electrical current flow, one of the terminals embedded
in the PTC element independently of said at least one bore and the
other terminal in electrical contact with the outer surface of the
PTC element, both terminals in electrical contact substantially
throughout their length with the PTC element, thereby heating up
said element until an electrical, thermal equilibrium is reached
limiting the temperature of the element.
7. An electric heating device according to claim 6 in which a
plurality of bores are provided in the element extending generally
parallel to an axis of the element, and
c. a lining of electrical insulation is located in each of the
bores.
8. An electric heating device according to claim 7 in which,
d. each bore has an end closed with electrical insulation.
Description
This invention relates to thermal apparatus and methods, and
particularly to electrical heating devices and methods for making
the same.
Electrical heating devices are many and varied; however, in the
prior art these devices have generally required the use of
thermostats along with a heating element to prevent overheating of
the heating element, i.e., as a safety means, and also to keep the
heating device in the environs of a desired temperature by turning
on and off the heating element current by use of movable contacts.
This, of course, requires the use of components in addition to the
heating element per se which adds significantly to the cost of
materials as well as labor in assembling the heating device and
further, due to mechanically movable parts, such devices have a
limited longevity and are less than perfectly reliable.
On relatively expensive heating devices when precise temperature
control is required another approach has been employed using
proportional control means whereby relatively complex electrical
circuits serve to limit the power input to the heating element to
equal the heat loss from the heating device. This is done, for
example, by providing a bridge containing a temperature-sensing
device which is used to balance a circuit containing the heating
element. This type of control eliminates the on/off moving contacts
and therefore provides more precise temperature control and more
constant power requirements. However, the device is relatively
complex and expensive.
It has been discovered that by the use of certain materials which
display a positive temperature resistivity coefficient, hereinafter
referred to as PTC material, a simple, inexpensive heating device
can be made which is self-regulating, i.e., the PTC material serves
a function analogous to the thermostat by limiting the amount of
heat produced. Reference may be had to copending applications of
Charles D. Flanagan, Ser. No. 435,165, filed Feb. 25, 1965, now
U.S. Pat. No. 3,414,704 and Leo Marcoux, Ser. No. 435,166, filed
Feb. 25, 1965, which was abandoned in favor of continuation-in-part
application Ser. No. 508,643, filed Oct. 24, 1965, now U.S. Pat.
No. 3,414,705, all assigned to the assignee of this application. In
these applications the use of a doped barium titanate as a
self-regulating heating device is disclosed. While this answers
many of the disadvantages of the prior art, there are some
limitations to the use of ceramiclike material. The preparation of
this material is exacting since cracks and occlusions must be
avoided which would deleteriously effect the uniformity of the
resistivity of the material. Further, these ceramiclike materials
are fragile and cannot readily be machined or extruded, etc.
It is an object of this invention to avoid the above-mentioned
liabilities of the prior art by the provision of an electrical
heating device which is simple, highly reliable and long
lasting.
It is an object of the invention to provide heating apparatus which
has a self-regulating temperature.
It is another object of the invention to provide a thermal device
which is of a self-regulating temperature nature which can be
furnished in complex configurations.
It is yet another object of the instant invention to provide a
method of heat regulation utilizing a self-regulating electrical
heating element.
The invention accordingly comprises the elements and combinations
of elements, steps and sequence of steps, features of construction
and manipulation, and arrangement of parts, all of which will be
exemplified in the structures and methods hereinafter described,
and the scope of the application of which will be indicated in the
following claims.
In the accompanying drawings:
FIG. 1 is a vertical cross section through one embodiment of the
invention;
FIG. 2 is a vertical cross section through a second embodiment of
the invention;
FIG. 3 is a cross section through line 3--3 of FIG. 2;
FIG. 4 is a partial cross section through a third embodiment of the
invention;
FIG. 4a is a cross section of a modification of the FIG. 4
embodiment;
FIG. 5 is a cross section through line 5--5 of FIG. 4;
FIG. 6 is a chart plotting linearly resistivity and power against
temperature of a steep-sloped PTC material usable in accordance
with this invention.
Similar reference characters indicate corresponding parts
throughout the several views of the drawings.
Dimensions of certain of the parts as shown in the accompanying
drawings may have been modified and/ or exaggerated for the
purposes of clarity of illustration.
Briefly, the invention involves the provision of an elongated
element composed of a material having a steeply sloped PTC
resistivity characteristic. Means to apply voltage across the
element include spaced terminals which are essentially coextensive
in length with the element. One of the terminals is shown to be
generally helical in configuration. A plurality of bores is
provided in the element and extend generally parallel to the
longitudinal axis of the element and may be lined with electrically
insulative material. These bores may be open ended or may have one
end closed with electrically insulative material.
The PTC elements used in accordance with this invention act as a
heater and also as their own temperature regulator. The PTC
material which is a semiconductive, steep-sloped material has a low
resistance in the cold state and initially when power is applied
through the heating circuit relatively large currents are drawn and
consequently relatively high power and heat are dissipated.
Many materials have a PTC characteristic, such as barium titanate
doped with lanthanum as disclosed in the copending applications
referred to supra. However, doped barium titanate is brittle and
cannot easily be formed in complex configurations. The instant
invention involves the use of a material which is ductile,
machinable, moldable, extrudable and can therefore be formed in
complex shapes in contradistinction to the ceramiclike materials
above referred to. FIG. 6 shows resistivity and power versus
temperature curves of a carbon black filled cross-linked
polyethylene No. 4510 obtainable from Cabot Corporation, 125 High
Street, Boston, Mass. A perusal of FIG. 6 will indicate the
characteristics of this material which result in its
self-regulating and current-limiting capability. FIG. 6 relates to
a nonlinear resistance element in a 6-volt circuit. With the
material at ambient temperature (for instance approximately
70.degree. F.) and when the circuit is closed, it will be noted
that resistance is at a relatively low level (curve C) but the
power (curve D) is at a relatively high level due to the low
resistance and hence the current value is relatively high (E=IR).
This power is dissipated as heat (I.sup.2 R) thereby warming up the
material. The resistance stays at a relatively low level as the
temperature increases until an anomaly point is reached at which
point the resistance rapidly increases with a slight temperature
rise. At the anomaly point, an increase .DELTA.T from point A to B,
or 25 percent change, results in an increase in resistivity from
about 7 ohm-inches to approximately 118 ohm-inches, or an increase
of 95 percent. So it may be seen that at the anomaly point an
increase in temperature is accompanied by a proportionally much
greater increase in resistivity. Concomitant with this increase in
resistivity in a decrease in power showing that current level drops
as the resistance increases thereby limiting the quantity of heat
generated (I.sup.2 R). As a result the heat generated always tends
to balance the heat dissipated. If the heat demand is increased,
the temperature of the PTC material is reduced causing a large drop
in resistance. This results in a concomitant increase in current
(E=IR) and hence increased generated power (P=I.sup.2 R) until once
again the temperature is increased causing the resistance to
increase so that the heat generated equals the heat dissipated. In
like manner, variations in line voltage and/or ambient temperature
will effect similar control. In other words, a change in power
dissipation as shown in curve D in FIG. 6 will cause a proportional
increase in temperature with a fixed-resistance heater. But when
PTC material is used, this large variation in power dissipation
referred to above takes place over a very narrow temperature range.
This shows clearly the degree of control obtained and how it
depends on the steepness of the R=f(T) curve.
As explained in more detail infra, the PTC element is encapsulated
in an electrical insulating jacket which could advantageously be
formed out of material having the same thermal expansion as the PTC
element, such as polyethylene with no carbon black contained
therein. This jacket would also serve as a thermal insulation on
the sides of the element which are not facing the area to be heated
by making the jacket substantially thicker on those sides. As the
PTC element heats up due to heat generated, the portions or layers
nearest the thermal insulation will increase in temperature and
will increase abruptly in resistance when the anomaly temperature
is reached. Thus the material in the high-resistance state, or in
other words, the anomaly point, will move from the side facing the
insulation layer through the element to the side facing the area
which is to be heated. Upon an increase in heat demand or load
(such as caused by inserting an object to be heated in the thermal
device), this anomaly point will move back through the PTC element
toward the side facing the insulation until the heat demand
decreases permitting an equilibrium to be again achieved. Minor
variations in heat demand will merely change the thickness of that
portion of the PTC element in the high-resistance state. This
thickness adjusts itself so that the total PTC element resistance
presented to the essentially constant voltage external circuit is
such that heat generated just offsets heat dissipated to the
ambient and/or the object being heated.
Materials other than carbon black filled cross-linked polyethylene
which have as a characteristic a large positive temperature
coefficient of resistance (PTC), that is, material in which the
percent change in resistance per degree change in temperature in
the so-called break or anomaly point is very large can be used.
Other polymers which can be cross-linked with carbon or other
elements may exhibit a PTC characteristic large enough to be useful
in this invention.
The particular quantity of electrical resistivity and the anomaly
temperature can be changed, for instance, by the amount of carbon
black loading and the amount of cross linking.
Referring now to the drawings, FIG. 1 depicts the first of several
of the possible embodiments of our invention. Numeral 10 represents
a utensil comprising a self-controlled heater. By way of example
but not of limitation, the utensil 10 could be used as a butter
dish so as to maintain butter at a predetermined temperature either
directly in the utensil or in a separate container placed within
utensil 10. Utensil 10 is formed out of PTC material such as carbon
black filled cross-linked polyethylene.
Utensil 10 has a PTC heater element 12 of PTC material having
electrical conductive layers 14 and 16, such as silver, attached to
two opposite sides of said element by any conventional means such
as by vacuum deposition. Element 12 is encased in electrical and
thermal insulation jacket 18 formed of polyethylene for example. It
will be noted that outer portion 20 of jacket 18 is of a greater
thickness than inner portion 22 so that heat loss to the ambient is
minimized by heat flow to the opposite side of the PTC element is
optimized. A cover 24 with handle portion 26 may conveniently be
supplied to complete an enclosure 28. The device may be mounted on
legs 30. L.sub.1 is connected to inner conductive layer 14, L.sub.2
is connected to outer conductive layer 16. An insulation sleeve 32
isolates layer 14 from layer 16 to prevent a short circuit by
L.sub.1.
FIGS. 2 and 3 show utensil 40 having a plurality of PTC elements,
42, 44, 46, 48 and 50. Elements 42-50 have different anomaly
temperatures (for instance, by varying the carbon black loading and
amount of cross linking) in order to provide a choice in
temperature selection. For instance, elements 44 and 50 may have an
anomaly temperature of 100.degree. C., elements 46 and 48 may have
an anomaly temperature of 120.degree. C., while wall portion
element 42 may have an anomaly temperature of 110.degree. C.
Elements 42-50 are electrically isolated by insulation layers 54
and jacket 18 which is shown, as in the FIG. 1 embodiment with a
relatively thick insulation layer 20 on the outside, and a
relatively thin insulation layer 22 on the inside to prevent heat
loss to the ambient on the one hand and to optimize heat flow to
the inside on the other hand. PTC elements 44-50 are coated by
conventional means with a conductive layer 52 e.g. silver, on the
upper surfaces thereof in any convenient manner and a conductive
layer 56 e.g. silver, on the bottom surfaces thereof. Wall portion
element 42 is coated with an inside conductive layer 58 and an
outside conductive layer 60 in the same manner. Apertures 62 and
insulation sleeves 64 are provided in element 42 to facilitate the
provision of electrical leads for the elements 42-50. L.sub.2 is
connected through switch S to conductor 70 which is connected to
layer 60. Layer 60 and layer 56 are connected by electrical
connectors 74 so that layers 60 and 56 are at the same electrical
potential. Line L.sub.1 is connected through switch S to conductive
layer 58 by conductor 72. Conductor 66 is electrically connected to
layer 52 of elements 44 and 50. Conductor 68 is electrically
connected to layer 52 of elements 48, 46.
Movable contact arm 76 of switch S is movable to electrically
connect L.sub.1 to either conductor 66 or 68 thereby energizing
either PTC elements 44, 50 or 46, 48 respectively, as well as
element 42. Arm 76 may be switched to an off position 78 whereby
only the wall PTC element 42 is energized.
FIGS. 4 and 5 illustrate a third embodiment generally referred to
by numeral 80 which comprises PTC element 82 in which is located
tubular members 84 of electrical insulating material such as
polyethylene, and conductor 86 of copper or other good electrical
conductive material. Conductor 88 of any convenient cross section
and good electrical conductive material is spiralled around element
82 which is then surrounded with electrical and heat insulation 90.
Conductor 88 could also take the form of a conductive coating
placed about the periphery of element 82 or any other conventional
contact means.
Utensil 80 may have tubes 84 open at both ends to facilitate
passage of a fluid medium therethrough which will be heated by the
PTC heating element. This would be useful for such appliances as
hair dryers or heat guns. On the other hand, as shown in FIG. 4a,
tubes 84 may be sealed with insulating material 85 on one end and
have a removable insulating cover for the other end so that various
ingredients can be heated up in the separate tubes.
A voltage is impressed between conductors 86 and 88. This causes
current to flow through PTC element 82 causing it to heat up as
explained supra.
Instead of placing electrical conductors 86, 88 generally parallel
to the longitudinal axis of the cylindrical PTC element 82, the
conductors may take the form of clamps placed at the ends of a
finite length of element 82 or that current flow is parallel to the
longitudinal axis of element 82 rather than perpendicular.
It will be noted that the PTC material used in this invention can
be molded, extruded, machined, etc., into any desired shape to give
a heating device which is simple, rugged, reliable, inexpensive yet
self-regulating.
In view of the above, it will be seen that the several objects of
the invention are achieved, and other advantageous results
attained.
As many changes could be made in the above constructions without
departing from the scope of the invention, it is intended that all
matter contained in the above description or shown in the
accompanying drawings, shall be interpreted as illustrative and not
in a limiting sense, and it is also intended that the appended
claims shall cover all such equivalent variations as come within
the true spirit and scope of the invention. Also, it is to be
understood that the phraseology or terminology employed herein is
for purposes of description and not of limitation.
* * * * *