Modular heater system

A heater system is provided that includes a hybrid insulation cover that has a first cover disposed around hinged carrier members and heat trace sections, and a second cover operatively engaged with the first cover and adapted for detachable placement around a heating target and its varying geometries. A flexible insulation jacket having a similar construction as the second cover is also provided for use with connector assemblies. Furthermore, a heater system is provided that includes at least one heat trace section encapsulated within adjacent insulating members for use with heating gaslines and pumplines of semiconductor processing systems.

FIELD

The present disclosure relates generally to electric heaters for use in pipelines, and more particularly to electric heaters for use in gaslines and pumplines such as, by way of example, semiconductor processing systems.

BACKGROUND

The supply of fluids such as oil, gas, and water, among others, from a supply, e.g., an oil well or a water reservoir, requires transfer of such fluids by conduits or the like. Maintaining a free or unrestricted flow of the fluids within the conduits is often necessary, in addition to maintaining the fluid at or above a certain temperature. Presently, an electric heater in the form of a cable or a tape, known in the art as a “heat trace,” is commonly used around the conduits to provide heat to the conduits and thus to the fluids. Additionally, the conduits and the heat traces are sometimes surrounded by a thermal insulation jacket to reduce heat loss to the surrounding environment.

Heat trace cables are a popular means for heating such fluid conduits due to their relative simplicity and low cost. Generally, heat trace cables are disposed along the length of the conduits or wrapped around the conduits and are fastened at regular intervals with bands, retaining straps or any other suitable fasteners, as shown in U.S. Pat. No. 5,294,780 to Montierth et al., U.S. Pat. No. 5,086,836 to Barth et al., U.S. Pat. No. 4,791,277 to Montierth et al., U.S. Pat. No. 4,152,577 to Leavines, U.S. Pat. No. 4,123,837 to Horner, U.S. Pat. No. 3,971,416 to Johnson, and U.S. Pat. Reissue No. 29,332 to Bilbro. Fastening heat trace cables to the pipe or conduit has proven to be time consuming and burdensome, particularly for replacement of utility lines and continuous manufacturing processes, among others, where time is of the essence.

To expedite the replacement of utility lines, U.S. Pat. No. 6,792,200 proposes a pre-fabricated heat-traced pipe, wherein a pipe to be heated, a heat trace, and a connector for electrically connecting the heat trace to a power source are cured and integrally formed beforehand and inventoried before a need for replacing an old pipe arises. While this prefabricated pipe saves some time with respect to replacement of utility lines, it requires a custom-made heat-traced pipe, thereby increasing undesirable inventory space and manufacturing and maintenance costs.

SUMMARY

In one form, a heater system is provided that comprises a plurality of hinged carrier members, each hinged carrier member defining an inner periphery surface, an outer receiving portion, and end portions. A plurality of heat trace sections are disposed within the outer receiving portions of the hinged carrier members, the heat trace sections defining end portions. End fittings are disposed proximate the end portions of the hinged carrier members and the end portions of the heat trace sections. A first cover is disposed around at least a portion of the hinged carrier members and the heat trace sections, the first cover being secured to the end fittings, and a second cover is operatively engaged with the first cover and adapted for detachable placement around at least a portion of the hinged carrier members and the heat trace sections.

In another form, a heater system is provided that comprises at least one heat trace section, a first insulating member disposed adjacent the heat trace section, and a second insulating member disposed opposite the first insulating member and adjacent the heat trace section. The first and second insulating members are secured to each other and encapsulate the heat trace section.

In yet another form, a heater system is provided that comprises a thermal insulation jacket having a body defining an outer wall and an inner wall, the body comprising at least one pocket disposed along the inner wall. At least one encapsulated heating element is disposed within the pocket, the encapsulated heating element comprising at least one heat trace section, a first insulating member disposed adjacent the heat trace section, and a second insulating member disposed opposite the first insulating member and adjacent the heat trace section. The first and second insulating members are secured to each other and encapsulate the heat trace section. A cover is disposed around the thermal insulation jacket.

In still another form, a heater system is provided that comprises a plurality of hinged carrier members, each hinged carrier member defining an inner periphery surface, an outer receiving portion, and end portions. A plurality of heat trace sections are disposed within the outer receiving portions of the hinged carrier members, the heat trace sections defining end portions. End fittings are disposed proximate the end portions of the hinged carrier members and the end portions of the heat trace sections. A flexible cover is operatively engaged with the end fittings and adapted for detachable placement around at least a portion of the hinged carrier members and the heat trace sections.

DETAILED DESCRIPTION

The structure of a heater in accordance with the present disclosure is now described in greater detail. At the outset, it should be understood that the word “conduit” as used throughout this specification includes, without limitation, tubes, pipes, and other enclosed or partially enclosed members for the transfer of fluids or other materials such as powders or slurries. The materials carried by the conduits described herein includes solids, liquids, and gases and may include, by way of example, fluids that are transferred within a semiconductor processing apparatus. The following description of the preferred embodiments with reference to such a semiconductor processing apparatus is merely exemplary in nature and is in no way intended to limit the disclosure, its application, or uses. Accordingly, the teachings of the present disclosure are not limited to a semiconductor processing apparatus and can be applied to any system of conduits while remaining within the scope of the present disclosure.

Referring toFIG. 1, a semiconductor processing system10is illustrated, which generally includes a heated gasline12that extends from a remote gas delivery system to a process tool, and a heated pumpline14that extends from the process tool, through a plurality of components as shown, and to a scrubber. During operation, both the gasline12and the pumpline14must be heated according to specific processing requirements, which has typically been accomplished with heat trace cables16as shown inFIG. 2. The heat trace cables16are placed or wrapped along the length of the gasline12or pumpline14as shown, and are secured to the gasline12or pumpline14using a glass tape18or other securing means. Additionally, insulation20is often placed around the heat trace cables16to reduce heat loss to the outside environment. The insulation20is typically wrapped around the heat trace cables16and secured in place by separate pieces of tape or ties around the gasline12or pumpline14.

Referring toFIGS. 3 and 4, the construction and materials of the heat trace cables16are illustrated and described in greater detail. The heat trace cable16typically includes a pair of bus-conductors22, which are surrounded by a semiconductive polymer material24that functions as a heating element. A dielectric or insulator material26surrounds the semiconductive polymer material24, which may optionally be surrounded by a metal braid material28as shown for additional functionality such as a ground plane. Further, an outer jacket30surrounds the metal braid material28to protect the overall assembly, and the outer jacket30is typically an insulating material such as a thermoplastic.

Although relatively lower cost than other heater systems, heat trace cables16must be cut to length in the field and spliced into an appropriate connector or terminal, which is often time consuming and cumbersome. Additionally, heat trace cables16are not as capable as other heating systems in providing a relatively uniform heating profile along the length of a conduit due to the limited area of coverage and the relatively crude means by which they are secured to the conduit. Heat trace cables16provide only casual contact with the conduit due to their stiffness and difficulty in forming to the shape of the conduit.

With reference now toFIGS. 5 through 8, a modular heat trace assembly adapted for use in a semiconductor processing system10in accordance with a first embodiment of the present disclosure is illustrated and generally indicated by reference numeral50. The modular heat trace assembly50comprises heat trace sections52for contacting and heating a conduit13of the semiconductor processing system10. The modular heat trace assembly50also comprises connectors54for securing adjacent heat trace sections52and for securing the modular heat trace assembly50to components of the semiconductor processing system10as described in greater detail below.

The heat trace sections52are preferably formed as an elongated shape as shown and include a curved portion56and a pair of opposing locking edges58extending in a longitudinal direction of the curved portion56. The curved portion56has an inner surface60defining an open channel62for placement around the conduit13. The inner surface60is preferably complementary to an outer surface of the conduit13to allow for securing the heat trace section52to the conduit13. The curved portion56preferably surrounds at least a half of the entire outer surface of the conduit13to provide more uniform heat transfer from the heat trace section52to the conduit13and to allow for self-locking of the heat trace section52around the conduit13by the locking edges58.

As shown, the locking edges58are spaced apart in a direction transverse to the longitudinal axis of the curved portion56and are so configured as to facilitate the mounting of the heat trace sections52to the conduit13. Since the heat trace material is flexible, when the channel62of the heat trace section52is placed around the conduit13, the locking edges58can be deflected outwardly and are then biased against the conduit13when released to secure the heat trace section52to the conduit13.

As further shown, a pair of conductors64are provided within the heat trace section52, preferably along the locking edges58as shown, wherein the conductors64extend outwardly from opposite ends66and68. The conductors64are configured for connection to a power source (not shown) for providing heat along the heat trace section52. The conductors64are also adapted, as described in greater detail below, for connection to an adjacent heat trace section52or to an adjacent connector54. Although not illustrated inFIGS. 5 through 8, it should be understood that the heat trace section52comprises the semiconductive polymer material, a dielectric or insulator material surrounding the semiconductive polymer material, and may also comprise optional materials for a ground plane and an outer jacket as previously described. These separate materials are not illustrated with the heat trace section52for purposes of clarity.

The heat trace sections52are preferably preformed in sizes corresponding to different sizes, or outside diameters for example, of the conduit13. The heat trace sections52are also capable of being cut to length, according to a desired length for a particular section of conduit13. Preferably, the heat trace sections52are provided in standard sizes and lengths for ease of repair and replacement within a conduit system such as the semiconductor processing system10as shown. Accordingly, the modular construction of the heater system according to the teachings of the present disclosure facilitates a relatively low cost heater system that is easily adapted to a conduit system.

Referring now toFIG. 9, a thermal insulation jacket for a heat-traced conduit, or a heated conduit (not shown), is generally indicated by reference numeral400. The thermal insulation jacket400preferably defines a tubular insulation body402, which has an outer wall403and an inner wall404defining a channel406for receiving a heated conduit, which may be a heat-traced conduit as previously described. The inner wall404defines a pocket408to house a conventional heat trace cable, as previously described, that is placed along the length of a conduit. Alternately, the pocket408may take any number of shapes, such as an arcuate pocket410as shown inFIG. 10, to accommodate the heat trace section52as shown and described herein. Accordingly, the shape of the pocket408is designed to mirror or conform to the shape of the heat trace section, whatever that shape might be. Additionally, the thermal insulation jacket400having pocket408can alternately be provided with a slit412so that the jacket400can be deformed and placed over a conduit rather than being slid along the length of the conduit. Moreover, the thermal insulation jacket400in the configurations as shown can serve to accurately position one or more heat trace sections against the conduit for the purpose of controlling the heat losses to atmosphere.

Referring toFIG. 11, another form of a thermal insulation jacket for a heated conduit is generally indicated by reference numeral420. The thermal insulation jacket420preferably defines a tubular insulation body422defining an outer wall423and an inner wall425. The tubular insulation body422is formed with a plurality of air chambers424extending longitudinally between the outer wall423and the inner wall425as shown. The air chambers424thus provide an area to improve the uniformity of heat dissipation along the heat trace sections and to reduce heat losses through the thermal insulation jacket420.

Referring toFIG. 12, another form of a thermal insulation jacket for heated conduit and having air chambers is generally indicated by reference numeral430. The thermal insulation jacket430preferably defines a tubular insulation body432having an outer wall433and an inner wall435. As shown, the tubular insulation body432has a plurality of air pockets434formed into the inner wall435and arranged in a somewhat random configuration along the longitudinal direction of the tubular insulation body432. Accordingly, the air pockets434reduce heat losses through the thermal insulation jacket430.

Referring toFIG. 13, still another form of a thermal insulation jacket for a heated conduit is generally indicated by reference numeral440. The thermal insulation jacket440defines a tubular insulation body442, which has a longitudinal slit444defined by opposing longitudinal edges446and448. The opposing longitudinal edges446and448are spaced apart in a circumferential direction and are properly spaced to allow for placement around a heated conduit. More specifically, the tubular insulation body442is made of a flexible material, e.g., silicone rubber sheet or foam, neoprene, polyimide foam or tape, among many others, such that the longitudinal edges446and448are deflected outwardly and are then biased against the heated conduit.

As further shown, one of the longitudinal edges446is provided with a flap452for properly engaging the other one of the longitudinal edges446after the thermal insulation jacket440is placed around the heated conduit. Using the flap452to close the longitudinal slit444helps to reduce heat loss to the outside environment. Preferably, the flap452is also made of a thermal insulation material to provide thermal insulation. The flap452may be made of an adhesive tape, or provided with an adhesive coating, or alternately may be Velcro® or a flap that includes mechanical snaps, among other securing techniques, such that the flap452is secured to the other one of the longitudinal edges448and along an outer surface of the tubular insulation body442.

In each of the thermal insulation jacket embodiments as described herein, it is preferable that the jackets are extruded. Additionally, it should be understood that any of the features, e.g., air chambers, pockets sized to the heat trace section geometry, longitudinal slit, and flap, may be provided alone or in combination with each other while remaining within the scope of the present disclosure. Moreover, multiple pockets may be provided to facilitate multiple heat trace sections52while not departing from the spirit and scope of the present disclosure.

Referring now toFIGS. 14-16, another form of a modular heater system is illustrated and generally indicated by reference numeral500. Generally, the modular heater system500comprises a heat trace assembly502and a connector assembly504. Only one (1) heat trace assembly502and one (1) connector assembly504are shown for purposes of clarity, and it should be understood that the modular heater system500can, and often does, include a plurality of either or both heat trace assemblies502and connector assemblies504, depending on the end application.

The heat trace assembly502is adapted for contacting and heating, for example, a conduit13of the semiconductor processing system10as previously described and shown inFIGS. 1 and 2. It should be understood that the modular heater system500can be applied to numerous end applications, and thus the semiconductor processing system10as illustrated and described herein is merely exemplary. Accordingly, these end applications are hereinafter referred to as “target systems” for the modular heater system500. The connector assembly504is also adapted for contacting and heating, for example, a joint, connector, or other component of the target system. Additionally, the connector assembly504secures adjacent heat trace assemblies502to each other and accommodates the joints, connectors, or other components of the target system. The connector assembly also provides both heat to the components of the target system and insulation from heat loss to the outside environment, among other functions, as described in greater detail below.

Similar to the previously described heat trace sections52(FIGS. 7 and 8), the heat trace sections510are preferably preformed in sizes corresponding to different sizes, or outside peripheries of, for example, the conduit13. The heat trace sections510are preferably extruded and are also capable of being cut to length, according to a desired length for a particular section of conduit13. Preferably, the heat trace sections510are provided in standard sizes and lengths for ease of repair and replacement within a conduit system such as the semiconductor processing system10as previously illustrated and described. Accordingly, the modular construction of the heater system according to the teachings of the present disclosure facilitates a relatively low cost heater system that is easily adapted to, for example, a conduit system.

Referring now toFIGS. 17 and 18, the connector assembly504comprises a shell700, which preferably includes a plurality of shell members702and704. Disposed inside the shell700are additional components of the connector assembly504, including a fitting heater assembly750, which is best shown inFIGS. 18-20. The fitting heater assembly750comprises a fitting adapter752, a heat trace section754, and an outer casing756that is preferably in two (2) pieces as shown. The fitting adapter752defines an opening760that is sized to mate with an adjacent fitting or component of the target system (not shown). Accordingly, it should be understood that the size and shape of the opening760as illustrated and described herein is merely exemplary and should not be construed as limiting the scope of the present disclosure.

The fitting adapter752also defines a recessed outer periphery762having grooves764, both of which are sized to accommodate the geometry of the heat trace section754as shown. Preferably, the fitting adapter752is a conductive material such as Aluminum, however, other materials may also be used while remaining within the scope of the present disclosure. Alternately, the fitting adapter752may include slits768(shown dashed) to provide for expansion of the opening760and thus more intimate contact with the adjacent fitting of the target system.

Preferably, the outer casing756is provided in symmetrical, interchangeable pieces as shown. The outer casings756include outer walls770and inner walls772that define conduits774therebetween. The conduits774provide a passageway for the lead wires (not shown) to connect to the heat trace section754. The outer casings756also include hinge elements776that cooperate with the hinge elements730of the shell members702and704, which are also shown inFIG. 49. As such, the hinge elements776preferably include pins778that are adapted for placement within holes731(FIG. 18) of the shell member hinge elements730. Additionally, the conduits774extend through the hinge elements776as shown to provide egress for the lead wires that connect to the heat trace section754. Preferably, the hinge elements776are disposed on an extension779as shown, wherein the extension779functions as a strain relief for the lead wires.

The outer casings756also preferably include standoffs780extending from their outer faces782as shown. These standoffs780function to center, or position, the fitting heater assembly750properly within the shell700.

In an alternate form of the outer casings756, as illustrated inFIG. 21, a snap feature is employed to securely connect each of the two outer casings756to each other. (Only one outer casing756is shown for purposes of clarity). More specifically, the casing756comprises flexible latches780that extend from a boss781, both of which are preferably integrally formed with the outer casing756. The flexible latches780define tapered end portions782that include relatively flat transverse faces783as shown. As further shown, a bore784is formed through an opposing boss785, which is also preferably integrally formed with the outer casing756. A counterbore786(shown dashed) is also formed in the opposing boss785, which defines an internal shoulder787(shown dashed). As the tapered end portions782engage the bore784of an opposing outer casing756(not shown), the flexible latches780deflect inwardly, towards each other such that the flexible latches780and the tapered end portions782can traverse the length of the bore784. As the tapered end portions782enter the counterbore786, the flexible latches780deflect back outwardly, and the transverse faces783engage the internal shoulder787to secure the outer casings756together. To separate the two outer casings756, the flexible latches780are deflected inwardly through the counterbore786until the transverse faces783clear the internal shoulder787, and the two outer casings756can then be pulled apart. It should be understood that this connecting device is exemplary only and thus other connecting devices for the outer casings756may also be employed while remaining within the scope of the present disclosure.

It should be understood that the exemplary connector assembly504as illustrated and described herein is configured for an elbow-type connection within the target system and that the geometry and features of the connector assembly504and its various components will vary depending on the connection employed within the target system. For example, if the connector assembly540were adapted for placement over a T-junction or a cross-type junction, or even a separate component such as a pump, by way of example, the size and shape of the connector assembly540components would be adjusted accordingly. Therefore, the specific design of the connector assembly540as illustrated and described herein should not be construed as limiting the scope of the present disclosure.

In another form of the present disclosure, the heat trace assemblies502are “matched” with the connector assemblies504to achieve even temperatures across their interfaces. More specifically, different power densities may be required at the connector assemblies504versus the heat traces assemblies502, and as such, different power densities are contemplated for each.

In yet another form, a reflective surface coating may be provided along the interior surfaces513of the insulation jacket512and/or the shell members702and704to reduce the power required and also to reduce the exterior surface temperatures of the modular heater system500components. Such a reflective surface coating preferably has low emissivity and may include, by way of example, an Aluminum foil or other low emissivity material applied by a vapor deposition process, by way of example. Similarly, a high emissivity material may be applied between the conduit13and the dielectric or insulator material26, or cover, that surrounds the semiconductive polymer material24, or conductive core, of the heat trace section510. (SeeFIGS. 3 and 4for basic construction of heat trace section and its terminology). As such, the high emissivity material would improve heat transfer between the heat trace section510and the conduit13.

Referring now toFIGS. 24 and 25, another form of a heat trace assembly is illustrated and generally indicated by reference numeral880. The heat trace assembly880comprises a carrier882that is adapted for placement around the conduit13, and a heat trace section884secured to the carrier882. In this embodiment, a standard/conventional heat trace section884can be employed without forming the heat trace section884to the shape of the conduit13as previously illustrated and described. Accordingly, the carrier882comprises an interior surface886that defines a shape complementary to the conduit13, along with extensions887that extend around at least one half of the periphery of the conduit13as shown. The carrier882further comprises a recessed upper surface888that is sized to receive the heat trace section884. The heat trace section884is then secured within this recessed upper surface888by any of a variety of means. For example, the heat trace section884may be press-fit or snapped into the recessed upper surface888, the carrier882may include a feature to secure the heat trace section884, an additional component (e.g. retaining clip) may be used to secure the heat trace section884to the carrier882, or an adhesive may be used to secure the heat trace section888within the carrier882, among other fastening or securing methods. Preferably, the carrier882is made of a material such as aluminum, brass, copper, or a conductive polymer so that the heat generated from the heat trace section884can be efficiently transferred to the conduit13. It should be understood that the insulation jackets as previously illustrated and described herein may also be employed with this heat trace assembly880while remaining within the scope of the present disclosure, even though such insulation jackets are not explicitly illustrated and described with this embodiment.

Referring toFIGS. 26aand26b, alternate forms of the carrier are illustrated and generally indicated by reference numerals882aand882b, respectively. As shown inFIG. 62a, the carrier882adefines a recessed upper surface888athat defines a curved geometry to accommodate a corresponding curved heat trace section884a. The curved geometry thus provides for improved heat transfer from the heat trace section884ato the conduit13since the heat trace section884agenerally follows the contour of the underlying conduit13. As shown inFIG. 62b, the carrier882bdefines multiple recessed upper surfaces888b, which may be curved as shown or relatively straight or flat as previously illustrated inFIGS. 60 and 61. As such, the carrier882bis preferably employed in applications where the conduit13has a relatively large size and requires multiple heat trace sections884bto sufficiently surround the conduit13.

In one form, the carrier882is preferably an aluminum extrusion, however, other materials that sufficiently transfer heat from the heat trace section884to the conduit13may also be employed while remaining within the scope of the present disclosure. For example, the carrier882may alternately be a polymer material. Additionally, alternate manufacturing methods other than extrusion, e.g., machining, may also be employed while remaining within the scope of the present disclosure.

In other forms of the present disclosure, various “indication” means are contemplated, wherein the state or condition of the heater system is indicated and can be monitored from the outside environment. For example, light emitting diodes (LEDs) may be placed along the heat trace assemblies at strategic locations to indicate whether or not the system is operational. The LEDs may be placed within individual sections of the heat trace assemblies or alternately in various electrical connections within the system. As another example, thermochromic coatings may be applied anywhere along exterior surfaces of the system, e.g., heat trace assemblies, connector assemblies, to indicate the temperature of the system at a certain location. Alternately, thermochromic additives may be employed within certain resin systems for use within, by way of example, the insulating jackets. Moreover, discrete temperature sensors may be employed within the system for temperature indications at desired locations, along with using the temperature sensors for temperature control. It should be understood that these various “indication” means are contemplated to be within the scope of the present disclosure.

Referring toFIGS. 27-29, a heater system in accordance with the principles of the present disclosure is illustrated and generally indicated by reference numeral110. Generally, the heater system110is designed for use in heating components in semiconductor processing systems such as gaslines and pumplines, as described in copending U.S. application Ser. No. 11/520,130, titled “Modular Heater Systems,” which is commonly assigned with the present application and the contents of which are incorporated herein by reference in their entirety. It should be understood, however, that the heater system110as set forth herein, including its various forms, is not limited to such an application and can be employed in any application to which a target is to be heated, and thus the application to semiconductor processing systems should not be construed as limiting the scope of the present disclosure.

As shown more clearly inFIG. 29, the heater system110comprises a plurality of carrier members112and a corresponding plurality of resistive heating elements114. The resistive heating elements114in this form of the present disclosure are heat trace sections, which are disposed within the carrier members112as shown. Although two carrier members112and two corresponding resistive heating elements114are illustrated, it should be understood that any number of carrier members112and resistive heating elements114may be employed while remaining within the scope of the present disclosure. End fittings116are disposed proximate end portions118of the carrier members112and end portions120of the resistive heating elements114. In one form, the end fittings116comprise external shells122and internal shields124, which are described in greater detail below.

A two-piece cover126is disposed around the carrier members112and the resistive heating elements114, and the cover126is secured to the end fittings116. Although the cover126is illustrated as being two pieces, the cover126may alternately be a single piece or multiple pieces, or take on the configurations as illustrated and described in copending U.S. application Ser. No. 11/520,130, titled “Modular Heater Systems” while remaining within the scope of the present disclosure. The cover126generally functions to retain the heat generated by the resistive heating elements114within the heater system110so that more heat is directed to the target (not shown) and heat losses to the outside environment are reduced during operation.

The heater system110also comprises retaining members130, which are disposed around at least a portion of the carrier members112to clasp the carrier members112around the target, which is further illustrated and described in greater detail below. Additionally, a standoff member132is disposed along the heater system110between the cover126and the target to provide a desired positioning between the resistive heating elements114and the cover126as described in greater detail below.

As further shown, the resistive heating elements114are electrically connected to a power source (not shown) through lead wires134as shown inFIG. 27, which in one form have connectors136disposed at their end portions138for ease of installation and removal of the heater system110. As such, and with reference back toFIG. 29, the resistive heating elements114include lead extensions140and crimps142for electrical connection to the lead wires134.

Referring now toFIGS. 30-33, the carrier members112and resistive heating elements114are now illustrated and described in greater detail. As shown, each carrier member112defines an inner periphery surface140and an outer receiving portion142. The inner periphery surfaces140of the carrier members112are adapted for close proximity with a heating target12(FIG. 33) such that the heat being generated from the resistive heating elements114is efficiently transferred to the heating target12, including through radiation. As such, in this form, the inner periphery surfaces140define a cylindrical configuration to match the shape of the heating target12, which is a conduit in one exemplary application of the heater system110. It should be understood, however, that any number of shapes and configurations of the inner periphery surfaces140may be employed to accommodate a variety of heating targets while remaining within the scope of the present disclosure.

The resistive heating elements114are disposed within the outer receiving portions142, and the outer receiving portions142are preferably configured to conform to the shape of the resistive heating elements114, which in this form are heat traces sections, as shown. As such, the outer receiving portions142define enlarged end portions144, an intermediate support146, and outer retaining walls148, which retain the resistive heating elements114within the carrier members112. Additionally, the resistive heating elements114are conformable to the shape defined by the outer receiving portions142of the carrier members112. The resistive heating elements114may be pre-formed to the shape of the outer receiving portions142prior to installation, or alternatively, the resistive heating elements114may be installed into the carrier members112and then the overall assembly (of the carrier member112and resistive heating element114) formed to the shape of the heating target12. Additionally, the heater system110may be provided with only one resistive heating element114as shown inFIG. 30, i.e. with an “empty” carrier member112, or each of the carrier members112having a corresponding resistive heating element114as shown inFIG. 31. It should also be understood that more than two (2) sets of carrier members112and resistive heating elements114may be employed while remaining with the scope of the present disclosure. For example, three (3) sets of carrier members112and resistive heating elements114may be disposed around the target12while remaining within the scope of the present disclosure.

As further shown, the carrier members112define connecting portions150, which in this form are hinge elements such that the carrier members112are hinged carrier members112. More specifically, and with reference toFIGS. 32 and 33, one of the carrier members112defines a longitudinal protrusion152having an internal channel154, and the adjacent carrier member112defines a longitudinal rib156. The longitudinal rib156is disposed within the channel154as shown to provide a rotatable connection between the carrier members112in this particular embodiment. Accordingly, each set of carrier members112and resistive heating elements114can be moved relative to one another so that the heater system112can be more easily installed onto and removed from a heating target. Additionally, the sets of carrier members112and resistive heating elements114are capable of being disposed in closer proximity to the heating target with the relative movement for more efficient heat transfer. It should be understood that the hinged carrier members112are merely exemplary and that other connecting portions150that are adapted to be secured to at least one of an adjacent carrier member112and a heating target may be employed while remaining within the scope of the present disclosure. Additional exemplary embodiments of such connecting portions150are illustrated and described in greater detail below.

Additionally, the carrier members112may be provided with internal recesses178(shown dashed) in order to accommodate a fitting or other adjacent component that may be disposed along the target12. The recesses178may be provided in any shape or size that corresponds with the shape of the fitting or adjacent component, and thus a single carrier member112can extend along a heating target12and its components without using separate, individual carrier members112or other specially designed members to accommodate the adjacent components or fittings. The recesses178may also be employed to accommodate temperature sensors or other discrete indication means incorporated within the heater system110, such as those disclosed in copending U.S. application Ser. No. 11/520,130, titled “Modular Heater Systems,” which has been incorporated herein by reference in its entirety.

Referring toFIG. 36, yet another form of a heater system is illustrated and generally indicated by reference numeral230. As shown, the heater system230includes a plurality of carrier members232extending along the length of individual resistive heating elements234. Accordingly, more than one carrier member232per resistive heating element234is provided in this form of the present disclosure. It should be understood that such variations for the carrier members shall be construed as being within the scope of the present disclosure and thus the specific shapes and orientations of the carrier members as illustrated and described herein shall not be construed as limiting the scope of the present disclosure.

Referring toFIGS. 37-39, a heater system having a hybrid cover is illustrated and generally indicated by reference numeral320. The heater system320comprises a plurality of hinged carrier members112as previously set forth, along with a plurality of heat trace sections114and end fittings116. Advantageously, the hybrid cover comprises a first cover322disposed around at least a portion of the hinged carrier members112and the heat trace sections114, and a second cover324operatively engaged with the first cover322. In one form, the first cover322is rigid, and the second cover324is flexible as described in greater detail below.

The second cover324is designed to accommodate a fitting326(or a plurality of fittings) that is present along the heating target12. As such, the second cover324is adapted for detachable placement around at least a portion of the hinged carrier members112and the heat trace sections114. More specifically, and with reference toFIGS. 38 and 39, the second cover324in one form is flexible and comprises cutouts328to accommodate the fitting326so that the heater system320can be readily installed onto and removed from the heating target12. Additionally, the second cover324further comprises a fastening mechanism, and in this form snaps330, to secure the second cover324around the heater system320. In the form as shown, there are three (3) snaps330disposed at end portions332of tabs334extending from a central portion336of the second cover324. It should be understood that any number of snaps330or fastening mechanisms can be used while remaining within the scope of the present disclosure. Other fastening mechanisms may include, by way of example, Velcro®, magnetic elements, lacing, latches, and straps. It should be understood that other forms of fastening mechanisms are to be construed as falling within the scope of the present disclosure.

As further shown, the second cover324comprises an outer jacket338and an inner insulating member340. The outer jacket338in one form is a silicone rubber material, and the inner insulating member340is also a silicone rubber material, in the form of a foam. As described in greater detail below, this foam material form may be preformed to accommodate varying geometries of a heating target, and thus the shape and configuration as shown herein is merely exemplary and should not be construed as limiting the scope of the present disclosure.

The second cover324is secured to the first cover322using an adhesive material, although other attachment mechanisms may be used. Alternately, the second cover324is not physically attached to the second cover324and is instead located by the fastening mechanisms and by components of the heating target12. With being secured to the first cover322and configured to wrap around the hinged carrier members112and the heat trace sections114, the second cover324is operatively engaged with the first cover322and adapted for detachable placement in accordance with the teachings of the present disclosure.

Referring now toFIGS. 40-42, the concept of the flexible second cover324as set forth above is extended to the connector assembly504as previously set forth (FIGS. 14-23). As shown, an insulation jacket350is disposed around the fitting heater assembly750(also shown inFIGS. 18-20). The insulation jacket350in one form is a flexible silicone rubber material, comprising an outer jacket352and inner insulation members354. The inner insulation members354in one form are silicone rubber foam, and may be preformed to conform to varying geometries of the heating target12. Additionally, the insulation jacket350in comprises a fastening mechanism, which in this form is a snap356, to secure the insulation jacket350around the fitting heater assembly750.

As shown inFIGS. 43-45, another form of a heater system is illustrated and generally indicated by reference numeral360. The heater system360comprises at least one heat trace section362, a first insulating member364disposed adjacent the heat trace section362, and a second insulating member366disposed opposite the first insulating member364and adjacent the heat trace section362. The first and second insulating members364,366are secured to each other and encapsulate the heat trace section362as shown. In one form, the first and second insulating members364,366are a flexible silicone rubber material. It should be understood, however, that other types of insulating materials may be employed while remaining within the scope of the present disclosure. Additionally, the first and second insulating members may be a single unitized member in another form of the present disclosure, rather than the two (2) members as illustrated herein.

Referring now toFIGS. 46-48, the heater system360as set forth above is employed within a construction adapted for placement around varying geometries of a heating target. More specifically, a heater system370comprises a thermal insulation jacket372comprising a body374defining an outer wall376and an inner wall378with at least one pocket380disposed along the inner wall378. (See also,FIG. 9). The encapsulated heating element, or heater system360, is disposed within this pocket380as shown. Furthermore, a cover382is disposed around the thermal insulation jacket372.

In one form, the thermal insulation jacket372is a preformed silicone rubber foam material. Additionally, the cover382in one form is a flexible silicone rubber material. As shown, the cover382comprises a fastening mechanism, which are snaps384in this form, to secure the heater system370around a heating target12. The cover382may be adhesively bonded to the thermal insulation jacket372for proper placement. It should be understood that other fastening mechanisms other than snaps, such as Velcro® or elements as set forth above, may be employed while remaining within the scope of the present disclosure.

As further shown, the thermal insulation jacket372comprises a longitudinal slit386to allow the heater system370to be resiliently installed onto and removed from a heating target. Moreover, the thermal insulation jacket372comprises a shape commensurate with the heating target12. In this exemplary form, the thermal insulation jacket372is curved to match the curvature of the heating target12. In other forms, the thermal insulation jacket372may be straight or take on other polygonal or splined shapes while remaining within the scope of the present disclosure.

Referring toFIGS. 49 and 50, yet another form of a heater system in accordance with the present disclosure is illustrated and generally indicated by reference numeral390. The heater system390is similar to the heater system320shown inFIGS. 37-39, with the exception that a continuous, flexible cover392is disposed around the carrier members112and heat trace sections114, rather than a portion being rigid and a portion being flexible as previously described. More specifically, the flexible cover392comprises an outer jacket394and an inner insulating members396. The outer jacket394in one form is a silicone rubber material, and the inner insulating members396are also a silicone rubber material, in the form of a foam. As set forth above, this foam material form may be preformed to accommodate varying geometries of a heating target, and thus the shape and configuration as shown herein is merely exemplary and should not be construed as limiting the scope of the present disclosure. Additionally, various cutouts398in the flexible cover392may be provided as previously set forth, in order to accommodate varying geometries of the heating target, such as the fitting399.

The flexible cover392is also provided with a fastening mechanism, as previously set forth, in one form of the present disclosure. As shown, the fastening mechanism is snaps397, however, it should be understood that other fastening mechanisms, such as those previously set forth herein, are to be construed as being within the scope of the present disclosure. The flexible cover392in one form is secured to the end fittings116and in another form may simply abut the end fittings116. As such, the flexible cover392is operatively engaged with the end fittings116and adapted for detachable placement around at least a portion of the hinged carrier members112and the heat trace sections114. Additionally, the flexible cover392is adapted for detachable placement around at least a portion of the hinged carrier members112and the heat trace sections114with the use of fastening mechanisms, cutouts, and its flexible nature.

Although the above-described heater systems have been illustrated and detailed as having a construction similar to a conventional heat trace cable, it should be understood that other types of heater construction besides a heat trace cable construction may also be employed while remaining within the scope of the present disclosure. A heater type such as a polymer heater or a layered film heater, among others, should be construed as being within the scope of the present disclosure. It should also be understood that other materials for the insulation jackets and covers besides the silicone rubber as set forth herein may be employed while remaining within the scope of the present disclosure. For example, other materials may include a polyimide or Aerogel®, among others.

The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the gist of the disclosure are intended to be within the scope of the disclosure. For example, the conductive polymer material used for the heat trace sections may be a semi-conductive material in order to self-regulate temperature or a non-semi-conductive material such that temperature is not regulated through the material but rather through a control system. Additionally, the thermal insulation jackets may be fitted with an external shell, e.g. rigid plastic, of any shape or geometry, in order to protect the thermal insulation jackets from damage from the outside environment. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.