Abstract:
A crushable ceramic heater core for an electric heater device which has a cylinder-like body of crushable ceramic material and grooves along the periphery of the body, the grooves being key shaped and adapted to receive a conductive pin in a groove. The invention also includes an electric heater device where such a core has been wound with heater wire and the conductive pin has been inserted in a core groove in contact with the wire, and the wire wound core has been installed in a sheath which has been filed with electoral insulting material. The sheath and its contents are swaged to create a compacted unitary heater assembly. The invention also includes the process for making the wire wound grooved core having a conductive pin therein in contact with the wire winding, and a method for making a heating device having such a core and which has been compacted to a theoretical density. The heater assembly and the method may also include installation of temperature sensing devices.

Description:
PRIORITY CLAIM 
       [0001]    Priority is claimed from U.S. Provisional Application No. 61/433,497, filed Jan. 18, 2011 and Patent Cooperation Treaty case number PCT/US2012/021453 filed Jan. 16, 2012. 
     
    
     BACKGROUND AND SUMMARY OF THE INVENTION 
       [0002]    This invention relates to a crushable heater core for an electric heater device, a compacted unitary electric heater device, and a method for making such devices. Such devices include, without limitation, swaged sleeve heaters, often in a hollow tube-like configuration, for delivering or processing material, such as plastic or other molten material, within or exterior to such a tube-like structure, for forming plastics, food processing, packaging, glue or other dispensing operations, in aerospace, liquid metal transfer, die casting, chemical, liquid processing, glass processes, gas heating equipment and other processes where close control is required. Such heaters can be constructed with sheaths of tool or stainless steel, super alloys and other critical materials, and may have special purpose coatings where required. 
         [0003]    Heater devices embodying the present invention offer heat transfer and performance characteristics and superior dielectric properties not found in conventional devices. The construction and design of such novel devices permit easy and effective control and performance enhancement, and may be constructed with distributed wattage, multiple independent heat zones, one or more integral thermocouples and singular or multiple thermowells which may accommodate sheathed, mineral insulated thermocouples for easy insertion or removability. 
         [0004]    Devices embodying the present invention utilize a novel cylindroid erushable ceramic core which has key hole shaped grooves on its interior surface for receiving lead pins in communication with a winding of electric heating wire, and the wound core is entrained in upper and lower sleeves and swaged to provide electrical contact between the lead pins and the heater element wire. 
         [0005]    The unique heating element embodying the present invention starts with one or more novel erushable ceramic core(s) of special configuration. Such core(s) comprises a cylindroid or cylinder which is fabricated with key hole shaped longitudinal grooves along their internal circumferential periphery. The entry to a groove comprises a keyhole like slot which is narrower at its entry and enlarged as it enters the circumferential wall of the cylindroid or cylinder. This keyhole slot may have a cross section which is rectangular or oblong or pillow shaped as long as its interior is of greater cross-section than its keyhole entry. 
         [0006]    The crushable ceramic core or cores are wound with heating element wire. The wire windings can be spaced as to provide distributed wattage, or cold zones on each core. The lead and terminal ends of the heating element wire are threaded into the cores in alignment with selected key slots. Selected alternate key slots in one or more cores of a multi-core assembly permits creation of independently powered cores to provide independently heated zones. Unwound cores can be placed at the ends of the core assembly or between multiple cores to provide additional cold zones to meet application or lead termination needs. 
         [0007]    A conductive pin having a cross section substantially conforming to the cross section of a key slot is slid into each groove having a heated wire end intersection with the groove, so that a pin and wire end contact one another. 
         [0008]    If thermowells for use with separate thermocouple sensors or thermocouple wires to create sensors for heat control are desired, they may be installed in one of the grooves. 
         [0009]    The interior of the wire wound ceramic core and arranged pin assembly is slid into a first tube like or solid metal sleeve and within a second outer metal sleeve so that the wire wound ceramic core and arranged pin assembly is sandwiched between the first and second metal sleeves. Preferably, the first inner sleeve is sized to accommodate the wire wound ceramic core to permit easy sliding of the core into place. 
         [0010]    Magnesium Oxide or similar insulating power is poured into the space between the core and the sleeves and the assembly is vibrated until the space between the parts is full and compacted to the extent possible by vibration. 
         [0011]    A tool rod or tube is inserted into or over the inner tube-like or solid sheath sleeve, and the assembly is inserted into a swaging machine and subjected to circumferential hammering until the outer diameter of the assembly is reduced to a size which compacts the internal ceramic core and insulating ceramic powder to near theoretical maximum density so that the connection between each of the pins and its associated element wire end is substantially unitized for effective electrical connection and that the ceramic powder in the key slots between the pin and the inner sleeve is compacted to provide the required electrical insulation properties between the pin and inner tube-like or solid metal sleeve. 
       OBJECTS AND ADVANTAGES OF THE INVENTION 
       [0012]    Compacted electric heating devices utilizing the novel core arrangement described constructed according to the present invention have the following attributes, objects and advantages:
   (a) They are more durable than conventional heaters because their high temperature heating element assemblies are imbedded in ceramic insulation compacted to near theoretical density providing optimum life and performance at temperatures up to 1600° F.   (b) They have optimum thermal and electrical properties because their swaged or compacted construction maximizes heat transfer while providing superior dielectric and insulation resistance.   (c) They can be constructed with thin total element and sheath wall sections to permit installation in restricted areas of tooling or with thin element wail and thick sheath wall sections to provide high strength for high pressure and mechanically demanding applications.   (d) They can be manufactured with large inside diameters, exceeding two inches, with a comparatively thin wall section and maintaining the desired dielectric and heat transfer properties.   (e) They are adequately versatile to accommodate simple sleeve heater arrangements or machined into sophisticated engineered configurations, with customized inner bores and precision fits,   (f) They have a construction which is capable of distributed wattage configurations to support multiple heating conditions along the length of the heater.   (g) They permit independent heat zones to be created.   (h) They provide superior heat uniformity circumferentially and longitudinally.   (i) They are capable of supporting optional custom coatings, special lead systems, and a wide selection of sensor options.   
 
         [0022]    Heaters embodying the present invention can be used in many kind of industries and systems, such as runnerless and injection molding systems, thermoplastic and thermoset plastic processing environments, blow molding, die casting, glass processing, sintering and curing equipment, extrusions, sealing heads, film rollers, plastic welding, branding, heater rollers, high temperature equipment, liquid and gas processing, brazing, soldering and steam equipment, among most other controlled heating requirements. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0023]    In the drawings: 
           [0024]      FIG. 1  is an end elevation view of a formed grooved erushable ceramic core embodying the present invention. 
           [0025]      FIG. 2  is a side elevation view of the core shown in  FIG. 1 , with the grooves shown in dotted lines. 
           [0026]      FIG. 3  is an end elevation view of the core shown in  FIG. 1  which has been wound with heater element wire. 
           [0027]      FIG. 4  is a side elevation view of the wire wound core shown in  FIG. 3 . 
           [0028]      FIG. 5  is an end elevation view of part of the wire wound core shown in  FIG. 3  with power pins installed. 
           [0029]      FIG. 6  is a side elevation view of a modified sleeve heater assembly with power pins installed. 
           [0030]      FIG. 7  is an end elevation view of a modified sleeve heater assembly with a thermocouple arranged in the crushable ceramic wind core and cold core. 
           [0031]      FIG. 8  is a side elevation view of a modified sleeve heater assembly with a thermocouple arranged in the crushable ceramic wind core and cold core. 
           [0032]      FIG. 9  is a detail enlarged end view of the power pin and resistance wire element connection for the sleeve heater assembly shown in  FIG. 6 . 
           [0033]      FIG. 10  is a detail enlarged end view of the thermocouple pin connection for the modified sleeve heater assembly shown in  FIG. 8 . 
           [0034]      FIG. 11  is a photograph of two finished heaters embodying the invention; and  FIG. 11A  is a photograph of the heated tip of a heater. 
           [0035]      FIG. 12  is a photograph of a heater sleeve embodying the present invention with sections cut away to show the interior of the heater sleeve, with the crushable ceramic core and MGO insulating powder and electrical components compacted by swaging. 
           [0036]      FIG. 13  is a perspective isometric view of an integral heated melt transfer tube for liquid metal and plastic made according to the present invention, broken apart to show its constituent layers. 
           [0037]      FIG. 14  is a perspective isometric view of an integral heated sprue bushing for plastic molding made according to the present invention, broken apart to show its constituent layers. 
           [0038]      FIG. 15  is a perspective isometric view of an integral heated melt pot container made according to the present invention, broken apart to show its constituent layers. 
           [0039]      FIG. 16  is a perspective isometric view of an integral heated molding machine nozzle made according to the present invention, broken apart to show its constituent layers. 
           [0040]      FIG. 17  is a perspective isometric view of an integral heated heat sealing head made according to the present invention, broken apart to show its constituent layers, 
           [0041]      FIG. 18  is a perspective isometric view of an integral heated heat sealing head with novel concentric layers of windings and pins provided to concentrate and more uniformly balance heat over a larger required end sealing surface, made according to the present invention, broken apart to show its constituent layers. 
           [0042]      FIG. 19  is a perspective isometric view of an integral heated heat sealing roller made according to the present invention, broken apart to show its constituent layers. 
           [0043]      FIGS. 20A-20H  illustrate common lead constructions for the devices embodying the invention, the leads being show broken away, and the inside diameter of the inner swaged sheath shown in dotted lines. 
           [0044]      FIGS. 21A-21F  shows the steps for making a heater having two or more longitudinally extending cores. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0045]    With reference to the accompanying drawing and particularly to  FIGS. 1-5 , the erushable ceramic core  10  illustrated in  FIG. 1  consists of a cylindrical or cylindroid device with an inner circumferential wall  11  and an outer circumferential wall  12 , and having on its inner circumference a series of longitudinal arranged parallel grooves or key slots  14 . Each of these key slots  14  has an entry  15  on the inner circumference wall  11  of the core  10  of reduced radius leading to an inner enlarged section  16 . The enlarged section  16  of each slot  14  is preferably oblong and wider than it is deep. At least two of these slots have a groove  17  extending from the outer circumferential surface  12  of the core  10 , one groove communicating with the enlarged section  16  of one slot  17  and another communicating with the enlarged section  16  of another slot  17 . 
         [0046]    Heater resistance wire  20  is wound around the outer or exterior circumference  12  of the core  10  in any selective arrangement depending upon the use and electrical requirements of the heater, which may be constructed to provide constant wattage, distributed wattage, sectional heating, and with or without cold sections. One end  21  of the heater wire  20  is threaded into one of the slots or grooves  17  communicating with a core key slot  14  and the other end  22  of the heater wire  20  is threaded into another slot communicating with another core key slot. If the heat provided by a finished heater is to be varied, other pairs of grooves  17  may be slotted and other ends of the heater wire for the varied arrangements may be inserted into other key slots  14  to achieve the selected heating arrangements desired. 
         [0047]    A conductive pin  25 , preferably having a substantially rectangular cross section but a bit smaller than the enlarged section  16  of a key slot  14  is threaded into each of the preferably oblong or enlarged sections  16  of a selected key slot in alignment and communicating with the end  21  or  22  on a winding of heater wire  20 . This conductive pin  25  may be as long as the key slot  14  or of a different length, depending upon the end use of the finished heater. The pin  25  must be long enough to communicate with electrical leads  26  exterior to the heater, of a length depending upon the end use of the finished heater device. 
         [0048]    An inner tube-like or solid sheath  30  is slipped into the central inside circumferential wall of the wire wound core  10  with its pins  25  in place, and an outer sheath  29  is slipped over the outer circumferential wall  12  of the wire would core  10 . These sheaths  29  and  30  may have relatively heavy walls and are preferably constructed of tool steel, stainless steel or similar heat transmitting material, and are substantially at least as long as the wire wound heater core  10 . 
         [0049]    At this point magnesium oxide insulation powder of fine sand-like consistency or similar insulating material is poured into all voids within the assembly. The open area of the key slots  14  also function as fill channels for the insulating material. The assembly is vibrated to pack the insulating material within the sheaths  29  and  30  and assembly of the core  10 , key slots  14 , pins  25  and winding of heater wire  20  substantially as much as possible. 
         [0050]    Following this packing and vibrating step, a round shaft (not shown) longer than the sheaths enclosing the wire wound core assembly is fit into or over the inner sheath. The assembly is swaged until a predetermined diameter for the assembly has been reached. Upon swaging, the core is crushed, the core and insulation are compacted to a near theoretical density, the pin and wire connection is secured, the key slot entry is collapsed, compacting the ceramic powder between the pins and inner sheath, fixing the pins in position, and the entire swaged assembly is unitized into a single mass. 
         [0051]    If the swaged heater assembly is to have heater material pass through the central opening in its inner sheath, the space between the sheaths is sealed, leaving the central opening open. Such sealing can be accomplished with a glue sealant or the like. If the swaged heater assembly is to be a heated melt pot, a sprue bushing, a molding machine nozzle, or in some other form, a suitable ring or disc end  33  in the direction of flow may be welded onto the exit of the assembly, with an appropriate gate or other exit arrangement, if desired. Appropriate leads  26 , exterior to the assembly, may be secured to the free ends of the pins. The assembly may also be formed on a lathe or with other components joined as appropriate. Conventional connections to power may be attached to the completed assembly, as desired. The leads  26  can exit at either end of the assembly or at any point on its outer or inner diameter. 
         [0052]    The novel open key slot  14  embodying the present invention, distinguished from conventional holes of various shapes used to form a swaged contact, allows extrusion tooling to have a slot portion of the tooling as part of the male portion of an extrusion die, which enables the manufacture of very thin sections while holding precise dimensions and location of the swaged contacts and pins  25 . Further this corc key slot  14  allows complete filling of all voids between the core  10  and sheaths  29  and  30 , even with high dielectric strength powders such as boron nitride to form a portion of the insulation between the pins  25 , core  10  and sheaths  29  and  30 . This open key slot  14  also permits fixtures equipped with blades to be used in the winding process for expeditiously rotating the core  10 . 
         [0053]    With referenced to FIGS.  7 - 8 - 10 , where a thermocouple  35  is desired in the assembly, that thermocouple may have its positive and its negative inserted into adjoining key slots  14  and a jumper wire may be installed between the positive and negative thermocouple elements, before the swaging operation, which locks the thermocouple in place. Such a thermocouple may take the form of ribbon wire. If a thermowell, consisting of a small diameter hvpo-tube, is desired, it may be inserted into one of the key slots  14  or into a special slot (not shown) formed to accommodate it, and it can also be swaged with the entire heater assembly.  44 .  FIGS. 13-19  show typical heated tool components constructed using the method described in this application and embodying the disclosed invention.  FIG. 13  shows an integral heated melt transfer tube  40  for liquid or plastic in isometric form, with parts broken away to show the compacted core  40   a,  with its crushed insulation and slots containing the conductive pins  45  and a temperature control, such as a thermocouple, and the wire winding  40   b.    FIG. 14  shows an integral heated sprue bushing  50  for plastics molding plastic in isometric form, with parts broken away to show the compacted core  50   a,  with its crushed slot containing the conductive pins  55  and a temperature sensor, such as a thermocouple, and the wire winding  50   b,  such a device having a melt channel  51  for delivering melted material and an orifice  52  for entry of the material into a mold.  FIG. 15  shows an integral heated melt pot container  60  in isometric form, with parts broken away to show the compacted core  60   a,  with its crushed slot containing the conductive pins  65  and a temperature sensor, such as a thermocouple, and the wire winding  60   b,  and containing a central pot  61  for holding heated material.  FIG. 16  shows an integral heated molding machine nozzle  70  in isometric form, similar to  FIG. 14 , with parts broken away to show the compacted core  70   a,  crushed slot containing the conductive pins  75  and a temperature control, such as a thermocouple, and the wire winding  70   b,  and having a melt channel  71  and orifice  72  for heated melted material. 
         [0054]    The inner and outer diameter of the finished compacted swaged heater assembly can be machined to precision tolerances, examples of which are shown in  FIGS. 13-19 . The ends of the assembly can be formed into flat sealing surfaces as shown in  FIG. 17  for use in specialty arrangements, such as in packaging machines requiring the sealing of adhesive coated covers to containers. Such assemblies can be formed into both short and long lengths, and in small and large diameters as required. A wide range of materials for the sheaths  29  and  30  can be employed to provide corrosion resistance, anti-stick properties or oxidation resistance, and the finished devices can be coated as desired. If a larger bottom sealing surface is needed, the novel use of concentric layers of windings and pins can be provided to concentrate and more uniformly balance heat over a larger required end sealing surface as shown in  FIG. 18 , which can be constructed by telescoping a larger diameter wound core and pin assembly over a smaller wound core and pin assembly, and such a design will also allow independent control of the inner and outer diameters of the end sealing surface. Such assemblies can be readily machined into integral heated roller assemblies for embossing and sealing applications as shown in  FIG. 19 . Such roller assemblies can be produced in configurations ready for installation of bearings, shafts and drive mechanisms. 
         [0055]    Some, but not all, available lead connection arrangements are illustrated in  FIGS. 20A-20H . In  FIGS. 20A-20B , the leads extend from the circumference of the swaged outer sheath  29  of the heater where they are connected to the ends of the conductive pins, and the leads  26  may be covered by a protective metal tube  76  or cap. In  FIGS. 20C-20D , the leads extend from the end  77  of the swaged heater device between the swaged inner and outer sheaths,  29  and  30 , where they are connected to the ends of the conductive power pins  25 . In  FIGS. 20E-20F , the leads  26  extend from each respective end  77   a  and  77   b  of the swaged heater device. In  FIGS. 20G-20H , the leads  26  extend from the swaged outer sheath  29  of the heater through a surface fitting  78  connected to the sheath wall, where they are connected to the ends of the conductive power pins. Other lead connections are also available, the important factor being that the heater construction permits novel power pin—lead connections from almost any point on the heater. A small hole can be ground from the outside of the corc through a selected key slot to connect the wire and pins for exit intermediate the core. 
         [0056]    With reference to  FIGS. 21A-21F , a sleeve heater with a two core parallel heating element assembly is shown, which can be utilized in multi-core arrangements. The end elevation of the cores  10  is shown  FIGS. 21A and 21B  shows the side elevation of two like crushable ceramic cores with key slots  14  on each core  10 . The end elevation of the cores  10  which have been wound with element heater resistance wire  20  is shown in  FIG. 21C , and side elevation of the wire wound cores is shown in  FIG. 21D . The end elevation of the wire wound cores  10  with the conductive power pins  25  inserted in the key slots  14  appears in  16 F, and the side elevation of the aligned wire wound cores joined by the arrangement of the conductive power pins  25  in the key slots  14  is shown in  FIG. 21F . With these multi-core arrangements, power supplies and/or lead arrangements for such structures may be independent or joined. 
         [0057]    The intimate association of the heating and heat transfer parts, compacted to a near theoretical density, permits the construction of an effective heated material delivery system with exceptional control, For example, a heated device is shown in the following photograph, having in orange-colored high temperature heated section of the part and in red and in varying red shades in other sections of lesser temperature, all of which can be well controlled by use of the novel devices and method taught in this application. 
         [0058]    While this invention has been shown and discussed in considerable detail, it is to be understood that the invention should not be limited to the exact constructions disclosed as many variations are possible and can be made without affecting the nature and scope of the invention