Patent ID: 7418992

Claim:
A temperature controller for at least one heater being utilized in an injection molding system, the temperature controller comprising: a regulated voltage supply that is electrically connected to the at least one heater being utilized in the injection molding system; at least one temperature sensor being positioned relative to the at least one heater being utilized in the injection molding system; and at least one digital signal processor being operatively connected to the at least one heater being utilized in the injection molding system, the at least one digital signal processor being configured to connect with the at least one temperature sensor, and being configured to connect with the regulated voltage supply, the at least one digital signal processor being configured for regulating temperature of the at least one heater being utilized in the injection molding system based on feedback being received from the at least one temperature sensor, wherein the at least one digital signal processor increases reliability of the at least one heater by: (i) increasing a duty cycle associated with the at least one heater, the duty cycle being a ratio of active time that the at least one heater is on to a total time that the at least one heater is on and off, and (ii) reducing a temperature excursion associated with the duty cycle of the at least one heater.