Abstract: The invention relates to polymer-encapsulated heating elements that are suitable for use in an aircraft compartment for modulating the temperature within the compartment. The heating elements can be used, for example, in the cockpit, the passenger compartment, or a cargo bay of an aircraft.

Abstract: A heated element assembly and method of manufacturing heated element assemblies is provided. The heated element assembly including a first and second molded sections shaped to mate with each other is provided. A resistance heating element is secured between the first and second molded sections by an interference fit. The resistance heating element includes a piercable supporting substrate and a resistance wire sewn thereon. The resistance wire is disposed in a predetermined circuit path which is substantially encompassed by the first and second molded sections. The resistance heating element is easily fixed in a position between the first and second molded sections and is capable of providing heat on vertical, horizontal and contoured surfaces.

Abstract: The present invention provides immersion heating elements, water heaters and methods for their fabrication and use. In the first embodiment of this invention, a resistance heating element is provided which includes a resistance heating material and an electrically insulating, substantially water impervious sheath disposed over the resistance heating material to form an active element portion having an envelope of about 50 in3, a total wattage of at least 1000 W, and a watt density of no greater than 60 W/in2. Such an element has been demonstrated to substantially reduce scale reduction in water containing calcium, calcium carbonate, or both in solution.

Abstract: A heated container is formed from a substantially continuous element structure. The substantially continuous element structure includes an electrically insulative first and second polymeric layers and a resistance heating layer laminated between the first and second polymeric layers. An interior surface of the container includes the first polymeric layer, and the first polymeric layer is thermally conductive. The resistance heating layer has a pair of terminal end portions that may be coupled to a pair of external power leads to energize the resistance heating layer.

Abstract: The present invention provides heating elements and methods for their fabrication and use. The heating elements of this invention include a spirally shaped structure having a plurality of spiral forms, and may contain a thermally conductive, electrically insulated polymeric coating, such as a fluorocarbon resinous coating of about 0.001-0.020 in. in thickness. The preferred spirally shaped heating elements of this invention provide a lower, preferably substantially lower, flux or watt density than that for a Tubular Heating Element of substantially similar Active Element Volume (in3), wherein said spirally shaped heating element has the same or greater overall wattage rating (total watts) than the Tubular Heating Element. The heating elements of this invention preferably have an Effective Relative Heated Surface Area of about 5-60 in2/in3, with a target range of about 20-30 in2/in3, but can generate a heat flux of about 10-50 w/in2.

Abstract: A semi-rigid heated element assembly and method of manufacturing semi-rigid heated element assemblies is provided. A heated element assembly includes a first thermoplastic sheet, a second thermoplastic sheet, and a resistance heating element laminated between the first and second thermoplastic sheets. The resistance heating element includes a supporting substrate having a first surface thereon and an electrical resistance heating material forming a predetermined circuit path having a pair of terminal end portions. The circuit path continues onto at least one flap portion that is capable of rotating about a first axis of rotation. The reformable continuous element structure may be formed into a final element assembly configuration whereby at least the flap portion is rotated along its axis of rotation to provide resistance heating in at least two planes. Semi-rigid heating elements may be formed into heated containers, heated bags, and other objects with complex heat planes.

Abstract: The heater includes a resistance heating element comprising a resistance heating wire having a pair of terminal ends connected to a pair of electrical connectors and encapsulated with a thin electrically insulating polymeric layer. The resistance heating wire is capable of maintaining a fluid initially heated by a primary heat source substantially at the desired use temperature. A first connecting body is configured to couple to the section of piping containing the fluid. The connecting body includes a fluid inlet port, a fluid outlet port, a fluid passageway defined between the fluid inlet and outlet ports, and an electrical connection port. The resistance heating element is disposed at least partially within the fluid passageway and at least a first one of the terminal ends is coupled to a respective one of the pair of electrical connectors through the electrical connection port.

Abstract: A heated element assembly and method of manufacturing heated element assemblies is provided. The heated element assembly including a first and second molded sections shaped to mate with each other is provided. A resistance heating element is secured between the first and second molded sections by an interference fit. The resistance heating element includes a piercable supporting substrate and a resistance wire sewn thereon. The resistance wire is disposed in a predetermined circuit path which is substantially encompassed by the first and second molded sections. The resistance heating element is easily fixed in a position between the first and second molded sections and is capable of providing heat on vertical, horizontal and contoured surfaces.

Abstract: Electrical resistance heating elements, hot water heaters containing such elements, and methods of preparing such elements are provided. The electrical resistance heating elements of this invention can be disposed through a wall of a tank for heating fluid, such as water. They include a skeletal support frame having a first supporting surface thereon. They also include a resistance wire wound onto the first supporting surface and preferably connected to at least a pair of terminal end portions. The support frame and resistance wire are then hermetically encapsulated and electrically insulated within a thermally-conductive polymeric coating. The skeletal support frame of this invention improves injection molding operations for encapsulating the resistance wire, and can include heat transfer fins for improving thermal conductivity.

Abstract: Heating elements, electrical devices and processes for manufacturing these components are provided. The heating elements and electrical components employ a fibrous support layer, such as a non-woven glass mat, which provides structural support to the relatively thin cross-section of the electrical device or resistance wire when a polymeric layer is applied.

Abstract: The present invention provides heating elements and methods for their fabrication and use. The heating elements of this invention include a spirally shaped structure having a plurality of spiral forms, and may contain a thermally conductive, electrically insulated polymeric coating, such as a fluorocarbon resinous coating of about 0.001-0.020 in. in thickness. The preferred spirally shaped heating elements of this invention provide a lower, preferably substantially lower, flux or watt density than that for a Tubular Heating Element of substantially similar Active Element Volume (in3), wherein said spirally shaped heating element has the same or greater overall wattage rating (total watts) than the Tubular Heating Element. The heating elements of this invention preferably have an Effective Relative Heated Surface Area of about 5-60 in2/in3, with a target range of about 20-30 in2/in3, but can generate a heat flux of about 10-50 w/in2.

Abstract: Methods of manufacturing electrical resistance heating elements are provided which include mating a pair of polymeric components around an electrical resistance heating material prior to fusing the polymeric components together, preferably by heat or pressure or both. Methods of stress relieving these polymeric components before, during or after fusing them together, are disclosed. Additionally, thermally conductive, non-electrically conductive additives can be added to improve the service life of the elements. In a further embodiment of this invention, a heating element and method of construction are provided in which first and second polymeric components are joined together with a resistance heating material therebetween. The polymeric components include retention means including a plurality of male connectors located on the first polymeric component, and a plurality of female receiving recesses located on the second polymeric component for mating with the male connectors of the first polymeric component.

Abstract: A toilet seat comprises a resistive wire sewn to a support material such as a fibrous mat. The wire is preferably sewn in an annular pattern or a sinuated pattern disposed throughout the seat. The heating element can be contained within a toilet seat core, which can have a shell molded thereon to form a toilet seat.

Abstract: Heating elements, electrical devices and processes for manufacturing these components are provided. The heating elements and electrical components employ a fibrous support layer, such as a non-woven glass mat, which provides structural support to the relatively thin cross-section of the electrical device or resistance wire when a polymeric layer is applied.

Abstract: Heating elements, electrical devices and processes for manufacturing these components are provided. The heating elements and electrical components employ a fibrous support layer, such as a non-woven glass mat, which provides structural support to the relatively thin cross-section of the electrical device or resistance wire when a polymeric layer is applied, such as by molding under pressure.

Abstract: Heating elements suitable for heating a printing media of a ink-jet printer are provided. The heating element includes an electrical resistance heating member for generating resistance heating and a polymeric supporting layer for substantially encapsulating the electrical resistance heating member. The heating elements of this invention can include a fibrous support layer disposed over the electrical resistance heating member for assisting in the application of the polymeric layer. Additionally, the provided heating elements can be formed into a portion of a media pathway for an ink-jet printer.

Abstract: A method of manufacturing a sheathed electrical heater assembly comprising the steps of: molding a core element into a desired shape, the core element having an outer surface; heating the core element at an elevated temperature sufficient to release organic material from the core element; placing a heating element in communication with the core element; and, encapsulating the core, and the heating element in an insulation protection layer, whereby the heater assembly is formed. Additionally shown is a sheathed electrical heater assembly comprising: a core made of an organo-ceramic material; a heating element in communication with the core; an insulation protection layer encapsulating the core and heating element to produce the heater assembly, the protection layer comprising and organo-ceramic material; and, a sheath encapsulating the heater assembly, the sheath also comprising an organo-ceramic material.