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: 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.