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: Electrical resistance heating elements are provided which are useful in heating fluid mediums, such as air and water. The heating elements include an element body having a supporting surface and a resistance wire wound onto the supporting surface which is connected to a pair of terminal end portions. Disposed over the resistance wire, and over most of the supporting surface, is a thermally-conductive polymeric coating which hermetically encapsulates and electrically insulates the resistance wire from the fluids to be heated. This thermally-conductive polymer coating has a thermal conductivity value of at least about 0.5 W/m .degree.K. Improved properties are preferably provided by ceramic powder, such as Al.sub.2 O.sub.3 and MgO, and glass fiber additives.

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: Electrical resistance retrofittable stove heating elements are provided which include a metal oxide-containing cooking top and a sheathed resistance heating element spaced from the lower surface of the cooking top. The stove element can also contain a housing bowl disposed below the sheathed resistance heating element for helping to reflect radiant heat from the heating element to the cooking top. The sheathed resistance heating element also includes a pair of plug-in terminals for selectively connecting said retrofittable stove element to a source of electric power. These stove elements can be used in original equipment or in older stoves having conventional electric stove elements.

Abstract: Hot water heaters are provided which contain improved temperature control devices and multiple resistance wire heating elements. The temperature control devices selectively deactivate at least one of the resistance wires to conserve electricity and preserve a steady-state hot beverage or hot water service temperature.

Abstract: Polymeric heating elements and water heaters containing these elements are provided by this invention which utilize polymeric materials in contact with electric resistance heating materials and in contact with fluid to be heated. These polymeric materials also provide a substantially self-supporting structure for the resistance heating material. The heating elements include an electrically conductive resistance material capable of heating fluid when energized. The winding is insulated and protected by a polymer layer integrally disposed over the resistance material. The elements are lightweight, inexpensive to produce and use, and minimize galvanic corrosion and lime depositing without sacrificing heating capacity.