Electric heater having laminated structure

• US 3,878,362 A
• Filed: 02/15/1974
• Issued: 04/15/1975
• Est. Priority Date: 02/15/1974
• Status: Expired due to Term

• Current Assignee: Henry Joseph Stinger
• Original Assignee: Henry Joseph Stinger
• Inventors: Stinger, Henry Joseph
• Primary Examiner(s): Mayewsky, Volodymyr Y.
• Application Number:
  US05/442,907
• Time in Patent Office: 424 Days
• Field of Search: 219/211,522,527,528,543,549 338/210,211,212
• US Class Current: 219/528
• CPC Class Codes: B32B 15/02 Layer formed of wires, e.g. mesh
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2307/206 Insulating
• CPC Class Codes: B32B 2367/00 Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 2457/00 Electrical equipment
• CPC Class Codes: B32B 27/00 Layered products comprising a layer of synthetic resin fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 3/02 characterised by features of form at particular places, e.g. in edge regions non-uniform thickness B32B3/263
• CPC Class Codes: F24D 13/02 solely using resistance heating, e.g. underfloor heating
• CPC Class Codes: H05B 2203/005 using multiple resistive elements or resistive zones isolated from each other
• CPC Class Codes: H05B 2203/011 Heaters using laterally extending conductive material as connecting means
• CPC Class Codes: H05B 2203/013 Heaters using resistive films or coatings
• CPC Class Codes: H05B 2203/017 Manufacturing methods or apparatus for heaters
• CPC Class Codes: H05B 2203/021 Heaters specially adapted for heating liquids
• CPC Class Codes: H05B 2203/026 Heaters specially adapted for floor heating
• CPC Class Codes: H05B 3/146 Conductive polymers, e.g. polyethylene, thermoplastics
• CPC Class Codes: H05B 3/38 Powder conductors
• CPC Class Codes: H05B 3/56 Heating cables
• CPC Class Codes: H05B 3/565 : flat cables
• CPC Class Codes: Y02B 30/00 : Energy efficient heating, ventilation or air conditioning [HVAC]

Abstract

A laminated composite polymeric structure having beneficial utility as an electric heating element which is thin, flexible, durable and efficient has the following components: (A) a bottom layer composed of a film of electrically insulating polymeric material, (B) in superposed adherent relation with layer (A), a discontinuous layer of electrically conductive elastomeric material containing electrically conductive carbon black dispersed in a heat-resistant elastomer, said discontinuous layer covering substantially all of layer (A) except for spacing areas which occur at predetermined intervals along the length of layer (A), said spacing areas extending across the width of layer (A) whereby layer (B) is divided into a series of coated areas of predetermined length, (C) at least two spaced-apart conductor wires in intimate contact with layer (B) and extending substantially the entire length of the laminated structure, and (D) a top layer composed of a film of electrically insulating polymeric material in superposed contact with layer (B) and said spacing areas of layer (A).

Claims

1. A LAMINATED STRUCTURE USEFUL AS AN ELECTRIC HEATING ELEMENT WHICH COMPRISES A. A BOTTOM LAYER COMPOSED OF A FILM OF ELECTRICALLY INSULATING POLYMERIC MATERIAL, B. IN SUPERPOSED ADHERENT RELATION WITH LAYER (A), A DISCONTINUOUS LAYER OF ELECTRICALLY CONDUCTIVE ELASTOMERIC MATERIAL CONTAINING ELECTRICALLY CONDUCTIVE CARBON BLACK DISPERSED IN A FLUOROCARBON ELASTOMER, SAID DISCONTINUOUS LAYER COVERING SUBSTANTIALLY ALL OF LAYER(A) EXCEPT FOR SPACING AREAS WHICH OCCUR AT PREDETERMINED INTERVALS ALONG THE LENGTH OF LAYER(A), SAID SPACING AREAS EXTENDING ACROSS THE WIDTH OF LAYER(A) WHEREBY LAYER(B) IS DERIVED INTO A SERIES OF COATED AREAS OF PREDETERMINED LENGTH, LAYER(B) HAVING A THICKNESS OF ABOUT 0.05-0.45 MIL, C. AT LEAST TWO SPACED-APART CONDUCTOR WIRES IN INTIMATE CONTACT WITH LAYER(B) AND EXTENDING SUBSTANTIALLY THE ENTIRE LENGTH OF THE LAMINATED STRUCTURE, AND BONDED WITHIN THE STRUCTURE BETWEEN LAYERS(A) AND (D), AND D. A TOP LAYER COMPOSED OF A FILM OF ELECTRICALLY INSULATING POLYMERIC MATERIAL IN SUPERPOSED ADHERENT CONTACT WITH LAYER(B) AND SAID SPACING AREAS OF LAYER(A), EACH OF SAID LAYERS(A) AND (D) BEING A FILM OF A HIGHLY FLEXIBLE NON-ELASTOMERIC DURABLE PLASTIC MATERIAL HAVING A THICKNESS OF ABOUT 0.5-15 MILS, AND SAID COATED AREAS OF LAYER(B) MEASURING ABOUT 11-15 INCHES, AND SAID SPACING AREAS MEASURING ABOUT 1-5 INCHES IN THE DIRECTION PARALLEL WITH THE CONDUCTOR WIRES.

2. A structure according to claim 1 wherein the laminated structure has a width of about 50-60 inches, and component (C) consists of four substantially evenly spaced parallel conductor wires, the distance between each wire and the next one being about 16-20 inches;

and each of said layers(A) and (D) is a polyester film.

3. A structure according to claim 1 wherein each of said film layers is a polyethyleneterephthalate film.