Heater, a method of manufacturing the same, and an anti-condensation mirror incorporating the same
First Claim
1. A heater comprising:
- a heating element made of a thermistor having a positive temperature coefficient of resistance;
electrodes formed on upper and lower surfaces of said heating element;
a pair of flat metallic terminals electrically connected to said electrodes;
a pair of feeders electrically connected to inner surfaces of said metallic terminals, said inner surfaces facing each other; and
an electrical insulating cover member for covering exposed portions of said heating element, said electrodes, and of said metallic terminals, and connections between said metallic terminals and said feeders so as to insulated them from outside wherein said electrical insulating cover member comprises an insulating base section integrally formed in said electric insulating cover member which defines a holding position of a heating unit in said electric insulating cover member, said heating unit including said heating element, said electrodes and said metallic terminals connected to said feeders.
1 Assignment
0 Petitions
Accused Products
Abstract
A heater includes a heating element made of a PTC thermistor, electrodes formed on upper and lower surfaces of the heating element, flat metallic terminals connected to the electrodes, lead wires connected to inner surfaces of the metallic terminals that face each other, and an insulating case for covering exposed portions of the heating element, electrodes, and of the metallic terminals, and the connections between the lead wires and the metallic terminals. With this structure, since no bumps are produced on the outer surfaces of the metallic terminals by connecting the lead wires to the metallic terminals, the thickness of the insulating case over the metallic terminals is reduced. This allows a reduction in the thickness of the heater and an improved heat transfer between the heating element and the heated object. A method of manufacturing the heater includes the steps of forming a heating unit by connecting the flat metallic terminals to the electrodes and connecting the lead wires to the metallic terminals, disposing the heating unit on a predetermined position of the base section of the insulating case, and sealing the exposed portions of the heating unit in the insulating case by injection-molding a cover section of the insulating case with insulating material after disposing the base section in a mold. This method enables the heating unit to be easily covered with the insulating case, thereby facilitating the manufacture of the heater.
47 Citations
38 Claims
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1. A heater comprising:
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a heating element made of a thermistor having a positive temperature coefficient of resistance; electrodes formed on upper and lower surfaces of said heating element; a pair of flat metallic terminals electrically connected to said electrodes; a pair of feeders electrically connected to inner surfaces of said metallic terminals, said inner surfaces facing each other; and an electrical insulating cover member for covering exposed portions of said heating element, said electrodes, and of said metallic terminals, and connections between said metallic terminals and said feeders so as to insulated them from outside wherein said electrical insulating cover member comprises an insulating base section integrally formed in said electric insulating cover member which defines a holding position of a heating unit in said electric insulating cover member, said heating unit including said heating element, said electrodes and said metallic terminals connected to said feeders. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. A method for manufacturing a heater comprising the steps of:
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forming a heating unit by connecting a flat metallic terminal to each of electrodes formed on upper and lower surfaces of a flat heating element made of a thermistor having a positive temperature coefficient of resistance and by connecting feeders to said metallic terminals; disposing said heating unit at a predetermined holding position on an insulating base section integrally formed in an electric insulating material which defines said predetermined holding position of a heating unit and said metallic terminals in said electric insulating material, said heating unit including said heating element, said electrodes and said metallic connected to said feeders; and sealing exposed portions of said heating unit in an electrical insulating cover member by injection-molding said insulating material after disposing said substrate in a mold. - View Dependent Claims (19, 20, 21)
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22. An anti-condensation mirror comprising:
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a mirror; a heat transfer plate closely attached to a rear surface of said mirror; and a plurality of heaters each covered with an individual electrical insulating cover member and mounted on a rear surface of said heat transfer plate, each of said heaters including therein a flat heating element made of a thermistor having a positive temperature coefficient of resistance. - View Dependent Claims (23, 24, 25, 26, 27, 28, 29, 30)
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31. An anti-condensation mirror comprising:
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a mirror; a heat transfer plate mounted on a rear surface of said mirror; a plurality of heaters covered with an electrical insulating cover member and mounted on a rear surface of said heat transfer plate, each of said heaters including therein a flat heating element made of a thermistor having a positive temperature coefficient of resistance; and a fixture for fastening said mirror closely to the rear surface of said heat transfer plate, said fixture including a base member attached to the rear surface of said mirror and a fastening member of a resilient material, said fastening member pressing said heat transfer plate against said mirror by engaging with said base member. - View Dependent Claims (32, 33, 34)
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35. An anti-condensation mirror comprising:
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a mirror; a heat transfer plate closely attached to a rear surface of said mirror; a plurality of heaters covered with an electrical insulating cover member and mounted on a rear surface of said heat transfer plate, each of said heaters including therein a flat heating element made of a thermistor having a positive temperature coefficient of resistance; and a junction member mounted on the rear surface of said heat transfer plate, said junction member having therein a connection area where feeders of said heating elements and a power cord are connected, said junction member covering connections between said feeders and said power cord. - View Dependent Claims (36, 37, 38)
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Specification