Immersion heating element with highly thermally conductive polymeric coating
First Claim
1. An electrical resistance heating element for use in connection with heating a fluid medium, comprising:
- (a) an element body having a supporting surface thereon;
(b) a resistance wire wound onto said supporting surface and connected to at least a pair of terminal end portions of said element; and
(c) a thermally-conductive polymeric coating disposed over said resistance wire and said supporting surface for hermetically encapsulating and electrically insulating said resistance wire from said fluid, said polymeric coating comprising a thermally-conductive, non-electrically conducting ceramic additive.
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Accused Products
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 °K. Improved properties are preferably provided by ceramic powder, such as Al2 O3 and MgO, and glass fiber additives.
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Citations
25 Claims
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1. An electrical resistance heating element for use in connection with heating a fluid medium, comprising:
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(a) an element body having a supporting surface thereon; (b) a resistance wire wound onto said supporting surface and connected to at least a pair of terminal end portions of said element; and (c) a thermally-conductive polymeric coating disposed over said resistance wire and said supporting surface for hermetically encapsulating and electrically insulating said resistance wire from said fluid, said polymeric coating comprising a thermally-conductive, non-electrically conducting ceramic additive. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A water heater comprising:
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(a) a tank for containing water; (b) a heating element attached to a wall of said tank for providing electric resistance heating to a portion of the water in said tank, said heating element comprising; a support frame; a resistance wire wound onto said support frame and connecting to at least a pair of terminal end portions; and a thermally-conductive polymeric coating disposed over said resistance wire and a major portion of said support frame for hermetically encapsulating and electrically insulating said resistance wire from said fluid, said polymeric coating including a thermally conductive, non-electrically conducting additive for providing a thermal conductivity value of at least about 0.5 W/m °
K. - View Dependent Claims (11)
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12. A method of manufacturing an electrical resistance element for heating a fluid, comprising:
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(a) providing a support frame; (b) winding a resistance heating wire onto said support frame; (c) applying a thermally-conductive, non-electrically conductive, polymer over said resistance heating wire and a substantial portion of said support frame to electrically insulate and hermetically encapsulate said wire from said fluid, said thermally-conductive polymeric coating having a thermal conductivity value of at least about 0.5 W/m °
K. - View Dependent Claims (13, 14, 15, 16, 17, 18)
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19. An electrical resistance heating element capable of being disposed through a wall of a tank for use in connection with heating a fluid medium, comprising:
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a. a polymeric support frame; b. a resistance heating wire having a pair of free ends joined to a pair of terminal end portions, said resistance heating wire wound onto and supported by said support frame; and c. a non-electrically conductive, polymeric coating containing an electrically insulating, thermally-conductive ceramic additive for improving the thermal conductivity of said coating, said coating disposed over said resistance wire and a portion of said support frame for hermetically encapsulating and electrically insulating said resistance wire from said fluid, said polymeric coating having a thermal conductivity value of at least about 0.5 W/m °
K. - View Dependent Claims (20, 21)
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22. An electrical resistance heating element for use in connection with heating a fluid medium, comprising:
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a. an element body having a supporting surface thereon; b. a resistance wire wound onto said supporting surface and connected to at least a pair of terminal end portions of said element; and c. a thermally-conductive, non-electrically conductive, polymeric coating disposed over said resistance wire and a substantial portion of said supporting surface for hermetically encapsulating and electrically insulating said resistance wire from said fluid, said polymeric coating comprising a thermally-conductive, non-electrically conducting ceramic additive for achieving a thermal conductivity value of at least about 0.5 W/m °
K through said coating.
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23. An electric resistance heating element for use in connection with heating a fluid medium, comprising:
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(a) an electrical resistance wire; (b) a ceramic material surrounding and electrically insulating said wire; (c) a metal sheath encasing said ceramic material and electrical resistance wire; and (d) a thermally conductive polymeric coating disposed over said metal sheath for hermetically encapsulating and electrically insulating said metal sheath from said fluid, said polymeric coating having a thermal conductivity of at least about 0.5 W/m °
K.
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24. An electric resistance heating element for use in connection with heating a fluid medium, comprising:
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(a) an electrical resistance wire; (b) a ceramic material surrounding and electrically insulating said wire; (c) a metal sheath encasing said ceramic material and electrical resistance wire; and (d) a thermally conductive polymeric coating disposed over said metal sheath for hermetically encapsulating and electrically insulating said metal sheath from said fluid, said polymeric coating comprising a thermally-conductive, non-electrically conducting ceramic additive. - View Dependent Claims (25)
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Specification