Heater with PTC element and buss system

• US 6,084,217 A
• Filed: 03/29/1999
• Issued: 07/04/2000
• Est. Priority Date: 11/09/1998
• Status: Expired due to Term

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Bulgajewski, Edward
• Primary Examiner(s): Walberg, Teresa
• Assistant Examiner(s): ROBINSON, DANIEL LEON
• Application Number:
  US09/281,099
• Time in Patent Office: 463 Days
• Field of Search: 219/219, 219/203, 219/505, 219/543, 219/553, 219/541
• US Class Current: 219/505
• CPC Class Codes: H05B 2203/006 using interdigitated electrodes
• 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 2203/02 Heaters using heating elements having a positive temperature coefficient
• CPC Class Codes: H05B 3/14 the material being non-metallic
• CPC Class Codes: H05B 3/146 Conductive polymers, e.g. polyethylene, thermoplastics
• CPC Class Codes: H05B 3/34 flexible, e.g. heating nets or webs
• CPC Class Codes: H05B 3/845 specially adapted for reflecting surfaces, e.g. bathroom - or rearview mirrors

Abstract

The heater is formed from a substrate layer, a feeder buss layer, a dielectric layer, a PTF (polymer thick film) conductor or main buss layer, a PTC (positive temperature coefficient) thermistor layer and an external laminated adhesive layer. All of the layers are substantially coextensive. The feeder buss layer, dielectric layer, main buss layer and PTC thermistor layers are preferably screen printed or otherwise selectively applied. The feeder buss layer includes first and second external electrical terminals formed on a single side thereof, and a buss for providing electrical communication from the first terminal to a connector diagonally removed from the second terminal. The connector and the second terminal provide electrical communication to diagonally opposed corners of the PTF conductor or main buss layer thereby providing relatively uniform current path distances through the thermistor layer.

Claims

1. A heater including:

a substrate layer;

a buss layer including a first terminal and a second terminal formed adjacent to a single side of said buss layer, and a first buss for providing electrical communication from said first terminal to an extended terminal portion, said extended terminal portion being formed on said buss layer at a distance from said second terminal greater than a distance between said first terminal and said second terminal;

a selective conducting layer having a third terminal in communication with first conducting strips via a second buss and a fourth terminal in communication with second conducting strips via a third buss, said third terminal being in electric communication with said second terminal, said fourth terminal being in electrical communication with said extended terminal portion; and

a thermistor layer providing electrical communication between said first conducting strips and said second conducting strips.

2. The heater of claim 1 wherein said substrate layer, said buss layer, said selective conducting layer and said thermistor layer are substantially coextensive.

3. The heater of claim 2 wherein said thermistor layer has an increased resistance in response to increased temperature.

4. The heater of claim 3 wherein the heater is substantially rectangular and said extended terminal portion is diagonally opposite from said second terminal.

5. The heater of claim 4 further including a dielectric layer between said buss layer and said selective conducting layer.

6. The heater of claim 5 wherein said dielectric layer includes passageways through which said third terminal is in electric communication with said second terminal and said fourth terminal is in electrical communication with said extended terminal portion.

7. The heater of claim 6 wherein said first conducting strips are parallel to each other, said second conducting strips are parallel to each other and are parallel to said first conducting strips, and said first conducting strips alternate with said second conducting strips on said selective conducting layer.

8. The heater of claim 7 wherein said first conducting strips are substantially free of electrical connection with said second conducting strips except through said thermistor layer.

9. The heater of claim 8 wherein said buss layer, said dielectric layer, said selective conducting layer and said thermistor layer are screen printed.

10. The heater of claim 9 further including an adhesive layer on an exterior surface thereof.

11. The heater of claim 10 wherein said substrate layer is polyester and includes eyelets through which said first terminal and said second terminal pass to said buss layer.