Fibrous supported polymer encapsulated electrical component
First Claim
Patent Images
1. An insulated electrical component comprising:
- a. an electrical device having a circuit path portion with a relatively thin cross-section which is susceptible to distortion under molding pressure;
b. a fibrous glass mat support layer being more resistant to distortion under molding pressure than said circuit path portion, disposed over said electrical device and said circuit path portion; and
c. a polymeric layer molded substantially around said fibrous support layer, said electrical device and said circuit path portion whereby said fibrous glass mat support layer provides structural support and distortion resistance to said circuit path portion when said polymeric layer is applied in a mold under pressure.
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Abstract
Heating elements, electrical devices and processes for manufacturing these components are provided. The heating elements and electrical components employ a fibrous support layer, such as a non-woven glass mat, which provides structural support to the relatively thin cross-section of the electrical device or resistance wire when a polymeric layer is applied, such as by molding under pressure.
171 Citations
29 Claims
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1. An insulated electrical component comprising:
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a. an electrical device having a circuit path portion with a relatively thin cross-section which is susceptible to distortion under molding pressure;
b. a fibrous glass mat support layer being more resistant to distortion under molding pressure than said circuit path portion, disposed over said electrical device and said circuit path portion; and
c. a polymeric layer molded substantially around said fibrous support layer, said electrical device and said circuit path portion whereby said fibrous glass mat support layer provides structural support and distortion resistance to said circuit path portion when said polymeric layer is applied in a mold under pressure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A resistance heating element comprising:
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a. an electrical resistance heating wire disposed in a circuit path, said wire having a pair of terminal end portions, said electrical resistance heating wire being susceptible to distortion under molding pressure;
b. a pair of electrical conductors fixed to said terminal end portions of said wire;
c. a first glass mat adhered to a top surface of said electrical resistance heating wire;
d. a second glass mat adhered to a bottom surface of said electrical resistance heating wire, said first and second glass mats being more resistant to distortion by molding pressure than said electrical resistance heating wire; and
e. a high temperature polymeric layer molded under a pressure of at least 500 psi substantially around said circuit path and said first and second glass mats, whereby said first and second glass mats assist in thermally insulating a portion of said polymeric layer from said electrical resistance heating member and provide structural support to said electrical resistance heating wire during said molding so as to resist distortion of said electrical resistance heating wire under said molding pressure. - View Dependent Claims (12, 13, 14, 15, 16, 17)
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18. A method of making an insulated, electrical component, comprising:
- providing an electrical device having a relatively thin cross-section portion which is susceptible to being distorted under molding pressure;
adhering said electrical device onto a fibrous glass mat support layer which is less susceptible to being distorted under molding pressure than said relatively this cross-section portion; and
molding said fibrous glass mat support layer and said electrical device within a polymer layer under pressure, whereby said fibrous glass mat support layer provides structural support to said relatively thin cross-section portion of said electrical device so as to resist distortion thereof when said polymer layer is applied. - View Dependent Claims (19, 20, 21, 22, 23, 24, 26, 28)
- providing an electrical device having a relatively thin cross-section portion which is susceptible to being distorted under molding pressure;
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25. A method of making an insulated heating element, comprising:
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providing an electrical resistance heating wire disposed in a looped circuit path, said wire having a relatively thin cross-section which is susceptible to distortion of its circuit path by movement thereof under a molding pressure;
disposing a pair of open pore, fibrous glass mat support layers on a top and bottom surface of said electrical resistance heating wire, said fibrous glass mat support layer being more resistant to distortion than said electrical resistance heating wire under said molding pressure and being joined to said electrical resistance heating wire to form an element precursor;
inserting said element precursor between a pair of polymer layers in a molding device; and
compression molding said polymer layers and said element precursor to form a substantially hermetic insulating polymeric layer around said circuit path whereby said pair of open pore, fibrous glass mat support layers provide distortion resistance to said electrical resistance heating wire under said molding pressure. - View Dependent Claims (27)
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29. An insulated electrical component comprising:
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a. an electrical device having a thin conductive or semi-conductive portion which is susceptible to distortion under a molding pressure;
b. a support layer joined to said electrical device, said support layer comprising a woven or non-woven, open pore mat which has an air permeability rating of at least about 1,000 cubic feet per minute and a distortion resistance to said molding pressure which is greater than said thin conductive or semi-conductive portion; and
c. a molded polymeric layer disposed around said electrical device and said support layer, whereby said support layer provides distortion resistance for said thin conductive or semi-conductive portion when said polymeric layer is applied in a mold under said molding pressure.
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Specification