Heating element containing sewn resistance material
First Claim
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1. A method of making an insulated, electrical component, comprising the steps of:
- (a) providing an electrical device having a relatively thin cross-section;
(b) sewing said electrical device to a supporting substrate with a thread to form an element precursor having a circuit path;
(c) mechanically deforming at least said circuit path; and
(d) substantially encapsulating at least said circuit path within a fusible layer, whereby said sewn thread supports said electrical device when said fusible layer is applied;
wherein the shape of said circuit path is mechanically deformed prior to the encapsulating step (d).
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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 resistance heating material, such as Ni-Cr wire, sewn with a thread to a supporting substrate, such as a non-woven glass mat. The sewn thread supports the relatively thin cross-section of the resistance material when a fusible layer is applied, such as by molding a polymer under pressure.
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Citations
19 Claims
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1. A method of making an insulated, electrical component, comprising the steps of:
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(a) providing an electrical device having a relatively thin cross-section;
(b) sewing said electrical device to a supporting substrate with a thread to form an element precursor having a circuit path;
(c) mechanically deforming at least said circuit path; and
(d) substantially encapsulating at least said circuit path within a fusible layer, whereby said sewn thread supports said electrical device when said fusible layer is applied;
wherein the shape of said circuit path is mechanically deformed prior to the encapsulating step (d).- View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method of making a polymeric heating element, comprising;
- the steps of;
a. providing a reinforcing support layer having a plurality of open pores;
b. sewing an electrical resistance heating material onto said reinforcing support layer to form an element precursor having a circuit path thereon;
c. mechanically deforming at least said circuit path; and
d. substantially encapsulating said element precursor within a polymeric material whereby a portion of said polymeric material flows into a portion of said open pores of said reinforcing support layer, while preserving the reinforcing capabilities thereof, wherein the shape of said circuit path is mechanically deformed prior to the encapsulating step (d). - View Dependent Claims (9, 10, 11, 12, 13, 14)
- the steps of;
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15. A method of making an electrical resistance heater, comprising the steps of:
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a. providing a sewable support layer;
b. sewing an electrical resistance heating member onto said sewable support layer to form an element precursor having a circuit path thereon;
c. mechanically deforming at least said circuit path; and
d. electrically insulating said electrical resistance heating member within a thermally conductive material which is capable of forming a fusion bond with said sewable support layer, wherein the shape of the circuit path is mechanically deformed prior to said electrically insulating step (d). - View Dependent Claims (16, 17, 18, 19)
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Specification