Deposited resistive coatings
First Claim
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1. A heater comprising at least one thermally sprayed resistive heating layer, wherein said thermally sprayed resistive heating layer comprises a mixture of a first material, a second material, and a third material, wherein said first material is an electrically conducting material, said second material is an electrically insulating material, and said third material alters thermal expansion of said resistive heating layer.
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Abstract
The present invention involves coatings deposited on a substrate including a layer having a selected resistivity. The resistive layer can serve as a heat source in a variety of applications and can be fabricated using an arc plasma spraying procedure.
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Citations
38 Claims
- 1. A heater comprising at least one thermally sprayed resistive heating layer, wherein said thermally sprayed resistive heating layer comprises a mixture of a first material, a second material, and a third material, wherein said first material is an electrically conducting material, said second material is an electrically insulating material, and said third material alters thermal expansion of said resistive heating layer.
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21. A method of fabricating at least one resistive heating layer, said method comprising the steps of:
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a) mixing a first material, a second material, and a third material, wherein said first material is an electrically conducting material, said second material is an electrically insulating material, and said third material alters thermal expansion of said resistive heating layer; and
b) thermally spraying the mixture of step (a) onto a subsfrate, thereby fabricating a resistive heating layer. - View Dependent Claims (22, 23, 24, 25, 26, 27, 28, 29)
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30. A heater comprising a thermally sprayed resistive heating layer that comprises a mixture of titanium diboride and aluminum oxide.
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31. A heater comprising a thermally sprayed resistive heating layer that comprises a mixture of molybdenum silicide and mullite.
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32. A heater comprising a thermally sprayed resistive heating layer that comprises a mixture of zirconium diboride and aluminum oxide.
- 33. A heater comprising a thermally sprayed resistive heating layer that comprises a mixture of a first material, a second material, and a third material, wherein said first material is an electrically conducting material, said second material is an electrically insulating material, and said third material alters a property of said resistive heating layer, wherein said first material has a positive temperature coefficient of resistivity and said third material has a negative temperature coefficient of resistivity.
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38. A method of fabricating a resistive heating layer, said method comprising the steps of:
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a) mixing a first material, a second material, and a third material, wherein said first material is an electrically conducting material, said second material is an electrically insulating material, and said third material alters a property of said resistive heating layer;
b) thermally spraying the mixture of step (a) onto a substrate, thereby fabricating a resistive heating layer; and
c) removing said resistive heating layer from said substrate.
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Specification