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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 d

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.

대표청구항 ▼

[ I claim:] [11.]11. A resistance heating element comprising: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 c

[ I claim:] [11.]11. A resistance heating element comprising: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; ande. 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.