Patent ID: 7662002
Filing Date: 2010-02-16
Classification: H01R

Abstract:
1. Carbon fiber heating element assembly comprising: a flexible carbon fiber tow of indeterminate length having a multiplicity of axially elongated carbon fibers, a metal electrical conductor having a plurality of discrete contact portions disposed in transverse overlying engagement with said tow and forming a matrix of discrete junctions therewith, a termination assembly including a lower energy director cradle and an energy director cap having respectively associated opposing cradle and cap clamping surface, said termination assembly including a matrix of fusions integral to both the cradle and the cap and maintaining the cradle and the cap clamping surface in parallel spaced apart relation to each other and in clamping engagement with the conductor contact portions and the tow, less than all of the fusions having carbon fibers associated with the tow embedded therein, the contact portions being in underlying bearing engagement with the cap clamping surface, the tow being in overlying bearing engagement with the cradle clamping surface, the cradle being free of embedded carbon fiber associated with the tow in a region underlying the cradle clamping surface and extending between fusions bordering the tow.