Patent ID: 6432344
Filing Date: 2002-08-13
Classification: H05B

Abstract:
A method of manufacturing an electrical resistance element comprising:(a) providing a support structure having a plurality of openings therethrough and a support surface thereon; (b) disposing a resistance heating wire on said support surface; and (c) molding a thermally-conductive polymeric material over said resistance heating wire and a major portion of said support structure to electrically insulate and hermetically encapsulate said wire and a major portion of said support structure, said thermally-conductive polymeric material contacting said resistance heating wire, where the electrical resistance element is an electrical resistance element for heating a fluid, the support structure is a skeletal support frame comprising a plurality of longitudinal splines, and said wire and a major portion of said support structure are encapsulated from said fluid, wherein step (a) comprises injection molding said skeletal support frame, and step (c) comprises injection molding said thermally-conductive polymer to encapsulate said resistance heating wire and at least about 90 percent of said skeletal support framewherein the remaining portion of said skeletal support frame that is not encapsulated comprises a plurality of heat transfer fins.