Patent ID: 8395092

Claim:
A heater assembly comprising: a substrate comprising: opposed end portions defining raised flanges; a slot extending between the opposed end portions; and opposed chamfered surfaces extending along the slot and across the raised flanges; a first dielectric layer disposed over the substrate; a resistive element layer disposed over the first dielectric layer; a pair of terminal pads disposed over the first dielectric layer and in contact with the resistive element layer; a second dielectric layer disposed over the resistive element layer and not completely over the terminal pads; a protective cover defining at least one aperture, the protective cover disposed over the second dielectric layer and secured to the raised flanges and the opposed chamfered surfaces of the substrate, wherein the aperture is disposed proximate the terminal pads; a pair of lead wires secured to the pair of terminal pads; and a lead cap assembly disposed around the pair of lead wires and secured to the protective cover.