Claims
- 1. A method of manufacturing a heated element assembly, comprising the steps of:
(a) providing a first molded section; (b) providing a second molded section shaped to mate with said first molded section; (c) providing a resistance heating element, comprising:
(i) a supporting substrate having a first surface thereon; and (ii) an electrical resistance heating material fastened to said supporting substrate, said electrical resistance heating material forming a predetermined circuit path having a pair of terminal end portions; and (d) securing said first molded section to said second molded section, such that said first and second molded sections substantially encompass said circuit path and at least a portion of said heating element is secured in a gapped area defined between said first and second molded sections by a mechanical fit between said molded sections.
- 2. The method of claim 1, wherein the step of securing said first molded section to said second molded section includes the step of fusing or melt bonding said first molded section to said second molded section.
- 3. The method of claim 1, wherein the step of securing said first molded section to said second molded section includes the step of spin welding said first molded section to said second molded section.
- 4. The method of claim 1, wherein the step of securing said first molded section to said second molded section includes the step of sonic welding said first molded section to said second molded section.
- 5. The method of claim 1, wherein the step of securing said first molded section to said second molded section includes the step of snap-fitting said first molded section to said second molded section.
- 6. The method of claim 5, wherein the step of snap-fitting said first molded section to said second molded section includes the step of O-ring snap fitting said first molded section to said second molded section.
- 7. The method of claim 1, wherein said step of securing said first molded section to said second molded section includes the step of evacuating a quantity of air from said gapped area defined between said first molded section and said second molded section and hermetically sealing said first molded section to said second molded section.
- 8. The method of claim 7, further comprising the step of introducing an inert gas to said gapped area before hermetically sealing said molded sections together.
- 9. The method of claim 1, wherein the step of securing said first and second molded sections together further comprises the step of introducing a thermally conductive fluid to said gapped area defined between said first and second molded sections and forming a fluid tight seal between said first and second molded sections.
- 10. The method of claim 1, wherein said securing step includes the step of detachably securing said first molded section to said second molded section.
- 11. The method of claim 1, further comprising the step of providing an expandable foam to said gapped area defined between said first and second molded sections.
- 12. The method of claim 1, further comprising the steps of coating said resistance heating element with a UV curable material and curing said material after positioning said heating element between said first and second molded sections.
- 13. The method of claim 12, wherein the step of coating said heating element includes the step of providing said UV curable material to said gapped area defined between said first and second molded sections.
- 14. A method of manufacturing a heated element assembly, comprising the steps of:
(a) providing a first molded polymeric section; (b) providing a second molded polymeric section shaped to mate with said first molded section; (c) providing a resistance heating element, comprising:
(i) a first heat resistant supporting substrate having a first surface thereon; (ii) an electrical resistance heating material sewn with a thread to said first heat resistant supporting substrate, said electrical resistance heating material forming a predetermined circuit path having a pair of terminal end portions; and (iii) a pair of electrical conductors fixed to said terminal end portion of said electrical resistance heating material; and (d) securing said first molded polymeric section to said second molded polymeric section, such that said first and second molded sections substantially encompass said circuit path and at least a portion of said heating element is secured between said first and second molded sections by a mechanical fit between said molded sections and said electrical resistance heating material is spaced apart from said first and second molded sections by an air gap.
- 15. The method of claim 14, wherein the step of securing said first molded section to said second molded section includes the step of fusing or melt bonding said first molded section to said second molded section.
- 16. The method of claim 14, wherein the step of securing said first molded section to said second molded section includes the step of spin welding said first molded section to said second molded section.
- 17. The method of claim 14, wherein the step of securing said first molded section to said second molded section includes the step of sonic welding said first molded section to said second molded section.
- 18. The method of claim 14, wherein the step of securing said first molded section to said second molded section includes the step of snap-fitting said first molded section to said second molded section.
- 19. The method of claim 18, wherein the step of snap-fitting said first molded section to said second molded section includes the step of O-ring snap fitting said first molded section to said second molded section.
- 20. The method of claim 14, wherein said step of securing said first molded section to said second molded section includes the step of evacuating a quantity of air from an area defined between said first molded section and said second molded section and hermetically sealing said first molded section to said second molded section.
- 21. The method of claim 20, further comprising the step of introducing an inert gas to said area before hermetically sealing said molded sections together.
- 22. The method of claim 14, wherein said securing step includes the step of detachably securing said first molded section to said second molded section.
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent application Ser. No. 09/544,873 of Theodore Von Ar, Keith Laken, John Schlesselman and Ronald Papenfuss, filed Apr. 7, 2000, entitled “Molded Assembly with Heating Element Captured Therein.”
[0002] This application is related to U.S. application Ser. No. 09/369,779 of Theodore Von Arx, filed Aug. 6, 1999, entitled “Electrofusing of Thermoplastic Heating Elements and Elements Made Thereby”; U.S. application Ser. No. 09/416,731 of John Schlesselman and Ronald Papenfuss, filed Oct. 13, 1999. entitled “Heating Element Containing Sewn Resistance Material”; and U.S. application Ser. No. 09/275,161 of Theodore Von Arx, James Rutherford and Charles Eckman, filed Mar. 24, 1999, entitled “Heating Element Suitable for Preconditioning Print Media,” now U.S. Pat. No. 6,233,398, which are all hereby incorporated by reference. This application is also related to U.S. Provisional Application No. 60/177,330, filed Jan. 21, 2000, entitled “Improved Cooking Grill,” which is also hereby incorporated by reference.
Divisions (1)
|
Number |
Date |
Country |
Parent |
09544873 |
Apr 2000 |
US |
Child |
10080047 |
Feb 2002 |
US |