A low leakage current fluid heater and systems and methods thereof. The fluid heater has a configuration whereby a heating element is isolated from a fluid channel so as to leak into fluid passing through the channel an allowed amount of leakage current. Fluid passing through the fluid heater can be heated to a desired temperature. A controller can provide control signals to driver the fluid heater to the desired temperature and maintain the temperature at the desired temperature.

A The heating element structure includes: a conductive metal substrate; a heating layer spaced apart from the conductive metal substrate and configured to generate heat in response to an electrical signal; electrodes in contact with the heating layer and configured to provide the electrical signal to the heating layer; and a first insulating layer on the conductive metal substrate, the first insulating layer comprising a first matrix material and a particle, wherein a difference between a coefficient of thermal expansion (CTE) of the first matrix material and a coefficient of thermal expansion of the particle is about 410.sup.6 per Kelvin or less.

The present disclosure generally relates to a system for heating a bulk medium includes two or more electrodes spaced apart from one another and coupled to the bulk medium; and a power control system coupled to the electrodes, the power control system configured to heat the bulk medium by shaping a density of the current along a current path between the electrodes, thereby, producing an effective resistance along the current path in the bulk medium that is greater than the resistance of the bulk medium to a DC current, in which the power control system shapes the density of the current within a depth of the bulk medium by tuning a skin-depth of the current, and in which the power control system shapes the density of the current in a direction across the current path by tuning a proximity effect of the current.

A low leakage current fluid heater and systems and methods thereof. The fluid heater has a configuration whereby a heating element is isolated from a fluid channel so as to leak into fluid passing through the channel an allowed amount of leakage current. Fluid passing through the fluid heater can be heated to a desired temperature. A controller can provide control signals to driver the fluid heater to the desired temperature and maintain the temperature at the desired temperature.

A heating element includes a matrix material and a nanomaterial filler, wherein the nanomaterial filler includes at least one of a nano-sheet and a nanorod.

A vehicle heater (10) comprises a main body (12) carrying a non-intrinsically safe heat conductor layer (14), and a temperature monitoring device (16, 18, 20, 44) assigned to the heat conductor layer (14). The temperature monitoring device (16, 18, 20, 44) is designed to distinguish and to report at least the three following states: normal operation, reversible malfunction and irreversible malfunction. Moreover, a method for monitoring a vehicle heater (10) is suggested in which the following states are distinguished and reported: normal operation, reversible malfunction and irreversible malfunction.

A vehicle heater comprises a main body carrying a non-intrinsically safe heat conductor layer, and a sensor device allocated to the heat conductor layer and provided to detect an exceedance of a temperature threshold value. The sensor device comprises a sensor layer arranged on the side of the heat conductor layer facing away from the main body which is monitored for current flows which may occur substantially in the direction of its surface normal. In a method for producing a vehicle heater a main body of the vehicle heater is equipped with a non-intrinsically safe heat conductor, and a sensor device for detecting exceedances of a temperature threshold value. A sensor layer provided to be monitored for current flows which may occur substantially in the direction of the surface normal of the sensor layer is allocated to the heat conductor layer on its side facing away from the main body to form the sensor device.

A heating paste composition, and a sheet heating element, a heating roller, a heating unit and a heating module, which use the composition, are disclosed. In one aspect, the heating paste composition includes 0.2 parts to 6 parts by weight of carbon nanotube particles, 0.5 parts to 30 parts by weight of graphite particles, 5 parts to 30 parts by weight of a binder mixture, 29 parts to 80 parts by weight of an organic solvent and 0.5 parts to 5 parts by weight of a dispersant, wherein the weights are with respect to 100 parts by weight of the heating paste composition.

The present disclosure generally relates to a system for heating a bulk medium includes two or more electrodes spaced apart from one another and coupled to the bulk medium; and a power control system coupled to the electrodes, the power control system configured to heat the bulk medium by shaping a density of the current along a current path between the electrodes, thereby, producing an effective resistance along the current path in the bulk medium that is greater than the resistance of the bulk medium to a DC current, in which the power control system shapes the density of the current within a depth of the bulk medium by tuning a skin-depth of the current, and in which the power control system shapes the density of the current in a direction across the current path by tuning a proximity effect of the current.

According to one aspect, a wax warmer includes a body to support a reservoir adapted to receive a wax melt. The wax warmer also includes a heater having a first heating state to heat the wax melt from a first temperature below a melting point of the wax melt to a second temperature above the melting point of the wax melt in a predetermined amount of time. The heater has a second heating state to substantially maintain the wax melt within a temperature range above the melting point of the wax melt.