An electrical fluid heater, in particular water heater, preferably for a motor vehicle, including at least one fluid accommodating container and at least one heating conductor having a conductive polymer structure, for heating fluid, in particular water, accommodated in the fluid accommodating container.

A method for manufacturing an electrical heating element is provided, especially for electrical heating devices and load resistors. The method includes the steps of defining at least one heating conductor, providing a heating element blank with geometric dimensions that are selected such that the defined at least one heating conductor can be arranged in a sub-volume of a space taken up by material of the heating element blank, and machining the heating element blank, so that the defined at least one heating conductor is generated by removing material from the heating element blank.

A low smoke, zero halogen self-regulating heating cable includes a semi-conductive heating core and two conductive wires embedded within and separated by the semi-conductive heating core. The cable also includes a primary jacket surrounding the semi-conductive core, a braid surrounding the primary jacket, and a final jacket surrounding the braid. At least one of the primary jacket and the final jacket includes a low smoke, zero halogen material.

A low smoke, zero halogen self-regulating heating cable includes a semi-conductive heating core and two conductive wires embedded within and separated by the semi-conductive heating core. The cable also includes a primary jacket surrounding the semi-conductive core, a braid surrounding the primary jacket, and a final jacket surrounding the braid. At least one of the primary jacket and the final jacket includes a low smoke, zero halogen material.

An electrical heating cable with a first power supply conductor, a second power supply conductor, and a third power supply conductor. Each of the first, second and third power supply conductors extend along a length of the cable. The electrical heating cable also includes an electrically conductive heating element body, wherein the first, second and third power supply conductors are electrically coupled to each other via the electrically conductive heating element body. The second power supply conductor is provided with a layer of electrically insulating material which covers only a part of a surface of the second power supply conductor. The layer is provided between the surface of the second power supply conductor and the electrically conductive heating element body.

Embodiments of the invention provide self-regulating heater cables utilizing substantially solid polymeric buffer layers surrounding the heating elements having improved heat transfer efficiency as well as improved reliability and endurance. The assembly includes first and second power supply wires configured to carry electrical power and separated by a solid spacer, a substantially solid electrically-insulating buffer layer in thermal contact with the heating element, and a cable jacket including a polymeric outer surface and an inner metallic sheath surrounding the buffer layer and in thermal contact with the buffer layer. The buffer layer includes a polymeric material having a thermal conductivity greater than air at standard temperature and pressure and surrounds the heating element, power supply wires, and spacer.

A self-regulating heater cable includes a PTC core formed of positive temperature coefficient material and disposed in electrical contact with at least two bus wires. The PTC core may encapsulate the bus wires and space the bus wires apart a predetermined distance via a connecting portion of the PTC core. The connecting portion has a tapered profile, and is thinner at the ends approximate the bus wires and thicker in a portion between the ends, which portion may be toward or at the center of the connecting portion. The thicknesses of the ends and the thicker portion are selected to produce a ratio that is within a range at which the heater cable produces heat at its outer surface with a substantially uniform profile, and primary heat generation of the heater cable has not shifted from the center of the connecting portion to the ends of the connecting portion.

A conductive heating composition includes a polyolefin elastomer, a crystalline non-grafted polyolefin, a crystalline polymer which is grafted or copolymerized with a monomeric unit, and a conductive filler. The composition has a surface resistivity ranging from 1.0E+01 ohm to 1.0E+06 ohm, and a volume resistivity ranging from 8.0E+01 ohm-cm to less than 1.0E+05 ohm-cm. When the composition is heated from 20 C. to 90 C., a log value of a resistance of the composition increases with a slope ranging from 3E02 log ohm/ C. to 9E02 log ohm/ C. After a specimen made of the composition is repeatedly bent 300 times, a surface resistance of the specimen at a room temperature increases by a rate of less than 300%.

Heating systems including heating elements and fastener materials covered and protected from the environment by a heating cap structure. The heating cap structure can interlock mating ribs or other structure in adjacent heating panels. Additional heating cap, transition, or flashing sections may further cover and protect heating system components. One or more heating elements may include heating cable or heating fluids or materials penetrating heating element bodies. The heating element bodies and heating cap panels and covers can include extruded or otherwise formed sections having a wide variety of shapes that can be varied to provide desired objectives, such as for example supporting strength, increased heat transfer, component cost minimization, component life, heating system weight, and ease of assembly, use, maintenance, expansion, contraction, and adaptability. The outer and other surfaces of the heating system may be painted, including to improve aesthetics. Sealing films and materials may be included.

A heating tape comprises an insulated heating element that includes a heating element layer comprising a polymer composite having conductive particles and at least one set of conductive electrodes at least partially embedded in the polymer composite and extending along at least a substantial portion of the length of the heating tape. A heating tape system for a pipe or other surface, further includes a power ramp controller having a solid state relay component to regulate an in-rush of current to the heating element. The heating tape system also includes a connector having multiple contact points.