Formable thermoplastic laminate heated element assembly

Abstract

A semi-rigid heated element assembly and method of manufacturing semi-rigid heated element assemblies is provided. A heated element assembly includes a first thermoplastic sheet, a second thermoplastic sheet, and a resistance heating element laminated between the first and second thermoplastic sheets. The resistance heating element includes a supporting substrate having a first surface thereon and an electrical resistance heating material forming a predetermined circuit path having a pair of terminal end portions. The circuit path continues onto at least one flap portion that is capable of rotating about a first axis of rotation. The reformable continuous element structure may be formed into a final element assembly configuration whereby at least the flap portion is rotated along its axis of rotation to provide resistance heating in at least two planes. Semi-rigid heating elements may be formed into heated containers, heated bags, and other objects with complex heat planes.

What is claimed is:  
     
         1 . A heated element assembly, comprising: 
 (a) a first thermoplastic sheet;    (b) a second thermoplastic; and    (c) a resistance heating element secured between and to said first and second thermoplastic sheets, said resistance heating element comprising: 
 (i) a supporting substrate having a first surface thereon;  
 (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  
 (iii) a first flap portion capable of rotation about a first axis of rotation, said circuit path continuing onto at least a portion of said flap portion  
   wherein said thermoplastic sheets and resistance heating element are laminated together to form a reformable continuous element structure, said reformable continuous element structure formed into a final element assembly configuration whereby at least said first flap portion is rotated about said first axis to provide resistance heating in at least two planes.    
     
     
         2 . The heated element assembly of  claim 1 , wherein said thermoplastic sheets are affixed with an adhesive.  
     
     
         3 . The heated element assembly of  claim 1 , wherein said reformable continuous element structure is thermoformed into said final element assembly configuration.  
     
     
         4 . The heated element assembly of  claim 1 , wherein said reformable continuous element structure is cut into a foldable profile, said foldable profile including at least one joining tab, said joining tab mated to an adjacent surface of said reformable continuous element structure when said reformable continuous element structure is formed into said final element assembly configuration.  
     
     
         5 . The heated element assembly of  claim 1 , wherein said electrical resistance heating material is glued, sewn, fused, or a combination thereof to said supporting substrate.  
     
     
         6 . The heated element assembly of  claim 5 , wherein said electrical resistance heating material is sewn to said supporting substrate with a thread.  
     
     
         7 . The heated element assembly of  claim 1 , wherein said supporting substrate comprises a woven or non-woven fibrous layer.  
     
     
         8 . The heated element assembly of  claim 1 , wherein said supporting substrate is a thermoplastic sheet.  
     
     
         9 . The heated element assembly of  claim 1 , wherein said supporting substrate includes thermally conductive additives.  
     
     
         10 . The heated element assembly of  claim 1 , wherein at least one of said thermoplastic sheets includes a thermally conductive coating.  
     
     
         11 . The heated element assembly of  claim 1 , further comprising a secondary device secured between said first and second thermoplastic sheets.  
     
     
         12 . The heated element assembly of  claim 1 , wherein one of said thermoplastic sheets is thicker than the other thermoplastic sheet.  
     
     
         13 . The heated element assembly of  claim 1 , wherein said heated element assembly is over molded with a thermoplastic such that said over molded thermoplastic and thermoplastic sheets form a substantially homogenous structure.  
     
     
         14 . The heated element assembly of  claim 1 , wherein said supporting substrate is shaped as a foldable profile of a container, said foldable profile including said first flap portion.  
     
     
         15 . A sheet of heated element assemblies, comprising: 
 (a) a first thermoplastic sheet;    (b) a second thermoplastic sheet; and    (c) a sheet of resistance heating elements secured between and to said first and second thermoplastic sheets, said sheet of resistance heating elements comprising: 
 (i) a supporting substrate having a first surface thereon; and  
 (ii) a plurality of spaced circuit paths, each of said spaced circuit paths comprising an electrical resistance heating material fastened to said supporting substrate to form a predetermined circuit path, said circuit path having a pair of terminal end portions, each of said circuit paths continuing onto a first flap portion of a resistance heating element capable of rotation about a first axis of rotation; and  
   wherein said first and second thermoplastic sheets and resistance heating elements are laminated such that said sheet of resistance heating elements is secured between and to said first and second thermoplastic sheets to form a continuous element structure.    
     
     
         16 . The sheet of heated element assemblies of  claim 15 , further comprising an adhesive affixing said first and second thermoplastic sheets.  
     
     
         17 . The sheet of heated element assemblies of  claim 15 , wherein said electrical resistance heating material is glued, sewn, fused, or a combination thereof to said supporting substrate.  
     
     
         18 . The sheet of heated element assemblies of  claim 17 , wherein said electrical resistance heating material is sewn to said supporting substrate with a thread.  
     
     
         19 . The sheet of heated element assemblies of  claim 15 , wherein said supporting substrate comprises a woven or non-woven fibrous layer.  
     
     
         20 . The sheet of heated element assemblies of  claim 15 , wherein said supporting substrate is an extruded thermoplastic sheet.  
     
     
         21 . The sheet of heated element assemblies of  claim 15 , further comprising a plurality of secondary devices, each of said secondary devices disposed between said first and second thermoplastic sheets and associated with one of said circuit paths.  
     
     
         22 . The sheet of heated element assemblies of  claim 15 , wherein at least one of said thermoplastic sheets includes a thermally conductive coating.  
     
     
         23 . A combination containment bag and heater with sidewalls, comprising: 
 at least two heated element assemblies fused to each other along mating edges to form a containment bag with flexible sidewalls, each of said heated element assemblies comprising: 
 (a) a first thermoplastic sheet;  
 (b) a second thermoplastic sheet; and  
 (c) a resistance heating element secured between and to said first and second thermoplastic sheets, said resistance heating element comprising: 
 (i) a supporting substrate having a first surface thereon;  
 (ii) an electrical resistance heating material joined to said 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 connectors fixed to said terminal end portions of said electrical resistance heating material,  
 said thermoplastic sheets and resistance heating element laminated together to form a continuous structure.  
 
   
     
     
         24 . The heated container of  claim 23 , further comprising a nozzle secured to said container, said nozzle providing access to an area defined within said container.  
     
     
         25 . A heated container, comprising: 
 a heated element assembly, comprising: 
 (a) a first thermoplastic sheet;  
 (b) a second thermoplastic sheet; and  
 (c) a resistance heating element secured between and to said first and second thermoplastic sheets, said resistance heating element comprising: 
 (i) a supporting substrate having a first surface thereon;  
 (ii) an electrical resistance heating material sewn to said supporting substrate with a thread, said electrical resistance heating material forming a predetermined circuit path having a pair of terminal end portions;  
 (iii) a pair of electrical connectors fixed to said terminal end portions of said electrical resistance heating material; and  
 (iv) a plurality of flap portions capable of rotation about a first axis of rotation, said circuit path continuing onto at least a portion of at least one of said flap portions,  
 
   wherein said thermoplastic sheets and resistance heating element are laminated together to form a reformable continuous element structure, said continuous element structure formed into a final element assembly whereby said flap portions are rotated about said first axes to provide resistance heating in a plurality of planes.    
     
     
         26 . The heated container of  claim 25 , wherein said supporting substrate is shaped as a foldable profile of a container, said foldable profile including said plurality of flap portions.  
     
     
         27 . The heated container of  claim 26 , wherein said reformable continuous element structure substantially conforms to said foldable profile shape.  
     
     
         28 . The heated container of  claim 27 , wherein said continuous element structure includes at least one joining tab, said at least one joining tab mated to an adjacent surface of said continuous element structure in said final element assembly.