Radiant heater

Abstract

A thick film, large area resistance heater including a substrate having an electrically non-conductive surface on which is deposited a film electrical resistor such as a thermally sprayed, photo resist etched foil or sol-gel graphite based material. A combination of an electrically conductive film coated backer board substrate composed of portland cement, sand, cellulose fibers and other selected additives. A mica substrate heater can be cemented to a cement backer board or a vinyl with adhesive backing.

1 . A heater comprising:
 an insulative substrate;   an electrically resistive material on a major surface of the substrate;   at least one contact terminal in contact with the resistive material; and,   a decorative layer covering the resistive material.   
   
   
       2 . A heater according to  claim 1  further comprising an underlying surface, and the insulative substrate mounted on the underlying surface. 
   
   
       3 . A heater according to  claim 5  wherein the insulative substrate is mica. 
   
   
       4 . A radiant heating system according to  claim 1  wherein the insulative substrate is formed from a cellulosic material. 
   
   
       5 . A heater according to  claim 1  wherein the insulative substrate is formed of a material selected from the group consisting of portland cement, gypsum, cementous materials, composite materials, polymeric materials, glass, ceramics, and minerals. 
   
   
       6 . A radiant heating system according to  claim 1  wherein the insulative substrate is formed of a water-resistant material. 
   
   
       7 . A heating system according to  claim 1  further comprising a plurality of electrically interconnected members, each member comprising:
 an insulative substrate;   a patterned resistive material on a major surface of the substrate;   at least one contact terminal in contact with the resistive material on the substrate; and,   a decorative layer covering the resistive material.   
   
   
       8 . A heater according to  claim 1  further comprising a controller, a temperature sensor in communication with a controller, the controller operable to regulate electrical current to the resistive material responsive to a signal from the temperature sensor. 
   
   
       9 . A heater according to  claim 1  wherein the resistive material forms a serpentine pattern having first and second ends, and the at least one contact terminal comprises a contact terminal connected to each of the first and second serpentine pattern end. 
   
   
       10 . A radiant heating system according to  claim 1  wherein the patterned resistive material comprises a rectilinear pattern having first and second opposed edges, and the at least one contact terminal comprises a contact terminal connected to each of the first and second opposed edges. 
   
   
       11 . A radiant heating system according to  claim 10  wherein the contact terminal connected to each of the first and second opposed edges comprises an elongate contact terminal. 
   
   
       12 . A radiant heating system according to  claim 1  wherein the resistive material comprises a graphite-containing material. 
   
   
       13 . A radiant heating system according to  claim 1  wherein the resistive material comprises a heat curable resistive material. 
   
   
       14 . A radiant heating system according to  claim 7  wherein each at least one contact terminal is positioned to contact a contact terminal of an adjacent member. 
   
   
       15 . A heating system according to  claim 7  wherein the plurality of electrically interconnected members connected in series. 
   
   
       16 . A heating system according to  claim 7  wherein the plurality of electrically interconnected members connected in parallel. 
   
   
       17 . A heater according to  claim 1  wherein the contact terminal is a conductive material in electrical contact with the resistive material. 
   
   
       18 . A heater according to  claim 1  wherein the contact terminal comprises a portion of the resistive material.