Low profile heater apparatus and method of manufacture

A heater apparatus, comprising:

• at least one lower assembly including:
• at least one first sheet made from at least one heat-resistant fabric;
• at least one heating sheet including at least one dielectric sheet, at least one heating element formed on the at least one dielectric sheet, and one or more pads formed on the at least one heating element, the one or more pads configured to allow one or more electrical leads to be attached in electrical communication with the at least one heating element;
• at least one intermediate sheet, including one or more passages formed on or therethrough and configured to permit the one or more electrical leads to traverse through the one or more passages and be securely attached in electrical communication with the one or more pads formed on the at least one heating element;
• at least one upper assembly including:
• at least one top sheet with at least one passage formed therein, the at least one passage configured to allow at least one lead sleeve to traverse therethrough, the at least one lead sleeve further including one or more split sleeves and at least one lead sleeve passage extending therethrough, the at least one lead sleeve passage configured to accept the one or more electrical leads from the at least one lower assembly to pass therethrough;
• and
• wherein the one or more split sleeves are fastened to the at least one top sheet by one or more split sleeve coupling features in the at least one top sheet;
• and
• one or more perimeter coupling features applied around at least one perimeter of the at least one lower assembly and at least one perimeter of the at least one upper assembly, wherein the one or more perimeter coupling features are configured to securely attach the at least one upper assembly to the at least one lower assembly, to form at least one heater body.

A method of manufacture of a low profile heater apparatus, comprising:

• providing at least one lower assembly, the at least one lower assembly comprising at least one first sheet, at least one heating sheet including at least one dielectric sheet with at least one heating element formed thereon, at least one intermediate sheet, and one or more electrical leads in communication with the at least one heating element;
• providing at least one least one upper assembly, the at least one upper assembly comprising at least one top sheet with one or more passages formed therein, the one or more passages configured to allow at least one lead sleeve to traverse therethrough, the at least one lead sleeve further including one or more split sleeves and at least one lead sleeve passage extending therethrough, the at least one lead sleeve passage configured to accept the one or more electrical leads from the at least one lower assembly to pass therethrough;
• forming one or more split sleeve strain relief structures in the at least one upper assembly by coupling the one or more split sleeves to the at least one top sheet with one or more split sleeve coupling features;
• and
• joining the at least one lower assembly to the at least one upper assembly with one or more perimeter coupling features applied around at least one perimeter of the at least one lower assembly and at least one perimeter of the at least one upper assembly, wherein the one or more perimeter coupling features are configured to securely attach the at least one upper assembly to the at least one lower assembly, to form at least one heater body.