Electrical heater

An electrical heater comprising;

• a first conductor,
• a second conductor,
• a fluoropolymer heating element disposed between the first conductor and the second conductor, and
• a temperature regulation element disposed between the fluoropolymer heating element and the second conductor;
• wherein the fluoropolymer heating element comprises an electrically conductive material distributed within a fluoropolymer, and
• wherein the electrical heater comprises a stack, the first conductor, the second conductor, the fluoropolymer heating element, and the temperature regulation element comprising layers of the stack.

A method of manufacturing an electrical heater, the electrical heater comprising a first conductor, a fluoropolymer compound, and a second conductor arranged in a stack, the fluoropolymer compound comprising an electrically conductive material distributed within a fluoropolymer and being disposed between the first conductor and the second conductor, wherein the first conductor is in direct contact with the fluoropolymer compound, the method comprising:

• raising the temperature of the fluoropolymer compound so as to melt the fluoropolymer compound;
• applying force to the first conductor and the fluoropolymer compound so as to force substantially all of the air from between the first conductor and the fluoropolymer compound and from within the fluoropolymer compound;
• and
• cooling the fluoropolymer compound to ambient temperature such that, when cooled, the fluoropolymer compound is arranged to form a fluoropolymer heating element and is bonded to the first conductor;
• wherein the method is a continuous process.

A method of manufacturing an electrical heater, the electrical heater comprising a first conductor, a fluoropolymer compound, and a second conductor arranged in a stack, the fluoropolymer compound comprising an electrically conductive material distributed within a fluoropolymer and being disposed between the first conductor and the second conductor, wherein the first conductor is in direct contact with the fluoropolymer compound, the method comprising:

• raising the temperature of the fluoropolymer compound so as to melt the fluoropolymer compound;
• applying force to the first conductor, the second conductor and the fluoropolymer compound so as to force substantially all of the air from between the first conductor and the fluoropolymer compound, and from between the second conductor and the fluoropolymer compound;
• and
• cooling the fluoropolymer compound to ambient temperature such that, when cooled, the fluoropolymer compound is arranged to form a fluoropolymer heating element and is bonded to the first conductor and the second conductor;
• wherein the method is a continuous process.

An electrical heater comprising:

• a first conductor which extends along a length of the electrical heater,
• a fluoropolymer heating element disposed around the first conductor and along the length of the electrical heater;
• and
• a second conductor disposed around the fluoropolymer heating element and along the length of the electrical heater;
• wherein the fluoropolymer heating element comprises an electrically conductive material distributed within a fluoropolymer.