Self-regulating heating cables with embedded dielectric layer

A self-regulating heating cable comprising:

• a core comprising a positive temperature coefficient material;
• a band of dielectric material embedded within the positive temperature coefficient material;
• a first conductive wire and a second conductive wire embedded within the core and separated by the band of dielectric material,
• wherein the core includes indentations formed therein extending from its outer surface toward the band of dielectric material;
• a primary jacket surrounding the core;
• a ground plane surrounding the primary jacket and providing a ground path;
• and
• a final jacket surrounding the ground plane.

A method of producing a self-regulating heating cable for use with an alternating current (AC) source, the method comprising:

• assembling a band of dielectric material between a first conductive wire and a second conductive wire, wherein the band of dielectric material includes substantially flat upper and lower edges between the first conductive wire and the second conductive wire, and protrusions extending outward from the substantially flat upper and lower edges;
• assembling a positive temperature coefficient core material over the band of dielectric material, the first conductive wire, and the second conductive wire such that the first conductive wire, the second conductive wire, and the band of dielectric material are embedded within the positive temperature coefficient core material, wherein the positive temperature coefficient core material creates electrical paths for conducting current between the first conductive wire and the second conductive wire when the first conductive wire and the second conductive wire are connected to the AC source;
• applying a primary jacket over the positive temperature coefficient core material;
• applying a ground plane over the primary jacket;
• and
• applying a final jacket over the ground plane.