Method of manufacturing a sheathed electrical heater assembly

A method of manufacturing an electrical heater assembly comprising the steps of:

• providing a molded solid core, said core comprising a compound including organic material;
• heating said core at a temperature sufficient to expel organic material from said core;
• placing a heating element in communication with said core;
• overmolding said core and said heating element with an organo-ceramic insulation protection layer such that a heating assembly is produced;
• and
• heating said heating assembly at a temperature sufficient to expel organic material from said heating assembly.

A method of manufacturing an electrical heater assembly comprising the steps of:

• providing a molded core having an open configuration, said core comprising a compound including an organic material;
• heating said core at an elevated temperature sufficient to expel organic material from said core;
• placing a heating element in communication with said core;
• and
• overmolding said core and said heating element with an organo-ceramic insulation protection layer such that a heating assembly is produced.

An electrical heater assembly comprising:

• a core, said core comprising an organo-ceramic material;
• a heating element in communication with said core;
• and
• an insulation protection layer overmolding said core and said heating element to produce said heater assembly, said insulation layer comprising an organo-ceramic material.