Method of formable thermoplastic laminate heated element assembly

A method of manufacturing a sheet of heated element assemblies, comprising the steps of:

• (a) providing a first thermoplastic sheet;
• (b) providing a second thermoplastic sheet;
• (c) disposing a sheet of resistance heating elements between said first thermoplastic sheet and said second thermoplastic sheet, said sheet of resistance heating elements comprising:
• (i) a supporting substrate having a first surface thereon;
• and
• (ii) a plurality of spaced circuit paths, each of said spaced circuit paths comprising an electrical resistance heating material fastened to said supporting substrate to form a predetermined circuit path, said circuit path having a pair of terminal end portions, each of said circuit paths continuing onto a first flap portion of a resistance heating element capable of rotation about a first axis of rotation;
• and
• (d) laminating said first and second thermoplastic sheets such that said sheet of resistance heating elements is secured between and to said first and second thermoplastic sheets to form a continuous element structure.

A method of manufacturing a final element assembly configuration, comprising the steps of:

• (a) providing a first thermoplastic sheet;
• (b) providing a second thermoplastic sheet;
• (c) disposing a sheet of resistance heating elements between said first thermoplastic sheet and said second thermoplastic sheet, said sheet of resistance heating elements comprising:
• (i) a supporting substrate having a first surface thereon;
• and
• (ii) a plurality of spaced circuit paths, each of said spaced circuit paths comprising an electrical resistance heating material fastened to said supporting substrate to form a predetermined circuit path, said circuit path having a pair of terminal end portions, each of said circuit paths continuing onto a first flap portion of a resistance heating element capable of rotation about a first axis of rotation;
• (d) laminating said first and second thermoplastic sheets such that said sheet of resistance heating elements is secured between and to said first and second thermoplastic sheets to form a continuous element structure including a sheet of heated element assemblies;
• (e) removing at least one heating element assembly from said sheet of heating element assemblies;
• (f) cutting said at least one heated element assembly into a foldable profile;
• and
• (g) forming said foldable profile into a final element assembly configuration whereby at least said first flap portion of a resistance heating element of said at least one heated element assembly is rotated about said first axis to provide resistance heating in at least two planes.

A method of manufacturing a heated element assembly, comprising the steps of:

• (a) providing a thermoplastic bag, said thermoplastic bag including a first and second thermoplastic walls;
• (b) disposing a resistance heating element within said thermoplastic bag and between said thermoplastic walls, said resistance heating element comprising:
• (i) a supporting substrate having a first surface thereon;
• (ii) an electrical resistance heating material fastened to said supporting substrate, said electrical resistance heating material forming a predetermined circuit path having a pair of terminal end portions;
• and
• (iii) a first flap portion capable of rotation about a first axis of rotation, said circuit path continuing onto at least a portion of said flap portion;
• (c) evacuating air from said bag to compress said bag around said resistance heating element and applying heat and pressure to said baa use said thermoplastic walls and secure said resistance heating element within said bag to form a reformable continuous element structure;
• and
• (d) forming said continuous element structure into a final element assembly configuration whereby at least said first flap portion is rotated about said first axis to provide resistance heating in at least two planes.