Food warming device and methods for its manufacture

A method for manufacturing a food-warming device, the method comprising:

• forming a partially open housing having an arcuate cross-sectional shape and an open side extending along a longitudinal length of the housing;
• inserting a first distinct piece of thermally insulative material that comprises microporous thermal insulation within the housing through the open side, the first distinct piece extending alone the longitudinal length of the housing and shaped to conform to the arcuate cross-sectional shape;
• inserting a second distinct piece of thermally insulative material that comprises microporous thermal insulation extending alone the longitudinal length of the first piece, wherein at least a part of the second distinct piece is disposed within an area defined by the arcuate shape of the first piece;
• attaching a heating element with the housing through a support member to dispose the heating element along the longitudinal length of the housing;
• and
• vapor sealing the first piece and the second piece of thermally insulative material to prevent exposure to moisture.

A food-warming device comprising:

• a partially open housing having an arcuate cross-sectional shape and an open side extending along a longitudinal length of the housing;
• means for heating extending along the longitudinal length of the housing;
• means for supporting the means for heating at the open side of the housing;
• a first distinct piece of thermally insulative material that comprises microporous thermal insulation disposed within the housing to insulate a surface of the housing from heat generated by the means for heating, the first distinct piece extending along the longitudinal length of the housing and shaped to conform to the arcuate cross-sectional shape;
• a second distinct piece of thermally insulative material that comprises microporous thermal insulation extending alone the longitudinal length of the first piece, wherein at least a part of the second distinct piece is disposed within an area defined by the arcuate shape of the first piece;
• and
• means for vapor sealing the means for thermally insulating.

A food-warming device comprising:

• a partially open housing having an arcuate cross-sectional shape and an open side extending along a longitudinal length of the housing;
• a heating element extending along the longitudinal length of the housing;
• a support member disposed to maintain a position of the heating element at the open side of the housing;
• a first distinct piece of thermally insulative material that comprises microporous thermal insulation disposed within the housing to insulate a surface of the housing from heat generated by the heating element, the first distinct piece extending along the longitudinal length of the housing and shaped to conform to the arcuate cross-sectional shape;
• and
• a second distinct piece of thermally insulative material that comprises microporous thermal insulation extending along the longitudinal length of the first piece, wherein at least a part of the second distinct piece is disposed within an area defined by the arcuate shape of the first piece,
• wherein the first piece and the second piece of thermally insulative material are each stitched substantially only along a longitudinal length of the thermally insulative material.