MOISTURE RESISTANT LAYERED SLEEVE HEATER AND METHOD OF MANUFACTURE THEREOF

摘要

A method of forming a layered heater assembly includes: forming a plurality of layers onto a substrate, the plurality of layers including a resistive element layer; forming electrical terminations in contact with the resistive element layer; securing a protective cover over the layers using a laser welding process, wherein edges of the protective cover are welded circumferentially around raised end portions of the substrate and welded longitudinally along a slotted portion of the substrate; securing a pair of lead wires to the electrical terminations; and securing a lead cap assembly around the pair of lead wires and to the protective cover using a laser welding process.

主权项

1. A method of forming a heater assembly comprising:
preparing a preformed protective cover, the preformed protective cover having a preformed shape and defining longitudinal edges, the longitudinal edges defining a longitudinal slot therebetween; forming a plurality of layers onto a substrate using a thermal spray process, the plurality of layers including a resistive element layer, wherein a recessed area for a termination is disposed on the layers; forming electrical terminations proximate the recessed area; disposing the preformed protective cover around the substrate with the longitudinal slot of the preformed protective cover aligned with a slotted portion of the substrate; securing the preformed protective cover over the layers after the forming of the plurality of layers onto a substrate, wherein edges of the protective cover are secured circumferentially around raised end portions of the substrate and the longitudinal edges of the protective cover are secured longitudinally along the slotted portion of the substrate; securing a pair of lead wires to the electrical terminations within the recessed area; and securing a lead cap assembly around the pair of lead wires and to the protective cover, wherein the protective cover is sealed to the substrate and the lead cap assembly to the protective cover to protect the thermally sprayed layers from moisture intrusion.