CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 62/102,169, filed January 12, 2015. The contents of U.S. Provisional Application No. 62/102,169 are incorporated by reference herein.

FIELD

The present invention relates to a fabric heating element and a method for manufacturing the fabric heating element.

SUMMARY

One embodiment comprises a fabric heating element including an electrically conductive, non-woven fiber layer having a plurality of conductive fibers collectively having an average length of less than 12mm. The fabric heating element also includes at least two conductive strips electrically connected to the fiber layer over a

predetermined length, positioned adjacent opposite ends of the fiber layer, and configured to be electrically connected to a power source.

In one embodiment, the fabric heating element also comprises a first adhesive layer adhered to a first side of the fiber layer and a first insulating layer, and a second adhesive layer adhered to a second side of the fiber layer and a second insulating layer.

In one embodiment a controller is electrically connected to the power supply and the at least two conductive strips. The controller is configured to apply a voltage from the power supply to the at least two conductive strips.

In one embodiment, the fiber layer has a uniform electrical resistance in any direction. In one embodiment, the fiber layer consists of the plurality of conductive carbon fibers, the binder, optionally one or more fire retardants, and optionally a plurality of non-conductive fibers. In one embodiment, each of the conductive fibers has a length in the range of 6-12mm, In one embodiment, the fiber layer consists essentially of individual unentangled fibers.

BACKGROUND

Heating elements capable of generating and sustaining moderate uniform temperatures over small and large areas are desirable for a variety of applications, ranging from under-floor heating to far infrared (FAR) heating panels for buildings to car seating, electric blankets and clothing for consumer use.

Historically, such applications have used resistive wire wound in a winding pattern that covers the area to be heated. In some applications, large amounts (e.g. 50 meters) of wire may be used just to cover a single square meter of heated area. Loops of resistive wire generally cannot provide desirable uniform temperatures. Wires which are sufficiently fine and closely spaced to provide the required temperatures without "hot spots" are often fragile and easily damaged, with the attendant dangers of fire and electrical shock. Also, resistive wires tend to be very thin so that they don't affect the material they are embedded in, as otherwise they may become a flaw or inclusion, which creates structural problems in the heater material after a short period of time.

Metal sheet and foils are generally suitable only for a limited range of applications in which corrosion resistance is not required, and cost is no object. Generally, such materials cannot feasibly be embedded as an internal heater element.

Because of the shortcomings of traditional metal wires and sheets, a great deal of effort has been devoted to developing woven and non-woven carbon fiber webs for use as heating elements. Short carbon fibers (e.g . fibers of 5 to 20 microns in diameter and between approximately 3 and 9 mm in average fiber length) are typically used to achieve a uniform sheet with the desired uniform heat dispersion properties. Average fiber lengths exceeding 9mm may cause technical difficulties manufacturing with uniformly dispersed carbon fiber throughout, such that irregularity in the resistance value from point to point in the sheet may become problematic.

There are a number of disadvantages, however, in making non-woven conductive webs with short carbon fibers. For example, conductivity varies roughly as the square of fiber length in a non-woven. Consequently, obtaining a given conductivity typically calls for a relatively high percentage of shorter fibers. Certain desirable mechanical properties, such as web tensile and tear strength and flexibility, also improve

significantly with increased average fiber length. Loading the web with large quantities of short carbon fiber makes it difficult to produce acceptable physical/mechanical properties in webs made on commercial machines.

Also, in order to capitalise on the range of electrical properties available in a non- woven web, the aerial weight may vary between 8 to 60gsm. At aerial weights below 20gsm, non-woven webs can be difficult to handle or are fragile and prone to damage when used in commercial applications as heating elements.

BRIEF DESCRIPTION OF THE FIGURES

Figure 1 is a cross sectional view of the fabric heating element construction, according to an embodiment of the present invention.

Figure 2 is a top view of the fabric heating element with and without perforations, according to an embodiment of the present invention.

Figure 3 is a top view of the fabric heating element with perforations and multiple busbar spacing distances, according to an embodiment of the present invention.

Figure 4 is an image of the heating element with perforations and multiple types of electrical connectors, according to an embodiment of the present invention. Figure 5 is a block diagram of a heating system including the heating element and a controller, according to an embodiment of the present invention.

Figure 6 is a flow chart describing an example operation of the heating system, according to an embodiment of the present invention.

Figure 7 is a flow chart describing an example method for manufacturing the heating device, according to an embodiment of the present invention.

Figure 8A is an image showing a magnification of a portion of an exemplary non- woven conductive fiber sheet fabric suitable for use in embodiments of the present invention.

Figure 8B is an image showing a magnification (greater magnification than Fig.

8A) of a portion of an exemplary non-woven conductive fiber sheet fabric suitable for use in embodiments of the present invention.

DETAILED DESCRIPTION

Provided is a fabric heating element that can be embedded in materials in need of heat (e.g . vehicle seat, clothing, etc.), and that is compatible with the material to be heated, thus providing heat from the inside, which is more efficient and faster than providing heat from the outside of the material .

In one example, the device includes a non-metallic porous or perforated fabric heating element comprising an electrically-conductive inner non-continuous fibrous web layer with integrated conductive busbar strips. The inner layer is bonded and

sandwiched between two outer insulating layers of woven or non-woven material, (e.g. continuous fiber) material. The fabric heating element is configured for use as a heated fabric or to be embedded in laminated or solid materials. In some embodiments, such as those in which the inner layer is perforated, the resulting construction may comprise adhesive extending between the inner and outer layers as well as through the

perforations in the inner layer. Applications of the device include any item containing such a fabric heating element, such as, for example, apparel or other textiles, and laminated or solid materials.

An exemplary process for manufacturing the fabric heating element, comprising adhesively bonding an electrically-conductive inner non-continuous fibrous web layer between outer insulating layers of woven or non-woven material is described herein.

The step of bonding the conductive busbar strips to the inner layer may be performed simultaneously with the step of bonding the inner and outer layers together, or prior to the inner/outer layer bonding step. In an embodiment in which the inner layer is perforated, the step of bonding the inner layer to the outer layers may comprise the adhesive used for bonding between the layers extending into the perforations in the inner layer. An application may comprise a process for embedding the fabric heating element as described herein into a composite structure, the process comprising forming the multi-ply fabric heating element as described herein, and then bonding the fabric heating element into the composite structure. Some embodiments may comprise, prior to the embedding step, perforating the fabric heating element, in which case the embedding step may comprise material from the composite structure penetrating the perforations in the fabric heating element.

The inner electrically conductive layer typically includes fine conductive fibers, typically carbon, dispersed homogeneously in the inner heater element to form a dense network, which convert electricity into heat by the act of resistive heating . By applying a voltage across the conductive (e.g. metallic copper) strips, the resistance of the electrically conductive layer causes a uniform current density, which in turn produces the uniform heating .

In one example, the fabric heating element 100 shown in Fig . 1 includes six layers of material that form a hybrid construction of busbars and fabric. These layers are shown in the cross-sectional view of Fig. 1 as Item 1, Item 2, Item 3, Item 4, Item 5 and Item 6. Items 1 and 6 are outer insulating and reinforced layers (e.g . woven glass fabric such as aerial weight in the range of 20- 100gsm). Items 2 and 5 are adhesive layers (e.g . thermoplastic Polyethylene terephthalate (PET) web having aerial weight of 15gsm). Item 4 is an inner electrically conductive non-woven fiber layer (e.g. carbon fiber having aerial weight of 8-60gsm). Item 3 refers to metallic (e.g. copper) strips having specific dimensions (e.g . 19mm wide and 50microns thick), which act as busbars.

In general, the outer layers comprise an insulating woven or nonwoven fabric (e.g . Items 1 and 6), typically made from a continuous filament. The term "continuous filament" or "continuous fiber" when used to characterize yarns, fabrics, or composites may not actually be "continuous" in the strictest definition of the word, and in actuality such fibers or filaments vary from as short as several feet in length to several thousand feet in length. Everything in this wide range is generally called "continuous" because the length of the fibers tends to be orders of magnitude larger than the width or thickness of the raw composite material.

The inner heating element layer (e.g . Item 4), sandwiched between the outer layers (e.g . Items 1 and 6), includes an electrically conductive material, such as a discontinuous non-woven carbon or carbon/glass fiber web as described herein. Bonded to the inner electrically conductive layer (e.g . Item 4) are two conductive (e.g. metallic copper) strips (e.g. Item 3) that act as electrical busbars. The copper strips ensure uniform current flow throughout the electrical conductive non-woven web, and hence uniform heating due to the resistance. These conductive strips also facilitate connection of power cables to the heater. Although often referred to herein as "copper" strips, it should be understood that the strips are not limited to any particular conductive materials.

The outer layers (e.g. Items 1 and 6) are bonded to the electrically conductive inner layer (e.g. Item 4) using a thermoplastic or thermoset web (e.g. Items 2 and 5) disposed between the inner and outer layers, which results in a hybrid construction heater material.

With reference to Fig. 1, exemplary heater elements may be constructed as follows, without limitation to the exemplary material types and features listed:

Items 1 and 6 (Outer insulating and reinforcing layers):

Material may comprise, for example, a glass fiber woven fabric using E-type fibers. Specific examples include but are not limited to Type 30® Single end roving fabric (Owen Corning Inc.) and Flexstrand® 450 Single End roving fabric (FGI Inc.). Exemplary features or characteristics may include:

Weave: US style 117 Plain

Warp Count: 54

Fill Count: 3

Warp yarn: ECD* 4501/2

Fill Yarn: ECD 4501/2

Weight: 83g/m2

Thickness: 0.09mm

Tensile Strength: 163 lbf/in(28.6N/mm)

*"ECD 4501/2" as a yarn type refers to:

E= Eg lass fiber type

C-Continuous fiber

D = fiber dia 0.00023

450 =tex or weight of strand (xlOOyd/lb), 2000 filaments/strand 1/2= 2 strands twisted together to form one yarn

An example of such an ECD 4501/2 yarn includes Hexcel Corp 117 Style.

Items 2 and 5: Adhesive film (between outer layers and heating film). Material may comprise a thermoplastic, such as a modified PET web, with the following exemplary features or characteristics:

Melt temperature: 130 deg C Peel strength to steel ; 150-300 N/75mm

Lap shear strength : 5- 10 Mpa

Item 3 : Conductive Stri ps. Material may comprise copper, having the following exemplary features or characteristics:

Copper thickness : 0.05mm

Adhesive thickness (between strip and heating film) : 0.02mm

Strip thickness : 0.075mm

Peel strength to steel (of adhesive) : 4.5N/cm

Tensile strength : 85N/cm

Temp resistance : 160degC

Electrical thru thickness resistance : 0.003 ohms Item 4 : Non-Woven carbon fiber heating film . Exemplary featu res or

characteristics may include :

Fiber type : High Strength Polyacrylonitrile (PAN)

Filament: 12 K

Fiber length : 6mm

Arial weig ht: 20gsm

Surface Electrical resistance : 4 ohms/square

Tensile Strength : 36N/15mm

The non-woven electrically conductive sheet may be formed by wet-laid manufacturing methods from conductive fibers (preferably carbon ), non-conductive fibers (glass, aramid, etc. to control overall resistance), one or more binder polymers, and optional flame retardants. Preferred lengths for the fi bers (both conductive and non-conductive) are in the range of 6- 12 mm in length. Exemplary binder polymers may i nclude : Poly vinyl alcohol, Co-polyester, Cross linked polyester, Acrylic and

Polyurethane. Exemplary flame retardant binders may include Polyimide and Epoxy. Suitable wet-laying techniques may comprise a state of the art continuous

manufactu ri ng process.

The amount of conductive fiber required depends upon the type of conductive fiber chosen, the voltage and power at which the heati ng element is to be used, and the physical size/configu ration of the heati ng element, which will determine the cu rrent path and density throug hout it. Lower voltages and longer current paths requ i re relatively more conductive fiber a nd lower electrical resistance. Ideal sheets have uniform electricai resistance in any direction. For example, the electrical resistance in the a first direction (e.g . the machine direction) is substantially equal (+/- 5%) to the electrical resistance in a second direction perpendicular to the first direction (e.g. the cross- machine direction).

An exemplary electrically conductive carbon fiber sheet known in the art is a

Chemitex 20 carbon fiber veil (CHM Composites, Ltd.). Chemitex 20 is a PAN based carbon fiber veil having an areal base weight of 17 g/m2, a styrene soluble binder, a thickness of 0.15mm, a tensile strength in the machine direction and in the cross- machine direction of 60N/15mm, and a resistivity of 5 ohms per square. However, standard commercial carbon fiber sheets (e.g. Chemitex carbon fiber sheets) have been found to be less than ideal for implementing preferred heating element embodiments for various reasons (e.g. fragility of the fiber sheet, non-uniformity of electrical resistance in different directions along the sheet, longer length of fibers in the sheet). It has also been found that conductive sheets having the characteristics discussed herein avoid the additional cost and burden required to add metallic particles to the sheet, as discussed in, for example, U.S. Pat. App. No. 4,534,886 to Kraus.

In one embodiment, all or a portion of the conductive and/or non-conductive fibers in the non-woven electrically conductive sheet are less than or equal to 12mm in length, such that the average fiber length is less than or equal to 12mm. The wet-laid manufacturing method used to manufacture the non-woven electrically conductive sheet does not require additional conductive material (e.g . conductive particles) to attain uniform electrical resistance. In another embodiment, all of the conductive and/or non- conductive fibers in the non-woven electrically conductive sheet are in the range of 6mm to 12mm in length, with no other additional conductive particles present.

Conductive fibers which have electrical resistances of 25,000 ohm/cm or lower, in the range of 25 to 15,000 ohm/cm, and which have melting points higher than about 500° C. are beneficial. Conductive fibers which are non-flammable, and are not brittle are also beneficial. It is also beneficial that neither their resistances nor their mechanical properties are significantly affected by temperature variations in the range of 0°-500° C. Other factors such as relatively low water absorption, allergenic properties, and adhesive compatibility may also enter into the selection processes. Suitable fibers include carbon, nickel-coated carbon, silver-coated nylon, and aluminised glass.

Carbon fibers are beneficial for use in heating elements for consumer applications such as under floor heating mats, since they have all the desired characteristics, are relatively inexpensive, and can be used in small but manageable concentrations to provide the desired heat output at standard household voltages. Heating elements for use at low voltages may also be produced. 25 volts, for example, is generally considered to be the maximum shock-proof voltage. In order to protect their patients, most hospitals and nursing homes require that their heating mats operate at this voltage. There are a number of potential applications for battery-powered heating elements, but these elements may operate at 12 volts or less. There has been a long-felt need for a heating element which could maintain temperatures in the range of 50°-180° C. at these voltages. Low-voltage heating elements can be manufactured by increasing the concentration of conductive fibers in the element or by using specific types of conductive fibers. For example, because of their high conductivity, metal-coated fibers such as nickel-coated carbon are suitable alternatives to carbon fibers for these applications, but carbon fibers and carbon fiber/metal-coated fiber mixtures have also been used successfully.

Referring now to Figs. 8A and 8B, there are shown two magnified photographs (Fig . 8B has greater magnification than Fig. 8A) of a representative portion of an exemplary non-woven fiber sheet that is particularly well-suited for use in connection with the claimed invention. As can be seen in these photographs, the fiber sheet comprises a plurality of individual, substantial straight unentangled fibers, all of which are fall within a specified range of lengths (e.g. 6- 12mm) . A sheet consisting of only individual, unentangled fibers (i.e. each fiber is "unentangled" with any other fiber) throughout the entire sheet is void of defects that can otherwise cause operational issues when the sheet is used practice as described herein. Such defects (not shown) to be avoided may include but are not limited to "logs or sticks" (i.e. bundles of fibers whose ends are aligned and thus act as if they are outside the specified range); "ropes" (i .e. fiber assemblages with unaligned ends that are not completely isolated from one another or that are entwined around one another along the axes of the fibers); "fused fibers" (i.e. bundles of fibers fused at the ends or along the fiber length) ; or "clumps" or

"dumbbells" (i.e. assemblages of normal-length fibers ensnared by one or more overly long fibers) .

While each individual fiber of the non-woven sheet is desirably in contact with one or more other individual fibers as part of the non-woven structure of the sheet, ideal contact differs from entanglement in that entanglement typically involves two or more fibers wound around each other along the longitudinal axis of the fibers, whereas preferred contact comprises straight, unentangled fibers having multiple points of contact with other straight unentangled fibers such that the longitudinal axes of the contacting fibers are at acute or perpendicular angles with one another. To ensure high quality performance, some embodiments may comprise sheets that have been visually checked (manually or with machine vision) to confirm the absence of defects such as but not limited to those described above, and only sheets consisting essentially of individual, unentangled fibers (i.e. sheets having a defect rate of less than 200 per 100 gram weight of material) may be used. Manufacturing processes for making sheets for use as described herein are therefore preferably designed to provide first quality as a high percentage of throughput.

Polyacrylonitrile (PAN) is an acrylic precursor fiber used for manufacturing carbon fiber. Other precursors, such as rayon or pitch base may be used, but PAN is a beneficial choice for performance, consistency and quality for this application. Beneficial heater element material characteristics may include:

Electrical resistance between 1-200 ohm / sq

Applied voltages across the copper strips : 0- 120VDC and 0-240vAC

Single phase 50Hz and 415vAC 3-phase 50HZg,

Typical maximum temperature : 400degC

Typical temperature uniformity: +/-2degC

Heat-up rates: up to 30 degC/min

Heater element materials that are flexible and can easily be draped or formed into 3D shapes are particularly advantageous. Use of a veil heater element that is not coated or treated, in combination with the other exemplary layers described herein, results in a fabric that includes an uncoated or dry perform that may be infused or impregnated with the material into which the fabric is intended to be later embedded .

Fabric heating element 100 shown in Fig. 1 may be manufactured in various configurations to be inserted in various applications (e.g . heated clothing, car seats, etc. ). Shown in Fig. 2 are top views of two examples of the manufactured fabric heating element 100 in Fig 1.

In one example, fabric heating element 200 includes a non-perforated fabric layer 206, and busbars 204 and 208. In another example, fabric heating element 202 includes a perforated fabric layer 212, and busbars 210 and 214. Although not shown, electrical wires are connected to the busbars to apply a voltage to the busbars and produce an electrical current flowing through the fabric layers 206 and 212 respectively.

Many factors may determine the amount of electrical current flowing through the fabric layers and therefore the amount of heat produced by the device. These factors include but are not limited to distance between busbars (e.g . closer busbars provide a lower resistance electrical path and therefore produce higher current/temperature), level of voltage applied to the busbars (e.g . higher voltage produces higher

current/temperature), and density/shape of perforations (e.g. higher density of perforations results in lower resistance and therefore higher current/temperature).

In addition to the dual busbar configurations shown in Fig. 2, the fabric heating element may be configured with more than two busbars as shown by the fabric heating element 300 in Fig. 3. By including more than two busbars, the device may have multiple independent heating areas that can be separately controlled . For example, as shown in Fig. 3, the fabric heating element includes three heating areas (e.g . 302, 304 and 306) produced by busbar pairs 308/310, 312/314 and 316/318 respectively.

In this example, each heating area may produce different amounts of heat for the same supply voltage due to the different spacing between the busbars (e.g. area 302 produces the least heat due to the large distance between busbars 308/310, whereas area 306 produces the most heat due to the small distance between busbars 316/318). Heat output may also be controlled independently using different supply voltages.

Electrical connections to the conductive strips shown in Figs. 2 and 3 may include, but are not limited to : soldered wire, soldered inserts or fasteners, bolts or rivets, clamp connectors, and any other type of suitable connector. Additional information about and illustration of exemplary connections is shown in Fig . 4. In this example, each of the busbars includes a different type of mechanical connection to the electrical wire. For example, busbar 408 includes a type 1 connector (e.g. soldered wire connection which may be useful in heated blanket, mold heating and industrial heating applications), busbar 406 includes a type 2 connector (e.g. rivet or bolt using crimped wire eyelet which may be useful in heated tables and industrial heating applications), busbar 404 includes a type 3 connector (e.g . soldered fixed insert "big head fastener" which may be useful in mould heating, processing composite materials and integrated product heating applications) and a type 4 connector (e.g. quick clamp connector which may be useful for under floor heating applications).

Heating element 300 shown in Fig . 3 may be cut from a roll of material having busbars 308, 310, 312, 314, 316, and 318 that extend longitudinally along the entire roll. The resulting roll of material can then be used not only for creating heating elements that span the entire width of the roll, but also heating elements that span less than the entire width of the roll. For example, longitudinal cuts between busbars 310 and 312 and/or between busbars 314 and 316 permit construction of multiple heating elements, each of different widths, from the same roll of material. Other embodiments of rolls or sheets may have multiple pairs of busbars that are equally spaced or only a single pair of busbars.

When embedded in composite materials, the connectors or fasteners shown in Fig. 4 may also have a protective plating or coating (e.g. an anodised coating for aluminum or zinc plating for steel). Brass fittings generally don't need any treatment. Additional discrete pieces of the insulation plies may be provided in the area of the connectors for fu rther electrical insulation if the fabric heater is to be embedded in carbon fiber composite laminate materials or other electrical conductive materials. Although the connections in Fig . 4 are illustrated on a PowerFilm™ heating element, comprising a carbon veil coated with a thermoplastic polymer, these types of connections are suitable for use with any type of heater element, including the uncoated carbon veil in an embodiment of the Power Fabric described herein. Coated carbon fiber veils, such as PowerFilm™ heating elements, have mechanical properties suitable for some heating applications in which the film may ultimately be intended for embedding in thermoset laminate materials or into other incompatible materials into which it is difficult to chemically bond or embed the film. An advantage of the composite heating fabric with an uncoated carbon veil as described herein, over the PowerFilm™ product, is that it is suitability for embedding in a wider variety of materials and greater flexibility than provided by a thermoplastic coated carbon veil. PowerFilm heating elements or other coated carbon fiber veils may also be used in composite fabric embodiments.

Maximum temperature may be controlled using a Proportional Integral Derivative (PID) controller receiving feedback from a sensor in a closed loop system to control the set temperature or by applying the correct input voltage based on power input calculations for a given set temperature. Voltage input (e.g . AC/DC) supply voltage can be regulated and controlled using a voltage regulator connected to the voltage supply, or a smoothing capacitor on the input supply voltage.

An example of a fabric layer heating system 500 including a controller is shown in Fig . 5. Fig. 5 shows a system with fabric layer element 202 and a temperature sensor 506 integrated in a device 508 (e.g . vehicle seat, clothing, etc. ), and electrically coupled to controller 502 which receives and distributes power from power supply 504 to fabric layer element 202.

The operation of fabric layer heating system 500, is described in the flowchart 600 of Fig. 6. In step 602, controller 502 receives an input from a user for setting a desired temperature (e.g. temperature of the vehicle seat). The input device is not shown in Fig. 5, but could include a dial, button, touchscreen, etc. In step 604, controller 502 applies a predetermined voltage to the busbars of fabric layer element 202 which then produces heat. In step 606, controller 502, uses temperature sensor 506 to monitor temperature of the fabric layer element 202. Temperature sensor 506 may be in direct contact, or in close proximity to fabric layer element 202. In step 608, controller 502 determines if the desired temperature has been reached . If the desired temperature has been reached, then in step 610, the controller 502 stops applying voltage to the busbars. If, however, the desired temperature is not reached, controller 502 continues to apply the voltage to the busbars.

Within the commercial constraints of the wet laid process for manufacturing non- woven web, use of short carbon fibers (e.g. fibers of 5 to 20 microns in diameter and between 3 and 9 mm average fiber length) may be desirable to achieve a uniform sheet having desirable uniform heat dispersion properties. When fiber length exceeds 9 mm, it may become technically difficult to manufacture the electrically conductive sheet containing uniformly dispersed carbon fiber throughout, with the result that irregularity in the resistance value from point to point in the sheet may become prohibitive.

Also, a dense network of short fibers causes the non-woven web to be relatively insensitive to holes or localised damage. The outer insulating and reinforcing layers and connecting adhesive layers of the heater element allow the use of the optimum fiber length in the non-woven web to provide uniformity of electrical resistance throughout the conducting non-woven layer. Weight of the outer layers typically varies between 20- 100 grams/m2.

Also, the outer layers can be compatible with the materials into which they are embedded, by having coated or impregnated reinforcing layers that match or otherwise favourably pair chemically to the material in which they are embedded . For example, outer layers comprising a woven glass coated Polyvinyl chloride (PVC) may be used in a heating element to be embedded in a PVC floor covering for a heated floor application, and woven nylon/acrylic fabric outer layers may be used for producing heated clothing.

In applications where the heater element is embedded in viscous materials, like rubber or concrete, it may be desirable to perforate the heater element material such that an additional mechanical bond is achieved. Since the non-woven web is insensitive to holes, the ability to include such perforations to provide mechanical bonding is an added advantage over other state of the art heaters. The electrical resistance of the perforated heater increases typically by 35-50% due to the reduced area. In some applications, an open area of 18-20% may give optimum heater performance. An exemplary hole pattern may comprise, for example, 1.5mm diameter holes spaced 3.5mm on center.

The adhesive layers connecting the outer plies to the inner conducting layer are typically applied at 15-20 g/m2, and may comprise any compatible thermoplastic or thermoset web adhesive, such as PET, Thermoplastic polyurethane (TPU), Ethylene-vinyl acetate (EVA), polyamide, polyolefin, epoxy, polyimide, etc. The heater hybrid construction material may be manufactured on a commercial basis on state of the art low pressure/temp continuous belt presses. Typical machine production speeds of 10 mts/min are achievable.

The copper busbar strips and bonded to the non-woven inner conductive layer such that full electrical continuity is achieved throughout the heater material. The copper busbar strips may be bonded to the inner conductive layer at the same time as the entire heating fabric is consolidated, or prior to consolidation with the other layers. In a typical bonding process, the inner conductive layer and copper busbar strips (with sufficient adhesive between them) alone, or together with the other layers as described herein, may be fed into a laminating machine, such as a laminating belt press.

A general example of the manufacturing process for the fabric heating element is described in flowchart 700 of Fig. 7. In step 702, for example, the manufacturer forms (e.g. via Wet- La id Manufacturing) the fiber layer (e.g . Carbon Fiber either Perforated or Non-Perforated) . In step 704, the manufacturer bonds metallic strips (e.g . Coated copper) to predetermined positions (e.g . specific distances from each other) on the formed fiber layer. In step 706, the manufacturer connects electrical wires to each of the metallic strips which allow application of the supply voltage. In step 708, the manufacturer applies adhesive layers to both sides of the fiber layer. Then, in step 710, the manufacturer applies insulating layers to both adhesive layers. In general, this manufacturing process produces the fabric heating element 100 shown in Fig. 1.

It should be understood that the invention is not limited to any particular materials of construction nor to any particular structural or performance characteristics of such materials, but that certain materials and structural performance characteristics may provide advantages, as set forth herein, and thus may be used in certain embodiments. Furthermore, it should be understood that the invention is not limited to any particular combination of components, and that each of the components as described herein may be used in any combination with any other components described herein.

In addition, although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather various modifications may be made in the details within the scope and range of equivalence of the claims and without departing from the invention.