US2939807A - Method of making a heating panel - Google Patents

Method of making a heating panel Download PDF

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US2939807A
US2939807A US594834A US59483456A US2939807A US 2939807 A US2939807 A US 2939807A US 594834 A US594834 A US 594834A US 59483456 A US59483456 A US 59483456A US 2939807 A US2939807 A US 2939807A
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sheet
coating
metal
heating
coated
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US594834A
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Basil A Needham
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Thermway Ind Inc
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Thermway Ind Inc
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    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05BELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00Ohmic-resistance heating
    • H05B3/20Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/22Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
    • H05B3/26Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base
    • H05B3/262Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base the insulating base being an insulated metal plate
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/49082Resistor making
    • Y10T29/49083Heater type

Definitions

  • This invention relates to heating devices and particularly to an improved electrically energized radiant heating element and the method of making it.
  • An object of the invention is to provide an improved radiant heating element suitable for use in space heating panels adapted to be mounted on the walls or ceilings of buildings, in portable heaters, and 'as a heating element for water heaters, ranges, etc.
  • My improved element is also suitable for use in industrial applications.
  • Another object is to provide an improved radiant heating element whichv is self supporting, has inherent rigidity, yet is rugged in construction and not easily subject to damage by mechanical or heat shock.
  • Still another object is to provide an improved electrical heating element wherein the resistor is fused on a self supporting backing member which may be llat or curved and wherein the resistor presents a relatively large area of heating surface.
  • Another object of the invention is to provide an improved electrically tenergized heating element of sheet form which includes ya metal sheet with a resistor element mounted thereon suitably insulated from the metal sheet, and which has a vitreous or porcelain enamel coating on the front surface of the sheet for diffusing the radiation thereof.
  • Fig. l is a rear view of my improved heating element with a portion of the protecting coating broken away to show the resistor;
  • Fig. 2 is 1an enlarged section taken on the line 2-2 of Fig. 1;
  • Fig. 3 is a section, similar to Fig. 2, of a modified form of element.
  • my improved heating element comprises a sheet which is preferably of metal but may be of other suitable material.
  • the sheet 10 may be of any desired thickness so long as it is self supporting and substantially rigid. Generally, met-al of sufficient section to provide the desired characteristics with lightest weight is used. While the sheet 10 is shown as at and rectangular, any regular or irregular shape may be used and the sheet may be formed into a cylinder or other shape.
  • the sheet 10 is coated with a layer of frit, vitreous enamel or porcelain enamel 12, and an electrical resistor 14 is applied to the refractory coating as indicated at 14.
  • Terminal electrodes 16 are suitably soldered or otherwise attached to the resistor as shown.
  • the other surface of the sheet 10 has a coating 18 of frit, vitreous or porcelain enamel, and preferably the rear (element carrying) side is coated with a layer 20 of corrosion retardant material such as silicone enamel, melamine resin, or the like.
  • the coating 20 protects the rear surface of the panel generally and prevents corrosion of the resistor 14 which might occur from exposure to air, water or a corrosive atmosphere. Such corrosion sometimes causes 4localized high resistance which, in turn, causes localized over heating and failure of the resistor.
  • a metal backing sheet 10 is first heated uniformly to approximately 1500 F. and the vitreous layers 12 and 18 are applied, preferably by spraying from a spray gun or nozzle, while the sheet lisrnaintained at the indicated temperature.
  • the coated sheet is then carefully annealed and brought to room temperature slowly such that the coating or coatings do not spall and no warping of the element takes place. It is of prime importance that the vitreous coating be uniform in thickness, and if coatings are applied to both sides of the sheet, the thickness should be the sa'me for best results.
  • the coated sheet is then cleaned, preferably in a vaporizing oven with a vaporized solvent, ⁇ and is reheated to a uniform temperature of 550-700 F. or somewhat higher and maintained at this temperature while the resistor 14 is applied.
  • the latter may be pure aluminum or an alloy and is applied by spraying molten metal from a gun or nozzle to a thickness of .O05 inch.
  • the sheet is moved at a uniform rate past the gun which is oscillated vertically or horizontally.
  • the metallic coating 14 m-ay be sprayed through a mask to provide the grid-like path desired, but I prefer to lapply a uniform coating of metal on the porcelain then etch the grid pattern. Accordingly, a silk screen I pattern is placed on the hardened metal coating and a coating of silicone Varnish or resin is squeezed over the entire surface of the sheet. The element is then placed in an etching bath, such as a 2% nitric acid solution, for a time sufficient to etch the metal completely away in the places not covered by the enamel.
  • an etching bath such as a 2% nitric acid solution
  • the element is removed from the etching bath and dried whereupon it is complete, the silicone still adhering to the resistor pattern forming an anti-corrosive layer.
  • a border 11 of bare metal is preferably left around the margin of the sheet 10 on both sides. This uncoated border protects the coatings from being chipped at their marginal edges dur-ing handling and provides space for holes 13 which can be used to fasten the element in a frame or other support.
  • Fig. 3 shows a modification wherein the element above described is provided with an additional coating 22 on its rear side.
  • This coating 22 may be of rock wool, foam glass, fibre glass, or other suitable heat insulating material, and improves the heat radiating qualities of the element by reducing rad-iation from the rear side which is generally against or close to the mounting surface, such ias a wall or ceiling.
  • the metal base sheet 10 may be of any suitable metal or alloy such as copper, aluminum, steel, etc.
  • Stainless steel has approximately the same coecient of expansion as the vitreous enamel and therefore works very well. In general, it may be ⁇ PatentedJune7,1960

Description

June 7, 1950 B. A. NEEDHAM 2,939,807
METHOD OF MAKING A HEATING PANEL Filed June 29. 1956 /7 f TQFNIK United States O.
METHOD OFMAKING A HEATING PANEL Basil A. Needham, Bayside, N .Y., assgnor to Thermway Industries, Inc., New York, N.Y., a company of Delaware Filed June 29, 1956, ser. No.s94,s34 t 4 claims. (ci. 111-212) This invention relates to heating devices and particularly to an improved electrically energized radiant heating element and the method of making it.
An object of the invention is to provide an improved radiant heating element suitable for use in space heating panels adapted to be mounted on the walls or ceilings of buildings, in portable heaters, and 'as a heating element for water heaters, ranges, etc. My improved element is also suitable for use in industrial applications.
Another object is to provide an improved radiant heating element whichv is self supporting, has inherent rigidity, yet is rugged in construction and not easily subject to damage by mechanical or heat shock.
Still another object is to provide an improved electrical heating element wherein the resistor is fused on a self supporting backing member which may be llat or curved and wherein the resistor presents a relatively large area of heating surface.
Another object of the invention is to provide an improved electrically tenergized heating element of sheet form which includes ya metal sheet with a resistor element mounted thereon suitably insulated from the metal sheet, and which has a vitreous or porcelain enamel coating on the front surface of the sheet for diffusing the radiation thereof.
Other objects and advantages of the invention will become apparent from the following specification which describes preferred embodiments of the invention.
In the drawing accompanying the specification,
Fig. l is a rear view of my improved heating element with a portion of the protecting coating broken away to show the resistor;
Fig. 2 is 1an enlarged section taken on the line 2-2 of Fig. 1; and
Fig. 3 is a section, similar to Fig. 2, of a modified form of element.
Referring to Figs. l and 2 of the drawing, it may be seen that my improved heating element comprises a sheet which is preferably of metal but may be of other suitable material. The sheet 10 may be of any desired thickness so long as it is self supporting and substantially rigid. Generally, met-al of sufficient section to provide the desired characteristics with lightest weight is used. While the sheet 10 is shown as at and rectangular, any regular or irregular shape may be used and the sheet may be formed into a cylinder or other shape.
The sheet 10 is coated with a layer of frit, vitreous enamel or porcelain enamel 12, and an electrical resistor 14 is applied to the refractory coating as indicated at 14.
Terminal electrodes 16 are suitably soldered or otherwise attached to the resistor as shown. The other surface of the sheet 10 has a coating 18 of frit, vitreous or porcelain enamel, and preferably the rear (element carrying) side is coated with a layer 20 of corrosion retardant material such as silicone enamel, melamine resin, or the like.
The coating 20 protects the rear surface of the panel generally and prevents corrosion of the resistor 14 which might occur from exposure to air, water or a corrosive atmosphere. Such corrosion sometimes causes 4localized high resistance which, in turn, causes localized over heating and failure of the resistor.
Application of the vvitreous coating and the resistor presents some difiiculty because the element in use is subjected to rapid heating and cooling and it has been found that unless the various coatings are applied under careilly controlled conditions, chipping and spalling may result. Furthermore, unless the vitreous coatings are applied correctly warping of the element results and this is highly objectionable. Heating elements made in accordance with the method outlined herein have proven completely satisfactory.
A metal backing sheet 10 is first heated uniformly to approximately 1500 F. and the vitreous layers 12 and 18 are applied, preferably by spraying from a spray gun or nozzle, while the sheet lisrnaintained at the indicated temperature. The coated sheet is then carefully annealed and brought to room temperature slowly such that the coating or coatings do not spall and no warping of the element takes place. It is of prime importance that the vitreous coating be uniform in thickness, and if coatings are applied to both sides of the sheet, the thickness should be the sa'me for best results.
I have found that steel coated with porcelain to a uniform thickness of one-sixteenth of an inch on each surface is ideal for the heating element herein described.
The coated sheet is then cleaned, preferably in a vaporizing oven with a vaporized solvent, `and is reheated to a uniform temperature of 550-700 F. or somewhat higher and maintained at this temperature while the resistor 14 is applied. The latter may be pure aluminum or an alloy and is applied by spraying molten metal from a gun or nozzle to a thickness of .O05 inch. During application of the metal coating, the sheet is moved at a uniform rate past the gun which is oscillated vertically or horizontally.
The metallic coating 14 m-ay be sprayed through a mask to provide the grid-like path desired, but I prefer to lapply a uniform coating of metal on the porcelain then etch the grid pattern. Accordingly, a silk screen I pattern is placed on the hardened metal coating and a coating of silicone Varnish or resin is squeezed over the entire surface of the sheet. The element is then placed in an etching bath, such as a 2% nitric acid solution, for a time sufficient to etch the metal completely away in the places not covered by the enamel.
Next, the element is removed from the etching bath and dried whereupon it is complete, the silicone still adhering to the resistor pattern forming an anti-corrosive layer.
As illustrated in Fig. l, a border 11 of bare metal is preferably left around the margin of the sheet 10 on both sides. This uncoated border protects the coatings from being chipped at their marginal edges dur-ing handling and provides space for holes 13 which can be used to fasten the element in a frame or other support.
Fig. 3 shows a modification wherein the element above described is provided with an additional coating 22 on its rear side. This coating 22 may be of rock wool, foam glass, fibre glass, or other suitable heat insulating material, and improves the heat radiating qualities of the element by reducing rad-iation from the rear side which is generally against or close to the mounting surface, such ias a wall or ceiling.
In either form of the invention, the metal base sheet 10 may be of any suitable metal or alloy such as copper, aluminum, steel, etc. Stainless steel has approximately the same coecient of expansion as the vitreous enamel and therefore works very well. In general, it may be `PatentedJune7,1960
stated that the coeicients of expansion of the metal base y and the refractory coatings used should be approximately ment is heated and cooled. This requirement is, ofi
course, not so critical if it is intended to operatethe element at'fairly low temperature. For space'heating, electrically energized panels of the sheet-element type are :operated at temperatures of approximately 150" to 375 F. In industrial use, much higher temperatures are utilized.
' I claim:
1. The method of making an electrical radiant heater.
comprising, heating a metal sheet to approximately 15 00v F. and While maintaining the sheet at such temperature? applying lan insulating, hard, vitreous coating to bothv surfaces of said sheet, annealing said coated sheet, re-
heating said coated sheet to a temperature of approxi-A 4 surfaces of said sheet, annealing said coated sheet, reheating said coated sheet to a temperature of approximately 550 F. and While maintaining the coated sheet at such temperature spraying one of the coated surfaces with molten metal, then etching said metal to provide a grid-like pattern.
4. The method of claim 3k including the stepv of Y applying facoating of silicone varnish to said grid-like pattern.
References Cited in the ile of this patent UNITED STATES PATENTS 617,375 'Voigt Jan. 10, 1899 2,061,107 Schellenger Nov. 17, 1936 2,119,680 Long June 7, 1938 2,179,566 Stoekle Nov. 14, 1939 2,357,473 Jira Sept. 5, 1944 2,432,800 Reichold Dec. 16, 1947 2,441,960 Eisler May 25, 1948 2,486,148 Glynn et al. Oct. 25, 1949 2,502,291 Taylor Mar. 28, 1950 2,542,726l Sullivan Feb. 20, 1951 2,679,569 Hall May 25, 1954 2,695,351 Beck Nov. 23, 1954 2,739,085 McBride f.. Mar. 20, 1956 FOREIGN PATENTS 162,632 Australia Apr. 29,

Claims (1)

1. THE METHOD OF MAKING AN ELECTRICAL RADIANT HEATER COMPRISING, HEATING A METAL SHEET TO APPROXIMATELY 1500* F. AND WHILE MAINTIANING THE SHEET AT SUCH TEMPERATURE APPLYING AN INSULATING, HARD, VITREOUS COATING TO BOTH SURFACES OF SAID SHEET, ANNEALING SAID COATED SHEET, REHEATING SAID COATED SHEET TO A TEMPEATURE OF APPROXIMATELY 550*F. AND WHILE MAINTAINING THE COATED SHEET AT SUCH TEMPERATURE APPLYING A COATING OF METAL TO ONE COATED SURFACE THEREOF, THEN ETCHING SAID METAL COATING TO PROVIDE A GRID-LIKE PATTERN.
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Cited By (53)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3026398A (en) * 1959-04-22 1962-03-20 Gen Electric Baseboard electric heating system and electric heating units therefor
US3057989A (en) * 1958-05-23 1962-10-09 Thermway Ind Inc Curtain wall
US3067310A (en) * 1959-12-02 1962-12-04 Frank C Walz Microfilm electric heaters
US3071749A (en) * 1960-05-17 1963-01-01 Budd Co Adjustable resistors and method of making the same
US3072500A (en) * 1959-05-06 1963-01-08 Motson Services Inc Printed circuit
US3108170A (en) * 1958-02-17 1963-10-22 Maxwell K Murphy Heating element
US3109228A (en) * 1959-08-10 1963-11-05 Thermway Ind Inc Manufacture of electric radiant heating panels
US3126470A (en) * 1964-03-24 Electric water heating apparatus
US3174211A (en) * 1965-03-23 Gaszak method of manufacturing a resistance-heating type water heater
US3177338A (en) * 1962-06-29 1965-04-06 Smith Corp A O Multi-operator resistor grid welding apparatus
US3197335A (en) * 1962-04-09 1965-07-27 Stanley W Leszynski Surface-mounted electrical resistance structure and method for producing same
US3202951A (en) * 1961-08-16 1965-08-24 Krinsky Albert Alloys and electrical transducers
US3231718A (en) * 1962-02-05 1966-01-25 Akay Corp Automatic electric food warmer tray
US3243313A (en) * 1960-04-25 1966-03-29 Ling Temco Vought Inc Heat-resistant article
US3252831A (en) * 1964-05-06 1966-05-24 Electra Mfg Company Electrical resistor and method of producing the same
US3259559A (en) * 1962-08-22 1966-07-05 Day Company Method for electroless copper plating
US3343329A (en) * 1964-05-14 1967-09-26 Arthur J Pohutsky Spacer-support clip for ceiling construction
US3349722A (en) * 1964-11-27 1967-10-31 Cleveland Technical Ct Inc Electrical resistance rail heater
US3370262A (en) * 1963-05-27 1968-02-20 Sprague Electric Co Electrical resistor
US3396055A (en) * 1965-04-16 1968-08-06 Vitreous Steel Products Compan Radiant heating panels and resistive compositions for the same
US3405381A (en) * 1965-05-04 1968-10-08 Vishay Intertechnology Inc Thin film resistor
US3505498A (en) * 1968-07-23 1970-04-07 Minnesota Mining & Mfg Cooking utensil with integral dielectric layer and electrical heating element
US3517436A (en) * 1965-05-04 1970-06-30 Vishay Intertechnology Inc Precision resistor of great stability
US3694623A (en) * 1969-09-11 1972-09-26 Matsushita Electric Ind Co Ltd Surface heater for a toaster
US3751633A (en) * 1971-10-08 1973-08-07 W Green Plug-in chamber furnace
US3767895A (en) * 1971-12-01 1973-10-23 Infra Red Circuits & Controls Portable electric radiant space heating panel
US3806701A (en) * 1972-11-03 1974-04-23 Rival Manufacturing Co Electric cooking utensil having a removable vessel
US3816704A (en) * 1972-03-20 1974-06-11 Gen Electric Surface heating apparatus
US3839620A (en) * 1972-10-13 1974-10-01 R Seibel Condensation free mirror
US3869596A (en) * 1973-09-28 1975-03-04 Safeway Products Inc Cookware heater
US3883719A (en) * 1974-05-10 1975-05-13 Gen Electric Glass-ceramic cooktop with film heaters
US3887788A (en) * 1972-10-13 1975-06-03 Seibel & Seibel Enterprises Condensation free mirror
US4063068A (en) * 1976-08-12 1977-12-13 Minnesota Mining And Manufacturing Company Food heating and cooking receptacle
US4250396A (en) * 1979-09-04 1981-02-10 Walter Leuca Heated drafting board
US4294009A (en) * 1978-06-29 1981-10-13 Le Material Telephonique Method of manufacturing a hybrid integrated circuit
WO1985003402A1 (en) * 1984-01-20 1985-08-01 Vitronics Corporation Infrared panel emitter and method of producing the same
US4542268A (en) * 1980-01-28 1985-09-17 Litton Systems, Inc. Browning heater for a microwave oven
US4677801A (en) * 1984-09-13 1987-07-07 Martin Bard Wall, ceiling and/or floor formation and a method for producing it
US4682009A (en) * 1985-06-11 1987-07-21 Thermotechnik G. Bauknecht Gmbh Wall mounted combined radiactive-convective electric space heater
EP0229351A1 (en) * 1985-12-19 1987-07-22 Buchtal Gesellschaft mit beschränkter Haftung Flat ceramic element
EP0280150A1 (en) * 1987-02-17 1988-08-31 Buchtal Gesellschaft mit beschränkter Haftung Space heating element consisting of a ceramic body provided with an electrically resistant layer, especially in the form of a ceramic plate
US4833301A (en) * 1984-01-18 1989-05-23 Vitronics Corporation Multi-zone thermal process system utilizing nonfocused infrared panel emitters
US4843218A (en) * 1985-12-20 1989-06-27 Bosch-Siemens Hausgerate Gmbh Heating element for thermal heating devices, especially cooking stations
US5026970A (en) * 1988-07-29 1991-06-25 Emaco Ltd. Cooking appliances
EP0675670A2 (en) * 1994-03-28 1995-10-04 Morillo Casals, Pilar Radiant panel with improved printed circuit
US5502293A (en) * 1992-05-26 1996-03-26 Terumo Kabushiki Kaisha Heater element for a tube connecting device
US6018288A (en) * 1997-05-09 2000-01-25 Indak Manufacturing Corp. Flat resistors for automotive blower motor speed control or other service
US20050002659A1 (en) * 2001-10-09 2005-01-06 Stylianos Panaghe Radiant electric heating element
US20050167414A1 (en) * 2004-01-30 2005-08-04 Po-Chun Kuo Cooking device with a thick film resistive element heater
FR2912277A1 (en) * 2007-02-01 2008-08-08 Muller & Cie Sa Soc Electrical heating apparatus, has screen with insulator whose melting temperature is greater than melting temperature of sheath, and heating element that is in contact with rear face connected to earth when sheath is melted
US20110085783A1 (en) * 2009-10-08 2011-04-14 Mccourt Mark J Dual chimney flat panel convection air space heater
US20130014772A1 (en) * 2011-07-12 2013-01-17 Qiuming Liu Electric flue-cured tobacco
US20170284701A1 (en) * 2016-03-31 2017-10-05 Gd Midea Environment Appliances Mfg Co., Ltd. Electric radiator

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Cited By (59)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3126470A (en) * 1964-03-24 Electric water heating apparatus
US3174211A (en) * 1965-03-23 Gaszak method of manufacturing a resistance-heating type water heater
US3108170A (en) * 1958-02-17 1963-10-22 Maxwell K Murphy Heating element
US3057989A (en) * 1958-05-23 1962-10-09 Thermway Ind Inc Curtain wall
US3026398A (en) * 1959-04-22 1962-03-20 Gen Electric Baseboard electric heating system and electric heating units therefor
US3072500A (en) * 1959-05-06 1963-01-08 Motson Services Inc Printed circuit
US3109228A (en) * 1959-08-10 1963-11-05 Thermway Ind Inc Manufacture of electric radiant heating panels
US3067310A (en) * 1959-12-02 1962-12-04 Frank C Walz Microfilm electric heaters
US3243313A (en) * 1960-04-25 1966-03-29 Ling Temco Vought Inc Heat-resistant article
US3071749A (en) * 1960-05-17 1963-01-01 Budd Co Adjustable resistors and method of making the same
US3202951A (en) * 1961-08-16 1965-08-24 Krinsky Albert Alloys and electrical transducers
US3231718A (en) * 1962-02-05 1966-01-25 Akay Corp Automatic electric food warmer tray
US3197335A (en) * 1962-04-09 1965-07-27 Stanley W Leszynski Surface-mounted electrical resistance structure and method for producing same
US3177338A (en) * 1962-06-29 1965-04-06 Smith Corp A O Multi-operator resistor grid welding apparatus
US3259559A (en) * 1962-08-22 1966-07-05 Day Company Method for electroless copper plating
US3370262A (en) * 1963-05-27 1968-02-20 Sprague Electric Co Electrical resistor
US3252831A (en) * 1964-05-06 1966-05-24 Electra Mfg Company Electrical resistor and method of producing the same
US3343329A (en) * 1964-05-14 1967-09-26 Arthur J Pohutsky Spacer-support clip for ceiling construction
US3349722A (en) * 1964-11-27 1967-10-31 Cleveland Technical Ct Inc Electrical resistance rail heater
US3396055A (en) * 1965-04-16 1968-08-06 Vitreous Steel Products Compan Radiant heating panels and resistive compositions for the same
US3405381A (en) * 1965-05-04 1968-10-08 Vishay Intertechnology Inc Thin film resistor
US3517436A (en) * 1965-05-04 1970-06-30 Vishay Intertechnology Inc Precision resistor of great stability
US3505498A (en) * 1968-07-23 1970-04-07 Minnesota Mining & Mfg Cooking utensil with integral dielectric layer and electrical heating element
US3694623A (en) * 1969-09-11 1972-09-26 Matsushita Electric Ind Co Ltd Surface heater for a toaster
US3751633A (en) * 1971-10-08 1973-08-07 W Green Plug-in chamber furnace
US3767895A (en) * 1971-12-01 1973-10-23 Infra Red Circuits & Controls Portable electric radiant space heating panel
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