Covered conductor and heater formed therewith

1. A heater comprising:

a substrate substantially configured as a panel; and

a conductor patterned over at least one surface of the substrate, the conductor including:

i) a conductive element; and

ii) a covering substantially surrounding the conductive element and having a substantially uniform thickness between about 0.001 inches and about 0.1 inches, at least a portion of the covering being activatable upon exposure to heat;

wherein the covering is integrated into the substrate for attaching the conductor to the substrate and conductive element is capable of emitting an amount of heat sufficient to activate the covering.

2. The heater of claim 1 wherein the conductive element includes multiple metal strands.

3. The heater of claim 2 wherein the multiple metal strands at least partially surround an insert.

4. The heater of claim 1 wherein the covering is a polymeric material that coats the conductive element.

5. The heater of claim 1 wherein the substrate is formed of a flexible material.

6. The heater of claim 5 wherein the substrate is formed of a fabric material selected from the group consisting of fleece, gauze and felt.

7. The heater of claim 1 wherein the thickness is between about 0.005 inches and about 0.05 inches.

8. A heater comprising:

a substrate substantially configured as a panel wherein the substrate is formed of a flexible material; and

a conductor patterned over at least one surface of the substrate, the conductor including:

i) a conductive element; and

ii) a covering substantially surrounding the conductive element, the covering having an inner portion and an outer portion, the inner portion having a melting point between about 80° C. and about 400° C., the outer portion having a melting point between about 40° C. and about 275° C.;

wherein the covering is integrated into the substrate for attaching the conductor to the substrate.

9. The heater of claim 8 wherein the conductive element includes multiple metal strands.

10. The heater of claim 9 wherein the multiple metal strands at least partially surround an insert.

11. The heater of claim 8 wherein the conductive element is capable of emitting an amount of heat sufficient to soften the outer portion of the covering.

12. The heater of claim 8 wherein the covering includes a polymeric material that coats the conductive element.

13. The heater of claim 8 wherein the substrate is formed of a fabric material selected from the group consisting of fleece, gauze and felt.

14. The heater of claim 8 wherein the inner portion of covering has a substantially uniform thickness and the uniform thickness is between about 0.001 inches and about 0.1 inches.

15. The heater of claim 14 wherein the thickness is between about 0.005 inches and about 0.05 inches.

16. A heater comprising:

a substrate substantially configured as a panel, the substrate being formed of a flexible fabric material; and

a conductor patterned over at least one surface of the substrate, the conductor including:

i) a conductive element formed of a metal material and configured to emit heat; and

ii) a covering substantially surrounding the conductive element, the covering having an inner portion and an outer portion, the inner portion having a melting point between about 170° C. and about 275° C., the outer portion having a melting point between about 110° C. and about 160° C.;

wherein the conductive element is capable of emitting sufficient heat to raise a temperature of the outer portion of the covering to the melting point of the outer portion: and

wherein the covering is integrated into the substrate for attaching the conductor to the substrate.

17. The heater of claim 16 wherein the outer portion and the inner portion of the covering are formed of a polymeric material.

18. The heater of claim 17 wherein the polymeric material of the outer portion includes a polymeric material selected from the group consisting of PTFE, PVC, polypropylene, HDPE, LDPE, chlorinated polyethylene and fluorinated polyethylene.

19. The heater of claim 1 wherein the covering comprises an extruded covering.

20. The heater of claim 8 wherein the covering comprises an extruded covering.

21. The heater of claim 12 wherein the polymeric material includes PTFE.

22. The heater of claim 12 wherein the polymeric material includes PVC.

23. The heater of claim 12 wherein the polymeric material includes polypropylene.

24. The heater of claim 12 wherein the polymeric material includes HDPE.

25. The heater of claim 12 wherein the polymeric material includes LDPE.

26. The heater of claim 12 wherein the polymeric material includes chlorinated polyethylene.

27. The heater of claim 12 wherein the polymeric material includes fluorinated polyethylene.