Abstract: A heating element includes first and second terminals and one or more heating element segments extending between the first and second terminals. The one or more heating element segments have a circuit trace that includes at least first and second portions, the at least first and second portions configured so that a surface temperature difference exists between the at least first and second portions when a voltage is applied between the at least first and second terminals. The heating element can also be made with a three dimensional shape, including one that is generated by fastening of the heating element to one or more support plates. The heating element can also have a cylindrical shape and be disposed in an insulating medium in a tubular member to provide varied heating capability along the tubular member length.

Abstract: A support insulator for an open coil electric heater includes an insulator body having at least one coil support portion and plate attachment slots. The support insulator has an arm extending from the insulator body, the arm having a slot on an end thereof. Depending on the mounting of the support insulator, the slot can receive a resistance wire as a portion of a coil break-turn, a wire as part of a coil section, a part of a lead wire, or a part of a run of resistance wire that is not a coil break-turn or coil section.

Abstract: A foldable electric resistance heater comprises at least a pair of insulator plates with a resistance wire threaded through openings in the insulator plates. In one mode, the insulator plates are folded with respect to each other and fastened together using one or more fasteners. In another mode, the plates can have other angled configurations with respect to each other. One or more insulators is positioned between the folded plates or adjacent the plates to isolate the resistance wire. The folded plate configuration and resistance wire provide significant advantages in manufacturing costs while forming a more robust heater configuration.

Abstract: A one-piece heater rack includes a number of arrays of attachment nodes and a surrounding peripheral structure. The attachment nodes are configured to allow the attachment of ceramic supports, the ceramic supports designed to hold open type coil electrical resistance heating elements that make up of a heater assembly using the heater rack. The attachment nodes allow attachment of the ceramic supports from above and below the heater rack for ease of installation. The heater rack also includes other features that providing mounting support for other heater assembly elements like terminals, thermostats, temperature limit switches, and air flow control over and through the heater using the peripheral structure, the arrays of attachment nodes or combinations thereof.

Abstract: A support insulator for an open coil electric heater includes an insulator body having at least one coil support portion and plate attachment slots. The support insulator has an arm extending from the insulator body, the arm having a slot on an end thereof. Depending on the mounting of the support insulator, the slot can receive a resistance wire as a portion of a coil break-turn, a wire as part of a coil section, a part of a lead wire, or a part of a run of resistance wire that is not a coil break-turn or coil section.

Abstract: An electric belly band heater is configured with only one end of the heater cable assembly thereof having lead wires extending therefrom. A single housing box is positioned at the end of the heater cable assembly where the lead wires exit to encompass the lead wires and includes an opening to receive a conduit to provide further protection to the lead wires exiting the housing box and being connected to a power source.

Abstract: A duct heater has a unique and symmetric arrangement of an auto limit and a pair of back up limits to permit the duct heater to be mounted in a duct in a number of different orientations. The duct heater can include a diffuser screen and have a particular size with respect to an upstream piece of equipment such as a single duct variable air volume damper box so that it can be used in these types of applications as well as stand alone applications in a duct.

Abstract: A silicone band heater assembly includes a silicone heater cable, lead wires, and a zip tie connection. The heater cable consists of a resistance heater wire that is optionally surrounded by a fiberglass braid, which in turn is encased in a silicone insulator. Each end of the heater cable includes an overmolded zip tie segment, which includes the splice connection between the lead wire and resistance wire, and the ability to link the ends of the heater cable assembly together when being clamped to a desired structure.

Abstract: An electrical resistance heating assembly comprises a heater ribbon woven through a first mica board. The heater ribbon extends upwardly from a top surface of the first mica board to provide heat to a fluid passing over the upwardly extending heater ribbon. The heat ribbon on an underside of the first mica board is electrically isolated by a second mica board positioned adjacent the first mica board. The first and second mica boards are held together with by a clamp-containing metal place positioned adjacent the second mica board with the clamps bent over the first mica board to keep the mica boards together.

Abstract: An open coil electrical resistance heater subassembly for use in a heater has a support plate dividing the heater into at least two portions. At least two resistance wire coils are supported on the support plate using a plurality of insulators. Each insulator is configured to provide support to a portion of the resistance wire coil. The at least two resistance wire coils are arranged with respect to the support plate so that the coil power for each coil is distributed generally evenly between the top and bottom of the support plate and across the width of the support plate.

Abstract: An electric belly band heater is configured with only one end of the heater cable assembly thereof having lead wires extending therefrom. A single housing box is positioned at the end of the heater cable assembly where the lead wires exit to encompass the lead wires and includes an opening to receive a conduit to provide further protection to the lead wires exiting the housing box and being connected to a power source.

Abstract: An open coil electrical resistance heater employs an insulator having a coil convolution engaging portion that is adapted to engage heater coils with small diameters, small wire diameters, and/or small pitches without distorting the coil and compromising heater performance.

Abstract: A silicone band heater assembly includes a silicone heater cable, lead wires, and a zip tie connection. The heater cable consists of a resistance heater wire that is optionally surrounded by a fiberglass braid, which in turn is encased in a silicone insulator. Each end of the heater cable includes an overmolded zip tie segment, which includes the splice connection between the lead wire and resistance wire, and the ability to link the ends of the heater cable assembly together when being clamped to a desired structure.

Abstract: A close quarter electric resistance heater comprises a ribbon heater element that is woven between ribbon support segments and within a heater shell. The ribbon support segments form an annulus on each end of the heater and are linked to each other using connectors. The connectors space the ribbon support segments apart from each other to facilitate the weaving of the ribbon element along the inside of the heater shell for heating purposes. The connectors also link the ribbon support segments to the shell. The ribbon heater element has faces that are wider than its edges and the ribbon heater element is woven on the support segments such that the edges face the heater shell. This configuration minimizes the migration of the ribbon heater element towards the shell and possible short circuiting of the heater.

Abstract: A duct heater has a unique and symmetric arrangement of an auto limit and a pair of back up limits to permit the duct heater to be mounted in a duct in a number of different orientations. The duct heater can include a diffuser screen and have a particular size with respect to an upstream piece of equipment such as a single duct variable air volume damper box so that it can be used in these types of applications as well as stand alone applications in a duct.

Abstract: An open coil electrical resistance heater employs an insulator having a coil convolution engaging portion that is adapted to engage heater coils with small diameters, small wire diameters, and/or small pitches without distorting the coil and compromising heater performance.

Abstract: An open coil electrical resistance heater subassembly for use in a heater has a support plate dividing the heater into at least two portions. At least two resistance wire coils are supported on the support plate using a plurality of insulators. Each insulator is configured to provide support to a portion of the resistance wire coil. The at least two resistance wire coils are arranged with respect to the support plate so that the coil power for each coil is distributed generally evenly between the top and bottom of the support plate and across the width of the support plate.

Abstract: A mica board heater has a mica board support plate assembly that isolates the mica boards from the frame of the heater. The mica board support plate assembly includes a mica board with openings sized to receive ends of the mica boards that support the resistance wires. The mica board with the specially sized openings is supported by a frame that is attached to the heater frame. By using the mica board support plate assembly, the mica boards are electrically isolated from the frame and without compromising the structural soundness of the frame.

Abstract: An electrical resistance heating assembly comprises a heater ribbon woven through a first mica board. The heater ribbon extends upwardly from a top surface of the first mica board to provide heat to a fluid passing over the upwardly extending heater ribbon. The heat ribbon on an underside of the first mica board is electrically isolated by a second mica board positioned adjacent the first mica board. The first and second mica boards are held together with by a clamp-containing metal place positioned adjacent the second mica board with the clamps bent over the first mica board to keep the mica boards together.

Abstract: A multiple stage open coil electrical resistance heater uses a unique coil configuration on either side of a dividing support plate so that the air passing through the heater is heated uniformly when one or more stages of the heater are energized. The coil configuration also creates a termination zone on one side of the heater so that the terminations of the coils can be situated on the cool side of the heater. The heater coils also includes specially configured terminals to facilitate connection to power using an elongated member such as a stud or bolt.