Abstract: A heater assembly includes a heating element assembly having a resistive heating element connected to a housing member. First and second guide members are oppositely and outwardly positioned with respect to the heating element assembly and extend away from the housing member. A patch plate includes an installation aperture and first and second wings extending away from the patch plate. The first and second guide members are positioned to individually slidingly engage with one of the first and second wings thereby defining a track system to permit the heating element assembly to be slidingly received through the installation aperture without contact between the resistive heating element and the patch plate.

Abstract: A heater assembly includes a heating element assembly having a resistive heating element connected to a housing member. First and second guide members are oppositely and outwardly positioned with respect to the heating element assembly and extend away from the housing member. A patch plate includes an installation aperture and first and second wings extending away from the patch plate. The first and second guide members are positioned to individually slidingly engage with one of the first and second wings thereby defining a track system to permit the heating element assembly to be slidingly received through the installation aperture without contact between the resistive heating element and the patch plate.

Abstract: A resistive heating element for a resistance heater includes a first heating section and a second heating section. The first and second heating sections are configured to jointly generate a power output that is equal to that generated by a single reference resistive element under a same applied voltage. The single reference resistive element has a reference length, a reference mass, and a reference surface area. The first and second heating sections are configured to transfer an amount of heat at least equal to that transferred by the single reference resistive element. A total mass of the first heating section and the second heating section is less than a reference mass of the single reference resistive wire.

Abstract: The present invention provides a heating coil assembly having metal bracket, a support rail, a heating coil, and a plurality of insulating supports. The metal bracket is attached to a terminal block and the support rail. The heating coil is electrically connected to the terminal block. Each insulating support has a hole to receive the support rail. Each insulating support further has a rigid body and a plurality of slots. Each slot is capable of receiving a portion of a coil turn of the heating coil. Each slot has a generally flat bottom and two inwardly projecting sidewalls. Each inwardly projecting sidewall is defined by a hook edge and ramp edge. The present invention further includes a method of assembling such heating coil assembly.

Abstract: The present invention provides a heating coil assembly having metal bracket, a support rail, a heating coil, and a plurality of insulating supports. The metal bracket is attached to a terminal block and the support rail. The heating coil is electrically connected to the terminal block. Each insulating support has a hole to receive the support rail. Each insulating support further has a rigid body and a plurality of slots. Each slot is capable of receiving a portion of a coil turn of the heating coil. Each slot has a generally flat bottom and two inwardly projecting sidewalls. Each inwardly projecting sidewall is defined by a hook edge and ramp edge. The present invention further includes a method of assembling such heating coil assembly.

Abstract: An electrical resistance heater (12) has an elongate electrical heating coil (C) with a plurality of convolutions (C1, C2). An electrical insulator (10) supports the convolutions and includes an insulator body (18) mountable to a support frame (19). A generally circular projection (20) extends from one side of the body and is integrally formed therewith. A generally arcuate section (26, 28) of the projection, on opposite sides of the projection, is spaced from an adjacent surface (30, 32) of the body. A notch (34, 36) is formed by the respective surfaces of the body and the projection for respective coil convolutions (C1, C2) to be received in the respective notches. The upper end (42, 44) of the faces (38, 40) of the projection are tapered outwardly from the top of the projection to facilitate coil installation. A shoulder (30s, 32s) formed on the insulator body adjacent each notch helps retain the coil convolutions in the notches.