Abstract: A heater having a frame rail and clips, attached to the rail, for securing insulators for supporting a heater coil. Each clip has a main body having a structural member for securing to the rail, and having a pair of flanges symmetrical about a central axis. Each flange has a cut-out for supporting an insulator, the cut-out having an open end, a back abutment edge and a pair of side abutment edges. A bendable tab is located at either side of the open end, each having a first and a second position. In the first position an insulator is insertable into the cut-out, and the insulator is secured by bending the tabs to their second position. Optionally the main body has a cross-section that accommodates the cross section of the rail and the rail is welded to the channel. Alternatively, a plurality of clinching flaps extend from the main body, the flaps shaped and dimensioned for bending around and clinching the rail.

Abstract: A conductive metal jumper strap has a plate portion with a pair of connection legs forming a u-shape. The connection legs are adapted to connect to terminals to make an electrical connection between two components of a heating device. The plate portion has a bend in it to allow flexing so that the connection legs can make a jumper connection between terminals where the terminal spacing may vary between heating devices.

Abstract: A heater having an insulating terminal mounting block, a thermostat and a terminal bushing mounted to a frame. The insulating terminal mounting block supports a plurality of removable terminal members. Each terminal member has a crimping structure at one end and a connection structure at its other end. A temperature sensitive fuse is crimped within the crimping structure of a first and a second of the terminal connection members. A unitary jumper strap connects between the connection structure of the second and a third of the terminal members. A fourth terminal member is supported by the terminal bushing. A second unitary jumper strap connects between the connection structure of the fourth terminal member and a terminal of the thermostat. One terminal of a resistive heating wire is crimped within the crimping structure of one of the terminal connection members supported by the terminal mounting block.

Abstract: A heater having a frame rail and clips, attached to the rail, for securing insulators for supporting a heater coil. Each clip has a main body having a structural member for securing to the rail, and having a pair of flanges symmetrical about a central axis. Each flange has a cut-out for supporting an insulator, the cut-out having an open end, a back abutment edge and a pair of side abutment edges. A bendable tab is located at either side of the open end, each having a first and a second position. In the first position an insulator is insertable into the cut-out, and the insulator is secured by bending the tabs to their second position. Optionally the main body has a cross-section that accommodates the cross section of the rail and the rail is welded to the channel. Alternatively, a plurality of clinching flaps extend from the main body, the flaps shaped and dimensioned for bending around and clinching the rail.

Abstract: A heater assembly includes a mounting structure, a securement structure, an insulator support structure, a conducting structure having a first portion and a second portion, a terminal structure, and a thermostat structure. The securement structure cooperates with the insulator support structure and the mounting structure to releasably and fixedly secure the insulator support structure to the mounting structure. The terminal structure is coupled to the first portion of the conducting structure, and is used to deliver power to the conducting structure. The thermostat structure is coupled to the second portion of the conducting structure. The insulator support structure is configured to cooperate with both the terminal structure and the thermostat structure to fixedly support the terminal structure or the thermostat structure in position.

Abstract: A heater assembly includes a mounting assembly, a conducting structure, a thermostat structure, a first terminal structure and a second terminal structure, and an insulator support structure including a terminal receiving opening formed therethrough. The conducting structure and the insulator support structure are releasably and fixedly secured to the mounting assembly. The terminal receiving opening of the insulator support structure cooperates with the first terminal structure to secure the first terminal structure to the mounting assembly. The second terminal structure is releasably and fixedly secured to the mounting assembly. The thermostat structure is connected to the first terminal structure and to the second terminal structure. The first terminal structure is then connected to a power delivering structure to receive power to be used by the heater assembly, and to deliver power, through the thermostat structure, to the conducting structure.

Abstract: A heater having a frame rail and clips, attached to the rail, for securing insulators for supporting a heater coil. Each clip has a main body having a structural member for securing to the rail, and having a pair of flanges symmetrical about a central axis. Each flange has a cut-out for supporting an insulator, the cut-out having an open end, a back abutment edge and a pair of side abutment edges. A bendable tab is located at either side of the open end, each having a first and a second position. In the first position an insulator is insertable into the cut-out, and the insulator is secured by bending the tabs to their second position. Optionally the main body has a cross-section that accommodates the cross section of the rail and the rail is welded to the channel. Alternatively, a plurality of clinching flaps extend from the main body, the flaps shaped and dimensioned for bending around and clinching the rail.

Abstract: A heater having an insulating terminal mounting block, a thermostat and a terminal bushing mounted to a frame. The insulating terminal mounting block supports a plurality of removable terminal members. Each terminal member has a crimping structure at one end and a connection structure at its other end. A temperature sensitive fuse is crimped within the crimping structure of a first and a second of the terminal connection members. A unitary jumper strap connects between the connection structure of the second and a third of the terminal members. A fourth terminal member is supported by the terminal bushing. A second unitary jumper strap connects between the connection structure of the fourth terminal member and a terminal of the thermostat. One terminal of a resistive heating wire is crimped within the crimping structure of one of the terminal connection members supported by the terminal mounting block.

Abstract: A heater assembly includes a mounting structure, a securement structure, an insulator support structure, a conducting structure having a first portion and a second portion, a terminal structure, and a thermostat structure. The securement structure cooperates with the insulator support structure and the mounting structure to releasably and fixedly secure the insulator support structure to the mounting structure. The terminal structure is coupled to the first portion of the conducting structure, and is used to deliver power to the conducting structure. The thermostat structure is coupled to the second portion of the conducting structure. The insulator support structure is configured to cooperate with both the terminal structure and the thermostat structure to fixedly support the terminal structure or the thermostat structure in position.

Abstract: A heater having an insulating terminal mounting block, a thermostat and a terminal bushing mounted to a frame. The insulating terminal mounting block supports a plurality of removable terminal members. Each terminal member has a crimping structure at one end and a connection structure at its other end. A temperature sensitive fuse is crimped within the crimping structure of a first and a second of the terminal connection members. A unitary jumper strap connects between the connection structure of the second and a third of the terminal members. A fourth terminal member is supported by the terminal bushing. A second unitary jumper strap connects between the connection structure of the fourth terminal member and a terminal of the thermostat. One terminal of a resistive heating wire is crimped within the crimping structure of one of the terminal connection members supported by the terminal mounting block.

Abstract: A heater having a frame rail and clips, attached to the rail, for securing insulators for supporting a heater coil. Each clip has a main body having a structural member for securing to the rail, and having a pair of flanges symmetrical about a central axis. Each flange has a cut-out for supporting an insulator, the cut-out having an open end, a back abutment edge and a pair of side abutment edges. A bendable tab is located at either side of the open end, each having a first and a second position. In the first position an insulator is insertable into the cut-out, and the insulator is secured by bending the tabs to their second position. Optionally the main body has a cross-section that accommodates the cross section of the rail and the rail is welded to the channel. Alternatively, a plurality of clinching flaps extend from the main body, the flaps shaped and dimensioned for bending around and clinching the rail.

Abstract: An electric multi-stage heater assembly that provides multi-level heating using a plurality of separately controllable heating elements within a housing that is readily interchangeable with standard single-stage heater housings that can be controlled by conventional power switching circuits. The multi-stage heater assembly of this invention has each electric heater element straddling a support member with a portion of the heater element extending from one side to the other to maintain the electrical continuity of the element. The support member has a plurality of cut-outs that provide space for routing the cross over portion of the heater element and sufficient clearance to accommodate the inevitable droop associated with heat cycling electric resistive heater elements. The support member is equipped with a plurality of insulators which support and electrically insulate the heater element. The insulators are arranged to cooperatively rotate within the support member to minimize sagging of the heater elements.

Abstract: An electric heater support and mounting assembly is described for reducing or substantially eliminating noise resulting from the vibration in the heating element. The support and mounting assembly comprises a housing having a plurality of unique openings for receiving a plurality of arms extending from a support plate. The openings firmly engage the arms so as to prevent rattling while enabling the arms to move within the opening to accommodate thermal expansion of the support plate.

Abstract: A terminal assembly is provided which is easy to assemble and disassemble. The assembly features male and female ceramic elements that interconnect and provide a passageway into which a terminal equipped with forward and rearward tabs is placed. After the terminal is positioned in the passageway, the forward tabs may be bent into a position at an angle to the terminal, thereby securing the terminal in place and holding the terminal assembly together. The male ceramic element is provided with a unique annular depression that reduces the amount of ceramic materials needed to make the assembly, while also providing the minimum surface spacing required by industry standards. In addition, the terminal assembly is provided with a v-shaped attachment element for conveniently attaching the assembly to a lead wire.

Abstract: An electric heater includes an electric heating coil that extends above the sidewalls of an air flow channel. The coil is formed in sections that extend transversely to the channel and are spaced by the width of a coil section to allow two heaters to be arranged face to face for shipping. This arrangement is very efficient because one of the heaters provides protection to the coil of the other of the heaters to reduce packaging costs.

Abstract: An heater includes an electric heating coil that extends above the sidewalls of an air flow channel. The coil is formed in sections that extend transversely to the channel and are spaced by the width of a coil section to allow two heaters to be arranged face to face for shipping. This arrangement is very efficient because one of the heaters provides protection to the coil of the other of the heaters to reduce packaging costs.

Abstract: A duct heater includes end brackets by frame bars. The end brackets are formed into a geometric shape whereby only corners of the bracket engage an inner suface of the duct. Assembly is facilitated by providing the end bracket as thin, flat strips having narrower and wider sections. The frame bars are attached to the wider sections, and when the strips are bent to form a closed geometric form, the thinner sections are curved to form duct-engaging corners while the wider sections remain substantially straight. Insulating supports are attached to the frame bars, and a heater coil is attached to the insulating supports. The structure may be easily slid into a duct because only the corners of the end brackets contact the duct. Thus, a method for forming the heater brackets and attaching heater elements is set forth.

Abstract: An electric heater incorporating simple support structure therefor. A frame is insulated from an electric resistance heater coil by insulator supports mounted within beam members of the frame. The supports incorporate structural features enabling the use of simplified supporting beams. The support insulators include additional structural features for retaining the resistance wire in place and for simplified engagement therewith. The insulators may project on both sides of the support beams and retain heater wires in two planes. The support insulators further provide an integrated structure easily fabricated and simply assembled to the frame.

Abstract: An insulator for an electric heater employs a central elongated slot and two guide surfaces. Below each guide surface is a notch for receiving an outer convolution of a heater coil, while the central slot terminates in a notch for receiving an intermediate convolution of the heater coil. The slot engages the central convolution of the heater coil before outer convolutions engage the guide surfaces to facilitate installation of the insulator. As the insulator is inserted into the heater coil, the guide surfaces engage the outer convolutions and direct them to respective notches for securely holding the heater coil. The insulator may support a single pass of the heater coil or may be arranged to have these surfaces and notches on opposite ends to support two passes of the heater coil.

Abstract: A duct heater includes end brackets connected by frame bars. The end brackets are formed into a geometric shape whereby only corners of the bracket engage an inner surface of the duct. Assembly is facilitated by providing the end brackets as thin, flat strips having narrower and wider sections. The frame bars are attached to the wider sections, and when the strips are bent to form a closed geometric form, the thinner sections are curved to form duct-engaging corners while the wider sections remain substantially straight. Insulating supports are attached to the frame bars, and a heater coil is attached to the insulating supports. The structure may be easily slid into a duct because only the corners of the end brackets contact the duct.