A clip for connecting one or two insulators to a rail (preferably a T-bar member) of an electric heater including a main body, a means for securing an insulator to the main body, and at least one bendable metal clinching member extending from the main body, where the clip is securable to the rail by bending the clinching member around the rail. Preferably, the clinching member is one or two T-shaped end members disposed on transverse ends of the main body. Opposite end sections of the ridge of the T-shaped end member constitute clinching flaps which, in use, are clinched around a stem of a T-bar of an electric heater. The clip is not welded to the T-bar.

Support clips and insulators for use in electric heaters and electric heaters containing same

There is disclosed an electrically resistance insulator for use in supporting a helical heater coil at seven locations on the coil. The insulator is supported from a support structure and has a pair of arms that extend from the base for supporting the heater coil. The arms have an intermediate slot and two inwardly extending notches at the bottom of the arms. The notches and the intermediate slot support three consecutive convolutions of the coil relative to the insulator at one axial side of the coil. The arms of the insulator further have shoulders which provide a widened slot area and defined lug portions at the upper parts of the arms. The width of the lug portions taper outwardly to permit for two adjacent convolutions of the heater coil to be supported on opposing sides of each of the lug portions. Since two lug portions are provided, one for each arm, the heater coil is supported at four locations consecutive coil convolutions by the lug portions of the insulator. The lug portions extend beyond the shoulder to support the four coil convolutions at convolutions diametrically opposed and interleaved with the three consecutive coil convolutions of the one axial side of the coil. The heater coil is held in place reducing bowing of the heater coil above the insulator.

Electrical resistance heater insulator

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.

Heating coil assembly and methods for assembling the same

An insulating support structure for a helical wire heating coil for an electric resistance heating element includes a plurality of insulating standoff members supported by a metallic support frame. The insulating standoffs each include a pair of wedge portions that are used to separate the individual convolutions of the helical wire heating coil. Located inwardly from each of the wedge portions are a pair of V-shaped coil grooves sized to receive a portion of an individual convolution of the helical wire heating coil. A retainer tab extends into and forms one surface of the coil groove such that the wire heating coil contacts the retainer tab and a pair of contact surfaces that define the coil groove. The insulating standoffs are each supported by an arm contained on the support frame. Each of the arms includes a pair of tines which combine to form an open slot within the arm. The insulating standoff is captured between the tines by a pair of locking projections on the outer end of the tines. The tines are positioned within a pair of recessed attachment slots in the standoff such that the standoff is securely held between the tines. The support frame is preferably stamped from sheet metal and is adapted to receive the standoffs using automated assembly techniques.

Heat coil support assembly and method

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.

Support apparatus for resistive coils and insulators in electric heaters

An open coil electric heater is disclosed having an open frame and an exposed, open heating coil of suitable resistance heating wire The coil is supported on the frame by so-called "point suspension" electrical insulators The insulators have a pair of apertures or holes therethrough for receiving a pair of spaced arms of a wire mounting clip The wire clip arms are crimped or are otherwise deformed adjacent the insulator so as to hold the insulator axially in place on the clip The clip is welded to the frame

Insulator Support Clip, Insulator and Assembly

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Insulator Support Clip, Insulator and Assembly