Air intake heater with flanged heating element

1. An air heater for heating air entering a combustion chamber of an internal combustion engine, the air heater comprising:

a heating element having a substantially planar portion and a flange portion, said flange portion being positioned at an angle to said planar portion, said planar portion being positioned within an air flow at an upstream location relative to said flange portion; and

a structure to position said heating element in communication with the air entering the combustion chamber of the engine, wherein said heating element includes a plurality of 180 degree bends and a plurality of planar portions positioned between said bends, said heating element further including a plurality of flange portions positioned adjacent said plurality of planar portions, wherein said planar portions are spaced apart from and positioned substantially parallel to one another.

2. The air heater of claim 1 wherein said flange portion is substantially planar.

3. The air heater of claim 2 wherein said heating element includes a plurality of 180 degree bends and a plurality of planar portions positioned between said bends, said heating element further including a plurality of flange portions positioned adjacent said plurality of planar portions, wherein said planar portions are spaced apart from and positioned substantially parallel to one another.

4. The air heater of claim 1 wherein said flange portions are spaced apart from and positioned substantially parallel to one another.

5. The air heater of claim 1 wherein said heating element is a one-piece monolithic component having said flange portion integrally formed with said planar portion.

6. The air heater of claim 5 wherein said flange portion extends less than a full length of said planar portion and includes a body interconnected at its ends to said planar portion by end portions extending at an angle from said planar portions.

7. The air heater of claim 5 further including another heating element spaced apart from said heating element, said another heating element having a flange portion and a planar portion, said planar portion of said heating element and said planar portion of said another heating element being positioned substantially parallel to one another.

8. The air heater of claim 3 wherein said structure includes first and second spaced apart holders supporting said heating element therebetween.

9. The air heater of claim 8 wherein said structure includes insulators being retained by said first and second holders, said insulators including pockets in receipt of said heating element bends.

10. An air heater for heating air entering a combustion chamber of an internal combustion engine, the air heater comprising:

a one-piece heating element positioned within an air flow, said heating element having a substantially planar portion and an upset portion, said upset portion extending at an angle to said planar portion along a trailing edge of said heating element; and

a structure coupled to said heating element, said structure being operable to maintain the position of said heating element in communication with the air entering the combustion chamber of the engine wherein said structure includes a plate adapted to be positioned between an engine head and an intake tube of the engine, said plate including a stanchion and a fastener attaching said heating element to said stanchion, wherein said fastener and stanchion are configured to allow relative movement therebetween when said heating element increases in length as a temperature of said heating element increases.

11. The air heater of claim 10 wherein said structure includes a plate adapted to be positioned between an engine head and an intake tube of the engine.

12. The air heater of claim 11 wherein said plate includes a stanchion and a fastener attaching said heating element to said stanchion.

13. The air heater of claim 12 wherein said fastener and stanchion are configured to allow relative movement therebetween when said heating element increases in length as a temperature of said heating element increases.

14. The air heater of claim 13 wherein said stanchion includes a slot in receipt of said fastener.

15. The air heater of claim 10 wherein said heating element includes a plurality of 180 degree bends and a plurality of planar portions positioned between said bends, said heating element further including a plurality of upset portions positioned adjacent said plurality of planar portions, wherein said planar portions are spaced apart from and positioned substantially parallel to one another.

16. The air heater of claim 15 wherein said structure includes first and second spaced apart holders supporting said heating element therebetween.

17. The air heater of claim 16 wherein said structure includes insulators being retained by said first and second holders, said insulators including pockets in receipt of said heating element bends.

18. The air heater of claim 10 wherein said upset portion is substantially planar.

19. The air heater of claim 10 wherein said upset portion is positioned to change the direction of air flow across the heating element.

20. The air heater of claim 19 wherein said upset portion increases a thermal distribution of heat generated by said heating element.