Open coil electric resistance heater with offset coil support and method of use

1. An open coil electrical resistance heater comprising:

a support,

at least one resistance wire coil having a longitudinal axis, and

a plurality of first insulators mounted to the support along a defined path, with a plurality of second insulators mounted to the support in a position offset from the defined path, each of the first and second insulators configured to provide support to a portion of the resistance wire coil along the defined path,

wherein the offset second insulators along with the first insulators on the defined path cause at least a portion of the longitudinal axis of the at least one resistance wire coil to follow a sinusoidal shape, the resistance wire coil with its sinusoidal shape being generally aligned with an air flow path of the heater.

2. The heater of claim 1 , wherein the support is a metal plate having a plurality of cutouts, each insulator engaging one of the cutouts for mounting, and a portion of the cutouts are offset from other cutouts on the path to create the offset between the plurality of first and second insulators.

3. The heater of claim 1 , wherein the insulators form sets of paths having a sinusoidal shaped resistance wire coil running along each path.

4. The heater of claim 1 , wherein the insulators are configured to support a resistance wire coil on each side of the support.

5. The heater of claim 3 , wherein the support is a metal plate having a plurality of cutouts, each insulator engaging one of the cutouts for mounting, and a portion of the cutouts are offset from other cutouts on the path to create the offset for the plurality of first and second insulators.

6. The heater of claim 5 , wherein the insulators are configured to support the resistance wire coil on each side of the support.

7. The heater of claim 1 , further comprising a circular duct surrounding and supporting the support.

8. The heater of claim 2 , wherein tension forces created by the sinusoidal shape of the resistance wire coil causes a side portion of each insulator to seat against a side portion of the cutout containing the insulator to dampen vibrations of the insulator against the support.

9. An open coil electrical resistance heater comprising:

a) a duct of defined cross section;

b) a metal plate supported by the circular duct;

c) a plurality of first and second cutouts in the metal plate, the first cutouts aligned along a path coinciding with an air flow path through the circular duct,

d) a plurality of insulators, each insulator mounted in one of the first or second cutouts;

e) at least one resistance wire coil supported by the plurality of insulators and adapted to connect to a power source for energizing of the heater,

f) wherein the second cutouts and the insulators mounted therein are offset from the first cutouts on the path, the offset creating a sinusoidal shape in at least a portion of the longitudinal axis of the at least one resistance wire coil, the resistance wire coil with its sinusoidal shape being generally aligned with an air flow path of the heater.

10. The heater of claim 9 , wherein the metal plate has sets of first and second cutouts and a plurality of resistance wire coils, each set of first and second cutouts supporting one of the resistance wire coils.

11. The heater of claim 9 , wherein the duct is circular in cross section.

12. The heater of claim 9 , wherein tension forces created by the sinusoidal shape of the resistance wire coil causes a side portion of each insulator to seat against a side portion of the cutout containing the insulator to dampen vibrations of the insulator against the support.

13. A method of reducing vibration and a shadowing effect in open coil electrical resistance heater comprising:

a) providing the open coil electrical resistance heater of claim 1 , and

b) passing air over the at least one resistance wire coil to heat the air.