Full support heating element apparatus

1. An electric heater apparatus for heating air, comprising:

a heater coil assembly including a coil support comprising a panel around which lies a coil of an electrical resistance element from approximately one end of the panel to approximately an opposite end, the coil of the electrical resistance element comprising a pass of spaced apart, elliptically-shaped, non-zigzagged loops helically positioned around the panel, the coil support configured to support the spaced apart loops.

2. The apparatus of claim 1 , wherein a portion of the pass of spaced apart loops extend past a longitudinal edge of the coil support.

3. The apparatus of claim 1 , wherein the coil support lies along a longitudinal axis of the coil of the electrical resistance element.

4. The apparatus of claim 1 , wherein the coil support comprises mica.

5. The apparatus of claim 1 , wherein the coil support comprises a heat resistant material.

6. The apparatus of claim 5 , wherein the heat resistant material is operable to withstand an operating temperature of at least approximately 1700° F.

7. The apparatus of claim 1 , wherein the coil support comprises a high dielectric constant.

8. The apparatus of claim 1 , comprising a pair of heater coil assemblies arranged side-by-side, wherein a single length of the electrical resistance element forms the coils associated with the pair of heater coil assemblies.

9. The apparatus of claim 8 , comprising a first plurality of pairs of heater coil assemblies and a second plurality of pairs of heater coil assemblies arranged offset and in staggered relation to the first plurality of pairs of heater coil assemblies.

10. The apparatus of claim 1 , wherein the electrical resistance element comprises resistance wire.

11. The apparatus of claim 1 , wherein the electrical resistance element comprises approximately 16 gauge or smaller resistance wire.

12. The apparatus of claim 1 , wherein the electrical resistance element comprises a low-nickel composition.

13. The apparatus of claim 12 , wherein the low-nickel composition comprises approximately 40% nickel.

14. The apparatus of claim 1 , wherein the electrical resistance element comprises a composition excluding nickel.

15. The apparatus of claim 1 , wherein the electrical resistance element comprises a ribbon.

16. An electric heater apparatus for an air handler, comprising:

a base plate;

a plurality of frame supports extending from the base plate;

a plurality of cross supports connected to the frame supports; and

at least one heating element assembly connected to the cross supports, the at least one heating element assembly comprising

a coil of resistance wire comprising a plurality of spaced apart, non-zigzagged elliptical portions arranged with respective vertices of the elliptical portions substantially aligned with one another; and

at least one coil support for supporting the coil of resistance wire, comprising a panel positioned inside the coil of resistance wire and at the respective vertices of the elliptical portions, the at least one coil support supporting the plurality of elliptical portions of the coil of resistance wire.

17. The apparatus of claim 16 , wherein the at least one coil support comprises mica.

18. The apparatus of claim 16 , comprising a first plurality of heating element assemblies and a second plurality of heating element assemblies arranged offset and in staggered relation to the first plurality of heating element assemblies.

19. The apparatus of claim 16 , wherein the resistance wire comprises approximately 16 gauge or smaller.

20. The apparatus of claim 16 , wherein the resistance wire comprises a low-nickel composition.

21. The apparatus of claim 20 , wherein the low-nickel composition comprises approximately 40% nickel or less.

22. The apparatus of claim 16 , wherein the resistance wire comprises a composition excluding nickel.

23. The apparatus of claim 16 , wherein the at least one coil support is positioned at an oblique angle relative to a direction of airflow.

24. The apparatus of claim 16 , wherein a side of the at least one coil support is engaged with a slot in the cross supports.

25. An electric heater apparatus for an air handler, comprising:

a base plate;

a plurality of frame supports extending from the base plate;

a plurality of cross supports connected to the frame supports for supporting the cross supports; and

at least two heating element assemblies connected to the cross supports on opposite sides of the cross supports in staggered relation to one another, the cross supports supporting the at least two heating element assemblies, each of the at least two heating element assemblies comprising

a plurality of spaced apart coils of resistance wire arranged side-by-side, at least one of the coils comprising a plurality of spaced apart, non-zigzagged elliptical portions arranged with respective vertices of the elliptical portions substantially aligned with one another, and

at least one coil support comprising at least one panel positioned inside each of the spaced apart coils and supporting a majority of turns of each of the spaced apart coils at each of approximately two locations of each such turn approximately opposite one another.

26. The apparatus of claim 25 , wherein a side of the at least one coil support is engaged with a slot in the cross supports.

27. The apparatus of claim 26 , wherein the at least one coil support and the cross supports are captively yet releasably coupled to one another opposite the slot without fasteners.

28. The apparatus of claim 25 , wherein the cross supports comprise a protrusion that engages an aperture in the at least one coil support, the cross supports and the at least one coil support being held together via a snap fit.

29. The apparatus of claim 25 , wherein the at least one coil support comprises mica.

30. The apparatus of claim 25 , wherein the resistance wire comprises a composition comprising approximately 40% nickel or less.

31. The apparatus of claim 25 , wherein the resistance wire comprises a composition that excludes nickel.

32. The apparatus of claim 25 , wherein adjacent spaced apart coils are electrically connected to one another in parallel by the resistance wire.

33. The apparatus of claim 16 , wherein the at least one coil support is positioned parallel to a direction of airflow.