Electric heating element support structures and method of making same

An integrally formed structure for supporting a plurality of heating elements in an electric heater housing formed from a single sheet of metal, comprising:

• a pair of substantially parallel, spaced apart longitudinally bent support rails, each support rail including a first flange integrally formed with a second flange in a substantially perpendicular relationship, said first flanges being adapted to be secured to opposing sides of the electric heater housing;
• a plurality of substantially flat support brackets integrally formed with and extending between said second flange of each support rail, each support bracket having opposing planar surfaces and a plurality of openings formed therethrough;
• a plurality of coil bushings each having a tubular body portion with an opening extending therethrough that is adapted to receive a portion of the heating coil, and a collar extending radially outwardly from one end of said body portion, one coil bushing being positioned inside each opening of said support brackets such that said body portion extends through said opening and said collar is maintained in abutment with one of the planar surfaces of said support bracket,
• said collar of said coil bushing being securely held in engagement with said support bracket.

An electric heater, comprising:

• one or more heating elements;
• a housing having said heating elements disposed therein;
• electrical circuitry disposed in said housing and operably connected to said heating elements for selectively energizing said heating elements;
• a support structure disposed inside said housing for supporting said heating elements therein, said support structure being integrally formed from a single sheet of metal, and said support structure including an L-shaped support rail having a first flange removably secured to said housing and a second flange extending inwardly from said first flange into said housing in a substantially perpendicular fashion, one or more neck portions integrally formed with and extending inwardly from said second flange, and a support bracket integrally formed with and extending inwardly from each neck portion, each support bracket having one or more openings formed therein;
• and
• an electrical insulator disposed in each opening of said support brackets, said insulator having an opening formed therein, said opening being adapted to receive therethrough a portion of said heating element.