Component Heaters: A Deep Dive into Industrial Heating Solutions

Like with innovative technology, component heaters play a vital role in a myriad of industrial tasks. They provide heat for specific processes and are far more efficient than traditional heaters. The following blog will highlight everything you need to know about industrial heaters, including their applications and types of component heaters.

What are Component Heaters?

In simple terms, a component heater is an electrical apparatus used to supply heat to a particular area of a given machine. Space heaters, on the other hand, warm up the entire area, unlike component heaters, which focus on delivering energy to the targeted area. This allows component heaters to be more efficient and versatile. In terms of size, component heaters offer a variety of options which can be grouped based on configuration and shape.

In construction, collecting, simulating and heating devices, Tempsens is the industry leader. They manufacture component heaters used in specific heating of industrial components, e.g. Cartridge Heaters, Flexible Heaters (silicone rubber heater), Strip Heaters, Band Heaters (mica band and ceramic band heater) for casing heating, etc. These component heaters find application in the fields of plastic packaging, shaping and extrusion, and surface heating by conduction or convection.

Classifications of Heaters

The following are several types of component heaters:

Cartridge Heaters: Designed to fit into drilled holes and offer localized heating. Therefore, the purpose of Cartridge Heater devices is to ensure consistent heating. Great heat transfer rate throughout the heating surface is maintained by tightly mounting the sheath and heating elements, resulting in greater internal losses at reduced temperatures. These devices have minimal gaps between the sheath and heating elements which results in smaller sized heaters operating at higher watt densities. They are used frequently in the plastic molding and die heating and sealing processes.

Band Heaters: Used for conductive heat transfer and wrapped around cylindrical objects such as pipes or nozzles. These include ceramic band heaters and mica band heater, which have a maximum operating temperature of 650°C. These are common in the use for plastic extrusion processes as well as injection molding and many other industrial processes.

Ceramic band heater .

Mica band Heater

Strip Heaters: These are characterized as flat rectangular heaters designed for surface heating. Strip heaters are composed of resistance wire wrapped around and coiled and glass insulator lined along the length and width of the heater providing even heating. They are preferable for use in heating tanks and molds.

Flexible Heaters: Heaters that are thin and light, constructed from silicone rubber or Kapton, are classified as flexible heaters. Utilized in numerous applications as a heating solution, these types of heaters are able to bend to irregular or curved surfaces. Flexible heaters increase the amount of heat transferred and reduce the amount of power needed. Flexible heaters come in two types:

• Wire Wound
• Etched Foil

Coil Heaters: Highly specialized, tape-like gadgets with band-like parts coiled around them. Precise and high temperature heating are required, for example with nozzles of hot runner systems, so these need to be set at accurate temperatures. Coil heaters are excellent for performing heating in tight compact spaces as much as 750°C. Thermocouples are another option for quick temperature control.

Applications of Component Heaters

Numerous industries use component heaters, including:

• Plastics Industry: Heating molds, dies, and nozzles for plastic processing.
  These industrial heaters designed for plastics are essential for the stretching and softening of polymers, which changes their shape to the resulting products that we are accustomed to.
• Packaging Industry: Seaming, labelling, and molding activities.
  Component heaters are heavily utilized among OEMs and end users of packaging machines.

• Automotive industry: Heating molds for the tire and other automotive component manufacturing.
• Food processing: Cooking and packaging food, as well as other food equipment like ovens and heating platens.
  As a frontrunner in system design, we at Tempsens have provided complete systems for various industrial equipment such as fryers, ovens, grills, etc. End users have made the most out of the industrial heaters provided by us through improved energy efficiency, effortless operation, consistency, reliable food-grade quality, and lower maintenance.
• Semiconductor industry: Chambers and equipment for heating semiconductors.
• Medical Industry: Sterilizing apparatus, incubators, and other medical equipment such as heating.
  Radiologists and X-ray technicians who need high limit thermocouples for temperature control use cartridge heaters. In medical labs, silicone rubber heaters are installed to combat condensation and humidity that could develop around patient samples.

Key Considerations When Choosing Component Heaters

Choosing the right component heater is important for good performance and efficiency. Pay attention to the following aspects:

• Wattage and Voltage: Understand the power needed for your heating task and check against your power source to ensure compatibility.
• Temperature Requirements: Decide on the highest temperature you need for your process and pick a heater that supports that temperature.
• Dimensions and Shape: Select a heater that fits the space you have and matches the shape of the item you’re heating.
• Sheath Material: Choose a covering material for the heater that is durable and resists corrosion, such as stainless steel, Incoloy, or brass, to endure the operating conditions.
• Mounting and Termination: Ensure that the heater is simple to attach and connect to the power supply for ease of use.
• Control and Safety: Implement temperature controls and safety devices to avoid overheating and ensure safe operation at all times.

Benefits of Component Heaters

• Efficient Heat Transfer: Component heaters focus heat directly where needed, making them very energy efficient as there’s minimal heat loss.
• Precise Temperature Control: These heaters allow you to control temperatures accurately, ensuring consistent and high-quality outcomes.
• Versatility: The design of component heaters can be customized to fit different shapes, sizes, and applications across various fields.
• Durability and Reliability: Built for industrial environments, these heaters are robust and can be relied upon for regular use.
• Cost-Effectiveness: They offer localized heating, which reduces overall energy use and cuts down on operating costs.

Conclusion

Component heaters are essential in today’s industrial environment. They deliver effective, reliable, and adaptable heating for numerous applications. By understanding the various types of component heaters and making informed decisions based on specific needs, industries can choose the best solutions to enhance productivity, save energy, and achieve high-quality results.

Frequently Asked Questions (FAQs)

Q: What is a component heater?
A: A component heater is a device used to heat specific parts of machines or systems, rather than an entire room or space.

Q: What are the types of component heaters?
A: Types include cartridge heaters, band heaters, strip heaters, flexible heaters, and coil heaters, each designed for particular applications and heating needs.

Q: What factors should I consider when choosing a component heater?
A: Consider wattage and voltage, temperature needs, size and shape, sheath material, mounting and termination options, and the requirements for temperature controls and safety measures.

Q: What are the benefits of using component heaters?
A: They offer focused and efficient heating, precise temperature control, adaptability to different uses, strength and dependability, and they lower costs by reducing energy consumption.

Q: In which industries are component heaters commonly used?
A: Numerous industries, including the semiconductor, food processing, plastics, packaging, automotive, and medical sectors, use component heaters.