Ceramic Heaters
Ceramic Heaters are a variety of efficient, durable resistors that glow infared long wavelength. Ceramic Type Heaters are used in many different industrial and engineering applications. Thermoforming pans are effectively used in outdoor heating and infrared saunas such as packaging industry, paint curing and drying, printing drying, preheating. These resistors, which can emit very high heat, have a very long lifespan because they undergo high heat. These resistors provide easy heating due to their ability to spread heat quickly and simultaneously throughout the entire area.
Ceramic Heaters
Ceramic Heaters
Ceramic Heaters
Ceramic Heaters
Technical Information
Such resistors be easily produced in different sizes for years with infrared technology. In addition, the other less preferred dimensions are 245*100 mm – 100*100m – 122*122 mm and 60*60mm. Thanks to the specially formulated body doughs, it is possible to achieve 1000 watts of power with FFE models of ceramic flat resistors that can reach up to 750 degrees Celsius. Ceramic Heaters
with a flat body surface and where you can achieve homogeneous infrared distribution have durability that you can use for many years.
Solid cast elements embedded in the of ceramic flat resistors that can work through infrared ceramic emitters allow you to achieve reliable operation. The heater body parts, which are flat solid fuel, also have different radiation outputs for different applications.
Such resistors provide heat close to the sun’s temperature. Ceramic flat resistors, which have the ability to convert the energy obtained from electricity into heat in a short time, are long-lasting resistors.
What are Ceramic Heaters?
Ceramic heaters are a type of electrical resistance made from materials with electrical resistance properties. Ceramic material is used due to its durability, heat resistance, and electrical insulation properties. Ceramic heaters can be used in many different applications, such as electronic and electrical devices that require high temperatures, thermoelectric devices, heat control equipment, and industrial temperature control systems. Ceramic heaters typically have high resistance values and are resistant to heat, making them long-lasting.
Ceramic Heaters Usage Areas
Ceramic heaters are commonly used in the following applications:
Electronic devices: They are used for thermal control or temperature adjustment in electronic devices such as televisions, radios, electric vehicles, and household appliances.
Industrial temperature control: They are used for industrial processes requiring heating, cooling, or temperature control.
Thermoelectric devices: They are used as temperature sensors for thermoelectric devices such as thermocouples, Peltier coolers, etc.
Heating elements: They are used for controlling the heat of electric water heaters, ovens, bathroom cabinets, dishwashers, and similar appliances.
Technical Specifications of Ceramic Heaters
The technical specifications of ceramic heaters may include:
Operating temperature range: For example, between -50°C to 1300°C.
Resistance value: In Ohms, for instance, 100 Ω, 1 kΩ, 10 kΩ, etc.
Tolerance: Maximum deviation percentage in resistance value, for example, ±1%, ±5%, etc.
Conductive material: Ceramic or another material, for instance, Alumina ceramic, etc.
Fracture mode determining voltage resistance: Determines the necessary voltage resistance to prevent cracking, for example, 10 V/mil, etc.
Conductivity: Conductivity value of ceramic materials, for example, 10^(-7) S/cm, etc.
Dimensions: Measurements such as length, width, thickness, etc. of the ceramic heater.
Types of Ceramic Heaters
Ceramic heaters can offer different designs and features for various operating conditions. These may include:
Flat Ceramic Heaters: Simple-designed, flat, and small-sized ceramic heaters.
Wire Heaters: Thin wire-shaped heaters made from ceramic materials.
Strip Heaters: Strip-shaped heaters made from ceramic materials.
Powder Heaters: Heaters made from ceramic powders, used in small-sized and lightweight constructions.
High-Temperature Heaters: Ceramic heaters capable of operating at temperatures above 1300°C.
Low-Resistance Heaters: Ceramic heaters with an unusual resistance value.
Ceramic Heaters
Ceramic heaters are durable electric resistors that efficiently emit radiation in the long wavelength spectrum. These types of resilient electrical resistors find applications across various industrial and engineering fields, ranging from thermoforming trays to the packaging industry, paint curing and drying processes. Additionally, they are effectively utilized in outdoor heating processes such as printing drying, preheating, and infrared saunas. Thanks to their high heat dissipation capacities, they offer longevity and stand out with their ability to quickly heat a large area. With these features, ceramic heaters provide a reliable heating solution in various applications by rapidly and uniformly distributing heat.
Technical Specifications of Ceramic Heaters
Ceramic heaters, a product of infrared technology with the ability to be produced in various sizes for many years, offer dimensions such as 245*100 mm, 100*100 mm, 122*122 mm, and 60*60 mm among the less preferred options. With specially formulated body compounds, ceramic flat heaters, capable of withstanding temperatures up to 750 degrees Celsius, offer the possibility of obtaining 1000 watts of power with FFE models. These flat heaters, with a smooth surface, provide homogeneous infrared distribution and exhibit long-term durability.
Ceramic flat heaters can operate through infrared ceramic emitters and provide reliable operation thanks to solid cast elements embedded in the ceramic body. Different solid fuel heater body parts have different radiation outputs for various applications.
These types of heaters operate by emitting heat similar to solar heat. Due to their ability to quickly convert electrical energy into heat, they are long-lasting.
Ceramic type heaters are generally produced in two different shapes. The most common ones are semi-curved models. Another shape is less preferred flat and flat-surfaced ceramic heaters.
These heater models can produce power between 125 W and 1000 W depending on their size. Supply voltages are typically 230 V and 400 V.
The main areas of use for these types of heaters include: cube sugar machines, plastic vacuum packaging machines, thermoforming machines, textiles, printing and paint drying processes, automotive paint drying systems, industrial ovens, and IR drying panels.
Ceramic Heaters Usage Areas
Electronic Devices: They are commonly used in electronic devices such as televisions, radios, electric vehicles, and household appliances like white goods, for thermal control or temperature adjustment.
Industrial Heating and Cooling Control: They are used in applications requiring heating, cooling, and temperature control for industrial processes. For instance, they are preferred for temperature control in systems like industrial ovens, refrigerators, and coolers.
Thermoelectric Devices: They are used as temperature sensors for thermoelectric devices such as thermojunctions, Peltier coolers, etc. These devices are typically used for cooling or heating purposes, and ceramic heaters play a significant role in temperature control for these devices.
Heating Elements: They are used as heating elements in household appliances like electric water heaters, ovens, bathroom cabinets, dishwashers, as well as in industrial applications. In these devices, ceramic heaters are used to control temperature and maintain the desired temperature level.
Technical Specifications of Ceramic Heaters
Operating Temperature Range: The temperature range within which the ceramic heater can be used, for example, between -50°C to 1300°C.
Resistance Value: The electrical resistance value expressed in Ohms, for instance, 100 Ω, 1 kΩ, 10 kΩ, etc.
Tolerance: The maximum deviation percentage in resistance value, for example, ±1%, ±5%, etc.
Conductive Material: The material from which the ceramic heater is made, typically alumina ceramic, etc.
Fracture Mode Determining Voltage Resistance: A parameter that determines the necessary voltage resistance to prevent cracking, for example, 10 V/mil, etc.
Conductivity: The conductivity value of the ceramic material, usually taking small values like 10^(-7) S/cm.
Dimensions: The measurements such as length, width, thickness, etc., of the ceramic heater, which typically vary depending on the purpose of production.
Types of Ceramic Heaters
Flat Ceramic Heaters: Simple designed, typically flat and compact ceramic heaters. These heaters are preferred in various industrial and household applications.
Wire Heaters: Ceramic heaters produced in thin wire form. Their wire form provides flexibility in some applications and can easily adapt to different shapes.
Strip Heaters: Resistant made from ceramic materials, wide and strip-shaped. They offer a more homogeneous performance in heat distribution.
Powder Heaters: Resistors made from ceramic powders, usually small in size. Their lightweight and small size make them preferred in some special applications.
High-Temperature Heaters: Ceramic heaters that can be safely used at temperatures above 1300°C. They are particularly preferred in applications requiring high temperatures such as industrial ovens.
Low-Resistance Heaters: Ceramic heaters with an unusual resistance value. They are used in applications requiring low resistance in some special cases, such as high-current circuits.
Ceramic Heaters
Ceramic Heaters Technical Details
Ceramic heaters are widely used in various applications due to their high temperature resistance, long lifespan, and efficient heating performance. These heaters are commonly found in industrial equipment, laboratory tools, home heating systems, and electric heating devices. Thanks to the properties of ceramic materials, ceramic heaters can withstand high temperatures, provide rapid heating, and offer high efficiency. Below are the key technical details of ceramic heaters:
1. Material Selection and Structure
Ceramic heaters typically consist of a heating element made of resistive wire or a heating element placed within a ceramic structure. Ceramic materials are known for their high temperature resistance and electrical insulation properties.
Ceramic Material: Common ceramic materials used include aluminum oxide (Al₂O₃), magnesium oxide (MgO), and silica (SiO₂). Aluminum oxide is the most commonly used material due to its excellent heat conductivity and resistance to thermal shock.
Heating Wire: The heating element within the ceramic structure is typically made of high-temperature resistant metal alloys such as Kanthal, Nichrome, or Incoloy. These alloys generate heat when electrical current passes through them, and the heat is effectively transferred to the ceramic for efficient heating.
2. Working Principle
The working principle of ceramic heaters is based on converting electrical energy into heat. The electric current passes through the heating wire, and due to the resistance of the wire, electrical energy is converted into heat. This heat is then transferred to the ceramic material, which radiates it into the surrounding environment. The process is explained in the following steps:
Conversion of Electrical Energy into Heat: As the electrical current flows through the resistive wire, the wire heats up. The higher the resistance of the wire, the more heat it generates.
Heat Transfer by Ceramic Material: The heated wire transfers the heat to the ceramic material, which, due to its high thermal conductivity, spreads the heat efficiently.
Temperature Distribution: Ceramic materials help evenly distribute the heat, providing consistent and steady heating.
3. High Heat Resistance and Efficiency
Ceramic materials can withstand extremely high temperatures, typically between 600°C and 1200°C, making ceramic heaters ideal for applications requiring high temperatures. Additionally, ceramic materials have high heat conductivity, ensuring that the heat is efficiently transferred.
Temperature Control: Thermostats or thermocouples are often used to control the temperature of ceramic heaters. This allows precise control over the heated area’s temperature.
4. Physical Structure and Design
Ceramic heaters can be designed in various shapes depending on the application. Some common designs include:
Cylindrical Structures: Ceramic heaters are commonly designed with the heating wire wrapped around a cylindrical ceramic structure. This design ensures that heat is distributed evenly for efficient heating.
Flat Ceramic Heaters: Flat ceramic heaters can also be used, especially in cases where a larger surface area is needed for more uniform heat distribution.
5. Insulation and Safety
Ceramic materials provide excellent electrical insulation, ensuring high safety during operation. These heaters are designed to maintain their structural integrity even under extreme heating conditions.
Insulation Features: Ceramic materials provide electrical insulation, ensuring safe operation even under high voltage. This insulation helps eliminate the risk of electrical shock.
Heat Resistance: Ceramic heaters are resistant to thermal changes and can maintain their structural integrity even under rapid temperature shifts.
6. Applications
Ceramic heaters are widely used in applications requiring high temperatures. Common applications include:
Laboratory Heating Devices: Ceramic heaters are frequently used in laboratory equipment where high temperatures are needed for chemical reactions and experiments.
Electric Furnaces: Ceramic heaters are used in high-temperature electric furnaces, drying machines, or cooking devices.
Home Heating: Electric heaters and fan heaters commonly used in homes also utilize ceramic heating elements.
Industrial Applications: Ceramic heaters are employed in various industrial processes, such as metalworking, plastic processing, and ceramics production.
7. Long Lifespan and Durability
Ceramic heaters are designed to last for a long time. Their electrical properties do not degrade over time, and their structural integrity is maintained for extended periods. They can operate safely even under excessive heat conditions without compromising their functionality.
Ceramic heaters offer significant advantages, including high heat resistance, safety, and efficiency. These heaters efficiently convert electrical energy into heat while providing consistent and reliable heating. Ceramic heaters are essential in various industrial, commercial, and residential applications, meeting diverse heating needs.
Ceramic Heater Dimension Details
Ceramic heaters are key components used for efficient heating in a variety of industrial and domestic applications. These heaters are designed in different sizes and configurations to meet specific heating requirements. Below are the detailed specifications for ceramic heaters. These measurements may vary depending on the heater’s capacity, working conditions, and design standards.
1. Diameter and Length
The physical dimensions of ceramic heaters, such as the diameter and length, vary depending on the type of ceramic material used and the arrangement of the heating element. Commonly used measurement ranges are as follows:
Diameter:
The diameter typically ranges from 4 mm to 25 mm. However, for special applications, these diameters can be larger or smaller.
Small Diameters (4 mm – 10 mm): These are used for compact and precision heating applications.
Medium Diameters (10 mm – 15 mm): Commonly used in general industrial applications.
Large Diameters (15 mm – 25 mm or more): Used for applications requiring higher power.
Length:
Ceramic heater lengths generally range from 50 mm to 300 mm. However, custom designs may include longer or shorter heaters.
Short Lengths (50 mm – 100 mm): Used in narrow or space-constrained applications.
Medium Lengths (100 mm – 200 mm): Common in industrial and laboratory applications.
Long Lengths (200 mm – 300 mm or more): Used in larger surface areas and for more powerful heating needs.
2. Power Capacity and Wattage
Ceramic heaters’ power capacities are typically measured in watts (W) and can range from 50 W to 2000 W. The wattage indicates the power at which the heater operates and how much heating it provides. Higher wattage ceramic heaters are used for larger spaces.
Low Wattage (50 W – 300 W): Suitable for small devices and lower heating requirements.
Medium Wattage (300 W – 1000 W): Used for larger areas or devices requiring continuous heating.
High Wattage (1000 W – 2000 W and beyond): Used in industrial heating applications and large devices.
3. Internal Resistance and Voltage
The internal resistance of ceramic heaters directly influences their heating speed and wattage. The working voltage varies depending on the type of application:
Internal Resistance:
Typically ranges from 1 ohm to 100 ohms. Lower resistance provides faster heating.
Voltage:
Most ceramic heaters operate at 220 V for residential use, while higher voltages (such as 380 V) are used in industrial applications.
4. Ceramic Layer Thickness
The thickness of the ceramic layer plays a crucial role in the heater’s thermal conductivity and mechanical durability. Ceramic layer thickness typically ranges from 3 mm to 10 mm. This thickness determines the durability and heat transfer capacity of the device.
Thin Layers (3 mm – 5 mm): Provide faster heating and are suitable for applications requiring lower temperatures.
Thicker Layers (5 mm – 10 mm): Ideal for applications requiring high temperature resistance and longer-term durability.
5. External Surface Height and Insulation
The external surface of ceramic heaters is designed to efficiently distribute heat while also providing insulation.
External Surface Height:
The height generally ranges from 10 mm to 40 mm. This height influences the heating efficiency and the spread of heat.
Insulation:
Ceramic materials have high thermal insulation properties, preventing heat loss and ensuring safe operation. The insulation also helps protect users from high temperatures.
6. Mounting Type and Connection Location
Ceramic heaters’ mounting and connection points can vary depending on the device’s design.
Connection Type:
Most ceramic heaters can be mounted using screws or threaded channels. These connections are typically made from copper or stainless steel.
Mounting Location:
Ceramic heaters are mounted in appropriate areas based on the device’s temperature requirements. The location depends on the heater’s size and type.
7. Various Standards
Ceramic heaters are manufactured according to security and performance standards that ensure quality and durability. Common standards include:
IEC (International Electrotechnical Commission): International security and performance standards.
UL (Underwriters Laboratories): North American safety certifications and standards.
RoHS (Restriction of Hazardous Substances): Standards for environmentally friendly materials.
Ceramic heaters are essential for providing efficient heating in various industrial and domestic applications. The size details of ceramic heaters, including diameter, length, power capacity, internal resistance, and ceramic layer thickness, should be chosen based on the specific heating needs. These heaters offer flexibility and durability, making them ideal for high-performance heating applications.
Ceramic Heater Working Principle
Ceramic heaters are widely used for efficient and high-temperature heating applications. The working principle of ceramic heaters relies on converting electrical energy into heat, which is then efficiently distributed through the ceramic material. Below is a detailed explanation of the working principle of ceramic heaters:
1. Electrical Resistance and Heat Conversion
Ceramic heaters are elements that heat up by passing electrical current through them. These heaters typically have a ceramic structure embedded with a conductive material such as metal wire or carbon sheets. When electrical current flows through these conductive materials, energy loss occurs due to the resistance of the material, and this lost energy is converted into heat.
Joule Heating Principle: As the electrical current passes through a conductor, energy loss occurs due to the resistance of the material. This energy loss turns into heat, and the ceramic material spreads the heat to warm the surrounding environment.
2. Heat Distribution by the Ceramic Material
Ceramic materials are highly heat-resistant, which allows them to efficiently distribute the heat generated by the electrical current. Ceramic materials are known for their ability to spread heat homogeneously, ensuring a continuous heating process.
High Heat Resistance: Because ceramic materials are especially heat-resistant, they can withstand very high temperatures, allowing ceramic heaters to generate heat up to 700°C.
Insulation and Heat Retention: Ceramic also serves as an excellent heat insulator, minimizing heat loss and ensuring efficient heating. Even when exposed to the surrounding environment, ceramic heaters operate with high efficiency.
3. Structure and Heat Transmission of Ceramic Heaters
Ceramic heaters typically feature metal or alloy wires inside. These wires conduct electrical current, heat up, and transfer this heat to the ceramic surface. While ceramic materials are not electrically conductive, they are highly effective at transferring high heat.
Interaction Between Metal Wire and Ceramic Surface: The high resistance of the metal wire heats up when electrical current passes through it, transferring heat to the ceramic surface. The ceramic material then transmits this heat effectively to the outer surface, spreading it efficiently.
4. Temperature Control and Stabilization
Ceramic heaters generally operate within a fixed temperature range. Due to the internal resistance and ceramic material, the heating element heats up steadily, and the temperature of the device can be regulated. Modern ceramic heaters often come with temperature regulation features, preventing overheating and energy loss.
Temperature Adjustments: Ceramic heaters are often equipped with thermostats or temperature sensors. These sensors ensure that the heater operates within a specified temperature range, preventing overheating and ensuring energy efficiency.
5. Applications
Ceramic heaters are used in many different industrial and residential applications. These heaters typically perform efficiently in the following applications:
Industrial Heating Applications: Used in areas that require high temperatures, such as metalworking, plastic molding, drying, and hot air blowing systems.
Residential Heating: Commonly found in electric heaters, hot water machines, ovens, and other household appliances.
Laboratory Equipment: Ceramic heaters are preferred for laboratory devices that require stable and reliable heating.
Ceramic heaters are effective components that convert electrical energy into heat and efficiently heat the environment. Their working principle begins with electrical resistance and heat transmission, with the ceramic material’s high heat resistance ensuring effective heat distribution. Their high-temperature durability offers safe and long-lasting use, making them ideal for various industrial and residential applications.
Ceramic Heaters
Ceramic resistors are heating elements that work with heating wires wrapped in high temperature resistant ceramic materials. Heat is generated when electric current passes through the heating wires and this heat is effectively dissipated through the ceramic material. Ceramic provides high temperature resistance and thermal conductivity.
Ceramic heating elements have the advantages of high temperature resistance, long life and energy efficiency. In addition, the ceramic material provides electrical insulation and helps to distribute heat uniformly. This makes them particularly ideal for precision heating applications.
Ceramic resistors can generally withstand temperatures between 600°C and 1500°C. This temperature range can vary depending on the ceramic material used and the design. Ceramics with high temperature resistance are suitable for heavy industrial applications.
Ceramic heating elements are commonly used in applications such as electric cookers, hot air guns, ovens, air heaters, plastic forming and metalworking. They are also preferred in areas with precise heating requirements, such as electronic devices and laboratory equipment.
The lifetime of ceramic heating elements varies depending on the conditions of use and the level of maintenance. Generally, good quality ceramic heating elements have a lifespan of 5-10 years. Regular maintenance extends its lifespan and makes it work more efficiently.
The voltage resistance of ceramic resistors generally ranges between 220V and 380V. However, there are models that can withstand higher voltage ratings depending on the design and application used. The voltage rating can affect the power and operating efficiency of the resistor.
Ceramic heating elements have a high conversion rate of electrical energy into heat, usually with an efficiency of over 90%. This high efficiency saves energy and allows appliances to operate more efficiently.
The installation of ceramic heating elements is usually carried out by making the correct electrical connections and correctly positioning the heating element. Furthermore, cooling systems or ventilation must be provided so that the ceramic material does not overheat.
Maintenance of ceramic heating elements usually consists of cleaning the surface and checking the electrical connections. In addition, extreme temperatures and corrosion must be avoided. Ceramic surfaces can become dirty over time, so they should be cleaned regularly and checked for signs of wear.
Ceramic heating elements are designed with materials with high thermal conductivity and low thermal losses. This ensures high energy efficiency and maximum conversion of electrical energy into heat. In addition, the ceramic material ensures an even distribution of heat, which results in more efficient heating.
