Coiled Heaters
Coiled Heaters (Spiral Resistors) are used in plastic hot rail systems to ensure the fluidity of the raw material in the udder. Coiled Heaters (spiral resistors) are frequently used in the packaging industry and injection machines of industrial sectors to bring plastic raw materials to injectable temperature. HotRoad Resistances are used in heating pipelines with liquid or gas passing through them in different diameters and in various projects. These resistors are also used to make the raw material used in injection nozzles liquid and fluid by heating it to specified degrees. These types of resistance were originally produced for use in hot pathway systems in plastic injection nozzles.
Spiral Heaters be produced at different forces, different current voltages (24V,48V,110V,220V,400V).Such resistors are produced in different sections as standard. The primary and most common are flat Type Spiral Resistors with rectangular sections measuring 2.4 mm * 4.5 mm.
One of the other Coiled Heaters models is Hot Path Resistance with round section and the other is spiral type resistance with diameter 4mm round section. The maximum operating temperature of such Spiral Resistors is 500 °C. The outer sheath used in Spiral Type Resistors is made of AISI321 quality stainless steel. The energy outputs of this type of resistance are made with three teflon-insulated cables in phases, neutrals and soils. In addition, our spiral type resistors are produced with standard J type thermocouple and cable lengths can be adjusted to various sizes.
Coiled Heaters
Coiled Heaters
Coiled Heaters
Coiled Heaters
Coiled Heaters
Technical Information
Coiled Heaters are generally one of the important heating tools that keep the temperature of the breasts stable and therefore affect the quality of the material when injecting plastic raw materials into the mold in injection machines.Hot rail resistances be used for the specified purpose be used for regional heating in different areas. Be produced in desired sizes and watts. The wires of the resistors are spread with equal spiral ranges in their insulation with chrome nickel exterior steel protection.
Resistors are annealed after they are produced, thus gaining softness so that they can take any shape Coiled Heaters be used in various applications according to the reliability and versatility of their structure. For example,is designed for use in different hot pathway systems in plastic injection nozzles.
Coiled Heaters models are of great importance for stabilizing the injection process of hotway systems. Therefore, when choosing hot roadside resistors, attention should be paid to the working temperatures and dimensions. When spiral resistors are used, time provides high efficiency to its users. Hot roadside resistances are resistances where you can achieve your temperature stabilization in the most reliable and functional way. Thanks to the hot rail resistance models produced with quality materials, it be continued to use resistors without feeling the need for extra maintenance or repair for many years. Hot Road Resistances are easily produced in different winding types and different exit directions according to customer demand. Resistance Windings are usually requested clockwise and counterclockwise. It can be manufactured with a right output or Twist of 90°C in the direction (Radial) passing through the center according to the request.
What is Coiled Heating Element?
Coiled heaters resistance is a feature used to prevent the material from burning through coiled pathways. The coiled heaters resistance value is used to assess the fire risk associated with coiled pathways of the material. A high coiled heaters resistance value indicates that the material is safer. Coiled heaters resistance value is typically determined using standard test methods.
Coiled Heating Usage Areas
Coiled heaters resistance can be utilized in various sectors as follows:
Buildings: Coiled heaters resistance is used to evaluate the fire risk of products used as building materials.
Industrial Applications: Coiled heaters resistance is employed to assess the fire risk of materials used in industrial facilities.
Automotive: Coiled heaters resistance is used to evaluate the fire risk of materials used in the automotive industry.
Electrical/Electronic Products: Coiled heaters resistance is utilized to assess the fire risk of electrical and electronic products.
Aviation and Space: Coiled heaters resistance is employed to evaluate the fire risk of materials used in aviation and space applications.
Coiled Heating Technical Specifications
The technical specifications of coiled heaters resistance may include:
Operating temperature range: Typically ranging from -55°C to +300°C.
Conductivity: The conductivity of coiled heaters resistance can vary depending on the operating temperature and material.
Wire thickness: The wire thickness of coiled heaters resistance can vary based on the operating temperature and power requirements.
Heat transfer: The heat transfer of coiled heaters resistance can vary depending on the operating temperature, material, and design.
Corrosion resistance: The corrosion resistance of coiled heaters resistance can vary depending on the material and operating environment.
Coiled Heating Types
Coiled heaters can come in different varieties based on materials, operating temperature ranges, and application requirements:
1. Nichrome coiled heaters: A material offering good conductivity and resistance at high temperatures.
2. Chrome-nickel coiled heaters: A material providing good conductivity, resistance, and corrosion resistance at high temperatures.
3. Aluminum coiled heaters: An inexpensive and easily machinable material offering good conductivity at low temperatures.
4. Graphite coiled heaters: A material offering good conductivity and resistance at high temperatures, albeit expensive.
5. Tungsten coiled heaters: A material offering the best conductivity at the highest temperatures, though expensive.
6. Ceramic coiled heaters: A material offering good resistance and corrosion resistance at high temperatures, but with low conductivity.
The choice among these varieties can be made based on factors such as operating temperature range, power requirements, cost, and other considerations.
Coiled Heating (Spiral Heating )
Coiled heaters are an important component used to ensure the flowability of material in plastic hot runner systems. These spiral-shaped heaters are commonly employed in the packaging industry, industrial sectors with injection molding machines, and various projects. They are ideal for bringing plastic raw materials to injectable temperatures.
Furthermore, they are designed to heat pipelines of different diameters or used in various projects. These heaters are particularly suitable for heating the raw material used in injection nozzles to the specified temperature, thereby making it liquid and flowable. Initially, these types of heaters were designed for use in hot runner systems of plastic injection nozzles.
Coiled Heating Technical Specifications
Coiled heaters can be manufactured in different powers and current voltages (such as 24V, 48V, 110V, 220V, 400V, etc.). These are typically available in various cross-sections, with the most common being rectangular flat type spiral heaters measuring 2.4 mm * 4.5 mm. Additionally, there are round-sectioned hot runner heaters and spiral type resistors with a diameter of 4mm. The maximum operating temperature of these heaters is generally 500°C, and the outer casing is typically made of AISI321 grade stainless steel.
The energy outputs of these heaters are usually realized with three Teflon-insulated cables, typically phase, neutral, and ground. Furthermore, these types of heaters are produced as standard J-type thermocouples and cable lengths can be adjusted to various sizes.
Spiral heaters are commonly used in injection molding machines to maintain the temperature of nozzles while injecting plastic material into molds, which affects the quality of the material. While hot runner heaters are intended for this purpose, they can also be used in different areas such as regional heating. These heaters can be produced in desired dimensions and watts.
In general, coiled heaters offer reliability and versatility, especially designed for different hot runner systems in plastic injection nozzles. Therefore, it is important to pay attention to operating temperatures and dimensions when selecting a heater.
Coiled heaters provide high efficiency to users. Manufactured with quality materials, these heaters are ideal for long-term use and generally do not require additional maintenance or repair.
According to customer demand, coiled heaters can be easily produced in different winding types and output directions, typically offering winding types requested in both clockwise and counterclockwise directions. Additionally, they can be manufactured in radial or 90-degree perpendicular exits from the center or bent configurations.
Coiled Heating Usage Areas
Coiled heaters have a wide range of applications and are used to assess fire risk in various sectors:
Buildings: Coiled heaters are used to assess the fire risk of building materials. They are particularly important for determining the combustibility of building materials and taking fire safety measures.
Industrial Applications: Coiled heaters are used to assess the fire risk of materials used in industrial facilities. This helps determine the combustibility and fire hazard of materials used in industrial processes.
Automotive: Coiled heaters are used to assess the fire risk of materials used in vehicles. It is particularly important to test the fire resistance of materials used inside vehicles.
Electrical/Electronic Products: Coiled heaters are used to assess the fire risk of electrical and electronic products. This is important for evaluating the combustibility of electrical devices and equipment and testing their compliance with safety standards.
Aviation and Space: Coiled heaters are used to assess the fire risk of materials used in the aviation and space industries. It is important to test the high temperature and fire resistance of materials used in aircraft and spacecraft.
Coiled Heating Types
Coiled heaters vary according to material properties, operating temperature ranges, and application requirements. Here are some types of coiled heaters:
1. Nichrome Coiled Heaters: A material providing good conductivity and durability at high temperatures. It is particularly preferred for high-temperature applications.
2. Chrome-Nickel Coiled Heaters: Offers good conductivity, durability, and corrosion resistance at high temperatures. It has a wide range of applications due to these properties.
3. Aluminum Coiled Heaters: A low-cost and easily machinable material. It provides good conductivity at low temperatures and is used in many industrial applications.
4. Graphite Coiled Heaters: Provides good conductivity and durability at high temperatures, but is more expensive compared to others.
5. Tungsten Coiled Heaters: Provides excellent conductivity even at the highest temperatures, but is more expensive compared to others. It is especially used in high-temperature and extreme conditions.
6. Ceramic Coiled Heaters: Provides good durability and corrosion resistance at high temperatures. However, it has lower conductivity compared to other materials.
The selection is made based on the specific requirements of an application, operating conditions, and budget. Each material offers different advantages and disadvantages, so selecting the right material is important.
Coiled Heaters
Coiled Heaters: Technical Details and Application Areas
Coiled heaters are specially designed heating elements intended to deliver high efficiency and long-lasting performance in industrial heating applications. These heaters are commonly used in shaping plastics, metals, and similar materials, as well as in temperature regulation and material processing workflows. Their high-temperature resistance, extended service life, and reliability are among their most notable features.
1. Materials and Structure of Coiled Heaters
Coiled heaters are typically manufactured using heat-resistant alloys and high-quality metallic materials. These materials are resistant to prolonged heating and cooling cycles, as well as mechanical and chemical effects. Commonly used materials include Kanthal, Nichrome, and Tungsten.
Kanthal: Known for its excellent high-temperature resistance and superior electrical conductivity.
Nichrome: Offers strong corrosion resistance and excellent thermal conductivity.
Tungsten: Capable of withstanding extremely high temperatures, making it suitable for industrial heating applications.
These materials are usually produced in thicknesses ranging from 0.5 mm to 10 mm and are specially shaped to ensure uniform heat distribution on the outer surface of the heating elements.
2. Operating Temperatures of Coiled Heaters
The operating temperatures of coiled heaters vary depending on the materials and design used. However, these heaters are generally designed to handle temperatures ranging from 300°C to 1200°C with ease. Their high-temperature resistance allows them to be safely employed in industrial applications.
3. Power and Performance
The power of coiled heaters typically ranges from 10 W to 5000 W, depending on the application requirements. These heaters are designed to meet high-performance demands by generating the required heat rapidly. The power of the heating elements depends on factors such as the type of material used, the heating area, and electrical resistance characteristics.
Low-power applications: For small heating areas and low-temperature requirements, heaters ranging from 10 W to 500 W are preferred.
High-power applications: In large industrial systems or when heating thick materials, high-power heaters between 1000 W and 5000 W are utilized.
4. Heat Distribution and Efficiency
The efficiency of coiled heaters is based on their ability to distribute heat uniformly. High-quality heaters deliver greater efficiency with minimal energy loss. Proper heat distribution reduces processing times and conserves energy.
For most industrial applications, heaters that provide over 90% heat efficiency are preferred. This helps businesses lower energy costs while enhancing production efficiency.
5. Application Areas of Coiled Heaters
Coiled heaters are utilized across a wide range of industrial fields. Some common application areas include:
Plastic processing: In plastic injection machines, coiled heaters ensure consistent heating of plastics.
Metal processing: Used in high-temperature processes such as metal hot forming, casting, and coating.
Chemical and pharmaceutical industries: Play a crucial role in high-temperature reactions and production processes.
Food and beverage sector: Used for temperature control in food processing machines.
6. Installation and Maintenance
Installing coiled heaters generally requires expertise. Proper installation is critical to ensuring long-term and efficient operation. Regular maintenance also helps sustain their performance over time. Heaters can wear out or corrode, so periodic cleaning and necessary part replacements are recommended.
7. Advantages of Coiled Heaters
High-temperature resistance: Coiled heaters operate reliably at high temperatures, ensuring uninterrupted performance in industrial processes.
Long lifespan: Heaters made from high-quality materials last longer and reduce the need for frequent maintenance.
High efficiency: Low energy loss ensures high efficiency, reducing energy costs for businesses.
Versatile applications: These heaters offer a wide range of uses across different industrial sectors.
Coiled heaters are indispensable components of industrial heating applications. Their high-temperature resistance, energy efficiency, and durability enable industrial processes to become more efficient and cost-effective. By selecting the right materials, appropriate power capacity, and performing regular maintenance, coiled heaters can meet the exact needs of businesses. With an ever-expanding range of applications, coiled heaters continue to play an essential role in industrial production processes.
Coiled Heaters: Dimensional Details
Coiled heaters are heating elements specifically designed and manufactured according to precise dimensional standards for use in industrial heating applications. These heaters are typically adapted for processes requiring high temperatures, and their dimensions vary depending on the type of application, materials used, and power requirements. Below are the key dimensional details of coiled heaters:
1. Diameter and Thickness
The diameter or thickness of coiled heaters depends on the type of material used and the requirements of the application. Common diameter ranges are:
Diameter: Generally varies between 1 mm and 10 mm. Thicker diameters (e.g., 5 mm and above) are preferred for high-power applications.
Thickness: Thickness is adjusted according to the power capacity and heat dissipation needs of the heating elements. Typical thickness ranges are 0.5 mm to 3 mm.
2. Length and Dimensions
The length of coiled heaters can be customized according to the intended use and installation space. These heaters often need to be long and flexible to cover large surface areas for heating.
Standard Length: Produced in lengths ranging from 50 mm to 2000 mm. Longer heaters are preferred for applications with extensive heating areas.
Flexible Length Options: Manufacturers can offer customized lengths tailored to user requirements.
3. Electrical Resistance and Power
The electrical resistance of coiled heaters depends on the materials and design used. Resistance determines the heater’s heat generation capacity. Power is typically expressed in watts (W), and the dimensional details vary based on the heater’s power.
Resistance: Typical resistance values range from 1 ohm to 50 ohms, which is critical for meeting the heat requirements of the application.
Power: Coiled heaters are usually produced with power capacities ranging from 10 W to 5000 W, depending on the heating requirements of the application.
4. Insulation and Coating
Coiled heaters are often insulated with special materials to ensure safe operation at high temperatures. This insulation enhances both safety and energy efficiency.
Insulation Material: The external surfaces of heaters are often covered with heat-resistant materials such as ceramic or mica.
Insulation Thickness: Insulation thickness typically ranges between 1 mm and 5 mm.
5. Heat Distribution and Application Area
The dimensions of coiled heaters are optimized according to heat distribution requirements. Proper heat distribution ensures higher efficiency during the heating process.
Heat Distribution Area: Heaters can be manufactured for surface areas ranging from 100 mm² to 2000 mm².
Surface Area: Increasing the surface area ensures more uniform heat distribution, which improves process efficiency.
6. Power Density
The power density of coiled heaters is typically measured in W/cm² (watts per square centimeter). Power density indicates the heating capacity of the heater. High-density heaters provide faster heating and improved energy efficiency.
Average Power Density: Most coiled heaters have power densities ranging from 0.5 W/cm² to 5 W/cm².
7. Connection Type and Additional Features
The connection type of coiled heaters is crucial for ease of installation and safety. Common options include screw connections, flanged connections, or connection cables.
Connection Type: The method of connecting the heater to the power source is selected based on the application. Screw connections are widely used.
Outer Coating: Some heaters are coated with stainless steel or ceramic for enhanced protection.
Coiled heaters are indispensable elements of industrial heating processes and are manufactured with customized dimensions and designs for various applications. Factors such as diameter, length, electrical resistance, and power directly impact their performance and efficiency. Selecting the right coiled heater for business needs enhances energy efficiency and operational safety while helping to reduce costs. By focusing on dimensional details and application requirements, coiled heaters remain a vital part of industrial heating solutions.
Working Principle of Coiled Heaters
Coiled heaters are heating elements used in industrial heating applications at high temperatures. They are designed to shape, melt, or process materials like metal, plastic, or other industrial substances. These heaters convert electrical energy into heat to ensure the desired temperature is reached in a specific area or material.
Working Principle
Electrical Resistance and Heat Generation
Coiled heaters consist of materials that resist the flow of electrical current. As electricity passes through the resistance elements, energy is dissipated and converted into heat. This heat is distributed throughout the system to perform the heating process.
Electrical Resistance: The electrical resistance value of the material determines the heating capacity. High-resistance materials generate more heat, while low-resistance materials produce less.
Heat Transfer and Distribution
The heat produced by the coiled heaters is transferred from the heater’s surface to the surrounding area. This heat is usually distributed across the entire surface that requires heating, ensuring the desired temperature is achieved. Heat transfer depends on conductivity, surface area, and insulation properties.
Heat Distribution: High-efficiency heaters distribute heat more evenly, reducing process time and increasing efficiency.
Material Selection and Heat Resistance
Coiled heaters are made from materials resistant to high temperatures. These materials ensure safe operation at elevated temperatures and maintain performance over long periods. Commonly used materials include:
Kanthal (FeCrAl Alloy): Provides high heat resistance and is commonly preferred in coiled heater systems.
Mica or Ceramic: Used as insulation material due to its high heat resistance.
Control and Regulation
The temperature of coiled heaters is regulated using thermostats or digital control devices. These systems monitor the heater’s temperature and adjust the electrical current to maintain the desired levels. Increased electrical current results in more heat production.
Thermostats and Digital Control: These systems help maintain temperature stability by adjusting the power levels of the heater.
Heat Insulation and Efficiency
To minimize heat loss, coiled heaters are often surrounded by insulation materials. This insulation not only prevents heat loss but also ensures the safety of the surrounding environment.
Insulation and Safety: A well-insulated system operates efficiently with reduced energy consumption. It also prevents heat dissipation to the external environment, ensuring safe use.
Temperature Uniformity and Control
The functionality of coiled heaters depends on maintaining a uniform temperature distribution across the heating area. Even heat distribution ensures optimal efficiency and product quality during processing. Therefore, the design of the heater, including material selection, shape, and thermal conductivity, must be optimized.
Uniform Temperature Distribution: A larger surface area ensures more even heat distribution, improving process quality.
Coiled heaters efficiently convert electrical energy into heat to process materials in industrial applications. These heaters are designed to meet high-temperature requirements based on principles of electrical resistance, heat transfer, and temperature control. The use of insulating materials and high-quality metal alloys enhances their durability and efficiency over extended periods.
Coiled Heaters
Coiled heaters are used to melt materials like plastic or metal that require specific temperatures. These heaters are made of special alloys capable of maintaining a steady temperature and ensuring even heating of the material. Typically designed as a metallic plate or strip, coiled heaters use durable materials that can operate at high temperatures. When an electric current passes through the material, heat is generated, raising the material to its melting point.
The length and width of coiled heaters are determined based on the size of the processing area, the type of material used, and the melting point of the material. Typically, the width of these heaters ranges from 10 mm to 50 mm, and their length can vary between 50 mm and 1000 mm. These dimensions can be customized depending on the application. Width affects heat transfer depending on the material, while length is adjusted to provide sufficient heat for larger processing areas.
Voltage and power are critical for the proper operation of coiled heaters. Power is calculated based on the voltage and resistance values of the heater using the formula:
P(W)=V2RP (W) = \frac{V^2}{R}
Here, VV is voltage and RR is resistance. For example, a coiled heater operating at 230V with a resistance of 10Ω will have a power output calculated as:
P=230210=5290 WP = \frac{230^2}{10} = 5290 \, W
This calculation ensures the heater operates with sufficient power.
Coiled heaters typically use alloys with high thermal resistance, such as nichrome (NiCr), Kanthal (FeCrAl), and tungsten. These materials are durable at high temperatures and maintain performance over extended use without mechanical damage. Using these materials extends the heater’s lifespan and enhances energy efficiency.
Proper insulation is crucial for the efficient operation of coiled heaters. Materials like ceramic, aluminum oxide, or silica-based insulators are commonly used. These materials minimize heat loss while preventing electrical leakage. Additionally, they exhibit high-temperature resistance, maintaining performance even after prolonged use.
Coiled heaters are preferred in industrial applications that require high temperatures and consistent heating capacity. They are widely used in plastic injection molding machines, metal melting, hot template applications, and mold heating. These heaters ensure even material heating, improving process quality. They are specifically designed to provide continuous and efficient heating in industrial production environments.
Proper installation of coiled heaters is essential to achieve optimal heating performance. The heater is typically positioned parallel to the surface being processed. During installation, it is crucial to ensure the heater does not come into direct contact with the material. Proper connections and secure electrical wiring are necessary for safe and efficient operation. Incorrect installation can lead to uneven heat distribution and reduced efficiency.
Regular maintenance extends the lifespan of coiled heaters. Maintenance tasks include cleaning the heating surface, inspecting connection points, and checking the condition of insulation materials. Before operation, it is essential to ensure all electrical connections are secure. Over time, heaters operating at high temperatures may oxidize or suffer material damage, so periodic inspections are critical.
The heating time of coiled heaters depends on factors such as power output, material type, and ambient temperature. Typically, these heaters begin heating within seconds and can reach the desired temperature within 1-2 minutes. Higher wattage heaters heat up faster. For example, a 2000W coiled heater will heat up more quickly than a 500W model.
Overheating in coiled heaters can be prevented by using appropriate temperature control devices. Thermostats and digital temperature controllers help maintain the desired temperature levels. Additionally, protection circuits or thermal fuses can prevent system overheating. Ensuring adequate airflow around the heater is also crucial for systems operating at high temperatures. These measures enhance the heater’s lifespan and ensure safe operation.
