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Heating Element Manufacturers India
Laboratory Equipment Manufacturing
Electrical appliances typically have heating elements, which are essential components that convert electrical energy into heat for various uses. They usually consist of open coils made from conductive alloys and supported by insulators, as well as wire terminals for electrical connection. Replacing traditional means with the convenience of electricity allows the integration of fire control in home appliances through heating elements.
What is a heating element?
A heating element is one of the key components in electrical appliances that converts electric current into heat. An electric current flowing through them produces heat because they are materials that offer resistance to an electric current passing through them. This can be passed to the surrounding medium, which may either be a gas, liquid, or mixture between air and water, such as gaseous oxygen, metallic mercury bromine solutions, etc. A common heater includes all heaters in general, but some usual forms include a coil, ribbon, or strip of wire where heat radiates equally in all directions, just like in the filament lamp.
Almost every product designed for space heating (like electric furnaces, electric ovens, and electric heaters) uses electricity to create warmth. In these devices, an example being a heating element converts electrical energy to thermal energy. To explain how it works, it would require mentioning the joule heating effect due to electric currents within solids. Heat generated by resistance results from passing an EMF across it.
One Leading Manufacturer of Heating Element
Bionic Consortium has emerged as one of India’s leading companies manufacturing scientific equipment and heating elements with a high reputation because they ensure the products meet CE and ISO standards strictly followed during production. The firm values accuracy and innovation in their up-to-date laboratory equipment covering various disciplines in science. As a way of achieving this process, the Consortium has been focussing on development as well as the provision of quality goods together with the best services towards customers. According to this theory, only identical things can make you superior to others, so then you will be considered the best. It is due to their commitment to being the best that they can that they are able to outdo their rivals.
Types of Heating Elements
There are heating elements that use electric current to generate heat, known as joule heating. Some types include metallic, ceramic, composite, thick film, semiconductor, and combination systems. The type of heating element depends on the size and structure of the apparatus or the region heated by resistance. A part of a device is usually heated; in some apparatus it may be hidden inside a given enclosure for safekeeping. Wire elements of resistance type consist of ceramic heating elements, metallic heating elements, infrared heaters, and ceramic heaters with nickel chrome (NiCr) wire and Constantan wire.
A heating element does this by passing an electric current through itself called joule heating. Thus, when electricity flows through an electrical conductor, it makes it resistive in nature, thereby leading to heat generation in these materials, which we refer to as the joules’ effect. These properties determine how each hot zone has been manufactured based on which classification based on structural observations and properties can be made.
Basic Heating Elements Types:
- Metal Heating Elements
- Ceramic and Semiconductor Heating Elements
- Thick Film Heating Elements
- Polymer PTC Heating Elements
- Composite Heating Elements
- Combination of Heating Element Systems
How do heating elements work?
Ribbon-straight or corrugated forms are some of the configurations that metallic resistance heating elements can take. The filaments used for lamps could be made from wires that look like strips, coils, or ridges. Different metals are applied in various appliances such as floor/ceiling heaters, industrial ovens, and hair dryers. In them, there are several main types of materials utilised.
Nickel-Chrome Alloy:
- Resistive wire heating elements
- For wire, tape, or band, make use of NiCr 80/20 (80% nickel, 20% chromium).
- It is perfect for its high resistivity and adhesion layer of chromium oxide.
- Wire does not get oxidised and thus cannot be broken up or burned off.
FeCrAl Alloy:
- Ferromagnetic materials with electrical resistance like that of nickel-chromium alloys.
- Applicable in the heating industry.
- Lower cost due to the absence of nickel, but more easily corroded.
- Broadest segment of the market for FeCrAl electric radiators.
CuNi Alloy:
- Its electrical resistivity is low.
- In contrast to oxidation and chemical corrosion, it shows good resistance features.
- A suitable material for heating apparatuses at low temperatures.
Etched Foils:
- The elements’ resistive wire is made from this same alloy family.
- Made via a subtractive photo-etching process.
- Starts out as a continuous sheet.
- Ends in highly elaborate patterns constituting almost any desired circuit’s resistance value.
- Precision heating applications commonly adopt them.
Ceramic and semiconductor heating
- Molybdenum Disilicide Heating Elements: Molybdenum disilicide (MoSi2) is used as a ceramic insulation within heating elements and has a moderate density with an operating temperature of 2030 °C for use in heat treatment furnaces, glass manufacturing, and semiconductors.
- Silicon Carbide Heating Elements: Silicon carbide heaters have higher operating temperatures and are found in different industries such as metal heat treatments, glass melts, ceramics, electronics manufacturing, pilot lights, and gas heater igniters.
- PTC Ceramic Heating Elements: PTC ceramic materials consisting of barium titanates and lead titanate composites undergo a positive thermal coefficient of resistance, which increases its resistance when heated. The nonlinearity of the material’s thermal response enables it to act like a thermostat, hence allowing current flow, especially when it is cold.
- Quartz Halogen Elements: Quartz halogen heaters provide fast radiant heating and cooling, which is suitable for quick cycle times and high heat demand applications like paper production.
Ceramic and semiconductor heating
- Molybdenum Disilicide Heating Elements: Molybdenum disilicide (MoSi2) is used as a ceramic insulation within heating elements and has a moderate density with an operating temperature of 2030 °C for use in heat treatment furnaces, glass manufacturing, and semiconductors.
- Silicon Carbide Heating Elements: Silicon carbide heaters have higher operating temperatures and are found in different industries such as metal heat treatments, glass melts, ceramics, electronics manufacturing, pilot lights, and gas heater igniters.
- PTC Ceramic Heating Elements: PTC ceramic materials consisting of barium titanates and lead titanate composites undergo a positive thermal coefficient of resistance, which increases its resistance when heated. The nonlinearity of the material’s thermal response enables it to act like a thermostat, hence allowing current flow, especially when it is cold.
- Quartz Halogen Elements: Quartz halogen heaters provide fast radiant heating and cooling, which is suitable for quick cycle times and high heat demand applications like paper production.
Application
- It is used widely in the research and production of ceramics, glass, refractory, metallurgical coke, steel-making, crystals, electronic components, and semiconductors.
- The models are BR1700 and BR1800.
Benefits of MoSi 2 Heating Elements
- It contains anti-oxidation and self-healing abilities.
- Continuously usable in an oxygen atmosphere.
- For this reason there is a provision for standard heating moulding plus model size.
- JV Weld and Impact Resistant Joint Moulding Process.
- High density, electrical conductivity, high heating rate, low power consumption.
- can be connected to old or new ones in the series.
Technical Specification
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Technical parameters |
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Hot zone diameter D1(mm) |
Cooling zone diameter D2(mm) |
Hot zone length Le (mm) |
Cooling zone length Lu (mm) |
Central distance (mm) |
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3 |
6 |
80-300 |
80-500 |
25 |
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4 |
9 |
80-350 |
80-500 |
25 |
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6 |
12 |
80-800 |
80-1000 |
25-60 |
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7 |
12 |
80-800 |
80-1000 |
25-60 |
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9 |
18 |
100-1200 |
100-2500 |
40-80 |
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12 |
24 |
100-1500 |
100-1500 |
40-100 |
Note:
- Special dimension can be designed to meet customer’s requirement.
- It takes 3 days for normal sizes only, so you better bear that in mind when ordering it.
- Model: BCR1700 – working at temperature of 1600℃ and BR1800 – working at temperature of 1700℃
- Before placing an order, please confirm the D1, D2, Le, Lu and A
