July 9, 2021 Off By Alicia Hunt

Heating is a key process in all manufacturing units. This can be done using different types of industrial heaters, that differ in terms of design, watt density, and effectiveness. Industrial heaters such as cartridge heaters are used in many industries to heat metals and plastics. They also have immersion capabilities. These heaters are now more popular than traditional industrial heaters. This article will explain the workings of industrial heaters and their applications.

Cartridge Heaters: A Short Overview

Cartridge heaters are distinguished by their tube-shaped design, which makes them versatile heating elements. These heaters can be inserted directly into holes that are drilled for heating metal parts. The cartridge heaters are similar to industrial heaters in that they can be made with different wattages depending on the specific application. These heaters are typically slightly smaller than their nominal diameter.

Cartridge Heaters: How do they Work?

The heater is made up of a resistance coil wound around a dielectric core. The structure is then covered with a metal sheet. AC current drives these heaters. The current flows through the heater and heats the resistance coil. This heats up and transfers heat energy to the metal sheath, and the surrounding area. Conduction is the process of heat energy being transferred. It is one of the most efficient industrial heaters because it transfers all the heat from the coil to the surrounding. For more details check cartridge heater manufacturer

Join FIREROD Cartridge Heating Systems

The first cartridge heaters, FIREROD, were introduced by Watlow in 1954. They have been very popular ever since! FIREROD cartridge heating units are widely loved for the following reasons.

  1. The heaters come with a nickel-chromium resistant wire that ensures both localized heating as well as heat distribution.
  2. They have magnesium chloride (Magnesium Oxide), insulation of a specific purity that guarantees excellent dielectric strength and quick heating.
  3. Inconel Alloy 800 provides resistance to heat and oxidation by creating the outer metal sheath.
  4. The design of the wire is so compact that only the sheath and the element wire are visible. This creates low internal temperatures.

Five Reasons Cartridge Heaters are preferred over other industrial heaters

Because of their widespread usage, you can find them today across many brands. These heaters are popular despite the fact that each brand has its own specifics. However, they all share some common features.

  1. Compact Construction The industrial heaters are constructed with a swaged structure that compresses the Magnesium Oxide and forms a dense dielectric with great heat transfer properties (changed to correct). Swaged designs help reduce vibrations and shocks (Omit). The compact design allows for easy slippage into closed structures like injection molds and die blocks.
  2. Suitable for a wide range of temperature applications: The versatility of cartridge heaters is unmatched! They can be used to regulate the air temperature of various devices that are susceptible to condensation. These heaters can also withstand temperatures as high as 1400°F.
  3. Effective energy transfer: These heaters have the advantage of transferring heat efficiently without losing heat. The heater element is protected from oxidation by the metallic sheet surrounding it. Heat transfer is made possible by direct contact with the element being heated.
  4. Lower Electricity Costs Low electricity bills can be achieved by minimizing heat loss. This can result in huge savings for users.
  5. You can customize your designs: Industrial heaters can be customized in many ways, but they have some limitations due to the design of their products. Cartridge heaters are highly customizable due to their flexible designs. To increase their life expectancy, heaters can have temperature sensing built in. These sensors prevent heaters from overheating. These heaters can also be coated with graphite if they are used for high temperatures. Teflon wires can be used to heat heaters where they might be exposed to moisture and contamination.

Cartridge heaters are used in a variety of applications

These heaters can be used to heat metal molds and plates, dies, as well as other metal parts within the metalworking industry. But is that all? It is not. These cartridge heaters are also used in the following applications.

  • Molding plastic
  • Medical equipment
  • Semiconductor wafer Processing
  • Hot runner molds
  • Heat liquids and gases
  • Laminating presses

You should only source cartridge heaters from trusted suppliers or manufacturers, as the benefits and working of these heaters have been clearly explained. Thermx is a leading supplier of FIREROD cartridge heating elements and other heaters in California, West Coast Region.