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Cartridge Heaters
Build-to-Order Heating Solutions
The Right Thermal Solution for You
Cartridge heaters are versatile and can be configured for optimized performance of a specific application. Many companies can make cartridge heaters. Nexthermal’s goal is to build your cartridge heater. The right cartridge heater, built specifically to your application is one of the most cost effective process improvements you can make. We want to know more about your application, challenges, and goals. Combining your experience with Nexthermal’s thermal transfer expertise will deliver the solution you need.
Common Applications
- Packaging
- Rubber Molding
- Form Fill & Seal
- Platen Heating
- HVAC Compressors
- Die Casting
- Hot Melt Adhesives
- 3D Printers
- Mass Spectrometry
- Food Manufacturing
- Hot Melt Adhesive
- Pellet Stove Igniter
- Torpedo Heaters for Injection Molding
- Heat Staking
- Extrusion
High Watt Density
Nexthermal High Watt Density Cartridge Heaters are fast responding and can be precisely profiled to help your equipment operate at peak performance levels. Nexthermal has developed industry-specific algorithms that calculate distribution profiles for plastics, rubber, packaging and other applications. Nexthermal High Watt Density Cartridge heaters core construction and available options deliver performance and durability you need.
– vs –
Medium Watt Density
The cost effective alternative for cartridge heaters greater than 8” long with watt densities below 65 watts per square inch. Medium watt density cartridge heaters have the resistance wire in the center of a ceramic core. Medium watt density heaters are swaged using the same method as our high watt density cartridge heaters. Medium watt heaters are every bit as durable as high watt density heaters with the additional advantage of fewer electrical connections on multi core (longer) heaters.
Though construction will differ between high watt density and medium watt density cartridge heaters, both are swaged heaters manufactured using advanced materials.
Both can be manufactured with an internal Type J or K thermocouple.
Distributed Wattage
Nexthermal can design the heating element using distributed wattage to correct the temperature curve, resulting in a more uniform heat profile. In the figure below, you can see how the increased wattage in the end zones creates a more uniform temperature curve.
The above image has the windings exposed to showcase the distributed wattage. The tighter windings are not limited to the end points; they can be applied anywhere on the heater to best suit your applications’ needs. Nexthermal can help put the heat exactly where you need it.
Cartridge Heater Recommendation
Cartridge Heater Options
Distributed Wattage
Nexthermal has developed industry-specific winding profiles to improve thermal profiles for packaging, rubber, and injection molding. We have also successfully developed OEM-specific winding profiles to compensate for challenging heater placement.
Moisture Resistance
For applications that require wash down, have high amounts of humidity in the ambient air, or have machining oil nearby, Nexthermal offers build-to-order options to deliver moisture resistance at your operating temperature.
Anti-Seize Coating
Building a heater that lasts longer can make removal more difficult when a heater must be replaced. Removal labor often costs more than the heater itself. Nexthermal’s in-house anti-seize coating is a cost effective option that can be added without impacting delivery.
Removal Aids
Nexthermal offers knock-out tabs and other removal aids that allow you to quickly and confidently remove a heater when it is time to replace it. Knock out tabs are recommended when you are installing the heater in a through-bore that’s prone to oxidation.
Right-Angle Exit
Nexthermal has redesigned the right-angle exit with flat sides, making it possible to use a wrench to precisely position lead exit and break oxidation bonds when removing a heater.
Right-Angle Block
The right-angle block has flat sides and substantial material to provide the strength needed for highly-corrosive environments (such as die casting) where the heater sheath can be bonded to the bore.
Flanges and NPT Fittings
For applications requiring a specific insertion depth, or that they must be held in place, Nexthermal offers standard flanges for most diameters. We can also design special flanges for your application. NPT fittings can be added to your cartridge heater.
Centerless Grind Tolerance
Nexthermal’s standard tolerance of 0.002″ compares favorably to other cartridge heaters. If heat transfer is critical to your application, Nexthermal offers premium centerless grind tolerances that are ±0.0008″. Designed to fit nominal cores.
Leads, Potting Options, & Lead Protection
Specifications
Dimensional / Electrical
High Watt Density
Medium Watt Density
1/8″ Heater
Length Tolerance
Premium Length Tolerance
Min. Heater Length
Max. Warranted Sheath Load
Standard Watt Tolerance
Premium Watt Tolerance
Std. High Volt Stability (Cold) ≤ 24 V
Std. High Volt Stability (Cold) > 24 V
Premium High Volt Stability (Cold) > 250 V
Insulation Resistance
Premium Insulation Resistance
Leakage Current
Max. Connection Volt (UL Rated)
Max. Connection Volt
±1.5% (min. ±1 mm)
Upon Request
1″, 25.4 mm*
160 Watts / in²
+5%, -10%
±5%, lower possible with specific designs
500 V AC @ 100 mA
1500 V AC @ 100 mA
Upon Request
≥ 5 MΩ @ 500 V DC
Upon Request
0.5 mA @ 253 V AC
600 V
600 V
±1.5% (min. ±1 mm)
Upon Request
8″, 203.22 mm**
65 Watts / in²
±10%
±5%
500 V AC @ 100 mA
1500 V AC @ 100 mA
Upon Request
≥ 5 MΩ @ 500 V DC
Upon Request
0.5 mA @ 253 V AC
600 V
600 V
±3.0%
—
1.25″, 31.75 mm
120 Watts / in²
+10%, -15%
+5%, -10%
Not Available
800 V AC @ 100 mA
Not Available
≥ 5 MΩ @ 500 V DC
Not Available
0.5 mA @ 253 V AC
N/A
250 V
*Shorter lengths may be possible depending on required wattage.
**Dependent on application requirements.
Length Tolerance
±1.5% (min. ±1 mm)
Premium Length Tolerance
Upon Request
Min. Heater Length
1″, 25.4 mm (Shorter lengths may be possible depending on required wattage.)
Max. Warranted Sheath Load
160 Watts / in²
Standard Watt Tolerance
+5%, -10%
Premium Watt Tolerance
±5%, lower possible with specific designs
Std. High Volt Stability (Cold) ≤ 24 V
500 V AC @ 100 mA
Std. High Volt Stability (Cold) > 24 V
1500 V AC @ 100 mA
Premium High Volt Stability (Cold) > 250 V
Upon Request
Insulation Resistance
≥ 5 MΩ @ 500 V DC
Premium Insulation Resistance
Upon Request
Leakage Current
0.5 mA @ 253 V AC
Max. Connection Volt (UL Rated)
250 V
Max Connection Volt
600 V
Length Tolerance
±1.5% (min. ±1 mm)
Premium Length Tolerance
Upon Request
Min. Heater Length
8″, 203.22 mm (Dependent on application requirements.)
Max. Warranted Sheath Load
65 Watts / in²
Standard Watt Tolerance
+10%
Premium Watt Tolerance
±5%
Std. High Volt Stability (Cold) ≤ 24 V
500 V AC @ 100 mA
Std. High Volt Stability (Cold) > 24 V
1500 V AC @ 100 mA
Premium High Volt Stability (Cold) > 250 V
Upon Request
Insulation Resistance
≥ 5 MΩ @ 500 V DC
Premium Insulation Resistance
Upon Request
Leakage Current
0.5 mA @ 253 V AC
Max. Connection Volt (UL Rated)
250 V
Max Connection Volt
600 V
Length Tolerance
±3.0%
Premium Length Tolerance
—
Min. Heater Length
1.25″, 31.75 mm*
Max. Warranted Sheath Load
120 Watts / in²
Standard Watt Tolerance
+10%, -15%
Premium Watt Tolerance
+5%, -10%
Std. High Volt Stability (Cold) ≤ 24 V
Not Available
Std. High Volt Stability (Cold) > 24 V
800 V AC @ 100 mA
Premium High Volt Stability (Cold) > 250 V
Not Available
Insulation Resistance
≥ 5 MΩ @ 500 V DC
Premium Insulation Resistance
Not Available
Leakage Current
0.5 mA @ 253 V AC
Max. Connection Volt (UL Rated)
N/A
Max Connection Volt
250 V
