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Applications

Heating elements play a crucial role in a wide variety of appliances and industrial settings, where precise and efficient heat generation is vital. In the home, devices like electric heaters and hair dryers use heating elements to generate warm air, providing comfort in chilly weather and aiding in hair styling. Soldering irons depend on heating elements to melt solder, allowing for the joining of electronic components. Showers and water heaters use them to heat water for bathing and other household needs. In kitchens, stoves utilize heating elements to ensure consistent cooking temperatures on cooktops and in ovens. Toasters quickly brown and crisp bread using these elements, and clothes dryers depend on them to efficiently dry laundry.

In industrial and commercial environments, heating elements are indispensable for a variety of applications. For example, in diffusion pumps, heating elements help create a vacuum by heating a vaporizable substance that then expels gas molecules from the chamber. Kilns and furnaces rely on heating elements to achieve the high temperatures necessary for processes such as pottery firing and metal smelting. Additionally, stainless steel liquid immersion heaters are prevalent in industrial settings where liquids like water or chemicals require heating. These immersion heaters, with heating elements encased in a protective sheath, are designed to be directly immersed in the liquid, ensuring efficient heat transfer.

Heating elements are crucial in many appliances and industrial settings, delivering consistent heat, precise temperature regulation, and boosting efficiency in diverse everyday and specialized tasks.

The History of Heating Elements

In 1879, Thomas Edison illuminated his incandescent light bulb using a carbon filament. This filament not only produced light but also generated heat, earning Edison recognition as the inventor of the first heating element. However, it wasn’t until the following century that such elements were utilized specifically for heat generation. Nonetheless, efforts in heating technology continued to progress during that time.

In the late 19th century, the principles of heating were articulated and refined into the first law of thermodynamics by pioneers Julius Robert Mayer and James Prescott Joule. This foundational understanding soon spurred inventors to harness thermodynamics for practical applications. In 1868, Benjamin Waddy Maughan, a London painter, crafted the first gas water heater. However, its lack of a ventilation system rendered it unsafe for domestic use. Two decades later, in 1889, Norwegian-American inventor Edwin Ruud introduced the first electric water heater, offering a significantly improved and safer solution for home heating needs.

One of the oldest heating elements still in use today is silicon carbide. Discovered in 1891 by American inventor Edward G. Acheson, this synthetic material emerged accidentally while he was attempting to create diamonds. Instead, he found silicon carbide, a substance renowned for its extreme hardness and suitability for high-temperature applications and semiconducting. A decade later, in 1905, Albert Marsh made a groundbreaking discovery with NiChrome (chromel). This material could reach temperatures 300 times higher than the heating elements of its era, transforming the industry. Marsh patented NiChrome in 1906, and just three years later, General Electric introduced the first successful electric toaster utilizing NiChrome. Soon after, manufacturers began electrifying tea kettles. Initially, they required heating on coil elements, but eventually, the heating elements were integrated directly into the kettles.

In the early days, heating elements were a luxury enjoyed only by the wealthy and profitable businesses. However, the post-World War II economic boom changed this landscape. Electrical appliances with heater elements became widespread and found their way into many homes. Among the popular heating appliances of the time were bar heaters, electric radiators, and portable oil-filled radiators. In the 1950s, radiant bar heaters gained immense popularity. Their portability and ability to be plugged in anywhere made them a convenient choice. They also provided quick heat, which was a significant advantage. Despite being safer than fuel-burning heaters, bar heaters posed risks due to insufficient protective shielding, exposing users to potential burns. They also had a high fire risk if knocked over or covered with clothes. Today, bar heaters are still in use but must adhere to much stricter safety standards than in the past. The bar heater inspired the development of various wire element heaters, including the infrared heaters we commonly use now.

As the 1960s rolled in, the growing reliance on home heating led to skyrocketing prices. To curb these costs, U.K. manufacturers developed a novel solution: the storage heater. These heaters utilized electric heating elements to warm thermal bricks overnight, allowing users to release the stored heat during the day without consuming additional electricity. By the 1970s, an oil crisis prompted governments worldwide to shift towards more electric heating solutions. However, storage heaters gradually fell out of favor due to their manual operation and the need for users to predict their heating needs. They also proved to be less energy-efficient. With the arrival of the 1990s, people began replacing their heating systems with modern electric radiators. These new radiators were easier to control, heated up faster, and were more energy-efficient. Another significant innovation of the 90s was the screen-printing of metal-ceramic tracks onto ceramic-insulated metal. These advanced heating elements became widely used in domestic appliances, such as kettles.

The digital revolution of the 21st century has transformed heating elements and their systems, making them incredibly sensitive, intuitive, and energy-efficient. Modern heating assemblies now boast features such as LED screens, Wi-Fi control, smart meters, digital keypads, and programmable temperature schedules. These advancements allow for precise and complex operation of heating elements. Additionally, contemporary heating elements have significantly reduced their dependence on fossil fuels, prioritizing sustainability, energy efficiency, and health.

Characteristics

Heating elements transform electricity into heat through the principle of Joule Heating. When electric energy passes through the element, it encounters a high-resistance material. This resistance converts the electrical energy into heat energy. The amount of heat generated depends on the material’s resistance to the electrical current. Engineers measure the resistivity of the element wire in ohms per meter, taking into account its resistance per unit length and cross-sectional area. This resistivity is then used to calculate the element’s kilowatt (kW) load, which indicates the amount of electrical power the heating element can handle.

Heating Element Types

Heating elements come in various types to suit industrial, commercial, and consumer needs. These include immersion heaters, quartz heaters, flexible heaters, infrared heaters, wire heaters, ceramic heaters, electric heaters, metal-based heaters, and composite heaters, among many others.

Immersion Heating Element

Immersion heating elements are designed to heat gasses and liquids directly, with a unique capability to be submerged in the substances they warm without failing. These heaters stand out for their rapid, efficient, and cost-effective performance. They are commonly used to heat a variety of materials, including plating baths, mild acids, oils, water, salts, air, and chemical solutions. These elements are integral to various systems such as process systems, boilers, water heaters, heat transfer systems, oil heaters, and storage tanks.

Quartz Heating Element

Quartz heating elements transform electrical currents into infrared rays by passing them through unique resistors, resulting in swift heating. This rapid heating capability makes them highly favored for industrial applications such as film curing, thermoforming, powder coatings, adhesive sealing, and paint drying. They are also essential in zone control applications across various industries, including automotive, printing, petrochemical, textile, glass, and electronics.

Flexible Heating Element

Flexible heating elements can attach to a wide range of materials and conform to various shapes, offering direct heating. Their thin and bendable nature makes this versatility possible.

Infrared Heating Element

Infrared heating elements generate heat through infrared waves, a type of electromagnetic radiation known for its efficient heat transfer capabilities. These elements are commonly paired with radiating heaters such as duct, immersion, and tubular heaters, which are designed to heat air or liquids on a large scale. They play a crucial role in various applications, including industrial ovens, pressure vessel heating, storage tank heating, boilers, water treatment plants, and steam generation systems.

Wire Heating Element

Heating elements, regardless of their type, are typically designed as coils or wires. In fact, wire heating elements are among the most popular for industrial and commercial drying applications. Manufacturers create these elements by designing detailed wire diagrams. You’ll find them in surface treatment heaters, kilns, and a variety of other drying equipment.

Ceramic Heating Element

Another kind of heating element used in convection heating is the ceramic heating element. These elements are integrated into space heaters, furnaces, and semiconductors. Ceramic heating elements come in various forms, such as molybdenum disilicide and PTC (Positive Temperature Coefficient).

Molybdenum Disilicide Element

Molybdenum disilicide is a unique material that combines the qualities of both metal and ceramic. With an impressive melting point of 3690ºF, it is perfect for various high-capacity heating elements. This versatility makes it indispensable across numerous industries, including glass manufacturing.

PTC

Positive thermal coefficient (PTC) materials, particularly high-profile ceramics, play a crucial role in various heating applications. These ceramics are commonly used in automotive rear-window defrost heaters, space heaters, and high-end hair dryers. Additionally, there are polymer-based PTC ceramics designed for specialized heaters. These elements enhance their heating capability as their resistance increases, making them ideal for self-regulating electric heaters due to their straightforward temperature control.

Electric Heating Element

Electric heating elements are widely used, particularly in industrial electric heaters.

Cartridge Heater

Cartridge heaters provide targeted heat to specific equipment components used in metal fabrication, foam fabrication, plastic molding, food processing, and packaging.

Metal-based Heating Elements

As their name implies, metal-based heater bodies are primarily constructed from various metals. Due to the excellent heat and electricity conduction properties of metal, these elements are highly efficient as heating components. They are widely utilized in both household appliances and industrial equipment. Metal-based heating elements can be further categorized into several subtypes, such as those made from nichrome and those based on resistance element wire.

Nichrome Heating Element

Many electric heaters feature elements crafted from nichrome, an alloy primarily composed of nickel and chromium. Specifically, these heaters utilize an alloy consisting of 80% nickel and 20% chromium.

Resistance Wire Heating Element

Many metal-based components consist of high-resistance wires and ribbons. These wires can be either straight or coiled, depending on the appliance’s design and heating requirements. These wires function as resistors and are commonly found in toasters and handheld body massagers. Popular metals for creating resistance wires include Kanthal, nichrome, and cupronickel.

Coil Heater

Coil heaters, band heaters, or strip heaters ensure that extruding channels and hoppers keep materials plastic and malleable throughout the extrusion process.

Composite Heating Elements

Composite heating elements are composed of a blend of metallic and ceramic materials. These versatile heating elements come in various forms, including tubular elements, radioactive elements, and removable ceramic core heating elements, among others.

Tubular Heating Element

Tubular elements are essentially metal tubes housing a slender coil of nichrome that generates heat for various applications. As the name suggests, these elements are tubular in shape and are commonly used in ovens, dishwashers, and other appliances. They can be formed into standard shapes or customized to fit specific needs.

Radioactive Heating Element

• Radioactive elements, often referred to as heat lamps, are powerful incandescent lamps designed to emit primarily infrared radiation rather than visible light. These lamps are commonly utilized in radiant space heaters and various food warmers. They are available in two primary forms: tubular and R40 reflector lamps. The reflector lamp heating elements are typically offered in three styles: gold-coated, ruby red-coated, and clear.
• Gold-coated lamps have an interior layer of gold dichroic film, which diminishes visible light while allowing most short and medium infrared waves to pass through. These lamps are mainly used for heating purposes.
• Ruby-coated lamps serve the same purpose as gold-coated lamps but at a significantly lower cost. However, they emit a much more intense visible glare.
• Uncoated clear lamps are primarily used in industrial production processes.

Removable Ceramic Core Element

These heating elements consist of coiled resistance wire woven through one or more cylindrical ceramic segments, which may include a central rod. They operate by being placed inside a metal tube or sheath sealed at one end. This design allows for easy replacement or repair of the removable elements without risk of damage. Typically, they are used to heat pressurized fluids.

Carbon Fiber Composite Element

These heating elements are crafted from a blend of carbon fiber and a resistive material such as nickel, combined with a thermoset like epoxy or a thermoplastic like PEEK. Carbon fiber composite elements boast impressive properties: they resist corrosion, withstand extreme temperatures, and are lightweight. These attributes make them ideal for applications in aircraft de-icing, consumer heating, and industrial heating systems.

Accessories

A range of accessories can be used to improve the performance and safety of heating elements in various applications. Wire and element holders, for example, provide sturdy support to keep the heating element stable and secure, ensuring it doesn’t shift or droop during use. Thermal switches, on the other hand, function as essential safety devices, monitoring the temperature and cutting off power to the heating element if it surpasses a set limit, thereby preventing overheating and potential dangers.

Pliers are essential tools for manipulating and shaping heating elements, particularly during installation and maintenance. Braided wire is frequently employed to enhance the flexibility and longevity of electrical connections between the heating element and other components. Additionally, silicone O-rings ensure a watertight seal when the heating element is submerged in liquids. Bolts are used to firmly attach heating elements to their mounting brackets or frames.

Adaptors and extension cords bridge the gap between various heating elements and power sources, or provide the extra reach needed to access distant outlets. Power cords are crucial for linking heating elements to electrical sockets, guaranteeing a safe and reliable power supply. Electrical boxes offer protective enclosures, securing the electrical connections and ensuring the safe operation of the heating elements.

Choosing the right accessories depends on the specific application and requirements of the heating element. For example, in industrial environments where safety is crucial, thermal switches and silicone O-rings are often indispensable. Wire and element holders play a vital role in securing the heating element, particularly in appliances subject to frequent movement or vibration. Pliers and braided wire are handy for managing heating elements with complex designs or when precision is necessary during installation or repair.

To acquire these accessories, individuals have several avenues to explore. Heating element manufacturers and suppliers often provide a variety of compatible accessories for their products, simplifying the search for the right components for a specific heating element model. Online retailers and specialized electrical or heating equipment stores are great places to browse and purchase these items. Local hardware stores may also stock common heating element accessories for household use. Additionally, consulting with heating element experts or professionals can offer valuable insights into selecting the most appropriate accessories for a particular heating element application.

Proper Care for Heating Elements

To ensure safe and efficient operations, it’s crucial to match your heating element properly with its intended use. Incorrect pairing can lead to short circuits, fires, product damage, or equipment loss.

Most heaters gradually lose their heating capacity as they age. This decline usually points to a problem with the heating element. Therefore, periodic replacement of the heating element is necessary. Manufacturers typically provide replacement elements that can be purchased or custom-made to meet specific needs. This replacement process is usually quick and considered part of routine maintenance. However, if a heating element fails in an end-user item like a hairdryer, it is often more cost-effective to replace the entire item rather than just the heating element.

Manufacturers can install the replacement element for you, or you can tackle the task yourself. If you’re ready to dive in, follow our step-by-step guide for testing and replacing an old heating element. We’ve included tips to ensure your safety throughout the process. However, if you’re uncertain at any point, it’s best to consult a professional.

1. Take a close look at the coil. If you spot any discoloration, damage, or burn marks, it’s time to replace the element. If everything appears normal, you can move on to the next step.
2. Determine the resistance of the component. This task involves some math, and you can use a calculator to help. The straightforward formula for this calculation is: R = (V x V) ÷ P. In this equation, R represents resistance, V represents voltage, and P represents the power required by the component.
3. After determining the resistance, the next step is to test the element with a multimeter. Adjust the multimeter to the resistance setting and select a suitable measuring scale. Ensure the heater is unplugged from the power source. Then, measure the element’s resistance by placing the multimeter leads on the heating element’s terminals.
4. Ensure that the resistance reading shown by the multimeter matches the value you calculated.

If the element matches, it indicates no issue with it. However, if you’ve observed any unusual heating patterns with your appliance recently, another problem might be at play. It’s best to have a repair service inspect and address the issue.

If the actual reading deviates from your calculation, it’s time to replace the element. You can either hire a professional service or watch a video tutorial to handle the replacement yourself.

NOTE: Before conducting this test on a water heater, ensure you drain all the water from the tank and let it dry thoroughly. Unplug the device and switch off the breaker panel for safety. Once that’s done, carefully detach the electric wires and open the tank to proceed with the test and replacement.

Standards

The production and utilization of heating elements must adhere to numerous standards to guarantee safety, efficiency, and conformity with industry regulations. In the United States, organizations such as Underwriters Laboratories (UL), the American National Standards Institute (ANSI), and the National Fire Protection Association (NFPA) establish these standards. They play a crucial role in ensuring uniform quality, minimizing hazards, and safeguarding consumers and workers from potential dangers related to heating elements.

The National Electrical Code (NFPA 70) plays a vital role in the realm of heating elements by setting forth essential guidelines and requirements for electrical installations. This ever-evolving code addresses the latest technologies and safety concerns, making it an indispensable resource for electrical contractors, engineers, and industry professionals. By following NFPA 70, professionals ensure that heating elements are installed properly, wired safely, and meet all required safety standards.

Using substandard heating elements can result in serious repercussions. These non-compliant components may present significant safety hazards, such as electrical fires, electric shocks, and other dangerous incidents. Furthermore, utilizing such heating elements could nullify warranties and insurance policies, making users responsible for any resulting damage or accidents. In commercial and industrial environments, employing non-compliant heating elements might also lead to legal complications and potential fines for breaching safety regulations.

Conversely, utilizing heating elements that adhere to established standards brings a wealth of advantages. Primarily, they guarantee the safety of the equipment, users, and the environment. These compliant elements have passed stringent testing and certification, ensuring reliable and efficient performance within their designed parameters. Adherence to standards also promotes interoperability and compatibility with other components and systems, minimizing the risk of malfunctions and boosting overall performance. Additionally, compliant heating elements often lead to long-term cost savings due to their extended lifespans and reduced need for frequent replacements or repairs.

In conclusion, adhering to standards for manufacturing and using heating elements is vital for ensuring safety, quality, and efficiency. In the United States, the National Electrical Code (NFPA 70) plays a significant role, specifying the requirements for electrical installations, including heating elements. Utilizing heating elements that meet these standards protects both individuals and property, while also mitigating the risk of legal and financial repercussions due to non-compliance. These compliant heating elements are known for their reliability, durability, and compatibility, making them the optimal choice for various heating applications.

How to Find the Right Manufacturer

For the best results when purchasing heating elements, start by exploring our comprehensive directory of heating element manufacturers. Each manufacturer’s profile page showcases their expertise and capabilities, and includes a contact form for direct communication. Utilize our unique website previewer to quickly understand each company’s specialties. Then, use our streamlined RFQ form to easily reach out to multiple manufacturers with a single request.

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