On this page you will find a comprehensive compendium of knowledge about ceramic heaters widely used in various devices. From this text you will learn, among other things:
- What is a ceramic heater?
- How do ceramic heaters work?
- What are the types of ceramic heaters?
- What are the most important advantages of ceramic heaters?
Ceramic heater - what is it?
Let's start with the basic definition. A ceramic heater is a type of electric heater that uses ceramic heating elements with a positive temperature coefficient PTC (English: PTC). Positive Temperature Coefficient). The ceramic materials used in heaters have sufficient electrical resistance and thermal conductivity to generate and conduct heat when current flows through them. Ceramic heaters are characterized by high strength and durability. Therefore, they work well as a heating element. The heating element of the ceramic heater itself is made of pure ceramic material. However, for the construction of industrial ceramic heaters, other materials are also used - mainly metals. The ceramic material in the heater acts as an insulator, but at the same time conducts heat to the environment, which minimizes the heat and energy losses associated with the non-insulated resistance wire.
Electric ceramic heaters are used in a wide range of industrial processes, such as drying, forming and melting products. They are also used in space heating. In many cases, it is a fast, safe and clean source of heat.
How do ceramic heaters work?
We already know what a ceramic heater is, now let's find out how this device works. Key to the operation of ceramic heaters is the phenomenon of resistive (resistive) heating. In a big simplification, this phenomenon consists in the generation of heat as a result of the flow of electric current. The body through which the current flows heats up and gives off heat to the environment.
The scientific basis of this phenomenon is described by Joule's law
The amount of heat released during the flow of an electric current through an electrical conductor is directly proportional to the product of the electrical resistance of the conductor, the square of the current strength and the time of its flow.
This phenomenon is beneficial for heaters and heaters. However, it is undesirable in the process of transferring power or the operation of many devices.
The mechanism of heat transfer in ceramic heaters
Ceramic heaters, depending on the type, transfer heat to the environment by convection, conduction or radiation. Conduction involves the transfer of heat between two objects in contact with each other. Convection is the transfer of heat between liquids and gases. In convection ceramic heaters, air flows through the heated heating element, raising the ambient temperature. Finally, in the case of thermal radiation, thermal energy is emitted directly to nearby objects and people in the form of electromagnetic waves.
PTC — dreduce the temperature coefficient
If the resistance (resistance) of the material increases with increasing temperature, we are talking about a positive temperature coefficient. Ceramics is a semiconductor that exhibits just such properties.
When the temperature of the ceramic heating element rises to a certain point, its resistance will increase infinitely, which will interrupt the flow of current and heat production. The set temperature depends on the composition of the ceramic material. Thanks to this self-regulation, ceramic heaters adapt to the ambient temperature and do not produce more heat than necessary, preventing excessive overheating. This ensures safer operation compared to heating elements made, for example, of metal.
Types and applications of ceramic heaters
Ceramic heaters are used both in complex industrial processes and in many popular household appliances. Of course, these heaters differ significantly in parameters and design. Our offer includes custom-made ceramic heaters tailored to individual solutions. Selected types of ceramic heaters we described below.
Ceramic and mikanite band heaters
Ceramic band heaters are constructed from wires or resistance bands wound onto ceramic elements. The whole is enclosed in a band usually made of high quality stainless steel. This band allows the heater to be mounted on a cylindrical element. They are used, among other things, for plastic injection molding machines.
Ceramic band heaters are used for heating the contents of cylindrical tanks, pipes and pipes from the side of the outer walls. They are attached to them with the help of ties, the diameter of which can be adjusted within a certain range. Various types of strap designs are available to allow the heater to adhere effectively to the surface of the tank or conduit. Are you interested in band heaters adapted to specific solutions? Contact our sales department!
They also have a very similar structure micanite band heaters. The fundamental difference lies in the use of micanite insulation instead of a ceramic insert. How band micanite heaters are built you can see in the diagram below.
Galvanic (immersion) heaters
Galvanic heaters is another type of heaters in which ceramic heating cartridges are used. Galvanic heaters are designed for direct heating of liquids in tanks and baths. Such a heater consists of a cover (matched to the type of heated liquid), a ceramic heating element and a polypropylene head that shields the current connection. Our offer includes galvanic heaters made to order according to the specifications provided by the customer. We are able to match the parameters and specifications of the heater to specific applications.
Tubular heaters
For tubular heaters, a resistance wire with a ceramic insulator is placed in a metal tube, which provides protection against oxidation and corrosion, and also increases the safety and efficiency of heating. In tubular heaters, magnesium oxide is usually used, which is characterized by high dielectric strength and thermal conductivity. Tubular heaters It is also part of our permanent offer.
The scheme of construction of a tubular heater looks like this:
We are talking about a ceramic tubular heater in a situation where the role of an insulating material is played by a ceramic element.
Ceramic heaters — the most important advantages
Ceramic heaters are heating elements with many advantages. They have a wide range of applications in industry.
- Ceramic heaters are powered by electricity, so they are a clean and emission-free source of heat.
- Ceramic heating elements have a very wide range of applications. From specialized industries, to space heating, to everyday household appliances.
- Ceramic heaters are a safe solution that minimizes fire risk in industrial applications. The use of ceramic insulators also minimizes the risk of an accidental spark that could ignite flammable materials. However, it is necessary to observe the basic safety rules when using electrical appliances with ceramic heaters and maintain a sufficient distance from exposed heating elements.
- They are compact and compact, generating a lot of heat despite their small size.
- Ceramic heaters can be easily combined with elements such as thermostats, thermocouples, thermistors, control panels and other devices, allowing better control of the heating process and increasing safety.
Ceramic heating elements — summary of the most important information
- Ceramic heaters are electric heaters that use a ceramic heating element with a positive temperature coefficient (PTC). The element can be made of pure ceramics or a composite of metal and ceramics.
- Ceramic heaters are widely used in industrial processes and space heating.
- Resistive (resistive) heating is the phenomenon of heat generation during the flow of current through a resistive material.
- The heat generated is transferred to the environment through conduction, convection and radiation.
- We distinguish different types of ceramic heaters, including band heaters, immersion tube heaters, flat heaters, insert heaters. A common denominator is the use of a ceramic heating element.
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