Nexthermal Industrial Heating Solutions

Engineering Services : 

Engineering Services

Our History: 

Our History 1986 - Hotset Corporation established in Battle Creek, Michigan as a separate entity and strategic partner to Hotset GmbH 1991 - Initial cartridge heater produced 1998 - U.S. coil heater production launched 2003 - Production facility expanded 2004 - Heater based assemblies unveiled 2007 - Manufacturing in Bangalore, India - Introduced anti-seize coating and highly moisture resistant coil heater head 2008 - Selected as the exclusive Elstein marketing agent in the United States - Engineering Services Team Created 2009 - Hotflow circulation heater invented, targeting electric vehicle, medical and food production markets 2010 - Renamed Nexthermal to emphasize commitment to heat management solutions worldwide. Location, manufacturing facilities and staff remain the same. - Introduced eheat , energy efficient cartridge heaters

Slide 4: 

Let us be your R&D!

Typical Product Development Cycle : 

Typical Product Development Cycle Idea Design Prototype Testing Analysis Iteration for each learning phase, multiple expenses of prototypes and testing for each design Design modification for each learning phase

Product Development with CAE: 

Product Development with CAE Idea Design Design Analysis Prototype Verification Design modification Lower risk of final testing not meeting customers needs

Quality as a Foundation: 

Quality as a Foundation Certified ISO 2001: 2008 standard In 2001, Nexthermal was the first electric heater manufacturer in the world to become certified under ISO 2001: 2000 standard All outgoing product is 100% checked for safety, performance and fit metrics All raw materials are checked with traceable certificate to prove acceptance All customer returns are diagnosed for root cause, regardless of cost

Materials and Construction: 

Materials and Construction Materials Stainless steel 321 vs. 316 Ti content resists intergranular corrosion at higher temperatures Heat treated in special atmospheric oven to realign grain structure for flexibility High purity MgO reduces electrical leakage and improves safety Further processed by Nexthermal for performance Heat treated resistance wire to provide long life Construction Highly compacted improves heat transfer - better heater life Unique assembly process controls wire position after forming Controlled heat pattern Welded electrical connections provide cleanest signal

Coil Heater: 

Coil Heater ‘Other’ Heater- note the twist in the resistance wire Poor heat management = Poor system efficiency

Coil Heater: 

Coil Heater X-ray sample of our coil heater showing resistance wire placement Improved performance and improved heat transfer efficiency

Nozzle Design for Optimal Heat Transfer: 

Nozzle Design for Optimal Heat Transfer Nozzle diameter tolerance for good heat transfer (important for heater ID) Minimum heat loss with adequate wattage distribution to offset Tip geometry to limit heat loss but engineered to prevent drool (correct design of contact and sealing surface) Minimum clearance from OD of heater to bore

Pressed in Brass vs. Reflection Sheath: 

Pressed in Brass vs. Reflection Sheath Note the reflection tube pushes the heat into the tool Less heat loss = more heat transfer to application (~15-20% reduction in watts needed) Lower duty cycle = Higher efficiency Pressed in Brass Pressed in Brass with reflection

Nozzle Design Optimal Heat Transfer: 

Nozzle Design Optimal Heat Transfer Nozzle diameter tolerance for good heat transfer (important for heater ID) Minimum heat loss with adequate wattage distribution to offset Tip geometry to limit heat loss but engineered to prevent drool (correct design of contact and sealing surface) Minimum clearance from OD of heater to bore

Effect of Additional Windings: 

Effect of Additional Windings Uniform heat – but not needed – Waste of energy, breakdown of plastic resin (FLIR photo)

Nozzle Profile without Reflection Tube: 

Nozzle Profile without Reflection Tube Good heat profile, but open coils allow heat loss

Thick Film Heater (competitor): 

Thick Film Heater (competitor) Too much heat in the center, not efficient

Injection Nozzle Profiling with Reflection Tube: 

Injection Nozzle Profiling with Reflection Tube Good heat profile Wattage reduced by 20% Higher efficiency Lower scrap

Innovative Solutions: 

Innovative Solutions

HotFlow Modular Circulation Heater: 

HotFlow Modular Circulation Heater By managing the fluid path and heat transfer area, we developed a high thermal efficiency fluid heater that outperforms standard immersion heater designs

HotFlow Improving Electric Vehicle Battery Performance and Life: 

HotFlow Improving Electric Vehicle Battery Performance and Life

Hole Punch Heater: 

Hole Punch Heater Due to the way standard cartridge heaters are used, heat is being created at exactly the wrong place for the application need Using a replaceable mini coil on a replaceable tool Tool wear is independent of heater, replace only when needed Heat is focused into the tool

Coated Heater: 

Coated Heater Benefits of Anti-Seize Coating Reduced cost due to faster replacement, minimum tool damage and rework time Quick, easy removal of heater after burn out Improved heat transfer due to special composition Special compound acts as a corrosion barrier Protects the heater bore from galling

Energy Saving: 

Energy Saving Reduces amount of energy to meet temperature set point by 24.3% Replaces SS321 heater sheath with a high thermally conductive alloy SS321 = 16-22 W/mK New alloy = 159 W/mK 622% improvement in rate of thermal transfer from heater to jaw Capable of a sustained 600F operating temperature

Improving versatility and use of existing product : 

Improving versatility and use of existing product Using a Ø3.2mm (0.125”), Ø1.8mm or a Ø1.4mm tubular heater form around heat loss areas Only heat the need Mini Manifold Form in Place Heater

Nexthermal developed product helps PCR company revolutionize PCR disease detection affordability and portability : 

Nexthermal developed product helps PCR company revolutionize PCR disease detection affordability and portability PCR (Polymerase chain reaction) Block

PCR Well Heating System: 

PCR Well Heating System

In House Lab Services: 

In House Lab Services Prototype services for custom design, validation and development Test services for temperature profiling, reliability/ performance testing and other applications with minimum engineering charge

Computer Aided Engineering: 

Computer Aided Engineering Opportunity: Work as a design partner to show effects of heat transfer Pictures create understanding, and choices In its simplest terms, design analysis is a software technology for simulating physical behavior of a product. Will it break? Will it deform? Will it get too hot? Where are the system inefficiencies and how to best address them Current market: Limited design support with other suppliers Costly for FEA support

TC to Heater Relationship Material Thickness Relationship: 

TC to Heater Relationship Material Thickness Relationship With proper material thickness, heat will be distributed over the application better. Thermocouple will read an accurate temperature, prevent overshoot

Types of Analysis: 

Types of Analysis Steady-state and transient thermal analysis Linear and Contact stress analysis Static Drop test Fatigue Frequency model analysis Buckling analysis Pressure - flow analysis Design Optimization

Plate with Coil Heater (working surface shown): 

Plate with Coil Heater (working surface shown) Higher temperatures demand a higher class of fit to the application to reduce the radiation losses from the heater

Standard heater power in each location: 

Standard heater power in each location Note shadow effect behind bolt hole Hot due to thicker section 8 cartridge heaters Plate Design

Staggered heater power, without internal wattage distribution: 

Staggered heater power, without internal wattage distribution Reduced temperature variance, further improvement possible with distributed wattage Plate Design

Packaging Jaw without wattage distribution: 

Packaging Jaw without wattage distribution 66% of jaw face within 6°F

Packaging Jaw with wattage distribution: 

Packaging Jaw with wattage distribution 86% of jaw face within 6°F

Slide 36: 

Thank you!