Nexthermal – Smart Heat Management


Presentation Description

If heat is essential to your process, systematic heat management thinking and development is key to your competitive edge. Nexthermal is committed to make our best resources – people, tools, testing, and facilities – available to accelerate your success. Your R&D department just cost effectively extended it’s capabilities.


Presentation Transcript

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10/24/11 Nexthermal Smart Heat Management

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10/24/11 Global Electric Heating Solutions Approachable International Innovative Dynamic Knowledgeable

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10/24/11 Nexthermal is the new name for the company you have known as Hotset Corporation, this new identity is representative of our transition to offer a broader range of solutions including heating elements, sensors, control systems, complete assemblies, and engineering services This name change is truly a vote of confidence by our ownership of 25 years to extend our smart heat management solutions worldwide. Our commitment to our customers is the reason for this change.

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10/24/11 Nexthermal accelerates the development and delivery of optimized heating systems, solutions and services for vital process heating applications. Mission Statement Worldwide leader in advancing process heating technology solutions in growth and emerging niche markets. Vision Statement

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10/24/11 American Roots, International Reach United States Headquarters and manufacturing strategically located in Battle Creek, Michigan (USA) since 1986 Manufacturing supporting Asia located in Bangalore, India. Nexthermal can collaborate with our customers via direct technical sales staff, R&D web updates, and Nexthermal trained north American and International distributors

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10/24/11 As you engage Nexthermal our goal is that you conclude we are: Approachable — Welcoming discussion, highly interested in the details of your application. Sincerely committed to helping you succeed. Dynamic — Responding with a sense of urgency, proactively anticipating and planning for challenges, demonstrating agility that incorporates your input and experience to accelerate the best solution. Knowledgeable — Our application experience, ability to understand your process, generating market driven solutions should lead you to clearly see that Nexthermal is your heat management expert. International — United States roots with a global reach. With customers and strategic partners worldwide Nexthermal has the resources to generate the right solution to you delivering world class benefits well beyond your investment in our products and services.

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10/24/11 Let us be your R&D! If heat is essential to your process, systematic heat management thinking and development is key to your competitive edge. Nexthermal is committed to make our best resources – people, tools, testing, and facilities – available to accelerate your success. Your R&D department just cost effectively extended it’s capabilities.

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10/24/11 Nexthermal Heaters… • Participated in the 2010 Olympics testing for controlled substances and creating snow • Helped make disease detection of Malaria, Bird Flu and more than 2000 other diseases faster, more affordable and portable • Enable Mass Spectrometry systems to detect parts per billion • Create energy savings opportunity and more hygienic design for food production companies • Improve effectiveness and life of electric vehicle batteries • Extend the capabilities of existing Hot Runner Injection Molding designs, and develop new product offerings • Improve Aerospace hydraulic system responsiveness and energy efficiency Imagine what we can do when your experience is combined with ours – focused squarely on your heat management needs.

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10/24/11 Low mass, Smaller Footprint Packaging Jaw Ø 1/8” pressed in place heater Minimum bending radius – 6mm Flexible, hand formable, can be sealed for wash down applications Ideal for low mass, small footprint applications Can incorporate type J thermocouple, positioned anywhere

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10/24/11 HotFlow Modular Circulation Heater Improving Electric Vehicle Battery Performance and Life

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10/24/11 Mini Manifold Improving versatility and use of existing product Wood pellet stove igniter Improved durability and performance

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10/24/11 Energy Saving Reduces amount of energy to meet temperature set point by 24.3% Replaces SS321 heater sheath with a highly thermally conductive alloy SS321 = 16 – 22W/mK New alloy = 159 W/mK 622% improvement in rate of thermal transfer from heater to jaw Capable of a sustained 600o F operating temperature

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10/24/11 PCR (Polymerase Chain Reaction) Block Nexthermal developed product helps PCR company revolutionize PCR disease detection affordability and portability PCR Well Heating System

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10/24/11 Plate design Standard heater power in each location Staggered heater power, without internal wattage distribution Reduced temperature variance, further improvement possible with distributed wattage

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10/24/11 Coil Heater Solutions

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10/24/11 Nexthermal coil heaters… your smart heat management choice. Nexthermal coil heaters are designed to deliver excellent performance in demanding applications. Factors such as movement, moisture, dimensional tolerances, operating temperature, material being heated and environmental conditions will impact the design of the coil heater. When we work together with you to build the right heater for your application — we design the most cost effective process improvement solutions you can implement. Nexthermal’s committed to deliver the best heater for your application — a coil heater built specifically for your need. Critical engineering decisions dramatically improve your heater’s performance including: product quality, cycle time, response rate and durability.

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10/24/11 Nexthermal manufactures heaters with better components, materials and precision… Design intent to maximize thermal efficiency and heat transfer. Unique ceramic cores designed to precisely position resistance wire avoiding twisting commonly seen on other coil heaters. Our standard stainless steel sheath is SS321 for improved corrosion resistance. (Nickel 200 is also available on mini coil heaters) Flat surface for better contact and better improved heat conduction. Computer controlled resistance wire winding for tighter ohms tolerance. Technical support and simulation program to understand your application and design a heater with your specific use in mind. Nexthermal has attained and maintained ISO 9001 since 2000. Many customers have told us that we are more responsive with quotation timing, sales order confirmation timing and shorter build to order and wind from stock coil heater lead times than any other heater manufacturer.

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10/24/11 Nexthermal coil heaters are the number one choice among US Hot Runner Injection Molding OEMs. Nexthermal coil heaters and coil heater assemblies are also the heater of choice for many leading scientific measurement, diagnostic and test OEMs worldwide. To further demonstrate the coil heater's flexibility of use, emerging markets include form fill and seal packaging, top seal packaging, rubber injection molding, liquid heating, electric vehicle systems and medical equipment. While many believe the name “coil heater” is derived from common winding patterns to heat nozzles, the name is actually related to the internally spiraled resistance wire. This coiled resistance wire greatly increases the watt density a coil heater can carry on the surface of the heater. Customers have found the ability to concentrate heat specifically where it is required reduces cycle time, improves quality, and expands the capability and accuracy of their equipment. What makes a coil heater unique?

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10/24/11 Form in groove capabilities… Highly annealed, the coil heater can be formed to hold shape or formed into a slot or groove. Coil heaters have been embedded and cast into functional components to provide protection from cold, or to apply process heat at a critical stage. Nexthermal coil heater “profiles”…height and width of a cross section …are designed to provide the engineer with options to meet size limitations, better hold form, and concentrate heat in a specific area.

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10/24/11 mini coil heater Precise, flexible and moisture resistant… As OEM engineers face continual pressure to reduce space claim, Nexthermal is responding with advancement of mini coil technology. The Nexthermal mini coil heater contains a precisely wound resistance wire to maximize watt density capability. The mini coil is extremely flexible, reduces required installation area, and the standard transition head construction is highly moisture resistant. Staggering transition heads allows for smaller wire channel dimensions. While originally designed for the Hot Runner Injection Molding industry, mini coil heaters are used in a wide range of markets including, high temperature simulation, packaging, component level deicing, and medical device. Given its precision and flexibility of installation, the mini coil is a heater that can be readily used in prototyping and cost effective at production levels.

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10/24/11 maxi coil heater The Nexthermal maxi coil heater is designed to provide longer service life in high temperature applications and challenging environments. The maxi coil heaters can carry higher watt density. Maxi coils are a high performance large diameter alternative to MI Band heaters, frequently replacing several heaters with one profiled heater. The Nexthermal maxi coil heater can be incorporated into a nozzle body assembly to create a high performance, durable solution for Zinc Pressure Diecast applications. Durable, high performance…

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10/24/11 high cavitation mini coil heater Hotlock coil heater Nexthermal’s next generation Hotlock maximizes high cavitation injection molding performance. Nexthermal’s unique locking mechanism precisely positions the Hotlock and holds a replaceable 1mm thermocouple firmly in place. Nexthermal has solved common problems associated with this heater style: Smallest unheated section, just .250” from tip. Smaller net outer diameter allowing for closer drops Nickel coated inside diameter for easier removal Axial Clamp coil heater Axial Clamp mini coil heaters positively clamp the heater against the nozzle. The application of physical theory and unique cam design ensure Nexthermal Axial Clamp heaters deliver excellent heat transfer and durability. The axial clamp heater can be tightened with one allen screw in front, compared to two on the side of a flange lock up heater. Tightening and removal is greatly simplified.

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10/24/11 coil heater embedded in brass Utilizing the three dimensional flexibility of Nexthermal coil heaters is likely much easier than you think. We welcome the opportunity to discuss your specific application and design objectives. Extending and refining coil heater performance… Nexthermal has developed coil heaters and mini coil heaters embedded in brass for the hot runner injection molding, measurement, analysis, and packaging markets. Traditionally this type of heater would be “cast in brass.” The embedded in brass heater provided more precise repeatability of winding profile, and longer thermocouple life due to the elimination of molten brass temperatures during the casting process. For demanding applications, the embedded in brass design also facilitates precise thermocouple placement. Originally designed to accommodate higher temperature applications to 650C, the embedded in brass design is creating new opportunity to heat difficult three dimensional applications, small space claim and thin faced packaging jaws, and hole punch applications.

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10/24/11 Wind from stock coil heaters

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10/24/11 Coil heater Performance options Pressed on sheath (with and without tab) A pressed on sheath ensures the best heat transfer, and is 20% more efficient in most injection molding applications. Recommended for operating temperatures exceeding 600F and inside diameters greater than 1''. Our tab option precisely locates and holds heater in place. Moisture resistance transition head Nexthermal has developed a highly moisture resistant transition head construction further improving durability in high humidity and washdown applications — reducing the need for soft starts. This head also protects against oil ingress and other contaminants. Compact coil heater head 5.5mm In response to emerging requirements for smaller space claim in wire channels, Nexthermal has developed a compact 5.5mm diameter coil heater head that is just 15mm long without compromising dielectric strength. Thermocouple options Nexthermal coil heaters can be built with an integrated Type J or Type K thermocouple. Mini coil heaters can be designed with an external thermocouple wound with no net impact to the OD of the heater. Other external TC options are available. Pressed in brass Nexthermal’s process of embedding coil heaters into machined brass components delivers strong life at high temperatures. Precise repeatable thermal profiles, 8% faster heat up and recovery times, improved TC performance and shorter lead times compared to cast in brass heaters. Form in groove and three dimensional heating Coil and mini coil heater’s precise OD tolerance and annealing process are ideal attributes to form into a machined groove. To engineers and designers this means that a structural component could be developed into a three dimensional heater without greatly affecting space claim. Easy to remove bore heater Nexthermal coil heaters can be designed slightly oversized to a bore with additional cold section at the tip. With a provided tool, you can compress the OD slightly, insert into the bore and allow to expand. Excellent fit and easy to remove heater for bores over 1'' in diameter. Laboratory, development and test process The coil heater’s stainless steel construction and ability to be formed into unique shapes make it the heater of choice for many laboratory, development and testing applications.

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10/24/11 leads Fiberglass (Standard) Temperature Rating 482 oF | 250 oC Teflon Temperature Rating 500 oF | 260 oC Teflon (High Amperage) Temperature Rating 500 oF | 260 oC Fiberglass (High Temp.) Temperature Rating 932 oF | 500 oC lead protection Fiberglass Sleeve Braided Metal Sleeve Armor Cable Armor Cable (Gas proof) lead, lead protection and exit options exit options

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10/24/11 Coil Heater Profiles Mini Coil Heaters Nexthermal offers a range of mini coil heaters, flat and round for when space is constrained. We can wind in thermocouples and support a bending radius of 3mm. 2.2 x 4.2mm Flat Coil Heater Thin enough to keep net outer diameter to a minimum, wide enough to bring more power to heating surface. Supports internal TC. Bending radius 6mm. 3.0mm, 3.18 and 4.0mm Round Coil Heater Proven coil heater product excellent for form in groove and 3D heating applications. Internal TC. Minimum bending radius 6mm. 4.6 x 8.6mm Maxi Coil Heater Highly durable heater used in large format injection molding and diecast applications. Minimum bending radius 10mm. 1.8 x 3.2mm Flat Coil Heater The power of a Nexthermal coil heater in a smaller size with a bending radius of 6mm. 2.5 x 3.4mm Coil Heater Our most popular coil heater and a standard for OEMs. Internal TC option. Bending radius 6mm. 3.0mm Square Coil Heater Structurally sound and increases the surface area in contact with form in groove assemblies and applications. Coil Heater Based Assemblies Hotlock Axial Clamp Pressed in brass Heater

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10/24/11 Cartridge Heater Solutions

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10/24/11 Nexthermal manufactures heaters with better components, materials and precision… High watt density heaters are built with 8" long ceramic cores, 33% longer than our competitors—resulting in fewer electrical connections on longer heaters. Standard stainless steel sheath is SS321 for improved corrosion resistance (Incoloy is also available). New, compact right angle exit with flat sides to aid removal (when heaters last as long as Nexthermal’s do, this is important). Anti-seize coating applied in house for faster delivery. Centerless grinding option to a tolerance of +/- .0008" for a better fit. Computer controlled winding ensures the right wattage distribution profile on every heater…every build. Technical support to understand your application and design a heater with your specific use in mind. Attaining and maintaining ISO 9001 since 2000.

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10/24/11 High watt density heaters The machine winding of the high watt density heater delivers the most precise distributed wattage profile. High watt density heaters can be built to your specifications from 1" long to over 100". Warranted to 160 watts per square inch. Both high watt and medium watt construction can be built as an energy saving eheat cartridge heater. Medium watt density heaters The medium watt density heater has a continuous resistance spiral throughout the heater delivering unparalleled reliability. For longer heaters there are fewer internal electrical connections. Medium watt density heaters start at 8" long, and can be built to over 100". Warranted to 65 watts per square inch. Specify a high watt density heater if: Watt density is greater than 65 watts per square inch.* And/or the heater is less than 8". And/or your application requires a precise wattage distribution. High watt density heaters are commonly built below 65 watts per square inch and in lengths up to 100" long for specific applications. Specify a medium watt density heater if: Watt density is less than 65 watts per square inch. And the heater is 8" or longer. And you do not need highly precise wattage distribution. In the past only high watt density heaters could support an internal Type J or K TC. Nexthermal can now manufacture medium watt density heaters with an internal TC.

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10/24/11 cartridge heater performance options Distributed Wattage Nexthermal has developed industry specific winding profiles to improve thermal profiles including packaging, rubber and injection molding. We have also successfully developed OEM specific winding profiles to compensate for challenging heater placement. Moisture Resistance If your application requires wash down, has high amounts of humidity in the ambient air, or has machining oil nearby — Nexthermal has a wide range of 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 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 prone to oxidation.

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10/24/11 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. Standard Flanges, Special Flanges and NPT If your application calls for specific insertion depth, or 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 ±.002" compares favorably to other cartridge heaters. If heat transfer is critical to your application, Nexthermal offers premium centerless grind tolerances that are ±.0008".

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10/24/11 cartridge heater based assemblies Nexthermal cartridge heaters are versatile. We work together with our customers, clearly focused on their objectives. Nexthermal has combined our electric heaters with ingenuity to create solutions that have generated new products and capabilities for our customers. Common Nexthermal assembly solutions include: Early stage new product design “Plug and play” assembly combining heaters and sensors into one plug to deliver a completed assembly that improves your production throughput Redesign of an existing component with multiple vendors or need for improved performance

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10/24/11 engineering services A heater is one component of a smart heat management system. To optimize performance one must carefully consider: Heater location Fit to mating surfaces Material being heated Control method Cycle time Sensing method and location Performance goals Engineering services include: Production and product development assistance Thermal engineering consulting Solid modeling Design optimization for performance and energy consumption FEA and lab simulation The more complex the design, and the more critical heat is to design performance, the greater the impact Nexthermal engineering service will have on your process. Your application, performance goals and future plans create a unique opportunity to explore the power of Nexthermal engineering services.

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10/24/11 eheat Cartridge Heater Solutions fewer system amps longer life 25 % energy savings faster responding Next Generation Energy Efficient Cartridge Heater patent pending

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10/24/11 eheat cartridge heaters improve performance and efficiency Nexthermal eheat cartridge heaters are constructed with a special high thermal transfer sheath material that creates a fast responding, longer lasting, more energy efficient heater. At the same rated wattage, Nexthermal eheat cartridge heaters have measured up to 25% improved energy efficiency over traditional build cartridge heaters. Nexthermal eheat Cartridge heaters are the fast responding, energy efficient and direct replacements for your existing cartridge heaters.  Extend the capabilities of your existing system with eheat cartridge heaters, or develop around its strengths to bring smart heat management capabilities to your market. Nexthermal eheat cartridge heaters: The high thermal transfer sheath results in a heater that can perform the same work with fewer watts - saving energy and reducing total system amperage. For higher watt density applications such as hot glue systems, the eheat delivers heat to the application faster, resulting in more heat delivered with a lower heater core temperature. This extends heater life. Nexthermal eheat cartridge heaters reach set point faster, and can reduce cycle times of demanding applications.

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10/24/11 Nextflex Tubular heaters Next Generation Flexible Tubular Heaters

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10/24/11 8.0mm available in Round and D-shape Nextflex Round vs. D-shape Traditional Round Shape Contact surface 50% Ease of installation Innovative D-shape contact surface 72% Improved heat transfer/energy efficiency Staking reduces need for holding mechanism Nextflex D-Shape The new heater for 8.0mm grooves Optimal heat transfer (above 72% and beyond)

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10/24/11 Nextflex compelling advantage Excellent Heat Transfer Nexflex D-shape heaters proven to be faster and more efficient than our previous generation flexible heater in side by side test. Ask your Nexthermal representative to show you the video. User formable — Shipped in simple to install straight lengths Availability — Nextflex heaters ship same day from stock for orders placed before 2:00 p.m. Eastern Standard Time Eliminate guesswork — Nextflex true to size heaters do not expand when installed, eliminating risk of heated section outside of the manifold Supporting tools — Reduce installation time and improve performance with Nexthermal installation tools Technical support — Nexthermal can assist you in selection, installation advice and improving application performance Nexthermal Tubular Heaters… the next generation flexible tubular heater.

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10/24/11 Nextflex tools Forming tool recommended for round NextflexForming and staking tool required for Nextflex D Shape Nextflex Forming tool Designed for Nextflex Helpful bending aid No damage of Nextflex Nextflex Staking tool Designed for Nextflex Helpful assembly aid Optimized compressing

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10/24/11 Nextflex heaters are simple and efficient Efficient to Install Best Practices Nextflex tools reduce installation time and eliminate the need for additional retention methods. Form the first bend at center location prior to striking. Making sure heater is directly above the groove, strike with Teflon® side of Nextflex forming tool. One hard strike is better than two soft ones. When bending, make sure the Nextflex tool handle is parallel with the uninstalled Nextflex. This puts the minimum bending radius protection in the correct position. Strike the Nextflex staking tool hard every 20mm (~.75"). This creates a firmly seated heater with excellent heat transfer. The first 10mm (~.40") after the connection area should always be straight. For optimal heat transfer, it is best to stake the Nextflex after assembly approximately every 20mm (~.75") into the groove. For bending the Nextflex we recommend our Nextflex toolset. This will allow the Nextflex to be seated optimally into the groove, resulting in maximum heat transfer.

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10/24/11 Nextflex heaters are stocked in 8mm and 8.5mm diameters NF Nextflex 08.5 8.5mm ø 300L 300mm Length 0650W 650W @ 230V NF 08.5 300L 0650W

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10/24/11 Nexthermal heaters… Imagine what we can do when we combine experience and innovate together. Improve effectiveness and life of electric vehicle batteries Extend the capabilities of existing hot runner injection molding designs and assist new product development Helped make disease detection of Malaria, Bird Flu and more than 2000 other diseases faster, more affordable and portable Participated in the 2010 Olympics testing for controlled substances and creating snow Improve aerospace hydraulic system responsiveness and energy efficiency Enable mass spectrometry systems to detect parts per billion Create energy savings opportunity and more hygienic design for food production companies

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10/24/11 Thank You!

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