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Nexthermal Industrial Heating Solutions


Industrial Heating Solutions, Engineering Services offered by Nexthermal Corporation, formerly, Hotset.

Industrial Heating Solutions, Engineering Services offered by Nexthermal Corporation, formerly, Hotset.

Published in Business , Technology
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  • 1. Engineering Services
  • 2. 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.
  • 3. Our History
    • 1986 - Hotset Corporation established in Battle Creek, Michigan as a separate entity and strategic partner to Hotset GmbH
    • 4. 1991 - Initial cartridge heater produced
    • 5. 1998 - U.S. coil heater production launched
    • 6. 2003 - Production facility expanded
    • 7. 2004 - Heater based assemblies unveiled
    • 8. 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
    • 9. 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
  • 10. 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.
  • 11. Idea
    Typical Product Development Cycle
    Design modification
    for each learning phase
    Iteration for each learning phase, multiple expenses of prototypes and testing for each design
  • 12. Design Analysis
    Product Development with CAE
    Design modification
    Lower risk of final testing not meeting customers needs
  • 13. Quality as a Foundation
    • Certified ISO 2001: 2008 standard
    • 14. In 2001, Nexthermal was the first electric heater manufacturer in the world to become certified under ISO 2001: 2000 standard
    • 15. All outgoing product is 100% checked for safety, performance and fit metrics
    • 16. All raw materials are checked with traceable certificate to prove acceptance
    • 17. All customer returns are diagnosed for root cause, regardless of cost
  • Materials and Construction
    • Materials
    • 18. Stainless steel 321 vs. 316
    • 19. Ti content resists intergranular corrosion at higher temperatures
    • 20. Heat treated in special atmospheric oven to realign grain structure for flexibility
    • 21. High purity MgO reduces electrical leakage and improves safety
    • 22. Further processed by Nexthermal for performance
    • 23. Heat treated resistance wire to provide long life
    • 24. Construction
    • 25. Highly compacted, improves heat transfer - better heater life
    • 26. Unique assembly process controls wire position after forming
    • 27. Controlled heat pattern
    • 28. Welded electrical connections provide cleanest signal
  • Coil Heater
    • ‘Other’ Heater- note the twist in the resistance wire
    • 29. Poor heat management = Poor system efficiency
  • Coil Heater
    • X-ray sample of our coil heater showing resistance wire placement
    • 30. Improved performance and improved heat transfer efficiency
  • Nozzle Design for Optimal Heat Transfer
    • Nozzle diameter tolerance for good heat transfer (important for heater ID)
    • 31. Minimum heat loss with adequate wattage distribution to offset
    • 32. Tip geometry to limit heat loss but engineered to prevent drool (correct design of contact and sealing surface)
    • 33. Minimum clearance from OD of heater to bore
  • Note the reflection tube pushes the heat into the tool
    • Less heat loss = more heat transfer to application (~15-20% reduction in watts needed)
    • 34. Lower duty cycle = Higher efficiency
    Pressed in Brass vs. Reflection Sheath
    Pressed in Brass
    Pressed in Brass with reflection
  • 35. Nozzle Design Optimal Heat Transfer
    • Nozzle diameter tolerance for good heat transfer (important for heater ID)
    • 36. Minimum heat loss with adequate wattage distribution to offset
    • 37. Tip geometry to limit heat loss but engineered to prevent drool (correct design of contact and sealing surface)
    • 38. Minimum clearance from OD of heater to bore
  • Effect of Additional Windings
    Uniform heat – but not needed – Waste of energy, breakdown of plastic resin (FLIR photo)
  • 39. Nozzle Profile without Reflection Tube
    Good heat profile, but open coils allow heat loss
  • 40. Thick Film Heater (competitor)
    Too much heat in the center, not efficient
  • 41. Injection Nozzle Profiling with Reflection Tube
    Good heat profile
    Wattage reduced by 20%
    Higher efficiency
    Lower scrap
  • 42. Innovative Solutions
  • 43. HotFlowModular 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
  • 44. HotFlow - Improving Electric Vehicle Battery Performance and Life
  • 45. 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
  • 46. Coated Heater
    Benefits of Anti-Seize Coating
    • Reduced cost due to faster replacement, minimum tool damage and rework time
    • 47. Quick, easy removal of heater after burn out
    • 48. Improved heat transfer due to special composition
    • 49. Special compound acts as a corrosion barrier
    • 50. Protects the heater bore from galling
  • Energy Saving
    • Reduces amount of energy to meet temperature set point by 24.3%
    • 51. Replaces SS321 heater sheath with a highly thermally conductive alloy
    • 52. SS321 = 16 – 22W/mK
    • 53. New alloy = 159 W/mK
    • 54. 622% improvement in rate of thermal transfer from heater to jaw
    • 55. Capable of a sustained 600o F operating temperature
  • Mini Manifold
    Form in Place Heater
    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
    • 56. Only heat the need
  • PCR (Polymerase chain reaction) Block
    Nexthermal developed product helps PCRcompany revolutionize PCR disease detection affordability and portability
  • 57. PCR Well Heating System
  • 58. In House Lab Services
    • Prototype services for custom design, validation and development
    • 59. Test services for temperature profiling, reliability/performance testing and other applications with minimum engineering charge
  • Computer Aided Engineering
    • Work as a design partner to show effects of heat transfer
    • 60. Pictures create understanding, and choices
    • 61. 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
    • 62. Costly for FEA support
  • TC to Heater RelationshipMaterial Thickness Relationship
    With proper material thickness, heat will be distributed over the application better.
    Thermocouple will read an accurate temperature, prevent overshoot
  • 63. Types of Analysis
    • Steady-state and transient thermal analysis
    • 64. Linear and Contact stress analysis
    • 65. Static
    • 66. Drop test
    • 67. Fatigue
    • 68. Frequency model analysis
    • 69. Buckling analysis
    • 70. Pressure - flow analysis
    • 71. Design Optimization
  • 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
  • 72. Plate design
    Standard heater power in each location
    8 cartridge heaters
    Hot due to thicker section
    Note shadow effect behind bolt hole
  • 73. Plate design
    Staggered heater power, without internal wattage distribution
    Reduced temperature variance, further improvement possible with distributed wattage
  • 74. Packaging Jawwithout wattage distribution
    66% of jaw face within 6°F
  • 75. Packaging Jawwith wattage distribution
    86% of jaw face within 6°F
  • 76. Any Questions?
  • 77. Thank You!