Engineering Services<br />
As you engage Nexthermal our goal is that you conclude we are:<br />Approachable — Welcoming discussion, highly interested...
Our History<br /><ul><li>1986 - Hotset Corporation established in Battle Creek, Michigan as a separate entity and strategi...
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</li></ul>-Introduced anti-seize coating and highly moisture resistant coil heater...
2010 - Renamed Nexthermal to emphasize commitment to heat management solutions worldwide. Location, manufacturing faciliti...
Let us be your R&D!<br />If heat is essential to your process, systematic heat management thinking and development is key ...
Idea<br />Design<br />Prototype<br />Testing<br />Analysis<br />Typical Product Development Cycle <br />Design modificatio...
Design Analysis<br />Verification<br />Idea<br />Design<br />Prototype<br />Product Development with CAE<br />Design modif...
Quality as a Foundation<br /><ul><li>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</li></li></ul><li>Materials and Construction<br /><u...
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</li></li></ul><li>Coil Heater<br /><ul><li>‘Other’ Heater- note the ...
Poor heat management = Poor system efficiency</li></li></ul><li>Coil Heater<br /><ul><li>X-ray sample of our coil heater s...
Improved performance and improved heat transfer efficiency</li></li></ul><li>Nozzle Design for Optimal Heat Transfer<br />...
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</li></li></ul><li>Note the reflection tube pushes the heat into the tool<br />...
 Lower duty cycle = Higher efficiency</li></ul>Pressed in Brass vs. Reflection Sheath<br />Pressed in Brass<br />Pressed i...
Nozzle Design Optimal Heat Transfer<br /><ul><li>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)
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Nexthermal Industrial Heating Solutions

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

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Nexthermal Industrial Heating Solutions

  1. 1. Engineering Services<br />
  2. 2. As you engage Nexthermal our goal is that you conclude we are:<br />Approachable — Welcoming discussion, highly interested in the details of your application. Sincerely committed to helping you succeed.<br />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.<br />Knowledgeable — Our application experience, ability to understand <br />your process, generating market driven solutions should lead you to <br />clearly see that Nexthermal is your heat management expert.<br />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.<br />
  3. 3. Our History<br /><ul><li>1986 - Hotset Corporation established in Battle Creek, Michigan as a separate entity and strategic partner to Hotset GmbH
  4. 4. 1991 - Initial cartridge heater produced
  5. 5. 1998 - U.S. coil heater production launched
  6. 6. 2003 - Production facility expanded
  7. 7. 2004 - Heater based assemblies unveiled
  8. 8. 2007 - Manufacturing in Bangalore, India</li></ul>-Introduced anti-seize coating and highly moisture resistant coil heater head<br /><ul><li>2008 - Selected as the exclusive Elstein marketing agent in the United States</li></ul>- Engineering Services Team Created<br /><ul><li>2009 - Hotflow circulation heater invented, targeting electric vehicle, medical and food production markets
  9. 9. 2010 - Renamed Nexthermal to emphasize commitment to heat management solutions worldwide. Location, manufacturing facilities and staff remain the same.</li></ul>- Introduced eheat, energy efficient cartridge heaters<br />
  10. 10. Let us be your R&D!<br />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.<br />
  11. 11. Idea<br />Design<br />Prototype<br />Testing<br />Analysis<br />Typical Product Development Cycle <br />Design modification<br />for each learning phase<br />Iteration for each learning phase, multiple expenses of prototypes and testing for each design<br />
  12. 12. Design Analysis<br />Verification<br />Idea<br />Design<br />Prototype<br />Product Development with CAE<br />Design modification<br />Lower risk of final testing not meeting customers needs<br />
  13. 13. Quality as a Foundation<br /><ul><li>Certified ISO 2001: 2008 standard
  14. 14. In 2001, Nexthermal was the first electric heater manufacturer in the world to become certified under ISO 2001: 2000 standard
  15. 15. All outgoing product is 100% checked for safety, performance and fit metrics
  16. 16. All raw materials are checked with traceable certificate to prove acceptance
  17. 17. All customer returns are diagnosed for root cause, regardless of cost</li></li></ul><li>Materials and Construction<br /><ul><li>Materials
  18. 18. Stainless steel 321 vs. 316
  19. 19. Ti content resists intergranular corrosion at higher temperatures
  20. 20. Heat treated in special atmospheric oven to realign grain structure for flexibility
  21. 21. High purity MgO reduces electrical leakage and improves safety
  22. 22. Further processed by Nexthermal for performance
  23. 23. Heat treated resistance wire to provide long life
  24. 24. Construction
  25. 25. Highly compacted, improves heat transfer - better heater life
  26. 26. Unique assembly process controls wire position after forming
  27. 27. Controlled heat pattern
  28. 28. Welded electrical connections provide cleanest signal</li></li></ul><li>Coil Heater<br /><ul><li>‘Other’ Heater- note the twist in the resistance wire
  29. 29. Poor heat management = Poor system efficiency</li></li></ul><li>Coil Heater<br /><ul><li>X-ray sample of our coil heater showing resistance wire placement
  30. 30. Improved performance and improved heat transfer efficiency</li></li></ul><li>Nozzle Design for Optimal Heat Transfer<br /><ul><li>Nozzle diameter tolerance for good heat transfer (important for heater ID)
  31. 31. Minimum heat loss with adequate wattage distribution to offset
  32. 32. Tip geometry to limit heat loss but engineered to prevent drool (correct design of contact and sealing surface)
  33. 33. Minimum clearance from OD of heater to bore</li></li></ul><li>Note the reflection tube pushes the heat into the tool<br /><ul><li>Less heat loss = more heat transfer to application (~15-20% reduction in watts needed)
  34. 34. Lower duty cycle = Higher efficiency</li></ul>Pressed in Brass vs. Reflection Sheath<br />Pressed in Brass<br />Pressed in Brass with reflection<br />
  35. 35. Nozzle Design Optimal Heat Transfer<br /><ul><li>Nozzle diameter tolerance for good heat transfer (important for heater ID)
  36. 36. Minimum heat loss with adequate wattage distribution to offset
  37. 37. Tip geometry to limit heat loss but engineered to prevent drool (correct design of contact and sealing surface)
  38. 38. Minimum clearance from OD of heater to bore</li></li></ul><li>Effect of Additional Windings<br />Uniform heat – but not needed – Waste of energy, breakdown of plastic resin (FLIR photo)<br />
  39. 39. Nozzle Profile without Reflection Tube<br />Good heat profile, but open coils allow heat loss<br />
  40. 40. Thick Film Heater (competitor)<br />Too much heat in the center, not efficient<br />
  41. 41. Injection Nozzle Profiling with Reflection Tube<br />Good heat profile<br />Wattage reduced by 20%<br />Higher efficiency<br />Lower scrap<br />
  42. 42. Innovative Solutions<br />
  43. 43. HotFlowModular Circulation Heater<br />By managing the fluid path and heat transfer area, we developed a high thermal efficiency fluid heater that outperforms standard immersion heater designs<br />
  44. 44. HotFlow - Improving Electric Vehicle Battery Performance and Life<br />
  45. 45. Hole Punch Heater<br />Due to the way standard cartridge heaters are used, heat is being created at exactly the wrong place for the application need<br />Using a replaceable mini coil on a replaceable tool<br />Tool wear is independent of heater, replace only when needed<br />Heat is focused into the tool<br />
  46. 46. Coated Heater<br />Benefits of Anti-Seize Coating<br /><ul><li>Reduced cost due to faster replacement, minimum tool damage and rework time
  47. 47. Quick, easy removal of heater after burn out
  48. 48. Improved heat transfer due to special composition
  49. 49. Special compound acts as a corrosion barrier
  50. 50. Protects the heater bore from galling</li></li></ul><li>Energy Saving<br /><ul><li>Reduces amount of energy to meet temperature set point by 24.3%
  51. 51. Replaces SS321 heater sheath with a highly thermally conductive alloy
  52. 52. SS321 = 16 – 22W/mK
  53. 53. New alloy = 159 W/mK
  54. 54. 622% improvement in rate of thermal transfer from heater to jaw
  55. 55. Capable of a sustained 600o F operating temperature</li></li></ul><li>Mini Manifold<br />Form in Place Heater<br />Improving versatility and use of existing product <br /><ul><li>Using a Ø3.2mm (0.125”), Ø1.8mm or a Ø1.4mm tubular heater form around heat loss areas
  56. 56. Only heat the need</li></li></ul><li>PCR (Polymerase chain reaction) Block<br />Nexthermal developed product helps PCRcompany revolutionize PCR disease detection affordability and portability <br />
  57. 57. PCR Well Heating System<br />
  58. 58. In House Lab Services<br /><ul><li>Prototype services for custom design, validation and development
  59. 59. Test services for temperature profiling, reliability/performance testing and other applications with minimum engineering charge</li></li></ul><li>Computer Aided Engineering<br />Opportunity:<br /><ul><li>Work as a design partner to show effects of heat transfer
  60. 60. Pictures create understanding, and choices
  61. 61. In its simplest terms, design analysis is a software technology for simulating physical behavior of a product. </li></ul>Will it break? <br />Will it deform? <br />Will it get too hot?<br />Where are the system inefficiencies and how to best address them<br />Current market:<br /><ul><li>Limited design support with other suppliers
  62. 62. Costly for FEA support</li></li></ul><li>TC to Heater RelationshipMaterial Thickness Relationship<br />With proper material thickness, heat will be distributed over the application better.<br />Thermocouple will read an accurate temperature, prevent overshoot<br />
  63. 63. Types of Analysis<br /><ul><li>Steady-state and transient thermal analysis
  64. 64. Linear and Contact stress analysis
  65. 65. Static
  66. 66. Drop test
  67. 67. Fatigue
  68. 68. Frequency model analysis
  69. 69. Buckling analysis
  70. 70. Pressure - flow analysis
  71. 71. Design Optimization</li></li></ul><li>Plate with Coil Heater (working surface shown)<br />Higher temperatures demand a higher class of fit to the application to reduce the radiation losses from the heater<br />
  72. 72. Plate design<br />Standard heater power in each location<br />8 cartridge heaters<br />Hot due to thicker section<br />Note shadow effect behind bolt hole<br />
  73. 73. Plate design<br />Staggered heater power, without internal wattage distribution<br />Reduced temperature variance, further improvement possible with distributed wattage<br />
  74. 74. Packaging Jawwithout wattage distribution<br />66% of jaw face within 6°F<br />
  75. 75. Packaging Jawwith wattage distribution<br />86% of jaw face within 6°F<br />
  76. 76. Any Questions?<br />?<br />
  77. 77. Thank You!<br />

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