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Nexthermal – Smart Heat Management

Nexthermal, formerly known as Hotset Corporation, is transitioning to offer a wider range of heating solutions including heating elements and control systems, emphasizing their commitment to smart heat management. The company aims to enhance process heating applications through innovative and efficient heating technologies, backed by their international presence and customer-focused approach. Their products are designed for diverse industries, including electric vehicle systems and medical devices, showcasing flexibility, durability, and improved thermal performance.

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Click to edit Master subtitle style 10/24/11 Nexthermal Smart Heat Management
10/24/11 Global Electric Heating Solutions Approachable International Innovative Dynamic Knowledgeable
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.
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
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
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
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.
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
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
10/24/11 HotFlow Modular Circulation Heater Improving Electric Vehicle Battery Performance and Life
10/24/11 Mini Manifold Improving versatility and use of existing product Wood pellet stove igniter Improved durability and performance
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 0 2 4 6 8 10 12 Eheat vs Standard heater Minutes-Seconds
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
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
10/24/11 Coil Heater Solutions www.nexthermal.com
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.
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.
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?
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.
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,
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…
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
10/24/11 Standard Hotlock and Axial Heaters Hotlock Stock List Part Number Diameter Width Watts Volts HL30220 “3/4” “(19.05mm)” 30mm 220W 240V HL30268 “3/4” “(19.05mm)” 30mm 268W 240V HL30350 “3/4” “(19.05mm)” 30mm 350W 240V HL40220 “3/4” “(19.05mm)” 40mm 220W 240V HL40350 “3/4” “(19.05mm)” 40mm 350W 240V HL50220 “3/4” “(19.05mm)” 50mm 220W 240V HL50350 “3/4” “(19.05mm)” 50mm 350W 240V HL60220 “3/4” “(19.05mm)” 60mm 220W 240V HL60400 “3/4” “(19.05mm)” 60mm 400W 240V HL70220 “3/4” “(19.05mm)” 70mm 220W 240V HL70400 “3/4” “(19.05mm)” 70mm 400W 240V HL80220 “3/4” “(19.05mm)” 80mm 220W 240V HL80400 “3/4” “(19.05mm)” 80mm 400W 240V HL90220 “3/4” “(19.05mm)” 90mm 220W 240V HL90400 “3/4” “(19.05mm)” 90mm 400W 240V HL100220 “3/4” “(19.05mm)” 100mm 220W 240V HL100400 “3/4” “(19.05mm)” 100mm 400W 240V HL110220 “3/4” “(19.05mm)” 110mm 220W 240V HL110400 “3/4” “(19.05mm)” 110mm 400W 240V HL130220 “3/4” “(19.05mm)” 130mm 220W 240V HL130400 “3/4” “(19.05mm)” 130mm 400W 240V HL150220 “3/4” “(19.05mm)” 150mm 220W 240V HL150400 “3/4” “(19.05mm)” 150mm 400W 240V HL170220 “3/4” “(19.05mm)” 170mm 220W 240V HL170450 “3/4” “(19.05mm)” 170mm 450W 240V HL190220 “3/4” “(19.05mm)” 190mm 220W 240V HL190450 “3/4” “(19.05mm)” 190mm 450W 240V HL210220 “3/4” “(19.05mm)” 210mm 220W 240V HL210450 “3/4” “(19.05mm)” 210mm 450W 240V Build-To-Order Hotlock Stock Axial Lock-up Heaters Diameter Width Minimum Width Maximum Wattages Voltage Max Diameter Width Watts Volts “3/4” “(19.05mm)” 30mm 210mm 100W-450W* 240V “3/4” “(19.05mm)” “1.2” “(30mm)” 149W 240V “7/8” “(22.22mm)” 30mm 110mm 100W-450W* 240V “3/4” “(19.05mm)” “1.2” “(30mm)” 268W 240V *Wattage capabilities depend on size of heater, contact Nexthermal for design assistance “7/8” “(22.22mm)” “1.2” “(30mm)” 268W 240V *All stock Axials can be re-fit with external wound in thermocouple for same or next day shipment.
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.
10/24/11 Coil Technical Data Chart Length Tolerance Wattage Tolerance Insulation Resistance Leakage Current Std. Shape Heated Unheated +10% Premium +5% +2% >= 5 Mohm @ 500V DC Special on Request <0.5 mA @ 250V AC Special on Request Lead Length (mm) Mini Flat 1.0x1.7 & 1.3x2.3 (only possible as wound or pressed in) Flat +2.5% +5% 1000 Mini Round ø1.4 and ø1.8 Round +2.5% +5% 1000 Mini Axial and Standard Clamp with 19.05 and 22.22 mm ID Flat Clamp +0 -0.5mm Customer Specified 1830 1.8 x 3.2mm Rectangle +1% +5% 1245 2.2 x 4.2mm Rectangle +1% +5% 1245 Round Coil ø2.6, ø3.0, ø3.18, ø3.25 & ø4.0mm Round +2.5% +5% 1245 2.5 x 3.4mm Rectangle +1% +5% 1245 Square Coil 3x3 Square +1% +5% 1245 Maxi Coil Heater 4.6 x 8.6 Rectangle +1% +5% 1245 Watt density limits for common coil heater installation • Coil –round: 39 W/in2 • Coil – Flat: 48 W/in2 • Coil – OD Sheath: 65 W/in2 • Mini – Pressed in brass: 80 W/in2 •Coil – Pressed in brass: 96 W/in2
10/24/11 Lead Protection Options FIBERGLASS SLEEVING BRAIDED METAL SLEEVING FLEXIBLE ARMOR CABLE Wind from stock coil heaters HEATED LENGTH (INCH) TOTAL LENGTH (INCH) WATT VOLT 10.5 14.5 215 240 12. 16.5 250 240 16 20 325 240 19 23 390 240 22 26 470 240 26 30 520 240 30 34 610 240 36 40 630 240 38 42 700 240 42 46 800 240 45 49 850 240 75.28 78.84 1050 240 79 82.56 1150 240 86.6 90.16 1300 240 All heaters available with and without thermocouple 2.5mm x 3.4mm (0.100” x 0.134”) Flat Coil Heater Standard 48” Teflon® and TPE Leads Ungrounded TC
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.
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
10/24/11 Standard wattage tolerance for Nexthermal coil heaters is +/-10%. Premium wattage tolerance is +/-5%. Standardized heaters may be designed with tighter than published wattage tolerances. Consult Nexthermal Engineering. Hotlock and Axial Clamp heaters are available with +/-2% wattage tolerance. Standard Coil Heater Configuration Chart Maximum Ratings Sheath Material Coil Heater Type Profile Minimum Inside Diameter Voltage Watt Density (per sq. inch) Straight Heated Length Thermo- couple SS321 Nickel Without Pressed on Sheath With Pressed on Sheath Pressed in Brass Inbuilt* inches mm inches mm inches mm J K Micro Mini 0.039x.067 1.0x1.7 0.236 6.00 240 38.7 52 80 112.2 2850 Mini Flat 0.051x.090 1.3x2.3 0.236 6.00 240 38.7 52 80 112.2 2850 Mini Round Ø0.055 Ø1.4 0.236 6.00 240 38.7 52 80 112.2 2850 Mini Round Ø0.070 Ø1.8 0.236 6.00 240 38.7 52 80 112.2 2850 Square 0.118x.118 3.0x3.0 0.472 12.00 240 38.7 52 80 86.6 2200 Flat 0.071x.126 1.8x3.2 0.472 12.00 240 38.7 52 80 86.6 2200 Flat 0.087x.165 2.2x4.2 0.472 12.00 240 38.7 52 80 86.6 2200 Flat 0.098x.134 2.5x3.4 0.472 12.00 240 38.7 52 80 86.6 2200 Round Ø0.118 Ø3.0 0.472 12.00 240 38.7 52 80 86.6 2200 Round Ø0.125 Ø3.18 0.472 12.00 240 38.7 52 80 86.6 2200 Coil ID Tolerance ID with Pressed on Sheath(mm) Coil ID (mm) Mini, Standard & Maxi ID Tolerance <30mm Long >30mm Long Mini +0.05 to +0.10 6.5-12 -0.05 to -0.2 -0.1 to -0.3 Standard +0.05 to +0.10 13-30 -0.1 to -0.3 -0.2 to -0.4 Maxi +0.05 to +0.15 31-50 -0.2 to -0.4 -0.3 to -0.6 Clamping strap recommended above 2”. Over 50mm – specified on your drawing Additional Options Pressed on Sheaths ID/OD Tube With Tab Without Tab Coil Heater Assemblies Mini Coil Heaters All Coil Heaters Hotlock Axial Clamp Pressed in Brass Lead Protection Fiberglass Sleeve Braided Metal Sleeve Armor Cable
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
Click to edit Master subtitle style 10/24/11 Cartridge Heater Solutions www.nexthermal.com
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.
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.
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.
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".
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
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 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.
10/24/11 Diameter Tolerances Construction Sheath Material Diameter Standard Swage to Size Tolerance Premium Centerless Grind Tolerance Maximum Heater Length High Watt Density Medium Watt Density Thermo– couple SS321 Incoloy 800 eheat Stainless NPT Size J K .125” .1240-.1201” 4.0” Teflon® Plug and Leads Only .250” .248-.244” .2488-.2472” 60.0” .125” .3125” .3105-.3066” .3114”-.3098” 70.0” .125” .375” .373-.369” .3732-.3717” 80.0” .250” .500” .498-.494” .4972-.4957” 100.0” .375” .625” .623-.619” .6232-.6217” 100.0” .500” .6785” .6866-.6850” 100.0” .500” .750” .748-.744” .7492-.7476” 100.0” .750” 1.0” .9984-.9969” 100.0” 1.00” 6.2mm 6.18-6.14mm 1524 mm Temp. Rating Movement Moisture O F O C Potting Options Ceramic 1000 538 Good Not Recommended Silicone - Standard 500 260 Excellent Excellent Silicone – High Temp. 650 343 Excellent Excellent Epoxy 600 315 Very Good Very Good Teflon® Plug 450 232 Very Good Not Recommended Fiberglass (Standard) 482 250 Good Not Recommended Teflon® (also available in high amperage) 500 260 Excellent Excellent Silicone 356 180 Excellent Excellent Silicone Cable 356 180 Excellent Excellent High Temp. Fiberglass 932 500 Not Recommended Not Recommended Lead Protection Fiberglass Sleeve Braided Metal Sleeve Armor Cable Gas Proof Cable Exit and Removal Right Angle Exit Right Angle Block Flange Knock Out Tab This chart is representative of standard cartridge heater configurations. Please call Nexthermal at 269-964-0271 for additional options, special configurations, and assemblies. Standard Cartridge Heater Configuration Chart
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
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
10/24/11 Diameter Tolerances Construction Diameter Standard Swage to Size Tolerance Premium Centerless Grind Tolerance Maximum Heater Length High Watt Density Medium Watt Density Thermo– couple J K .250” .248-.244” .2488-.2472” 60.0” .3125” .3105-.3066” .3114”-.3098” 70.0” .375” .373-.369” .3732-.3717” 80.0” .500” .498-.494” .4972-.4957” 100.0” .625” .623-.619” .6232-.6217” 100.0” 6.5mm 6.48-6.44mm 1524 mm 8.0mm 7.98-7.94mm 1178 mm 9.0mm 8.98-8.94mm 1178 mm 9.5mm 9.48-9.44mm 2032 mm Temp. Rating Movement Moisture O F O C Potting Options Ceramic 1000 538 Good Not Recommended Silicone - Standard 500 260 Excellent Excellent Silicone – High Temp. 650 343 Excellent Excellent Epoxy 600 315 Very Good Very Good Lead Options Fiberglass (Standard) 482 250 Good Not Recommended Teflon® 500 260 Excellent Excellent Silicone 356 180 Excellent Excellent Silicone Cable 356 180 Excellent Excellent Lead Protection Fiberglass Sleeve Braided Metal Sleeve Armor Cable Exit and Removal Right Angle Exit Right Angle Block Flange This chart is representative of standard cartridge heater configurations. Please call Nexthermal at 269-964-0271 for additional options, special configurations, and assemblies. eHeat Cartridge Heater Reference Chart maximum recommended continuous operating temperature 650 oF
10/24/11 Nextflex Tubular heaters Next Generation Flexible Tubular Heaters www.nexthermal.com
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)
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 Nexthermal Tubular Heaters… the next generation flexible tubular heater.
10/24/11 Nextflex tools Forming tool recommended for round Nextflex Forming 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
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.
10/24/11 Nextflex heaters are stocked in 8mm and 8.5mm diameters Length Heated Length 6.5mm Diameter 8.0mm Diameter 8.5mm Low Watt 8.5mm Standard Round D-Shape Round D-Shape min. bending radius 9mm groove tolerance 6.6-7.7mm min. bending radius 10mm groove tolerance 8.1- 8.2mm min. bending radius 10mm groove tolerance 8.6-8.7mm min. bending radius 10mm groove tolerance 8.6-8.7mm Part Number one week lead time Part Number ship same day Part Number one week lead time Part Number ship same day 300 240 NF06.5-0300L-0450W NF08.0-0300L-0560W Special Order NF08.5-0300L-0650W 350 290 NF06.5-0350L-0450W NF08.0-0350L-0675W Special Order NF08.5-0350L-0750W 400 340 NF06.5-0400L-0500W NF08.0-0400L-0795W Special Order NF08.5-0400L-0900W 450 390 NF06.5-0450L-0600W NF08.0-0450L-0910W Special Order NF08.5-0450L-1050W 500 440 NF06.5-0500L-0700W NF08.0-0500L-1025W NF08.5-0500L-0700W NF08.5-0500L-1100W 550 490 NF06.5-0550L-0750W NF08.0-0550L-1145W NF08.5-0550L-0750W NF08.5-0550L-1250W 600 540 NF06.5-0600L-0850W NF08.0-0600L-1260W NF08.5-0600L-0850W NF08.5-0600L-1400W 650 590 NF06.5-0650L-0900W NF08.0-0650L-1380W NF08.5-0650L-0950W NF08.5-0650L-1550W 700 640 NF06.5-0700L-1000W NF08.0-0700L-1495W NF08.5-0700L-1000W NF08.5-0700L-1700W 750 690 NF06.5-0750L-1050W NF08.0-0750L-1615W NF08.5-0750L-1100W NF08.5-0750L-1850W 800 740 NF06.5-0800L-1200W NF08.0-0800L-1730W NF08.5-0800L-1200W NF08.5-0800L-2000W 850 790 NF06.5-0850L-1250W NF08.0-0850L-1845W NF08.5-0850L-1250W NF08.5-0850L-2150W 900 840 NF06.5-0900L-1300W NF08.0-0900L-1960W NF08.5-0900L-1350W NF08.5-0900L-2300W 950 890 NF06.5-0950L-1350W NF08.0-0950L-2080W NF08.5-0950L-1450W NF08.5-0950L-2450W 1000 940 NF06.5-1000L-1400W NF08.0-1000L-2195W NF08.5-1000L-1500W NF08.5-1000L-2600W 1050 990 NF06.5-1050L-1450W NF08.0-1050L-2316W NF08.5-1050L-1600W NF08.5-1050L-2650W 1100 1040 NF06.5-1100L-1500W NF08.0-1100L-2430W NF08.5-1100L-1650W NF08.5-1100L-2700W 1150 1090 NF06.5-1150L-1550W NF08.0-1150L-2545W NF08.5-1150L-1750W NF08.5-1150L-2750W 1200 1140 NF06.5-1200L-1600W NF08.0-1200L-2665W NF08.5-1200L-1800W NF08.5-1200L-2800W 1250 1190 NF06.5-1250L-1650W NF08.0-1250L-2780W NF08.5-1250L-1900W NF08.5-1250L-2850W 1300 1240 NF06.5-1300L-1700W NF08.0-1300L-2895W NF08.5-1300L-2000W NF08.5-1300L-2900W 1350 1290 NF06.5-1350L-1750W NF08.0-1350L-3015W NF08.5-1350L-2050W NF08.5-1350L-2950W 1400 1340 NF06.5-1400L-1800W NF08.0-1400L-3130W NF08.5-1400L-2150W NF08.5-1400L-3000W 1450 1390 NF06.5-1450L-1850W NF08.0-1450L-3245W NF08.5-1450L-2250W NF08.5-1450L-3050W 1500 1440 NF06.5-1500L-1900W NF08.0-1500L-3365W NF08.5-1500L-2300W NF08.5-1500L-3100W 1550 1490 Special Order NF08.0-1550L-3480W Special Order Special Order 1600 1540 Special Order NF08.0-1600L-3600W Special Order Special Order 1650 1590 Special Order NF08.0-1650L-3600W Special Order Special Order 1700 1640 Special Order NF08.0-1700L-3600W Special Order Special Order 1750 1690 Special Order NF08.0-1750L-3600W Special Order Special Order 1800 1740 Special Order NF08.0-1800L-3600W Special Order Special Order 1850 1790 Special Order NF08.0-1850L-3600W Special Order Special Order 1900 1840 Special Order NF08.0-1900L-3600W Special Order Special Order 1950 1890 Special Order NF08.0-1950L-3600W Special Order Special Order 2000 1940 Special Order NF08.0-2000L-3600W Special Order Special Order 2050 1990 Special Order NF08.0-2050L-3600W Special Order Special Order 2100 2040 Special Order NF08.0-2100L-3600W Special Order Special Order Nextflex Stocking List All Nextflex heaters are 230V. Connections: 6.5mm/M3, 8.0mm/M4, 8.5mm/M4 Nextflex part numbers are easy to decode. NF Nextflex 08.5 8.5mm ø 300L 300mm Length 0650W 650W @ 230V N F 08. 5 30 0L 0650 W
10/24/11 Nexthermal heaters… Imagine what we can do when we combine experience and innovate • 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
10/24/11 Thank You!

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Nexthermal – Smart Heat Management

  • 1.
    Click to editMaster subtitle style 10/24/11 Nexthermal Smart Heat Management
  • 2.
    10/24/11 Global Electric HeatingSolutions Approachable International Innovative Dynamic Knowledgeable
  • 3.
    10/24/11 Nexthermal is thenew 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.
  • 4.
    10/24/11 Nexthermal accelerates thedevelopment 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
  • 5.
    10/24/11 American Roots, InternationalReach 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
  • 6.
    10/24/11 As you engageNexthermal 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
  • 7.
    10/24/11 Let us beyour 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.
  • 8.
    10/24/11 Nexthermal Heaters… • Participatedin 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
  • 9.
    10/24/11 Low mass, SmallerFootprint 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
  • 10.
  • 11.
    10/24/11 Mini Manifold Improving versatilityand use of existing product Wood pellet stove igniter Improved durability and performance
  • 12.
    10/24/11 Energy Saving • Reduces amountof 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 0 2 4 6 8 10 12 Eheat vs Standard heater Minutes-Seconds
  • 13.
    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
  • 14.
    10/24/11 Plate design Standard heaterpower in each location Staggered heater power, without internal wattage distribution Reduced temperature variance, further improvement possible with distributed wattage
  • 15.
  • 16.
    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.
  • 17.
    10/24/11 Nexthermal manufactures heaterswith 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.
  • 18.
    10/24/11 Nexthermal coil heatersare 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?
  • 19.
    10/24/11 Form in groovecapabilities… 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.
  • 20.
    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,
  • 21.
    10/24/11 maxi coil heater TheNexthermal 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…
  • 22.
    10/24/11 high cavitation minicoil 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
  • 23.
    10/24/11 Standard Hotlock andAxial Heaters Hotlock Stock List Part Number Diameter Width Watts Volts HL30220 “3/4” “(19.05mm)” 30mm 220W 240V HL30268 “3/4” “(19.05mm)” 30mm 268W 240V HL30350 “3/4” “(19.05mm)” 30mm 350W 240V HL40220 “3/4” “(19.05mm)” 40mm 220W 240V HL40350 “3/4” “(19.05mm)” 40mm 350W 240V HL50220 “3/4” “(19.05mm)” 50mm 220W 240V HL50350 “3/4” “(19.05mm)” 50mm 350W 240V HL60220 “3/4” “(19.05mm)” 60mm 220W 240V HL60400 “3/4” “(19.05mm)” 60mm 400W 240V HL70220 “3/4” “(19.05mm)” 70mm 220W 240V HL70400 “3/4” “(19.05mm)” 70mm 400W 240V HL80220 “3/4” “(19.05mm)” 80mm 220W 240V HL80400 “3/4” “(19.05mm)” 80mm 400W 240V HL90220 “3/4” “(19.05mm)” 90mm 220W 240V HL90400 “3/4” “(19.05mm)” 90mm 400W 240V HL100220 “3/4” “(19.05mm)” 100mm 220W 240V HL100400 “3/4” “(19.05mm)” 100mm 400W 240V HL110220 “3/4” “(19.05mm)” 110mm 220W 240V HL110400 “3/4” “(19.05mm)” 110mm 400W 240V HL130220 “3/4” “(19.05mm)” 130mm 220W 240V HL130400 “3/4” “(19.05mm)” 130mm 400W 240V HL150220 “3/4” “(19.05mm)” 150mm 220W 240V HL150400 “3/4” “(19.05mm)” 150mm 400W 240V HL170220 “3/4” “(19.05mm)” 170mm 220W 240V HL170450 “3/4” “(19.05mm)” 170mm 450W 240V HL190220 “3/4” “(19.05mm)” 190mm 220W 240V HL190450 “3/4” “(19.05mm)” 190mm 450W 240V HL210220 “3/4” “(19.05mm)” 210mm 220W 240V HL210450 “3/4” “(19.05mm)” 210mm 450W 240V Build-To-Order Hotlock Stock Axial Lock-up Heaters Diameter Width Minimum Width Maximum Wattages Voltage Max Diameter Width Watts Volts “3/4” “(19.05mm)” 30mm 210mm 100W-450W* 240V “3/4” “(19.05mm)” “1.2” “(30mm)” 149W 240V “7/8” “(22.22mm)” 30mm 110mm 100W-450W* 240V “3/4” “(19.05mm)” “1.2” “(30mm)” 268W 240V *Wattage capabilities depend on size of heater, contact Nexthermal for design assistance “7/8” “(22.22mm)” “1.2” “(30mm)” 268W 240V *All stock Axials can be re-fit with external wound in thermocouple for same or next day shipment.
  • 24.
    10/24/11 coil heater embeddedin 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.
  • 25.
    10/24/11 Coil Technical DataChart Length Tolerance Wattage Tolerance Insulation Resistance Leakage Current Std. Shape Heated Unheated +10% Premium +5% +2% >= 5 Mohm @ 500V DC Special on Request <0.5 mA @ 250V AC Special on Request Lead Length (mm) Mini Flat 1.0x1.7 & 1.3x2.3 (only possible as wound or pressed in) Flat +2.5% +5% 1000 Mini Round ø1.4 and ø1.8 Round +2.5% +5% 1000 Mini Axial and Standard Clamp with 19.05 and 22.22 mm ID Flat Clamp +0 -0.5mm Customer Specified 1830 1.8 x 3.2mm Rectangle +1% +5% 1245 2.2 x 4.2mm Rectangle +1% +5% 1245 Round Coil ø2.6, ø3.0, ø3.18, ø3.25 & ø4.0mm Round +2.5% +5% 1245 2.5 x 3.4mm Rectangle +1% +5% 1245 Square Coil 3x3 Square +1% +5% 1245 Maxi Coil Heater 4.6 x 8.6 Rectangle +1% +5% 1245 Watt density limits for common coil heater installation • Coil –round: 39 W/in2 • Coil – Flat: 48 W/in2 • Coil – OD Sheath: 65 W/in2 • Mini – Pressed in brass: 80 W/in2 •Coil – Pressed in brass: 96 W/in2
  • 26.
    10/24/11 Lead Protection Options FIBERGLASS SLEEVING BRAIDEDMETAL SLEEVING FLEXIBLE ARMOR CABLE Wind from stock coil heaters HEATED LENGTH (INCH) TOTAL LENGTH (INCH) WATT VOLT 10.5 14.5 215 240 12. 16.5 250 240 16 20 325 240 19 23 390 240 22 26 470 240 26 30 520 240 30 34 610 240 36 40 630 240 38 42 700 240 42 46 800 240 45 49 850 240 75.28 78.84 1050 240 79 82.56 1150 240 86.6 90.16 1300 240 All heaters available with and without thermocouple 2.5mm x 3.4mm (0.100” x 0.134”) Flat Coil Heater Standard 48” Teflon® and TPE Leads Ungrounded TC
  • 27.
    10/24/11 Coil heater Performance options Pressedon 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.
  • 28.
    10/24/11 leads Fiberglass (Standard) Temperature Rating 482oF | 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
  • 29.
    10/24/11 Standard wattage tolerancefor Nexthermal coil heaters is +/-10%. Premium wattage tolerance is +/-5%. Standardized heaters may be designed with tighter than published wattage tolerances. Consult Nexthermal Engineering. Hotlock and Axial Clamp heaters are available with +/-2% wattage tolerance. Standard Coil Heater Configuration Chart Maximum Ratings Sheath Material Coil Heater Type Profile Minimum Inside Diameter Voltage Watt Density (per sq. inch) Straight Heated Length Thermo- couple SS321 Nickel Without Pressed on Sheath With Pressed on Sheath Pressed in Brass Inbuilt* inches mm inches mm inches mm J K Micro Mini 0.039x.067 1.0x1.7 0.236 6.00 240 38.7 52 80 112.2 2850 Mini Flat 0.051x.090 1.3x2.3 0.236 6.00 240 38.7 52 80 112.2 2850 Mini Round Ø0.055 Ø1.4 0.236 6.00 240 38.7 52 80 112.2 2850 Mini Round Ø0.070 Ø1.8 0.236 6.00 240 38.7 52 80 112.2 2850 Square 0.118x.118 3.0x3.0 0.472 12.00 240 38.7 52 80 86.6 2200 Flat 0.071x.126 1.8x3.2 0.472 12.00 240 38.7 52 80 86.6 2200 Flat 0.087x.165 2.2x4.2 0.472 12.00 240 38.7 52 80 86.6 2200 Flat 0.098x.134 2.5x3.4 0.472 12.00 240 38.7 52 80 86.6 2200 Round Ø0.118 Ø3.0 0.472 12.00 240 38.7 52 80 86.6 2200 Round Ø0.125 Ø3.18 0.472 12.00 240 38.7 52 80 86.6 2200 Coil ID Tolerance ID with Pressed on Sheath(mm) Coil ID (mm) Mini, Standard & Maxi ID Tolerance <30mm Long >30mm Long Mini +0.05 to +0.10 6.5-12 -0.05 to -0.2 -0.1 to -0.3 Standard +0.05 to +0.10 13-30 -0.1 to -0.3 -0.2 to -0.4 Maxi +0.05 to +0.15 31-50 -0.2 to -0.4 -0.3 to -0.6 Clamping strap recommended above 2”. Over 50mm – specified on your drawing Additional Options Pressed on Sheaths ID/OD Tube With Tab Without Tab Coil Heater Assemblies Mini Coil Heaters All Coil Heaters Hotlock Axial Clamp Pressed in Brass Lead Protection Fiberglass Sleeve Braided Metal Sleeve Armor Cable
  • 30.
    10/24/11 Coil Heater Profiles MiniCoil 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
  • 31.
    Click to editMaster subtitle style 10/24/11 Cartridge Heater Solutions www.nexthermal.com
  • 32.
    10/24/11 Nexthermal manufactures heaterswith 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.
  • 33.
    10/24/11 High watt densityheaters 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.
  • 34.
    10/24/11 cartridge heater performanceoptions 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.
  • 35.
    10/24/11 Right Angle Exit Nexthermalhas 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".
  • 36.
    10/24/11 cartridge heater basedassemblies 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
  • 37.
    10/24/11 engineering services A heateris 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 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.
  • 38.
    10/24/11 Diameter Tolerances ConstructionSheath Material Diameter Standard Swage to Size Tolerance Premium Centerless Grind Tolerance Maximum Heater Length High Watt Density Medium Watt Density Thermo– couple SS321 Incoloy 800 eheat Stainless NPT Size J K .125” .1240-.1201” 4.0” Teflon® Plug and Leads Only .250” .248-.244” .2488-.2472” 60.0” .125” .3125” .3105-.3066” .3114”-.3098” 70.0” .125” .375” .373-.369” .3732-.3717” 80.0” .250” .500” .498-.494” .4972-.4957” 100.0” .375” .625” .623-.619” .6232-.6217” 100.0” .500” .6785” .6866-.6850” 100.0” .500” .750” .748-.744” .7492-.7476” 100.0” .750” 1.0” .9984-.9969” 100.0” 1.00” 6.2mm 6.18-6.14mm 1524 mm Temp. Rating Movement Moisture O F O C Potting Options Ceramic 1000 538 Good Not Recommended Silicone - Standard 500 260 Excellent Excellent Silicone – High Temp. 650 343 Excellent Excellent Epoxy 600 315 Very Good Very Good Teflon® Plug 450 232 Very Good Not Recommended Fiberglass (Standard) 482 250 Good Not Recommended Teflon® (also available in high amperage) 500 260 Excellent Excellent Silicone 356 180 Excellent Excellent Silicone Cable 356 180 Excellent Excellent High Temp. Fiberglass 932 500 Not Recommended Not Recommended Lead Protection Fiberglass Sleeve Braided Metal Sleeve Armor Cable Gas Proof Cable Exit and Removal Right Angle Exit Right Angle Block Flange Knock Out Tab This chart is representative of standard cartridge heater configurations. Please call Nexthermal at 269-964-0271 for additional options, special configurations, and assemblies. Standard Cartridge Heater Configuration Chart
  • 39.
    10/24/11 eheat Cartridge Heater Solutions fewersystem amps longer life 25 % energy savings faster responding Next Generation Energy Efficient Cartridge Heater patent pending
  • 40.
    10/24/11 eheat cartridge heatersimprove 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
  • 41.
    10/24/11 Diameter Tolerances Construction DiameterStandard Swage to Size Tolerance Premium Centerless Grind Tolerance Maximum Heater Length High Watt Density Medium Watt Density Thermo– couple J K .250” .248-.244” .2488-.2472” 60.0” .3125” .3105-.3066” .3114”-.3098” 70.0” .375” .373-.369” .3732-.3717” 80.0” .500” .498-.494” .4972-.4957” 100.0” .625” .623-.619” .6232-.6217” 100.0” 6.5mm 6.48-6.44mm 1524 mm 8.0mm 7.98-7.94mm 1178 mm 9.0mm 8.98-8.94mm 1178 mm 9.5mm 9.48-9.44mm 2032 mm Temp. Rating Movement Moisture O F O C Potting Options Ceramic 1000 538 Good Not Recommended Silicone - Standard 500 260 Excellent Excellent Silicone – High Temp. 650 343 Excellent Excellent Epoxy 600 315 Very Good Very Good Lead Options Fiberglass (Standard) 482 250 Good Not Recommended Teflon® 500 260 Excellent Excellent Silicone 356 180 Excellent Excellent Silicone Cable 356 180 Excellent Excellent Lead Protection Fiberglass Sleeve Braided Metal Sleeve Armor Cable Exit and Removal Right Angle Exit Right Angle Block Flange This chart is representative of standard cartridge heater configurations. Please call Nexthermal at 269-964-0271 for additional options, special configurations, and assemblies. eHeat Cartridge Heater Reference Chart maximum recommended continuous operating temperature 650 oF
  • 42.
    10/24/11 Nextflex Tubular heaters NextGeneration Flexible Tubular Heaters www.nexthermal.com
  • 43.
    10/24/11 8.0mm availablein 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)
  • 44.
    10/24/11 Nextflex compelling advantage ExcellentHeat 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 Nexthermal Tubular Heaters… the next generation flexible tubular heater.
  • 45.
    10/24/11 Nextflex tools Forming toolrecommended for round Nextflex Forming 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
  • 46.
    10/24/11 Nextflex heaters aresimple 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.
  • 47.
    10/24/11 Nextflex heaters arestocked in 8mm and 8.5mm diameters Length Heated Length 6.5mm Diameter 8.0mm Diameter 8.5mm Low Watt 8.5mm Standard Round D-Shape Round D-Shape min. bending radius 9mm groove tolerance 6.6-7.7mm min. bending radius 10mm groove tolerance 8.1- 8.2mm min. bending radius 10mm groove tolerance 8.6-8.7mm min. bending radius 10mm groove tolerance 8.6-8.7mm Part Number one week lead time Part Number ship same day Part Number one week lead time Part Number ship same day 300 240 NF06.5-0300L-0450W NF08.0-0300L-0560W Special Order NF08.5-0300L-0650W 350 290 NF06.5-0350L-0450W NF08.0-0350L-0675W Special Order NF08.5-0350L-0750W 400 340 NF06.5-0400L-0500W NF08.0-0400L-0795W Special Order NF08.5-0400L-0900W 450 390 NF06.5-0450L-0600W NF08.0-0450L-0910W Special Order NF08.5-0450L-1050W 500 440 NF06.5-0500L-0700W NF08.0-0500L-1025W NF08.5-0500L-0700W NF08.5-0500L-1100W 550 490 NF06.5-0550L-0750W NF08.0-0550L-1145W NF08.5-0550L-0750W NF08.5-0550L-1250W 600 540 NF06.5-0600L-0850W NF08.0-0600L-1260W NF08.5-0600L-0850W NF08.5-0600L-1400W 650 590 NF06.5-0650L-0900W NF08.0-0650L-1380W NF08.5-0650L-0950W NF08.5-0650L-1550W 700 640 NF06.5-0700L-1000W NF08.0-0700L-1495W NF08.5-0700L-1000W NF08.5-0700L-1700W 750 690 NF06.5-0750L-1050W NF08.0-0750L-1615W NF08.5-0750L-1100W NF08.5-0750L-1850W 800 740 NF06.5-0800L-1200W NF08.0-0800L-1730W NF08.5-0800L-1200W NF08.5-0800L-2000W 850 790 NF06.5-0850L-1250W NF08.0-0850L-1845W NF08.5-0850L-1250W NF08.5-0850L-2150W 900 840 NF06.5-0900L-1300W NF08.0-0900L-1960W NF08.5-0900L-1350W NF08.5-0900L-2300W 950 890 NF06.5-0950L-1350W NF08.0-0950L-2080W NF08.5-0950L-1450W NF08.5-0950L-2450W 1000 940 NF06.5-1000L-1400W NF08.0-1000L-2195W NF08.5-1000L-1500W NF08.5-1000L-2600W 1050 990 NF06.5-1050L-1450W NF08.0-1050L-2316W NF08.5-1050L-1600W NF08.5-1050L-2650W 1100 1040 NF06.5-1100L-1500W NF08.0-1100L-2430W NF08.5-1100L-1650W NF08.5-1100L-2700W 1150 1090 NF06.5-1150L-1550W NF08.0-1150L-2545W NF08.5-1150L-1750W NF08.5-1150L-2750W 1200 1140 NF06.5-1200L-1600W NF08.0-1200L-2665W NF08.5-1200L-1800W NF08.5-1200L-2800W 1250 1190 NF06.5-1250L-1650W NF08.0-1250L-2780W NF08.5-1250L-1900W NF08.5-1250L-2850W 1300 1240 NF06.5-1300L-1700W NF08.0-1300L-2895W NF08.5-1300L-2000W NF08.5-1300L-2900W 1350 1290 NF06.5-1350L-1750W NF08.0-1350L-3015W NF08.5-1350L-2050W NF08.5-1350L-2950W 1400 1340 NF06.5-1400L-1800W NF08.0-1400L-3130W NF08.5-1400L-2150W NF08.5-1400L-3000W 1450 1390 NF06.5-1450L-1850W NF08.0-1450L-3245W NF08.5-1450L-2250W NF08.5-1450L-3050W 1500 1440 NF06.5-1500L-1900W NF08.0-1500L-3365W NF08.5-1500L-2300W NF08.5-1500L-3100W 1550 1490 Special Order NF08.0-1550L-3480W Special Order Special Order 1600 1540 Special Order NF08.0-1600L-3600W Special Order Special Order 1650 1590 Special Order NF08.0-1650L-3600W Special Order Special Order 1700 1640 Special Order NF08.0-1700L-3600W Special Order Special Order 1750 1690 Special Order NF08.0-1750L-3600W Special Order Special Order 1800 1740 Special Order NF08.0-1800L-3600W Special Order Special Order 1850 1790 Special Order NF08.0-1850L-3600W Special Order Special Order 1900 1840 Special Order NF08.0-1900L-3600W Special Order Special Order 1950 1890 Special Order NF08.0-1950L-3600W Special Order Special Order 2000 1940 Special Order NF08.0-2000L-3600W Special Order Special Order 2050 1990 Special Order NF08.0-2050L-3600W Special Order Special Order 2100 2040 Special Order NF08.0-2100L-3600W Special Order Special Order Nextflex Stocking List All Nextflex heaters are 230V. Connections: 6.5mm/M3, 8.0mm/M4, 8.5mm/M4 Nextflex part numbers are easy to decode. NF Nextflex 08.5 8.5mm ø 300L 300mm Length 0650W 650W @ 230V N F 08. 5 30 0L 0650 W
  • 48.
    10/24/11 Nexthermal heaters… Imagine whatwe can do when we combine experience and innovate • 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
  • 49.