High-Performance Custom Flange Cartridge Heating Element for Industrial Use
Our cartridge heater is ingeniously designed with a durable cylindrical stainless steel tube that promises outstanding corrosion resistance. At its core lies a precisely wound heating wire, coiled around a top-tier ceramic core, which forms the powerhouse of this high-performance heater.
The coil count is expertly customized to match the heater's power specifications, guaranteeing exceptional heat distribution and an extended heater lifespan. This design innovation also significantly reduces the oxidation of the heating wire, even under high temperatures. Distinguished for heating solids, liquids, or gases, our cartridge heaters provide rapid heat transfer through conduction when in direct contact with the heat sink. They are the preferred choice for manufacturing plastic and rubber components in the automotive sector, and are equally indispensable in the food processing, chemical, electronics, medical equipment, packaging, and nuclear industries.
Beyond our extensive standard inventory, we excel in custom-developing and manufacturing cartridge heaters precisely tailored to meet your unique specifications and operational needs.
Cartridge heaters are engineered with a crimped-on or swaged-in construction, featuring a superior nickel-chromium resistance wire that ensures remarkable performance.
This resistance wire is intricately wound around a high-quality MgO core, perfectly aligned within a stainless steel casing for optimal efficiency.
Cartridge heaters are expertly crafted for varied heating applications, including metal parts and liquid heating when equipped with threaded bushings. These heaters can achieve metal temperatures soaring up to 760°C, ensuring peak performance with the appropriate material selection, watt density, and fitting.
Performance capabilities:
1. Part temperatures reaching a staggering 1400°F (760°C) with an alloy 800 sheath
2. Impressive watt densities of up to 40W/cm²
3. Operating voltage versatility ranging from as high as 480VAC to as low as 5VAC
4. A minimum diameter as slender as 3mm
5. A maximum diameter extending to 35mm
Benefits:
1. Simple and cost-effective installation
2. Crafted with high-quality materials
3. Optimized for superior heat transfer efficiency
4. Effortless maintenance procedures
5. Consistent and even temperature distribution
6. Robust resistance to oxidation and corrosion
7. Unmatched durability
8. Proudly certified by TÜV Rheinland (CE certification)
Technical Details:
1. Tube diameter: Φ3mm-Φ30mm
2. Tube Material: SS304; SS316, SS321, NICOLOY800, and more.
3. Insulation Material: Ultra-high purity MgO
4. Resistance wire element: Options include Ni-Cr or FeCr
5. Various lead connection options available: Secure your connections with our expertly Crimped or Swaged leads, ensuring reliability and durability in every use.
6. Lead and Type of Connection Leads: Our standard 10" Fiberglass leads provide robust and dependable performance.Wire Options: Choose from Silicone or High Temperature Fiberglass to suit your specific heating needs..
Specification of Cartridge Heaters: Ingeniously engineered for precision and performance.
| Sheath material |
SS304.321.316L,Incoloy800.840,Titanium |
| Insulation material |
High-purity MgO |
| Resistance |
Ni-Cr or FeCr |
| Maximum voltage |
480VAC |
| Wattage density |
high/middle/low(5-40w/cm2) |
| Wattage tolerances |
toloerance :+5% -10% |
| Dimensional |
Diameter: Min. dia:3mm |
| Length: |
Customized |
| Lead options |
Crimped- on / Swaged- in |
| Lead types |
Swage fiberglass insulation nickel wire ( 750°C ) |
| Crimp on silicone lead ( 250°C ) Crimp |
| Silicon insulated wire ( 200°C ) |
| Crimp fiberglass insulation nickel wire ( 450°C ) |
| Internal |
Type J or K available thermocouple |
| Lead protection options |
Stainless steel braid |
| Stainless steel flexible hose |
| other options |
Bent heaters, in no-heat section, up to 90° angle |
| mounting flange |
Feature: Discover the innovative features that set our cartridge heaters apart.
Common cartridge heaters can be divided into two types based on density, catering to diverse heating needs:
1. High Power Density: Boasting a heat area surface power of 10~25 W/cm², ideal for intense applications.
Working temperature ≤ 450°C, delivering consistent and reliable heat.
2. Middle to Low Power Density: Heat area surface power of 5~11 W/cm², perfect for moderate to low-intensity tasks.
Working temperature ≤ 300°C, ensuring efficiency and safety.
Voltage: Versatile voltage options, ranging from 12~250V, or customized to your specific requirements. 12~250V (or as per requirement)
High Density Construction: Built to withstand the toughest environments with high-quality materials.
High-quality stainless steel construction ensures long-lasting protection, even in the most demanding industrial environments.
Protected with a stainless steel sheath, our heaters can achieve a watt density of up to 50 W/cm² and operate at temperatures soaring up to 800°C.
More Photos of Our Cartridge Heaters: Explore our gallery to see the quality craftsmanship of our heaters.
Factors - How to Choose the Right Cartridge Heaters: Simplify your selection process with our helpful guide.
Consider the following factors to select the right cartridge heater for your specific needs:
1. Operating temperature: Match the heater to your required temperature range.
2. Watt density of the heating element: Ensure optimal performance with the right power density.
3. Sheath material (corrosive or non-corrosive): Select a material that suits your environment's demands.
-
- Temperature of the corrodent: Account for the chemical makeup and temperature of your environment.
-
- Degree of aeration of exposed corrodent: Consider the level of exposure to air in corrosive conditions.
-
- Velocity of the corrodent: Factor in the movement speed of corrosive agents impacting the heater.
Dimensional Data: Tailor your heater's dimensions for precision fit and performance.
(This table shows minimum and maximum sheath lengths for available diameters.)
| |
Diameter |
|
|
Length |
|
| Normal |
Actual |
Min |
|
|
Max |
| in. |
in. |
mm |
in |
mm |
in |
mm |
| 1/8 |
0.122 |
3.1 |
7/8 |
22.2 |
12 |
305 |
| 1/4 |
0.246 |
6.3 |
7/8 |
22.2 |
36 |
915 |
| 3/8 |
0.371 |
9.4 |
7/8 |
22.2 |
48 |
1220 |
| 1/2 |
0.496 |
12.6 |
7/8 |
22.2 |
60 |
1520 |
| 5/8 |
0.621 |
15.8 |
1 |
25 |
72 |
1830 |
| 3/4 |
0.746 |
18.9 |
1 |
25 |
72 |
1830 |
| 1 |
0.996 |
25.3 |
1 1/4 |
32 |
72 |
1830 |
(Indicates recommended maximum sheath length; however, longer lengths may be available.)
Termination Options: Customize your connection with our versatile termination choices.
1. Swaged-in Flexible Leads: Versatile and durable, perfect for bending needs at the heater exit point.
Swaged-in flexible leads with silicone-fiberglass insulation are recommended for applications where the leads must be bent at the exit point from the heater.
Unless a longer length is specified, 250mm
(10 in.)
leads are supplied, offering standard convenience and flexibility.
Heaters 150mm
(6 in.)
or shorter generally have a 6mm
(1/4 in.)
no-heat section, ensuring safe and effective operation. Heaters up to 250mm
(10 in.)
require a 25mm
(1 in.)
no-heat section. Heaters greater than 250mm may require more than a 25mm no-heat section. To order, please specify the desired length forswaged-in flexible leads, tailored to your needs.
2. Right Angle Leads: Perfect for high-flex applications and space-constrained environments, with lead wires exiting at a 90° angle.
Right angle leads are used in applications with a high degree of flexing and when space limitations are critical. Lead wires exit at a 90° angle through the side of the heater sheath.
A right-angle tube may be necessary for certain constructions. To order, specify the requirement forright angle leads, ensuring compatibility and efficiency. and lead length.
| Diameter mm |
Min No-Heat Length mm(in.) |
| 6.5 |
15 (9/16) |
| |
15 (9/16) |
| 108.0 |
17 (2/3) |
| 12.5 |
18 (11/16) |
| 16.0 |
20 (3/4) |
| 20.0 |
21 (13/16) |
3.Premium Stainless Steel Braid
Our robust stainless steel braid is meticulously designed to safeguard leads from abrasion against sharp edges, offering an unparalleled level of durability and reliability for your heating solutions.
For various lead exit configurations, we present customized solutions: When leads exit straight out, the braid is seamlessly swaged into the no-heat section of the heater. For right-angle exits, a crimp connector firmly attaches the braids, ensuring a perfect, cohesive integration.
Unless otherwise specified, our standard leads measure 250 mm
(10 in.)
in length. The braid is a convenient 200 mm
(8 in.)
long. Customize your order by specifying your preference for straight or right-angle stainless steel braid, lead length, and no-heat section requirements.
| Diameter |
Min. No-Heat Length |
| Straight |
Right Angle mm |
| mm |
| mm (in.) |
|
(in.) |
| |
|
| 6.5 |
30 (1 1/8) |
|
N/A |
| 8.0 |
30 (1 1/8) |
15 |
(9/16) |
| 10.0 |
30 (1 1/8) |
17 |
(2/3) |
| 12.5 |
30 (1 1/8) |
18 |
(11/16) |
| 16.0 |
30 (1 1/8) |
20 |
(3/4) |
| 20.0 |
30 (1 1/8) |
21 |
(13/16) |
4. Durable Stainless Steel Hose
Our premium stainless steel hose offers superior protection against abrasive surfaces, ensuring smooth handling and streamlined wiring even in the most demanding environments.
For right-angle lead exits, the hose is expertly silver soldered to the sheath. Unless otherwise specified, standard leads extend to 250 mm(10 in.) in length, with the hose measuring 200 mm(8 in.) in length. To place an order, please specify your desired stainless steel hose, lead length, and no-heat section.
| |
Min. No-Heat Length |
| Diameter |
Straight |
Right Angle mm |
| mm |
mm (in.) |
|
(in.) |
| 6.5 |
30 (1 1/8) |
|
N/A |
| 8.0 |
30 (1 1/8) |
15 |
(9/16) |
| 10.0 |
30 (1 1/8) |
17 |
(2/3) |
| 12.5 |
30 (1 1/8) |
18 |
(11/16) |
| 16.0 |
30 (1 1/8) |
20 |
(3/4) |
| 20.0 |
30 (1 1/8) |
21 |
(13/16) |
5. Galvanized Conduit Protection
Our galvanized conduit delivers protection on par with stainless steel hose against abrasive conditions.
The conduit is securely attached with a 90° elbow copper coupler, overlapping the heater sheath. Unless specified, we offer a standard 200 mm(8 in.) conduit, with leads extending 50 mm longer than the conduit. To order, specify your preference for galvanized conduit, lead length, and no-heat section.
| |
Min |
|
|
Galvani |
| Diam |
Dimensio |
Dimensio |
zed |
| No-Heat |
| eter |
n A |
n B |
conduit |
| Length |
| mm |
mm(in.) |
mm(in.) |
O.D. |
| mm(in.) |
| |
|
|
mm(in.) |
| |
|
|
|
| 6.5 |
12(7/16) |
22(7/8) |
29(1 1/8) |
10(3/8) |
| 8.0 |
12(7/16) |
22(7/8) |
29(1 1/8) |
10(3/8) |
| 10.0 |
12(7/16) |
22(7/8) |
29(1 1/8) |
10(3/8) |
| 12.5 |
12(7/16) |
28(1 1/8) |
30(1 3/16) |
14(1/2) |
| 16.0 |
12(7/16) |
28(1 1/8) |
34(1 5/16) |
14(1/2) |
| 20.0 |
12(7/16) |
29(1 1/8) |
36(1 7/16) |
16(5/8) |
6. High-Temperature Ceramic Bead Insulation
Our ceramic bead insulation provides unbeatable protection for leads in extreme temperatures exceeding 450°C(840°F). The ceramic beads fit over solid conductors and extend to cooler areas, allowing secure attachment of flexible wires. To order, specify your requirements for ceramic beads and length, and additional lead length requirements.
7. Versatile Stainless Steel Flanges
Our stainless steel flanges offer both a practical mounting solution and an effective way to position heaters in your applications. Flange style and specifications are customized to meet your specific needs. These flanges can be positioned in any designated no-heat section of the heater sheath. To order, specify flange, flange size, and location. .
Immersion Cartridge Heaters for Liquid Applications:
For applications involving liquid immersion heating, we recommend utilizing brass or stainless steel threaded bushings for optimal performance.
Threaded bushing sizes are matched according to the pipe diameter. Available specifications include G thread, NPT thread, and BSPP thread , among others.
Step-by-Step Guide to Installing Cartridge Heaters:
1. Begin by crafting an exact hole in the area intended for heating.
2. Ream a sleek and smooth hole to ensure optimal contact and superior heat transfer efficiency.
3. Extend the hole throughout the section to enable easy removal of the unit whenever required.
4. If a through hole is impractical, enlarge the hole size within allowable tolerances.
5. Minimize vibration and flexing of the lead wires to significantly extend the service life.
6. Shield the heater's end to prevent any liquid contamination.
When ordering Cartridge Heaters, please provide the following details: :
1. Specify the Type of Cartridge Heater (refer to Termination Options for guidance).
2. State the Diameter of the Cartridge Heater required.
3. Disclose the Overall Length of the straight Cartridge Heaters needed.
4. Indicate both the Wattage and Voltage specifications.
5. Detail the Type of Lead (glass fibre/PTFE) and the necessary lead length.
FAQ
(1). Q: Can you offer a discount?
A: Discounts depend on the order quantity-the more you purchase, the bigger the discount you'll receive.
(2). Q: How can I obtain a sample?
A: For most products, samples are available free of charge for small quantities, with shipping costs covered by the customer. Alternatively, provide your DHL, FEDEX, EMS, or UPS account number. For larger quantities, a sample fee may apply.
(3). Q: Why is your price higher than other Chinese suppliers?
A: Our focus is on crafting high-quality, high-performance products to foster long-term, harmonious relationships with our customers.
While our prices might not be the lowest, the value and performance are unmatched.
(4). Q: How do you ensure the quality of mass production matches the sample sent to me?
A: Our warehouse team retains an identical sample marked with your company name before dispatching the original, guaranteeing consistent production quality.
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