Integrating Electrical Heating Elements in

Offers details on the utilization of electrical heating elements in consumer appliance design and industrial processes. The text includes basic theory, metallurgy and production advice for developing more reliable and cost-effective heaters. It provides tables comparing resistivity and surface resistance of different materials, and listing the resistance and weight per metre as well as surface per ohm of whole and half B&S wire and ribbon sizes for common standard resistance heating alloys. The book also contains calculation equations suitable for use in BASIC programs.

Preface

iii

(8)

Symbols

xi

1. Metallic Resistance Heating Wire

1

(62)

1.1 Standard Resistance Heating Alloys

1

(3)

1.2 Metallurgical Background

4

(2)

1.3 Oxidation Resistance and Heater Life

6

(18)

1.4 Influence of the Surroundings: Corrosion

24

(3)

1.5 Mechanical Properties

27

(4)

1.6 Magnetic Properties and Noise

31

(2)

1.7 Electric Resistance

33

(10)

1.8 Other Properties

43

(6)

1.9 Wire Surface Load

49

(1)

1.10 Comparison of Different Wire Alloys

50

(2)

1.11 Wire Gauges

52

(2)

1.12 Ribbon and Ribbon Standard Sizes

54

(4)

1.13 Weight of Wire and Ribbon

58

(1)

1.14 Forms of Delivery

58

(1)

1.15 Tolerances

59

(1)

1.16 Checking Resistance Heating Wire

60

(1)

References

60

(3)

2. Wires (and Ribbons) Made of Materials Different From Resistance Heating Alloys

63

(18)

2.1 Metals and Alloys for Low Operating Temperatures

63

(11)

2.2 The Halogen Tubular Heater

74

(1)

2.3 Cermet Wire

75

(3)

References

78

(3)

3. General Information About Electrical Heating Elements

81

(88)

3.1 Definition of an Electrical Heating Element

81

(1)

3.2 Heat Transfer

82

(14)

3.3 The Straight Wire

96

(4)

3.4 The Coil

100

(31)

3.5 Terminals

131

(4)

3.6 Corrugated Ribbon

135

(2)

3.7 Insulating Materials

137

(14)

3.8 Safety Rules

151

(1)

3.9 Element Calculation

152

(10)

3.10 Element Surface Load and Temperature of Element and Wire

162

(2)

3.11 Requirements for Elements

164

(1)

3.12 Classification of Heating Elements

164

(2)

3.13 Limits for Use of Metal Wires

166

(1)

References

167

(2)

4. Suspended Elements

169

(18)

4.1 Elastically Suspended Wire or Ribbon

169

(4)

4.2 Straight or Corrugated Wire or Ribbon on Fixed Supports

173

(3)

4.3 Suspended Coil

176

(5)

4.4 Zigzag Elements

181

(3)

4.5 Suspended Punched Strip

184

(2)

References

186

(1)

5. Supported Elements

187

(48)

5.1 Wire and Ribbon on Ceramic Fiber

187

(7)

5.2 Coil on Flat Ceramic Plate

194

(1)

5.3 Wire on (Cylindrical) Ceramic

195

(14)

5.4 Open Mica Element

209

(5)

5.5 Tube Heaters

214

(11)

5.6 Porcupine

225

(3)

5.7 Bead-Insulated Coil

228

(2)

5.8 Cigarette Lighter

230

(1)

5.9 Coil in Water

231

(1)

References

232

(3)

6. Embedded Elements

235

(108)

6.1 Metal-Sheathed Tubular Element

236

(70)

6.2 Powder-Filled Cartridge Element

306

(4)

6.3 Embedded in Metal Groove

310

(4)

6.4 Embedded in Ceramic

314

(1)

6.5 Cement-Insulated Element

314

(1)

6.6 Sheathed Mica Element

315

(4)

6.7 Foil Element

319

(17)

6.8 Heating Cable and Rope Heater

336

(2)

6.9 Embedded Tube Heaters for Heating of Fluids

338

(1)

6.10 Embedded in Ceramic Fiber

339

(1)

References

340

(3)

7. Film Elements

343

(12)

7.1 Thin Film Elements

344

(4)

7.2 Thick Film Elements

348

(4)

7.3 Pressure-Sensitive Elements

352

(1)

References

352

(3)

8. PTC Elements

355

(18)

8.1 Survey

355

(1)

8.2 PTC Elements of the Ceramic Type

356

(13)

8.3 PTC Elements of the Polymer Type

369

(2)

References

371

(2)

9. Silicon Carbide and Carbon Elements

373

(4)

References

375

(2)

10. Domestic Appliances and Heaters

377

(6)

10.1 Cooking

378

(1)

10.2 Heating of Water and Beverages

379

(1)

10.3 Drying and Ironing

380

(1)

10.4 Space Heating and Room Comfort

380

(1)

10.5 Hair Care

381

(1)

10.6 Individual Body Comfort

381

(1)

10.7 Tools

381

(1)

10.8 Vehicles

382

(1)

10.9 Miscellaneous

382

(1)

Appendix

383

(66)

Index

449

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Integrating Electrical Heating Elements in Product Design

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Table of Contents

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