Used to heat rooms, pools, and industrial tanks, heating solutions are nearly as varied as the applications that employ them. Heating systems vary in cost, size, shape, and power, and for a system to be effective, these variables should align with application demands.
At Pelonis, we offer specialized heat transfer solutions for clients from a wide range of industries. In this guide, we cover our main product options and their uses to help you determine which heating solution is right for your needs.
Positive temperature coefficient (PTC) heaters are powerful ceramic heaters ideal for small spaces and containers. Safe, effective, and self-regulating, PTC heaters come in two main designs that maximize airflow for optimal heat dispersion.
- Fin PTC Heaters. Fin PTC heaters are so-named for their large aluminum fins, which circulate air across a large surface area for efficient heat transfer. These elements are designed with temperature-limiting effects, which reduce the risk of overheating, making them a safe option for settings ranging from operating rooms to airline interiors.
- Honeycomb PTC Heaters. Honeycomb heaters combine small heating discs with over 1,200 holes for high-volume airflow. Honeycomb PTC heaters, like fin heaters, operate at a safe temperature while still producing significant heat output.
More PTC Heating Equipement:
- PTC Thermistors. While many heaters use typical resistors, a thermistor is a special type of resistor dependent on temperature. PTC thermistors specifically increase resistance with a rise in temperature.
- PTC Conductors. Serving as safe, energy-efficient solutions for many different product designs, PTC heat conductors and natural convection heaters are available in a range of sizes and mounting options to allow for quick, easy installation.
Applications of PTC Heaters
PTC heaters are safe, powerful, and compact, so they find many applications across industries:
- Transportation. Small, lightweight PTC heaters are a common choice for heating vehicle interiors, including cars, buses, and airplanes.
- Healthcare. PTC heaters are safe and efficient enough to heat rooms and equipment in hospitals.
- Recreational. When woven into clothing, PTC heating elements keep users warm during winter recreation.
- Food and Beverage. PTC heaters keep fluids and food at a constant temperature in food processing and distribution.
- Public Spaces. In addition to heating indoor spaces and vessels, PTC heaters can also warm outdoor seating areas at restaurants, hotels, stadiums, and similar gathering places.
Ultra-Thin Flexible Heaters
Ultra-thin flexible heaters, as the name suggests, pack heating elements into materials weighing as little as 0.04g/cm². Their bendable nanotechnology elements warm quickly and hold temperatures constant with minimal electromagnetic emissions. Common varieties include:
- Polyimide Ultra-Thin Flexible Heaters. Polyimide heaters are among the thinnest and most flexible heaters available. Created from an organic polymer, polyimide heaters offer high dielectric strength and excellent performance in demanding applications
- Etched Foil. Patterned foil creates a conductive surface, which may contain embedded NTC or PTC thermistors for temperature control. They are suitable for low-resistance applications requiring temperatures up to 200° C.
- Nano-Carbon Non-Printed Heaters. Using nanoscale carbon for even heat transfer, these heating elements withstand higher temperatures and resistances than etched foil.
- Polyester (PET) Flexible Film Heaters. PET heaters are cost-effective, waterproof heating elements commonly used with an adhesive backing. Like other ultra-thin, flexible heaters, they can be wound or shaped into many configurations, depending on the application. PET film heaters are effective at temperatures up to 120 °C.
- Silicone Rubber Heaters. Silicone rubber heaters are powerful and can rapidly heat to temperatures as high as 300 °C. These heaters combine a super-conductive heating sheet with silicone insulation to maintain even temperatures across their heating range.
- Mica Heaters. Mica heaters coat heating elements with mica layers to accommodate the highest temperature applications (up to 1000 °C). They combine this impressive temperature resistance with excellent voltage resistance and tensile strength, so they are suitable for the most demanding applications. Mica heaters can also be integrated into metal molds for versatility.
- Transparent Film Heaters. Transparent film heaters use very thin heating elements to offer glare-free visible transparency that exceeds conventional glass. Like PET heaters, they can maintain temperatures of 120 °C despite being thin and translucent.
Applications of Ultra-Thin Flexible Heaters
Ultra-thin flexible heaters have many specialty applications across industries. They can conform to virtually any geometry and fit narrow spaces to provide even and precise heating. These include:
● Seat heaters
● Condensation and freezing protection for outdoor equipment
● Battery heating
● Home appliance heating
● Optical, photographic, or electronic applications
● Laboratory and medical equipment
● LCD displays
Temperature controllers are designed to monitor and automatically regulate heat levels. These devices protect against dramatic temperature fluctuations, which can damage sensitive electronics. They also help maintain temperature levels necessary for industrial processes. Common types of temperature controller include:
- Micro Temperature Controllers. Compact micro temperature controllers are lightweight and fit into products with extreme space constraints. These controllers are self-contained, requiring no additional controls, so they fit easily into existing circuitry.
- Four-Phase Temperature Controllers. Four-phase temperature controllers are simply temperature controllers with four incremental power settings.
- Digital Temperature Controllers. Digital temperature controllers offer precise, configurable temperature regulation, with memory systems to retain past settings.
Among four-phase temperature controllers, Pelonis offers two distinct lines of sleek and efficient regulators:
- DTC-S series. The DTC-S models offer four time settings (one, two, four, and eight hours) and four power settings (25% through 100%). These models are compatible with AC and DC voltages and a wide variety of heaters.
- DTC-N series. DTC-N models use pulse-width modulation to control power input, creating four temperature settings (40, 45, 50, and 55° C) rather than power settings.
Additionally, there are two main lines of digital controller:
- DTC-A series. DTC-A controllers hold temperatures within 1 °C on time intervals from 30 minutes to 24 hours. These controllers are best for high-precision applications such as those found in medical research or chemical processing.
- DTC-T series. DTC-T controllers offer easy control of four power settings as well as customized time and temperature settings. DTC-T models are ideal for controlling AC and DC voltages.
Applications of Temperature Controllers
Temperature controllers are useful anywhere that a temperature fluctuation could damage equipment or inhibit a chemical process.
- Healthcare and Biotechnology. Temperature controllers keep laboratory equipment at the proper temperature for tests and specimen storage.
- Food and Beverage. Food and beverage processing often requires precise temperature control to ensure food safety. In these settings, temperature controllers are critical to maintaining regulatory compliance and product quality.
- Plastics. Plastic manufacturing involves a range of temperature-sensitive processes. Temperature controllers ensure that these procedures yield the desired results so that the final products meet specifications.
- Heat Treating. Heat treatments are a common final step in manufacturing, used to set coatings or strengthen materials.
- Packaging. Temperature regulators can be used to activate thermal adhesives.
High-temperature ceramic immersion heaters sit in a vat of liquid to evenly and efficiently heat its contents. Less commonly, immersion heaters may be used to heat air and gas. Pelonis immersion heaters resist corrosion and damage from chemicals, including highly acidic or basic fluids, so they are compatible with almost any industrial process. They are also safe and self-regulating and can withstand a minute of exposure to 2500 V.
Immersion heaters take two primary forms:
- Flange-Mounted Immersion Heaters. Tubular, hairpin heating elements join to a plate, forming a cylindrical unit that can be immersed in fluids. These are the most common heaters used in holding and storage tanks.
- Pipe Thread Heaters. Pipe thread heaters are usually used in circulating fluid systems. In these models, the same tubular hairpin heating elements are welded to a screw plug rather than a flange, allowing them to be screwed into threaded openings.
Applications of Immersion Heaters
Our powerful immersion heaters achieve temperatures up to 1200 °C in a dry environment along with 98% heating efficiency in liquids. Applications include:
- Steam generators
- Wastewater treatment equipment
- Ignition devices
- Air conditioners and HVAC units
- Fluid heaters
Pelonis Technologies offers a full catalog of heaters for diverse industry applications. Our offerings include PTC heaters, ultra-thin flexible heaters, temperature controllers, and immersion heaters, all of which are available in multiple customizable configurations depending on customer requirements.
With over 25 years of experience in the heating industry, Pelonis offers premium, innovative heating products to serve clients with varied temperature control needs. To learn about Pelonis' individualized, customer-centric approach, contact Pelonis Technologies today.
Curious to learn more about Pelonis’s selection of heating products? Browse our products today.