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Nexthermal Industrial Heating Solutions

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

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Nexthermal Industrial Heating Solutions

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  1. Engineering Services

  2. 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 solution to you delivering world class benefits well beyond your investment in our products and services.

  3. Our History • 1986 - Hotset Corporation established in Battle Creek, Michigan as a separate entity and strategic partner to Hotset GmbH • 1991 - Initial cartridge heater produced • 1998 - U.S. coil heater production launched • 2003 - Production facility expanded • 2004 - Heater based assemblies unveiled • 2007 - Manufacturing in Bangalore, India -Introduced anti-seize coating and highly moisture resistant coil heater head • 2008 - Selected as the exclusive Elstein marketing agent in the United States - Engineering Services Team Created • 2009 - Hotflow circulation heater invented, targeting electric vehicle, medical and food production markets • 2010 - Renamed Nexthermal to emphasize commitment to heat management solutions worldwide. Location, manufacturing facilities and staff remain the same. - Introduced eheat, energy efficient cartridge heaters

  4. 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.

  5. Idea Design Prototype Testing Analysis Typical Product Development Cycle Design modification for each learning phase Iteration for each learning phase, multiple expenses of prototypes and testing for each design

  6. Design Analysis Verification Design Idea Prototype Product Development with CAE Design modification Lower risk of final testing not meeting customers needs

  7. Quality as a Foundation • Certified ISO 2001: 2008 standard • In 2001, Nexthermal was the first electric heater manufacturer in the world to become certified under ISO 2001: 2000 standard • All outgoing product is 100% checked for safety, performance and fit metrics • All raw materials are checked with traceable certificate to prove acceptance • All customer returns are diagnosed for root cause, regardless of cost

  8. Materials and Construction • Materials • Stainless steel 321 vs. 316 • Ti content resists intergranular corrosion at higher temperatures • Heat treated in special atmospheric oven to realign grain structure for flexibility • High purity MgO reduces electrical leakage and improves safety • Further processed by Nexthermal for performance • Heat treated resistance wire to provide long life • Construction • Highly compacted, improves heat transfer - better heater life • Unique assembly process controls wire position after forming • Controlled heat pattern • Welded electrical connections provide cleanest signal

  9. Coil Heater • ‘Other’ Heater- note the twist in the resistance wire • Poor heat management = Poor system efficiency

  10. Coil Heater • X-ray sample of our coil heater showing resistance wire placement • Improved performance and improved heat transfer efficiency

  11. Nozzle Design for Optimal Heat Transfer • Nozzle diameter tolerance for good heat transfer (important for heater ID) • Minimum heat loss with adequate wattage distribution to offset • Tip geometry to limit heat loss but engineered to prevent drool (correct design of contact and sealing surface) • Minimum clearance from OD of heater to bore

  12. Note the reflection tube pushes the heat into the tool • Less heat loss = more heat transfer to application (~15-20% reduction in watts needed) • Lower duty cycle = Higher efficiency Pressed in Brass vs. Reflection Sheath Pressed in Brass Pressed in Brass with reflection

  13. Nozzle Design Optimal Heat Transfer • Nozzle diameter tolerance for good heat transfer (important for heater ID) • Minimum heat loss with adequate wattage distribution to offset • Tip geometry to limit heat loss but engineered to prevent drool (correct design of contact and sealing surface) • Minimum clearance from OD of heater to bore

  14. Effect of Additional Windings Uniform heat – but not needed – Waste of energy, breakdown of plastic resin (FLIR photo)

  15. Nozzle Profile without Reflection Tube Good heat profile, but open coils allow heat loss

  16. Thick Film Heater (competitor) Too much heat in the center, not efficient

  17. Injection Nozzle Profiling with Reflection Tube • Good heat profile • Wattage reduced by 20% • Higher efficiency • Lower scrap

  18. Innovative Solutions

  19. HotFlowModular Circulation Heater By managing the fluid path and heat transfer area, we developed a high thermal efficiency fluid heater that outperforms standard immersion heater designs

  20. HotFlow - Improving Electric Vehicle Battery Performance and Life

  21. Hole Punch Heater • Using a replaceable mini coil on a replaceable tool • Tool wear is independent of heater, replace only when needed • Heat is focused into the tool Due to the way standard cartridge heaters are used, heat is being created at exactly the wrong place for the application need

  22. Coated Heater • Benefits of Anti-Seize Coating • Reduced cost due to faster replacement, minimum tool damage and rework time • Quick, easy removal of heater after burn out • Improved heat transfer due to special composition • Special compound acts as a corrosion barrier • Protects the heater bore from galling

  23. 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

  24. Improving versatility and use of existing product Mini Manifold Form in Place Heater • Using a Ø3.2mm (0.125”), Ø1.8mm or a Ø1.4mm tubular heater form around heat loss areas • Only heat the need

  25. Nexthermal developed product helps PCRcompany revolutionize PCR disease detection affordability and portability PCR (Polymerase chain reaction) Block

  26. PCR Well Heating System

  27. In House Lab Services • Prototype services for custom design, validation and development • Test services for temperature profiling, reliability/performance testing and other applications with minimum engineering charge

  28. Computer Aided Engineering • Opportunity: • Work as a design partner to show effects of heat transfer • Pictures create understanding, and choices • In its simplest terms, design analysis is a software technology for simulating physical behavior of a product. • Will it break? • Will it deform? • Will it get too hot? • Where are the system inefficiencies and how to best address them • Current market: • Limited design support with other suppliers • Costly for FEA support

  29. TC to Heater RelationshipMaterial Thickness Relationship • With proper material thickness, heat will be distributed over the application better. • Thermocouple will read an accurate temperature, prevent overshoot

  30. Types of Analysis • Steady-state and transient thermal analysis • Linear and Contact stress analysis • Static • Drop test • Fatigue • Frequency model analysis • Buckling analysis • Pressure - flow analysis • Design Optimization

  31. Plate with Coil Heater (working surface shown) Higher temperatures demand a higher class of fit to the application to reduce the radiation losses from the heater

  32. Plate design Standard heater power in each location 8 cartridge heaters Hot due to thicker section Note shadow effect behind bolt hole

  33. Plate design Staggered heater power, without internal wattage distribution Reduced temperature variance, further improvement possible with distributed wattage

  34. Packaging Jawwithout wattage distribution 66% of jaw face within 6°F

  35. Packaging Jawwith wattage distribution 86% of jaw face within 6°F

  36. Any Questions? ?

  37. Thank You!

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