Everything That You Need to Know About Cartridge Heaters

Heating is an important process for manufacturing units across industries. This is done by using different types of industrial heaters, which vary in designs, watt densities, and effectiveness. Cartridge heaters are one type of industrial heater that is widely used for heating metals, plastic, and also in immersion applications. These heaters have been gaining popularity over the years and are now preferred over several traditional industrial heaters. This article will introduce you to the cartridge heaters, their working principle, applications, and everything that you need to know about them.   

Structure of Cartridge Heaters   

A cartridge heater is a type of heating element that consists of a resistive electrical circuit enclosed in a metal sheath with proper insulation. It is designed to slide into holes of metric drill sizes, typically ranging from 4mm to 20mm in diameter. The length of a cartridge heater may vary from less than an inch to a few feet. Depending on the needs of the application, cartridge heaters can be designed with different watt densities. As a general rule, these heaters tend to be slightly smaller in diameter than their intended usage.  

How do they work?  

A cartridge heater is made up of a resistance coil wound around a ceramic core, with dielectric surrounding it. The whole thing is encased in a metal sheath, which heats up when power is transferred through the coil. The heat from the metal sheath transfers to the inside metal part that needs heat. This heat energy transfer is known as conduction. The entire heat generated in the coil is transferred to the surroundings, making it an effective industrial heater.  

Operating Temperatures of Cartridge Heaters  

Low, medium, and high watt density cartridge heaters are designed to operate at temperatures up to 1400°F. The optimal operating temperature will depend on the application for which you are using the cartridge heater.  

However, various factors can affect the temperature of an industrial heater, such as the watt density of the cartridge heater, the tightness of the cartridge inside the hole, and the thermal conductivity of the material being heated.   

Electrical terminals are an important thing to think about when you’re using cartridge heaters. If you’re using them at high temperatures, the terminals should be different than the lead wires. Or, the cartridge should be designed in a way so that the temperature around the lead wires is lower than the temperature limit of the lead wire.  

Features of Cartridge Heaters   

The distinctive features of cartridge heaters that make them preferable for industrial heating processes include: –  

  • Provided with flanges and fittings  
  • Excellent Durability  
  • Available in a number of configurations and constructions as per the specific application.  
  • Great performance in terms of uniform heating  
  • These are available with lead wire options.   
  • They are designed with internal thermo-couples.  

Common Applications  

Cartridge heaters are often used for heating dies, molds, and other metal parts by insertion into drilled holes. Along with this, they are also used in liquid immersion applications. Here are some common and specific applications such as: –  

  • Plastic processing plants  
  • Heating gases and liquids  
  • Hot stamping   
  • Medical equipment   
  • Semiconductor   
  • Plastic molding  
  • Scientific equipment   
  • Labeling machinery  

Cartridge heaters are manufactured with custom features and specifications to suit specific applications. For example, heaters with crimped-on leads, stainless steel braid, stainless steel armored cable, right-angle fiberglass leads, right-angle stainless-steel braid, right-angle stainless-steel Armour, and many others. From composition to lead angle, every feature of these heaters is customizable making them highly desirable in various industries.  

Summing Up!  

Marathon Heater India Private Limited is one of the largest heater manufacturing companies in the world. They started the development of heaters in 2007 with a joint venture between Marathon Heater Inc. and Tempsens Instruments India. In 2016, Marathon Heater India became a fully independent Indian company associated with Tempsens Instruments after the merger of Marathon Inc.   

 Marathon’s commitment to customer service and engineering brought rapid growth to the company. They now have a vast array of heater models and types that are suitable for any number of applications. No matter what your needs are, they can help you find the perfect heater for your business requirements and needs. Check out their website now! 

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