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PTFE INSULATED RESISTANCE/HEATING WIRES & DEVICES

PTFE Insulated Resistance/Heating Wires and Devices

Poly Tetra Fluoro Ethylene (PTFE) is a plastic which is flexible up to -200°C and stable up to 260°C.  These features have been utilised to develop safe, efficient and long-life PTFE insulated heaters.  Such heaters find applicationsin

1. Flexible car seats, pads, carpet or blanket heating.

2. Floor heating under dry or moist conditions (heaters pre-cast and terminated during floor installation); such installation may be with or without parallel-laid/ spiral-wrapped sensor wire.

3. Temperature control for electronics display devices, obstruction/shadow-free, by using high strength fine conductor and thin wall insulation.

4. Immersion heating insulated coils for distillation with prescribed cold leads; Zone temperature control of distillation columns and heat tracer for pipes.

5. Anti-freeze roof edge, Window edge, Gasket heating.

CONSTRUCTION  Three main parts of heating wires and devices are
1. Heating resistance wire capable of long-life stability at the required temperature.  These are single or multi-strand, or helically wound 1, 2, 3 strands (on glass-fibre cord) of plated/unplated Copper, Copper alloy, Stainless Steel or resistance alloy.

2. PTFE insulation with the desired Radial Thickness of Insulation (RTI), minimum 0.15 mm to maximum 1.5 mm.  This insulation is guaranteed concentric multi-layer tape-wrapped and heat-fused.

3. Temperature Sensor; protection system such as braid shields for ease of handling.

PTFE Insulated Resistance/Heating WiresPRECAUTIONS  The maximum operating temperature of PTFE related systems are limited to 260°C (total maximum spot temperature, i.e. temperature rise plus ambient).  Although PTFE is known to withstand 380°C for short durations (without mechanical stress), the transition temperature is only around 325°C.  Therefore, suitable protection must be provided to prevent accidental increase beyond 260°C.  This protection is very critical for liquid heating systems which generally operate at high heat fluex densities.  Such systems must never be allowed to run dry (out of liquid).  Any spot of the heating element, if exposed, will rise in temperature towards self-destruction, electrical hazard and fire.  Explosion may follow.  Alternate built-in protection is to provide a longer length element with low watts per linear metre so that the spot temperature even under dry condition does not rise beyond 260°C.  The cost will be higher for such systems.

TYPICAL PRODUCT FORMS

a) Round, single and multi-strand with desired RTI of PTFE.  These are simplest and most widely used.  The slight oval, flat strip or twin parallel-laid constructions offer better heat transfer.

b) Multi-conductor bonded flat cables or woven flat cables for integrated surface heating.

c) 1, 2, 3 strands helically wrapped on Glass Fibre cord with PTFE insulation and Nickel Plated Copper/Stainless Steel braid shield for outdoor use.

d) Insulated heating wire with parallel-laid temperature sensor wire of pure Copper or Silver Plated Copper having high temperature coefficient of resistance, under a common PTFE jacket (with zero moisture absorption) for floor heating.

e) Fixed wattage and fixed length heating elements with integral heating leads under common PTFE cover with same or different colour to identify the heating zone, for heating of remote areas.

TECHNICAL CHARACTERISTICS
1. Ohmic value from 0.05 ohm/metre to 500 ohms/metre.

2. Radial thickness of primary PTFE insulation (RTI) 0.15 mm to 1.5 mm.

3. The watts/sq cm or liner watts/metre can be designed to suit the application, subject to safe maximum spot temperature of 260°C.

4. These designs can be made to suit the prescribed working voltage from few volts to several thousand volts, subject to satisfactory protection system.

SPECIAL FEATURES
  • Concentric PTFE primary insulation, multi-wraps and multi-pass tape-wrapped and sintered
  • Integrated conductor facility
  • R&D help towards optimisation with more than 30 years' experience
  • Low set-up charges and short lead times
  • Fine control on resistance, diameter, weight and end-piece break-down voltage
  • 100% finished product testing with actual test certificate
  • Flexible economic small volume production and prompt overseas door-delivery at low cost.
WIRES FOR FLOOR HEATING AND HEATING PADS/MATS

Following is a list of standard Heating Elements for use at 230 V AC RMS.  The typical product form consists of round Heating Wires with Stainless Steel Braid Shield and PTFE jacket with final OD 1.8 mm to 2.2 mm.  Conductor used for heating element is multi-strand (dia 0.25 - 0.68 mm).

Table of standard elements for floor heating and pad heating
 

Druflon Electronics Private Limited - Premier Heating Cables Manufacturer and High Temperature Cables Manufacturer. Leading High Temperature Cables Manufacturer and Heating Cables Manufacturer to develop safe, efficient and long-life PTFE insulated heaters.