Self-regulating heater

Type of resistive heater

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A positive-temperature-coefficient heating element (PTC heating element), or self-regulating heater, is an electrical resistance heater whose resistance increases significantly with temperature. The name self-regulating heater comes from the tendency of such heating elements to maintain a constant temperature when supplied by a given voltage.

PTC heating elements are a type of thermistor.

Properties

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PTC heating elements have large positive temperature coefficients of resistance, which means if a constant voltage is applied, the element produces a large amount of heat when its temperature is low, and a smaller amount of heat when its temperature is high. In comparison, most electrical heating elements also have positive temperature coefficients, but those coefficients are so small that the elements produce approximately the same amount of heat regardless of temperature.[1]

Some PTC heating elements are designed to have a sharp change in resistance at a particular temperature. These elements are called self-regulating because they tend to maintain that temperature even if the applied voltage[1] or heat load[2] changes. Below that temperature, the element produces a large amount of heating power, which tends to raise the temperature of the heating element. Above that temperature, the element produces little heating power, which tends to allow it to cool.

In some applications, this self-regulating characteristic allows PTC heaters to be used without thermostats or overtemperature protection circuits.[1] One very important use of self-regulating heating elements is to assure the heating element will not become so hot as to damage itself or other parts of the heater. In some applications where the heating element is directly connected to the item being heated a self-regulating heater may also provide adequate temperature control of the item to be heated.

However, many applications require control of two temperatures. For example, space heaters use heating elements much hotter than the room being heated. In these applications, a thermostat may be better able to sense and control the temperature of the item being heated. Nevertheless, a self-regulating heating element may still be used to keep the heating element from damaging itself or other parts of the heater.

Fast warm-up

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If the heat required to hold the desired temperature is known, a PTC heating element can be selected to provide the correct amount of heat at the desired temperature. Such a heating element will warm up quickly because it produces more heat at low temperatures. In contrast, a conventional heating element that produces the correct amount of heat at the desired temperature will produce the same amount of heat at low temperature, resulting in long warm-up times.

Adjustable heat output

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In some applications it is desirable to regulate the heat output (typically measured in watts) as opposed to regulating the temperature. The heat output of any electrical heating element can be regulated by regulating the electrical power input. PTC heating elements also can be regulated indirectly. For example, a PTC heating element with a sharp change in resistance at a particular temperature can be fitted with a constant voltage source and a variable-speed fan. With the fan at a low setting, the heating element draws only a small amount of current, resulting in a low heat output. With the fan at a high setting, the air draws away more heat, and the heating element responds by producing more heat.[citation needed]

Adjustable temperature

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If being able to adjust the temperature is more important than holding a fixed temperature, then a PTC material whose resistance changes smoothly with temperature can be used. The temperature such a material tends to hold can be adjusted by changing the voltage applied.

More shapes of heating elements feasible

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PTC heating elements can be made in more shapes than conventional heating elements. Conventional heating elements are constrained to be long and thin (often coiled to save space) to prevent current hogging. If the element was made thick or irregular in shape, then there would be more than one path for the electrical current. The path with the least resistance would tend to heat more than the rest of the element. In severe cases, this would cause a cascading failure where the path of least resistance overheats and fails, redirecting the current to other parts of the element, leading them also to overheat and fail.

PTC elements can be built thick or irregularly shaped, because if one path through the element heats more than the rest, the resistance of the path will increase, redirecting the electrical current without overheating.[citation needed]

One application of a specially shaped heating element is to increase the surface area of the heating element. A large surface area means the element can operate at a lower temperature and still deliver a large amount of heat. The lower temperature may make a heater safer. However, other safety measures can assure the safety of conventional heaters.[citation needed]

Another application of a specially shaped heating element is to closely match the shape of the item being heated, which helps assure the object is maintained close to the same temperature of the heating element.[citation needed]

PTC materials

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Positive temperature coefficient heating elements can be made of several materials.

Ceramic type

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Although the most commonly available ceramic materials are electrical insulators, some conduct electricity with a positive temperature coefficient. Such PTC ceramic heating elements are often called "stones".[1][3]

Polymer

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Some polymers are suitable as PTC heating materials. These have the useful property that they can be made in the form of inks. Heating elements of complex shape can be easily manufactured using printing techniques. If the inks are printed onto a flexible substrate, then the whole heating element can be flexible.[4]

One type of polymer is a PTC rubber, which is a type of silicone rubber.

Operation

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Since PTC heating elements are a kind of thermistor, they share the same principles of operation. The details depend on the type of material, but a class of materials widely used are crystalline ceramics. During manufacture, dopants are added to give the material semiconductor properties. These materials have somewhat negative temperature coefficients at low temperatures and at high temperatures, however there is a temperature range in between where they have useful positive temperature coefficients. These materials have a critical temperature where the resistivity changes quite markedly. This temperature is called the Curie temperature because the material's magnetic properties also change markedly.

The temperature coefficient of a PTC heating element generally is a function of temperature. The Steinhart&#;Hart equation is often used to approximate this function. In some applications where the heater is used only in a narrow temperature range, a simple linear equation may be adequate.

References

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PTC heaters are made up of specialized heating discs with sophisticated ceramic materials with a positive temperature coefficient. These heaters are safe, powerful, and energy-efficient, allowing for excellent heat production and transfer even in the tiniest of areas. 

Fin elements and honeycomb shapes are the two types of PTC heaters. While both types of heaters have several advantages over traditional heaters, users should be informed of the advantages and disadvantages of each before choosing one.

What is a PTC heater, and how does it work? 

Traditional resistance wires and coils are used to create heat in most ordinary heaters. This is not the case with a PTC heater. 

Instead, it uses ceramic stones made of barium titanate as heating components. The PTC heater can operate as a sensor because of the material&#;s unique features. Without the use of additional diagnostic or feedback controls, the heater can operate in an open-loop mode. As a result, there is no risk of overheating with a PTC heater. It&#;s also much more efficient and trustworthy than the regular model, making it perfect for products that need to be heated safely, quickly, and uniformly.

What Can a PTC Heater Do for Your Next Project?

Now that we&#;ve learned a little more about PTC heaters let&#;s look at how they may help you with your next industrial project. 

1. Improved Heating Functionality

We&#;ll start with one of the greatest benefits of PTC heaters. They enable users to generate the same amount of heat as a normal model while posing a fraction of the safety danger. 

PTC heaters from Narain Cooling have a unique design that avoids all of the failure modes and hazards common with resistive wire, carbon fiber, and etched foil heaters. If a problem occurs, the system will &#;fail to cold&#; to make the effect unnoticeable. The heater component that failed will no longer take any extra current, while the rest of the heater will continue to operate normally. 

2. Self-Limiting Characteristics

Because of its self-regulating properties, when the resistance of a PTC heater increases, the current within the device drops, the heater can sense the temperature around it and turn off if it rises above its specified setting. 

This built-in safety and security function ensures that you&#;re not creating too much or too little heat for your project&#;s requirements.

3. Self-Regulating Characteristics

A PTC heater is also self-regulating and self-controlling.

A PTC heater modifies its usage in response to changes in the environment. When it reaches an ideal temperature, it can slow down production over time. The heater can keep its lowest output and maintain its temperature when it turns off. 

4. Complex Heating Patterns

Narain Cooling Engineers can create a PTC heater to meet specific heating solutions as detailed as required, as indicated above.

You may set your temperature zones exactly where you want them to ensure maximum coverage while constructing your units. You can also alter the watt density and create custom holes and cuts as needed with simple tweaks. 

This user control ensures that heat is distributed evenly and consistently. Every point on the surface of a PTC heater maintains its fixed temperature independently, eliminating hot and cold areas. 

5. There are fewer components to deal with

A PTC heater has fewer working components than a traditional radiator. There will be less wear and tear to contend with, as well as fewer expensive components to replace. Additionally, your system&#;s ceramic components are less sensitive to water, chemical abrasion, and corrosion. These advantages boost your investment&#;s return and ensure that your control system lasts as long as feasible. 

The few parts that make up a PTC heater only turn on when they&#;re needed, rather than maintaining high temperatures all the time. This feature contributes to the parts&#; long-term durability and stability. It doesn&#;t take long for high temperatures to wear down materials when they are applied at a continuous rate. 

6. Cost-Effective Compared to Traditional Models

Ptc Heating is a smart and straightforward way to heat your home. 

In the long term, this means less energy consumption, saving users a lot of money. 

PTC heaters are designed to use full power at lower temperatures, allowing them to reach their threshold temperature as quickly as possible. They use less energy than typical heaters after they reach a constant state. When you pick PTC heaters, you can save money on a variety of things in addition to your utility bills. The lesser number of parts on a PTC heater, for example, helps to reduce maintenance and upkeep costs. 

7. Materials that are compact and lightweight

Forget about those clumsy old heaters. When you buy a PTC heater from Narain Cooling, you get a small system and light. The footprint of the PTC unit should be as compact as possible. 

Silicone heaters are less flexible than PTC heaters. You can even connect additional PTC heaters in parallel to meet the heating needs of a very wide area. 

These materials aren&#;t very bulky, but they&#;re far from inconsequential. They&#;re the backbone of Ptc Heating Technology, both innovative and efficient. Creating them, on the other hand, has no negative impact on the environment.

Here&#;s where you&#;ll find your next PTC heater

Are you ready to discover the ideal PTC heater for your industrial manufacturing environment now that you know a few of the top benefits they provide?  If that&#;s the case, you&#;ve come to the correct place. Narain Cooling provides a wide selection of industrial Ptc Heating Solutions, from fans and convection units to surface and air heaters, thermoelectric coolers, and innovative controllers. Please feel free to go over our online inventory and contact them if you have any queries. 

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