Cartridge heaters are cylindrical electrical heating elements with an integrated resistance wire. They efficiently convert electricity into heat and release it evenly into the environment via their metal sheath. Thanks to their compact design, high-performance cartridge heaters reach temperatures of up to 750 °C and power densities of up to 60 W/cm².

Areas of application:
Plastics processing
Packaging machines
Food production
Medical technology
Mold and tool heating
Nozzles, plates, laboratory equipment

By using high-quality materials, which we continuously develop together with our partners, we create the basis for the longest possible service life of our heating elements.
However, the actual operating time depends largely on the individual operating conditions, for example:

• Operating temperature

• Type of heating process and temperature control

• Mechanical installation situation and heat transfer efficiency

• Exposure to vibrations, shocks, moisture, dust or corrosive environments

The design and configuration of the heating element also play an important role, including:

• Surface load of heating wire and sheath

• Protective measures

The service life of our HKE-tec heating elements can therefore vary. Our engineering team will be happy to help you select the most suitable heating element for your specific application.

The electrical power (P) results from the product of voltage (U) and current (I).
Since a heating element essentially represents an ohmic resistance, the power can also be calculated using the formula
P = U² / R
are described, whereby U the voltage in volts [V], R the electrical resistance in ohms [Ω] and P is the power in watts [W].

If a lower voltage than the rated voltage is applied, the output is reduced accordingly. As a result, the desired temperature may not be reached.

However, if the voltage is doubled, the power quadruples while the resistance remains the same.

A higher voltage than intended can therefore lead to excessive heat output and possibly damage the heating element.

Shortening or structural modification of heating elements is not permitted. Tampering with the structure can impair the functionality, jeopardize operational safety and lead to the destruction of the heating element.

This also applies in particular to silicone heating mats - they must not be cut to size under any circumstances, as this can cause irreparable damage.

Our ground standard heating cartridges have a nominal diameter with a tolerance of -0.02 mm to -0.06 mm.
To keep the air gap between the cartridge and the bore as small as possible, we recommend a bore design to tolerance H7.
These tolerances may vary depending on the diameter and length of the cartridge.

Heating elements must be stored in a dry and dust-free environment.

As the connection ends of many heating elements are not completely sealed against moisture, the filling can absorb ambient moisture. This leads to a drop in the insulation resistance.

It is therefore important to ensure that the atmosphere is as dry and clean as possible, both during storage and when not in use.

In addition, it is recommended that the heating cartridges in particular are put into operation using suitable "start-up circuits".

Strand types and their temperature limits:

• Glass silk-insulated stranded wire, silicone-impregnated - up to max. 350 °
• Glass-fiber insulated stranded wire, reinforced version - up to max. 450 °C
• PTFE-insulated stranded wire - up to max. 260 °C
• Silicone braid - up to max. 180 °C
• Flexible silicone braid - up to max. 180 °C
• Silicone cable - up to max. 180 °C
• With ceramic beads, bare nickel wire - up to max. 750 °C

Important notes:

• The specified maximum temperatures apply to static installation, i.e. installation without movement.
• Glass silk coated strands are not suitable for moving applications, as the silicone impregnation evaporates at temperatures above 200 °C, causing the coating to lose its flexibility.

Bending radii during installation:

• Statically laid: At least 5 times the outer diameter (OD) of the stranded wire
• Moving installation or glass silk sheathing: At least 7.5 to 10 times the OD outer diameter of the strand.

Certain areas can be heated differently by distributing the power accordingly within a heating element.
Separately switchable zones are also possible, which specifically switch individual sections on or off.

Depending on the size and type of internal wiring of the HKEtec heating element, several separately switchable zones can be implemented.

Assembly pastes are only useful if it can be guaranteed that they will not decompose under permanent exposure to temperature and will not release any fission products that could damage the heating element.

The filling of heating cartridges can absorb moisture from the ambient air, which leads to a reduction in the insulation resistance.

Start-up circuits ensure that the heating element is first heated to a defined temperature (e.g. 120 °C) for a certain period of time at reduced power before the desired operating temperature is then reached at full power.

This procedure allows the absorbed moisture to outgas, which reduces leakage currents.

Such a heater consists of a wire or etched resistor laminated between layers of silicone rubber material. These heaters are ideal for heating surfaces in a variety of applications.
https://www.hke-tec.com/silikonheizelemente/
These heaters cannot be subsequently cut or drilled.
The heating elements are pure resistors and can therefore be designed for any supply voltage - whether alternating current (AC) or direct current (DC), single-phase or three-phase.
Silicone heating elements from HKEtec can be supplied with permanently integrated temperature limiters directly on the heating element. Temperature sensors such as thermocouples, PT100 or thermistors can be built into the heating mat in order to be connected to external process controllers. Simple controllers up to 200°C can be integrated.
Silicone heating elements are manufactured with protection class IP64 as standard. On request, we can also manufacture heating mats with protection class IP65.

All silicone heaters can be manufactured in UL.

Areas of application:

• Infrared panel heaters
• Heating of cutting beams
• Kitchen technology hot plates
• Heating of 3d printer surfaces
• Heating pipes and gutters
• Frost protection, also for electrical systems and devices
• Barrel / container heating
• for drying molds
• For condensate avoidance
• Laboratory and analytical equipment , Medical technology

Virtually any shape, size or design is possible - including drill holes, recesses and slots within our maximum production limits. Whatever your requirements, we will be happy to advise you.

Wire-wound heating elements are made from a resistance wire that is wound around pins. They are particularly suitable for smaller quantities, larger dimensions and cost-effective sample production. They can be used in self-adhesive, permanently installed applications as well as where repeated bending is required.

Etched foil heating elements use a chemically etched conductor track - similar to a printed circuit board - and are suitable for high power densities and medium to large quantities. They are mainly used in non-moving applications where uniform heat distribution is crucial.

The operating temperature of a silicone heating mat depends on the material used and other factors.
Silicone is suitable for temperatures from -60 °C to +250 °C.