Mica insulated band & nozzle band heaters are efficient and economical solutions to the heating requirements of many applications. Although their maximum sheath temperature is limited to 900°F, with different electrical termination styles, clamping mechanisms, and ability to accommodate holes and cutouts, band heaters are successfully used in many applications.
Our band heaters utilize different types of top grade mica. The thickness of each mica layer is carefully selected to balance between the insulating characteristics of Mica and the ease of heat transfer from the resistance ribbon to the machine barrel.
The resistance ribbon used in a is not restricted to the capabilities of Nichrome wire. Different alloys are considered for different applications. The internal winding is carefully designed to ensure uniform heat distribution throughout the heater.
To maximize the surface-to-surface contact, our band heaters are carefully rounded and formed to optimize the grip on a machine barrel. The external metallic protective sheath of the band heater is made of a special alloy, which expands less than the barrel when heated. This difference in thermal expansion makes the heater grip the barrel firmly once it is energized, and this improves heat transfer. Poor heat transfer acts like a throttle and makes the resistance element inside the heater function at elevated temperatures, which eventually leads to the premature failure of the heater.
Our band heaters are made in different construction styles,
clamping mechanisms, and terminal types. Holes, cutouts, slots, thermocouple
or mounting brackets can be accommodated in the design.
Maximum performance and ease of installation are two major considerations when selecting the construction style of a band heater. The following are the most common construction styles.
One Piece ConstructionOne-piece construction is used when a heater can be installed on a barrel without extensively expanding it. Diameter: 5/8” min; 22” max |
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Two Piece or moreTwo or more pieces are for ease of installation. A practical choice when the barrel diameter is large. Diameter: 2” min; 44” max |
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PartialPartial heaters are recommended where obstructions or complicated holes prevent having complete coverage on the surface of the barrel. |
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One Piece FlexibleOne-piece flexible heaters are used in applications where two-piece
construction is not practical, and expanding the heater is necessary
during installation. These heaters should not be opened more than twice. |
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ConicalConical or irregular shaped heaters are made to fit unconventional forms. Heat transfer considerations impose limitations on the overall design and construction of these heaters. Our engineers are available to discuss the requirements of each application. |
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Square and rectangularMica bands can be made square, rectangular or multi-sided to suit your specific requirements. |
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ReverseReverse heaters are used in applications where heating from inside the barrel is required. The outside shell of these heaters is the heating surface and all the terminations and clamps are located on the inside of the heater. Diameter: 3” min; 36” max |
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Independent strapThese straps evenly distribute the drawing force around the band heater by clamping the heater tightly around the surface of the cylinder. This distributed force is transferred to the internal windings, improving heat transfer through effective surface contact and elimination of air gaps. |
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Built-in barrel nutThis clamping mechanism combines the drawing quality of an independent strap with ease of installation. The top sheet is transformed into a strap by incorporating barrel nut fasteners at both sides of the gap. Recommended when holes and cut-outs prevent the usage of an independent strap. |
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Spot welded strapsThis clamping mechanism combines the drawing quality of an independent strap with ease of installation. The top sheet is transformed into a strap by incorporating barrel nut fasteners at both sides of the gap. Recommended when holes and cut-outs prevent the usage of an independent strap. |
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Flange lock-upThe most economical fastening style, flange lock-up is used mostly on narrow heaters. |
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Wedge lockLow profile clamp. Used when clearance above the heater is limited. A wedge-like clamp slides on the lips of the heater located on both sides of the gap. The normal height from the inner diameter (ID) to the highest point of the wedge lock is 5/16". |
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Latch and trunionIdeal when fast detachment is required. The clamp is released with a flip of the thumb, eliminating the usage of any tools. The spring loaded 1/4-20 bolt absorbs thermal expansion in the fastened position. |
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HingesUsed when a heater band has two sections. A piano hinge is incorporated
on one side of the heater, while the other side can have any kind of
clamp. |
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Spring-loaded barrel nutsIndependent straps, built-in barrel nuts and spot welded straps can have longer screws with incorporated die springs. These springs help to keep the band heater tight during thermal expansion. Only available in 1/4-20 screws |
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Clamping padsMostly used in two section partial heaters. When an obstruction prevents
the usage of a complete band heater, it becomes necessary to create
a large gap and fasten the heater to the cylinder on both sides of the
gap. It is not advisable to have clamping pads on both sides of the
same section of a heater, because thermal expansion might detach the
heater from the cylinder. |
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Screw Terminals
Stainless steel screw terminals are the most convenient and economical means to connect a heater to an electrical power source. They are mostly recommended when high amperages (up to 30 amps) are involved. The temperature limitation is 840°F. Our standard screw size is #10-32. For finer applications, #8-32 screws are available. Screws have 3/4" height above the barrel with A, B1 and B2 styles. When ceramic covers (V) are used, the terminals are 1” long. See following illustration:
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Lead Wire Terminals
High temperature wire is internally connected to the heater. This provides a safer electrical connection. However, it is physically impossible to conceal heavy gauge wire under the top metallic sheet. This limits the maximum amperage applicable to 20 Amps.
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European Plugs
European plugs are safe and simple to use. They provide a quick solution in applications where the electrical termination has to be disconnected frequently. They can be used on all our construction and clamping styles. EP terminals provide practical electrical connections when a failed heater has to be replaced. European plugs are available either with the two round prongs (6 mm) or three flat prongs (one of which is ground).
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Last revised: May 2004
