Thermal Solutions Design Guide Build the perfect solution today This Design Guide is meant to provide introductory considerations for selecting appropriate heater technologies, as well as an index of heaters available for immediate shipment for testing and evaluation purposes. It also highlights design, integration, and assembly capabilities that enable Minco to work with you to develop comprehensive thermal solutions. Getting Started Selecting a Minco Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Heater Selection and Design Thermofoil Solutions for Heating. . . . . . . ....

Getting Started The Minco Difference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Selecting a Minco Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Harness Minco’s knowledge and diverse product lines to create the perfect solution Custom and integrated components Minco operates four different product lines, all coordinated in the same facility for faster, seamless integration that can boost your time-to-market. This makes us unique in our ability to customize and integrate components into turnkey assemblies and complete thermal, sensing and flex circuitry solutions. All of our components can be designed, manufactured, and integrated to perfectly fit your application while providing matched system accuracy. Minco seeks to help our customers...

Selecting_a_Minco_HeaterFollow these steps to select your heater 1. Choose insulation type Pick from the available insulation types. When selecting insulation consider temperature range, maximum resistance density and maximum heater size. Insulation options are available on page 7. 2. Choose installation option Proper installation is crucial for optimal heater performance. Determine the best method to install flexible heaters in your application so you can achieve desired results in your thermal system. Minco installation options are available on page 8. 3. Calculate required wattage The heater...

Thermofoil Solutions for Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Custom Design Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Heater Insulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Installing a Thermofoil Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Istallation Method Comparison. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Maximum Watt Density....

Thermofoil™ Solutions for Heating Industry-leading heater technology Flexible Thermofoil™ Heaters Thermofoil™ heaters are thin, flexible components consisting of an etched-foil resistive heating element laminated between layers of flexible insulation. Since their introduction by Minco over 55 years ago, Thermofoil heaters have demonstrated significant advantages over conventional electric heaters. Precise heating Thermofoil heaters put heat where you need it. You simply apply them to the surface of the part to be heated. The thin construction provides close thermal coupling between the heater...

Custom Design Options Heater designs to perfectly fit your application Methods to derive the profiling pattern include: Minco’s Unmatched Design Options Experimentation: Lay out a pattern with standard heaters and vary the power levels until temperature reaches the desired uniformity. Or, Minco can provide a custom heater with separately powered zones for prototyping. Minco will then reproduce the successful profile with a single element. Finite Element Analysis (FEA): Although more expensive, FEA modeling of thermal systems can reduce the number of trials required to design a profiled heater....

Custom Design Options Value-added assemblies and complete thermal solutions. Overview Clamped mica heaters For best heater performance and reduced installation costs, consider Minco’s capabilities in mounting heaters to make complete thermal subassemblies. You can furnish the heat sinks or we can fabricate them to your specifications. Either way, you get a guaranteed bond, superior reliability, and the benefits of Minco’s experience with advanced adhesives and lamination equipment. In many cases we can affix the heater to the mating part in the same step used to bond its layers together. That...

Custom_Design_OptionsIntegrating sensors and thermal cut-outs Temperature sensors Integrating sensors into heaters simplifies your assembly operations by providing a gradient-free system with excellent temperature control. The sensor sits in a window of the heating element. It reacts to temperature changes in the component beneath the heater, yet remains close to the heating element itself. This tight coupling of heater, sensor, and heat sink can greatly improve heating control and accuracy. Sensors can be electrically connected via leadwires or flex circuitry. Surface Mount RTDs and Thermistors...

Heater InsulationsCompare the insulations Minco uses in its heaters Material See technical specifications on pages 22-24. Polymide film with teflon -328 to 392°F 22" x 42" 450 O/in2 See technical specifications on pages 25-26 (foil) and pages 27-28 (wire-wound) See technical specifications on pages 19-22. See technical specifications on pages 32-34. adhesive Silicone rubber -45 to 235°C 560 mm x 2285 mm 31 O/cm2 Rubber film with rubber -49 to 455°F 22" x 90" 200 O/in2 temporary binder Optical grade polyester -55 to 120°C 280 mm x 560 mm 185 O/cm2 Polyester film with acrylic -67 to 248°F 11" x...

Installing_a_Thermofoil_HeaterChoose the best method for your application Versatile Thermofoil heaters allow a variety of mounting methods. Proper installation is crucial to heater performance. The heater must be in intimate contact with the surface beneath, as any gaps can block heat transfer and cause a hot spot resulting in premature heater failure. Pressure-sensitive adhesive (PSA) Liquid adhesives require more care in application than PSA, but generally provide higher temperature/wattage performance. Easy installation methods for cylindrical surfaces #6 RTV Cement Room temperature vulcanizing...