YOUR WORLD LEADING PARTNER IN INTELLIGENT HEATING & CONTROL HEATER + MEASUREMENT & CONTROL = COMPLETE SOLUTION PRODUCT DEVELOPMENT We work together in a gate model to make sure we reach target in cost and production SOP Evaluation / Design / Development: (A-SAMPLES) Specification work Feasibility First proposals Design preparation Prototype design Prototype development: (B-SAMPLES) Initial testing Verification and analysis of A samples Production development: (C-SAMPLES) Production work / Final design Documentation and preparation Pre-production Functional testing and evaluation Production engineering Approval to start: First serial delivery Testing & validation DVP Work PPAP QUALITY CERTIFICATIONS We strive to deliver the highest quality products combined Backer Calesco is certified with a flexible way of working. This permeates the whole by Intertek ISO 9001 ISO 14001 Project management Final report Final design process including sales, product development, manufactur- 2 ing, customer service and logistics. Backer Calesco delivers Our facilities in China, Poland & Vietnam products that meet all relevant standards and tests, cer- are certified according to ISO 14001, tifying products according to customer specifications. We ISO 9001 and IATF 16949 are also able to carry out tests in modern labs, constantly Third-party approvals: improving our product performance and energy efficiency. VDE / ETL / S / UL
WE MAKE IT HAPPEN Our heating products together with our measurement and control devices offer our customers complete solutions. Our engineers will not only suggest solutions, they can also take part in and contribute to your product development by using our advanced technical tools and lab facilities. Our extensive experience and competence as well as our reliable quality and service guarantee your success. Our ambition is to not only be Customized solutions a supplier, but your preferred partner. Together we can make it happen! Innovations for the future A partnership with Backer Calesco gives you a dedicated team of designers, project engineers and technical experts in the fields of electric heating, measurement and control, ready to provide you with the optimal solutions for your needs. 3
INTELLIGENT HEATING WHERE IT S NEEDED
TABLE OF CONTENTS 6 8 10 AUTOMOTIVE LIFE SCIENCE RAILWAY 12 14 16 BATTERY COMFORT COMMERCIAL EQUIPMENT 18 TECHNOLOGY 5
RELIABILITY SUSTAINABILITY COMFORT AUTOMOTIVE With over 30 years of experience in the automotive industry, and as one of the largest suppliers of rear-view mirror heating concepts, we have a vast knowledge of the demands of the transportation business. We keep your thumbs warm when operating a snowmobile or keep tanks from freezing on trains. We heat the handlebars for ATVs and the floors in trams. With a product range from lens and sensor heaters to heating batteries. The possibilities are endless. APPLICATIONS Vision systems Fluid systems Rear-view mirrors Seat heaters Floor heaters Windshield wipers Filters Alco locks HEATING SOLUTIONS CAMERA HEATER Backer Calesco provides heat for different types of systems, for example, front-view, side-view, rear-view & parking cameras. All systems need heat to keep the lens free from moisture and ice to ensure a safe drive. REAR-VIEW MIRROR HEATER Backer Calesco designs heaters for every specific rear-view mirror, either in Constant Wattage or PTC. We meet most of the car manufacturers specifications, through high and low power, depending on the allowed maximum temperature on the glass. UREA HEATER AdBlue freezes at -11 C and needs heat to be able to pump liquid in all climates. Backer Calesco provides heating solutions for these systems with added temperature control. 6
OVER 30 YEARS OF EXPERIENCE IN THE AUTOMOTIVE INDUSTRY
SAFETY RELIABILITY TEMPERATURE CONTROL LIFE SCIENCE Backer Calesco supports many segments of the Life Science and analytic industry where precise heat and maintaining exact temperatures are important in many processes. We recognize the importance of technological advancements and are developing and designing heating solutions that will work in the medical field. Our knowledge and expertise in heating products will allow us to produce a heater that meets your heating specifications. We can fit thermostats, temperature fuses and sensors of the thermo-element type, thermistors and resistance sensors directly on elements in accordance with customer specifications. This helps to ensure reliable control. APPLICATIONS Magnetic stirrers Autoclaves Surgery beds Incubators Fluid heaters (Infusion) Dehumidifiers DNA Analysis Laboratory research equipment Respirators Sterilization equipment Washing machines Intelligent controls HEATING SOLUTIONS AUTOCLAVE HEATER Our flexible foil heaters can be used as booster heaters and for applications such as autoclaves and vaporizers. Our heaters prevent dripping from the top of the vessel and speed up the cycling time. TEST TUBE HEATER Backer Calesco designs and produces heaters that require small, exact and direct heat. Our heaters are good for applications that need the heater to route around tubes and have different power zones. ANESTHESIA HEATER Backer Calesco customizes the heat so it is exactly at the right spot, for both temperature and range. Vaporizing moisture and keeping the right climate are important. By using a flex foil with an integrated controller, we can optimize and ensure proper functioning. 8
WHEN TEMPERATURE MATTERS TEMPERATURE IN CONTROL
RELIABILITY SUSTAINABILITY COMFORT RAILWAY Backer Calesco has been supplying flexible foil to the Railway industry for decades. Our foil is approved for high-tech, weightmanagement applications. A space-saving efficient alternative to be used in, for example, as floor heating, frost protection, rearview mirror heating and seat heating. The flexible foil is supplied in various materials such as PVC, Polyester, Silicon and Mica. APPLICATIONS Floor heating systems Couplers Steps Windshield wipers Headlights Lens heaters Heating in driver s cabins Heating of water pipes Switch points Rear-view mirrors HEATING SOLUTIONS SWITCH POINT HEATING With our switch point heating system, you get an energy saving system, which secures reliable railway traffic through the switch points even under severe winter weather conditions. FLOOR HEATING With our electric radiant heated floor solutions, you can save space and weight by installing foil as floor heating. Power output: 50W - 700W/m² Supply voltage: 48-800VAC/DC STEP HEATING We offer a range of customized special solutions for easy installation on all steps and disabled ramps. In particular, our range of flexible foils for defrosting and hydraulic oil heating save space and weight. 10
APPROVED FOR HIGH-TECH, WEIGHT-MANAGEMENT APPLICATIONS
INCREASED LIFETIME INCREASED CAPACITY FASTER CHARGING TIME RELIABILITY BATTERY The need for environmentally-friendly vehicles creates a demand for more efficient batteries both for Hybrid and Electrical cars. When batteries are exposed to cold weather the temperature of the battery drops and the chemical reactions occur more slowly, so the battery cannot produce the same amount of current that it can at room temperature. When decreasing below -20 C in some situations, the chemical reactions will happen so slowly and generate so little APPLICATIONS Lead-acid Nickel Metal Hydride Lithium Ion Sodium Ion Zebra Lithium Metal Polymer power that the battery will appear to be dead when, in fact, if it is warmed up, will return to normal output. The batteries charging rate is affected by temperature and by adding heating to the batteries, both lifetime and efficiency will increase. HEATING SOLUTIONS INTERNAL HEATING When our heater is mounted between the pouch it makes the heating fast and heat distribution even. With foil heaters you get safe heat with direct contact and low surface power. You can also use the heater as a load dump cell. PRISMATIC CELL & POUCH Our heaters can be laminated with an aluminum pouch to improve heat transfer. We can offer self-regulated PTC heaters or constant wattage heaters for prismatic cell and pouch batteries. Max. temperature is +80 C for this type of application. 12
BACKER HEATING - PROLONGS CAPACITY AND LIFETIME OF YOUR BATTERY
RELIABILITY ENERGY EFFICIENCY COMFORT COMFORT Backer Calesco offers a variety of solutions for comfort heating. Our heaters are found in applications such as waterbeds, floors for housing or RVs, bathroom mirror demisters, panel heaters and towel heaters. Our domestic products offer you great solutions for easy and safe heating. We give you warmth where it s needed most for enhanced comfort. APPLICATIONS Mirrors Waterbeds Floors Infrared Panels Radiators Heat pumps HEATING SOLUTIONS FLOOR HEATING Our heating film is a low profile heater (0.3 mm) and the parallel circuits ensure a robust operation of the heating element. Our floor heating does not need to be glued or fastened with a filler, which ensures easy installation. It can be used for wood/laminate floors for housing and for RVs. MIRROR HEATING (DEMISTER) Foil heaters are used for bathroom mirrors and the heaters are simple to install and prevent the mirror from steaming up. The heaters have a low, even temperature that makes the mirror safe to touch but still keeps the mirror clear, and they have a very low running costs. INFRARED PANEL HEATING We design customized heaters for infrared heating panels. Our thin flexible foil heaters fit perfectly in the compact and customized panels, which can be designed to provide other functions such as wall decoration. 14
WE STRETCH YOUR COMFORT ZONE
RELIABILITY ENERGY EFFICIENCY TEMPERATURE CONTROL COMMERCIAL EQUIPMENT Backer Calesco produces many types of heaters for food rethermalization. The heaters are easy to design for custom needs, with space-saving solutions that can also be produced in different power densities. The heating systems are cost efficient, hygienic and can be designed for easy cleaning. You can use our heaters for anything from cup warmers in espresso machines to professional cooking equipment like griddles and cook-serve systems. APPLICATIONS Heating cabinets Espresso machines Professional kitchen equipment Defrosting Cooking tables Water baths Brewery HEATING SOLUTIONS ESPRESSO MACHINE (CUP WARMERS) We can preheat the cups so that the espresso does not lose heat while being poured into the cup. This provides a better experience for the coffee drinker and ensures quality and taste. WATER BATH HEATERS Maintaining exact temperatures in water baths is crucial to getting the best result when pre-cooking sous vide or making chocolate. We can engineer exact temperatures and even heating over a large surface. HEATING CABINETS Safe temperature, even distribution and robustness are key features for delivering safe and fresh food. By integrating a flex foil heater into the cabinet, you can ensure a long lifetime and robustness of the cabinet. We can heat individual plates or the whole compartment, dividing the heat into different power zones by integrating thermistors or measuring the resistance of the foil to regulate temperature. 16
RELIABILITY, ENERGY EFFICIENCY & TEMPERATURE CONTROL
Innovations TECHNOLOGY At Backer Calesco, we develop new products and solutions in close cooperation with customers, transforming a customer request into a working solution. The process is successfully achieved based on our broad experience, advanced design tools and efficient production capabilities. Foil elements provide excellent thermal transfer where you need it most and are used in thermal control design to protect components under cold-case environmental conditions or to make up for heat that is not dissipated. At Backer Calesco s innovation center, highly qualified and experienced engineers continuously take on the challenge of new applications and materials.
POLYIMIDE Thin and semi-transparent with excellent dielectric strength. Resistant to chemicals. Max. power density: 1.3W/cm² Max. temperature: +200 C Military and aerospace / Medical diagnostic instruments / LCD displays / Lens heaters / SILICONE Excellent temperature properties. Can be vulcanized to metal parts. Max. power density: 1.3W/cm² Max. temperature: +230 C Food service equipment / Medical respirators / Ultrasonic cleaners / Freeze protection and condensation prevention Laboratory research MICA High power density. Fast warm up and high working temperatures. Max. power density: 5W/cm² Max. temperature: +600 C Food service appliances / Semiconductor industry / DNA analysis / Radiators, PVC Very flexible, waterproof and acid resistant with high mechanical strength. Max. power density: 0.1W/cm² Max. temperature: +70 C Waterbed heaters / Water heaters / Military equipment / Slim blankets / Surgery beds heating panels / Packing/strapping/sealing equipment FRTP (Fiber Reinforced Thermoplastic) Stiff, extremely durable, water resistant. Max. power density: 0.1W/cm² Max. temperature: +100 C Radiator panels / Heaters for rough conditions PEN PEN is similar to PET but has higher chemical, thermal, mechanical and electrical properties. More cost effective compared to polyimide. Max. power density: 1W/cm² Max. temperature: +160 C Electronic devices / Radiators / DNA Analysis / High power standard elements POLYESTER - ETCHED FOIL Superior heat transfer and uniform heat output. Fast warm up with long life cycle. Max. power density: 0.6W/cm² Max. temperature: +105 C Mirror heaters / De-icing equipment / Hand grip heaters / Rear-view mirrors / - PTC PRINTED POLYMER Self-regulating, robust and corrosion resistant with PTC characteristics. Max. power density: 0.3W/cm² Max. temperature: +70 C Rear-view mirrors / Lens heaters / Waterbed heaters / Low temperature applications / De-icing Battery heaters - PRINTED POLYMER Low power, constant wattage with a large span of resistivity. Insensitive to small damage. Max. power density: 0.1W/cm² Max. temperature: +70 C High voltage, small area applications / Waterbed heaters / IR targets / Floor heating 19
WE ARE WITH YOU ALL THE WAY! Idea Shipping Manufacturing Specification SOLUTION Approval Development Testing Presentation INTELLIGENT HEATING & CONTROL
FOIL HEATING BASICS A foil heating element is built up with one or more layers of insulation and a heat circuit. Among the insulating materials used are PVC, Insulation material polyester, silicone rubber and mica. The circuit material may be a resistance heating alloy, such as copper, brass or aluminum. We can also provide a carbon or silver-based circuit. The operating voltages may be from 1 or 2 V up to 700 V AC/DC. Element temperatures range up to 600 C. Several circuits may be arranged on the same heater. A foil element provides even heat distribution over the entire surface. It is also Circuit Insulation material possible to divide the heater into different heat zones and power densities. Foil elements can also be designed to be EMF free. Foil heating advantages Customized shapes Multiple temperature zones Flexibility Thin Light weight Simple assembly Quick heating Efficient heat transmission Low energy consumption High quality CUSTOMIZED MULTIPLE CIRCUITS FLEXIBLE Foil heating elements are designed according to customer needs and requirements. Elements can generate different heat levels on the same surface area. Elements can be attached to products with many different shapes. EVEN TEMPERATURES PRECISE SENSOR LOCATION MULTIPLE VOLTAGES Elements can be designed with varying output to compensate for heat loss at the edges. Sensors can be added in any location on the same level as the heating circuit. An element can combine 220V/12V to standardize one element for different voltage products. 21
TECHNICAL INFORMATION Element type PVC Polyester Polyimide Silicone Mica FRTP Max. element temp. (depending on application) 70 C 105 C 200 C 230 C 600 C 100 C Min. element temp. -40 C -60 C -60 C -50 C -50 C -40 C High voltage resistance at 20 C as per ASTM KV/mm Thermal conductivity at 100 C W/(m x K) Moisture absorption as per ASTM D-570-63 24h immersion at 23 C Moisture resistant as per IEC 335-1 sect. 15-16 Waterproof as per IEC 335-1 sect. 15-16 Constant of dielectricity at 25 C 50Hz Constant of dielectricity at 150 C 50Hz 15 220 200 17 32 5 0.17/70 C 0.16 0.17 0.24 0.30 0.36 0.2% 0.8% 2.9% 0.1% 1.0% 0.025% yes yes yes yes yes yes yes yes - yes - yes 5-9 3.3 3.5 2.9-3.6 4-5.5 3-3.7 3.1-6.2 - UV radiation resistance limited limited limited good very good limited Solvent resistance very limited limited limited limited limited limited Bending radius, min. 20 mm 1 mm 1 mm 10 mm - 400 mm Max. element width 600 mm 600 mm 600 mm 600 mm 600 mm 600 mm Min. thickness 1.2 mm 0.15 mm 0.15 mm 0.8 mm 0.5 mm 1.5 mm Resistance Resistance tolerance Rated voltage 0.01 ohm/cm² to 6000 ohms/cm² As standard, ±10% of nominal. Tolerance down to ±2% available to special order. Up to 500 V AC/DC single or 3-phase. Temperature curves and required effect Foil heater mounted in free air Temperature rise C C 140 0.60 W/cm 2 0.50 W/cm 2 140 Temperature rise The following information will assist in the design of 120 0.40 W/cm 2 120 elements and rough calculation of data. Optimum effect and temperature conditions for specific applica- 100 80 60 0.30 W/cm 2 0.25 W/cm 2 0.20 W/cm 2 0.15 W/cm 2 100 80 60 tions are usually determined experimentally. The diagram shows temperature rise as a function of time for certain applications and various types of elements with different surface ratings. Surface rating is defined as the total power divided by the ef- 40 20 0.10 W/cm 2 0.05 W/cm 2 40 20 fective area of one side of the element. The figures refer to elements suspended horizontally in free air. 0 0 10 20 30 40 Sec 0 Power density W/cm² 0.05 0.10 0.15 0.20 0.25 0.30 0.40 0.50 0.60 End temperature increase in C 25 45 60 80 90 105 130 160 175 22
Foil heater mounted on heat sink Temperature rise C 340 5.0 W/cm 2 4.0 W/cm 2 3.5 W/cm 2 C 340 320 300 3.0 W/cm 2 320 300 280 260 2.5 W/cm 2 280 260 240 240 220 200 2.0 W/cm 2 220 200 180 160 1.0 W/cm 2 0.75 W/cm 2 1.5 W/cm 2 180 160 140 140 120 0.5 W/cm 2 120 100 1.0 W/cm 2 100 80 0.3 W/cm 2 80 60 0.5 W/cm 2 60 40 0.2 W/cm 2 0.1 W/cm 2 40 20 0.05 W/cm 2 20 0 0 0 2 4 6 8 10 min Foil mounted on an aluminum plate (5 mm thickness) with adhesive and suspended horizontally in free air. Power density W/cm² 0.05 0.10 0.20 0.30 0.50 End temperature increase in C 25 45 80 105 160 Foil mounted between two aluminum plates (5 mm thickness) and suspended horizontally in free air. Power density W/cm² 0.5 1.0 1.5 2.0 End temperature increase in C 160 260 330 410 23
Calculation of power The following formula can be used to determine the required rating P to heat a given material approximately. P = Weight of material (g) x spec. heat (Ws/(g C)) x temp. rise ( C) Time sec. W Specification of heat and density for common materials: Material Spec. heat Ws/(g C) Density g/cm 3 Aluminum 0.90 2.7 Copper 0.39 8.9 Stainless Steel 0.50 8.0 Iron 0.46 7.8 Water 4.18 1.0 Leakage currents for foil heaters at 220 1.15 V for various insulation materials and thicknesses A max (single-sided) (cm 2 ) 5000 4000 3000 2000 1000 0.380 mm 0.190 mm 0.300 mm 0.125 mm 0.200 mm 0.075 mm 0.050 mm 0.025 mm Electrical insulation and calculating leakage current When a foil element is fitted on a metal surface, leakage current must be taken into account. In industrial and low-voltage (<48V ~) applications there are no limitations regarding leakage current, while strict limitations apply to household appliances. The basic standard for heating appliances is laid down in the test rules IEC 6605, on which various national standards (SEMKO, NEMKO, DEMKO, VDE, etc.) are based. The maximum level of leakage current for Class I (grounded) appliances is 0.75 ma/kw while for Class II (double insulated) appliances it is 0.25 ma/kw. 0 0 1 2 3 I I (ma) Medical appliances are subject to special leakage current restrictions as per IEC 601. Polyester Polyimide Silicone Micanite 24
PTC Heating Elements The Calesco self-limiting heating foil with PTC effect (Positive Temperature Coefficient) is based on a special carbon filled polymer material that increases resistance with temperature and hence automatically limits the power generated by the heater. The resistance increases gradually from room temperature up to 80 C by about 5 6 times. When 80 C is reached the power decreases 80 85% from the initial value. The benefit with this type of PTC heater is the decreased risk for overheating, compared with a traditional resistive metal heating element. Even though metals also increase resistance with temperature, the effect is not as dramatic as for the PTC/ polymer element. The nature of polymer PTC heaters makes them the most suitable for low temperature applications with operating temperatures below 30 C. Due to the variable nature of the resistance in the element, it is rather difficult to predict the exact heating power. It is highly dependent on the heat dissipation of the heat sink it is attached to. Power related to Power at 20 C 1,6 1,4 1,2 1 0,8 0,6 0,4 0,2 0-40 - 20 0 20 40 60 80 100 PTC Effect related to Resistance at 20 C 8 7 6 5 4 3 2 1 0-40 - 20 0 20 40 60 80 100 Temperature C Temperature C Temperature control In conjunction with Backer Calesco foil heating elements it is usually necessary to arrange some form of control to ensure that the desired temperature is maintained. A foil to minimize element temperature and accept a deviation from the ideal working temperature. The final decision on thermostat temperature settings and location can often be made only after practical tests. element has very small mass and is quickly heated. Accurate temperature control is therefore needed. This can be achieved with electromechanical thermostats of the bimetallic type when temperatures and surface ratings are low, while electronic thermostats are preferred when temperatures and surface loads are high. We can fit thermostats, temperature fuses and sensors of the thermo-element type, thermistors and resistance sensors directly on elements in accordance with customer specifications. This helps to ensure reliable control. The placing of components can vary. It is often preferable 25
Methods of assembly Typical methods: Adhesive Tensioned elements Threaded fixings Shrink tubes Vulcanizing (carried out by Backer Calesco) Assembly Advice Adhesive A general rule is that successful assembly with adhesive requires a flat surface. It takes at least 24 hours for the adhesive to cure properly. Surface Preparation Remarks Metals and glass Clean thoroughly For best results, working temperature should be over 15 C. Ensure exclusion of air pockets. Pressing from center outwards. Plastic Clean thoroughly As above. Note that plastics containing plasticizer, i.e., certain thermoplastics, are unsuitable for adhesive assembly. Tensioned elements Spring or clamp connections used to secure the heating element with even pressure onto a surface. Threaded fixings The clamping screws or bolts must be arranged to yield even pressure over the whole area of the element. The position of screw holes must be taken into account in the design of the element. The clamping plate must be rigid so that pressure is evenly distributed over the whole area. An insulating layer may be used between the plate and the element to equalize pressure. Shrink tubes Elements may be fitted to pipes with shrink tubes. The right gauge and size needs to be determined. Vulcanizing Elements can be attached to various metal surfaces in different shapes. 26
BACKER WORLD WIDE MEMBER OF BACKER GROUP Backer develops, produces and sells customized solutions and components for electric heating, measurement and control. The original technology was stainless steel tubular elements. However, the constant growth of the Group, both organically and through acquisitions, has enabled the integration of several new technologies. Today the Group offers a far wider product range, with a vast number of technologies for several industry sectors and a large variety of applications. BACKER TECHNOLOGIES 8000 employees and 60 production units on 4 continents 70 years of accumulated competence and experience in the industry International organization with local presence Many specialized R&D departments to bring new innovative solutions to the market Customized solutions fulfilling special requirements Strong focus on components and systems for sustainable energy solutions Volume and industry production in different parts of the world Backer BHV AB / Div. Calesco Västra Åvägen 11 SE-734 51 Kolbäck, Sweden Tel: +46 (0) 220 453 00 backercalesco.com EVERYDAY EVERYWHERE 27