Happy Thanksgiving from BCE

Happy Thanksgiving from BCE

Mini Clean Flow (MCF) Air Heater – Three Phase

Mini Clean Flow (MCF) – Three Phase

BACKGROUND 

The application requirement was a 2” Stainless Steel heater capable of 120 CFM with a 250⁰C outlet temperature.  The inlet temperature was ambient air.  The heater required two Conflat Flanges (CF2.75), which could be used in a parallel flow configuration at the customer site.  The heater needed to be air tight.    

SCOPE

MCF – Three Phase:
  • 250⁰C @ 120CFM using (2) units in a parallel flow pattern
  • Stainless steel 304, all wetted parts 
  • Pressure tested to 90 PSI (or equivalent 5 x 10 ¯⁴ ATM, cc/sec or better)  
  • 3-phase with three heated zones 
  • (3) independent internal type “K” thermocouples for each zone 
  • 11KW (± 10%) , 240 Volt, 3-phase (or 1-phase optional) 
  • 36” Lead wires for each zone with 12” wire braid for strain relief
  • 304SS CF 2.75 inlet and outlet flange   
  • Medium being heated: Air, ambient  
  • He Leak Tested = 5 x 10¯⁴ ATM, CC/sec or better 

OUTCOME

The heater was laser welded on the flanges and brazed on the heater zones.  The heater helium leak test passed up to 1 x 10 ¯⁸ cc/sec in during the testing phase.  There were no problems heating ambient air at 2.5CFM to 200°C during the live power test at BCE.  The part was cleaned and passed the required 700 Volt DC Hi-pot test for 5 seconds @ 0.5mA.  

Mini Clean Flow (MCF) – Large DI Water Heater

Mini Clean Flow (MCF) – Large DI Water Heater


BACKGROUND:

Deionized water application requiring the recirculation of 3 gallons per minute to reach 66ºC in 2 hours. NEMA 4 moisture resistant housing was required.

SCOPE:

MCF – Large DI Water Heater:
  • Temperature from 18ºC to 66ºC in 2 hours
  • 316 Stainless Steel All wetted parts
  • Pressure tested to 90 PSI
  • NEMA 4 Housing
  • RTD, 3-wire 100 ohm process sensor built-in near outlet
  • An additional TC for bottom temperature read
  • 16KW (± 10%) , 208 Volt, 3-phase
  • Mounting threads on the bottom of the assembly
  • Medium being heated: Deionized Water (DI Water)
  • Recirculate at 3gpm

OUTCOME:

The heater zones were individually heated at lower voltage then pressure tested up to 90 PSI at 20ºC - 25ºC. The typical ramp temperature for a bench test prior to shipping is 100ºC. The response time in an air medium environment was immediate as the temperature was achieved in under 20 minutes. All zones passed the recommended 700 VDC for 5 seconds on the Hi-Pot test prior to shipping. The heater was cleaned & packaged then sent out for delivery.

BCE

+1 510-274-1990

Vacuum Chamber Heater Platen 350mm

Vacuum Chamber Heater Platen 350mm

BACKGROUND 

Find a solution in a Vacuum Chamber for the testing and processing of silicon and glass components ~650⁰C.  The heater surface, 350mm x 300mm x 12.7mm thick, was flat with no lift pin holes or gates to hold the product in place.   The long length cold pin section exiting from the center of the heater to the flange, needed to be long enough to exit into the atmosphere.  A slotted designed bottom plate was welded to keep the heat source in place and increase heater efficiency.  

SCOPE

The Vacuum Heater Platen:
  • Temperature 650⁰C-700⁰C  
  • 18” Long cold pin section with CF Vacuum Flange  on the bottom 
  • Helium Leak rate of 1 x 10̄¯9 cc/sec He on CF Flange only 
  • 300mm x 350mm x 12.7mm thick for silicon and glass products 
  • Thermocouple built-in for over-temp protection or control  
  • 2,400  Watt (± 10%) , 240 Volt
  • Mounting threads on the bottom of the assembly  
  • Material:  304 Stainless Steel 
OUTCOME

The Vacuum Heater Platen was ramped to 650⁰C at 75% of power (1800 watt) in atmosphere with a ceramic fiber insulation cover.  After a 1 hour ramp, the heater reached 650⁰ C and was turned off to let cool.    There was discoloration on the top surface, however this is expected in atmosphere at this temperature.  The electrical specifications were checked again and the heater was cleaned & packaged for delivery.  

BCE

+1 510-274-1990

ALD Vacuum Chamber Pedestal Heater with Extended Sleeve

ALD Vacuum Chamber Pedestal Heater with Extended Sleeve

BACKGROUND
Heating solution for an ALD Vacuum Chamber Heater testing 6” (152mm) wafers up to 450⁰C.  There were obvious space constraints at the customer site requiring an extended sleeve of 25”.  The extra-long length enabled the placement of the wafer on the top surface eliminating the need to modify the existing chamber.  

SCOPE
The Vacuum Pedestal Heater needed to satisfy the following:
  • Temperature 450⁰C  
  • 25” Long sleeve with 2.75 CF Flange on the bottom 
  • Body must pass Helium Leak rate of 1 x 10̄¯9 cc/sec He 
  • 6” overall diameter for 6” (152mm) wafers
  • Top surface must have a flatness of  ± .005” 
  • Thermocouple for additional temperature measurement
  • 1,000  Watt (± 10%) , 120 Volt
  • Material was 304 Stainless Steel
OUTCOME
The Vacuum Pedestal Heater was ramped in atmosphere to 450⁰C in approximately 45 minutes.  Due to the 360⁰ weld, there was some deflection on the top surface causing it to be out of tolerance.  After the 450⁰C ramp, the Vacuum Pedestal Heater was polished down to below ± .005”.  A leak test was performed to spec and cleaned to high purity standards then shipped in clean room bags.

Mini Clean Flow Heater for Harsh Environments

Mini Clean Flow Heater for Harsh Environments

BACKGROUND

The BCE application was a custom heating solution for harsh environments where the medium material needed to be heated using low carbon metals.  Stainless steels such as 316L and 304L are the best option for low carbon, these materials were not readily available on the a standard Mini Clean Flow (MCF) heater.  BCE adapted making all wetted parts 316L or 304L while being heated with a 321 stainless steel heat source.   

SCOPE

The Mini Clean Flow Heater - Harsh Environment needed to satisfy the following:
  • Temperature outlet needed to be 100⁰C  
  • Perpendicular configuration, with locking fittings
  • Body must pass Helium Leak rate of 1 x 10-7 cc/sec He 
  • Pressure test of 50PSI 
  • Ability to place heater in a series flow configuration if necessary
  • Thermocouple for additional temperature measurement
  • 400 Watt, 120 Volt
  • All wetted surfaces must be 304 or 316 Stainless Steel L (low carbon) 
OUTCOME

This BCE MCF heater was tested to 100⁰C with the mass of the heater being slightly above 5 lbs.  The 100⁰C temperature was reached within about 2 minutes.  This efficiency was achieved by maintaining good contact with the internal heat source and the low carbon steel MCF heater body.  


BCE

+1 510-274-1990 

Experienced Electric Heating Element Designers Speed Development Time and Save Money in OEM Product Development

Electric Heating Element Designers

The application of localized electric heating elements is one area that OEM design engineers find themselves navigating in unchartered waters. Very logically, they often attempt to use an off-the-shelf cartridge, silicone rubber, or mica heaters for their specialized heating requirement. Unfortunately, this approach compromises layout, packaging, and performance. A better alternative is considering a custom heating element developed in consultation with an experienced custom heater manufacturer.


Technology advances rapidly, and findings in material science, medicine, pharmacology, biology, and semiconductors occur daily. These advancements in technology open the door for performance improvements leading to new treatments, medications, materials, and processes. Original equipment manufacturers (OEM's) of analytical, semiconductor, biomedical, life-science, and aerospace equipment continually design new equipment to apply and leverage these new discoveries. 


Experienced custom electric heater designers provide many essential benefits throughout the product development cycle. For instance:

  • Front-end, practical design review to optimize manufacturability.
  • Timely prototype development.
  • Strong alliances with vendors.
  • Single source responsibility.
  • Testing, calibration, and QC.
  • Inventory management.
  • Value-added assembly.

The heater manufacturer partner provides:


  • Critical guidance in material selection.
  • Power requirements under load.
  • Temperature vs. time data.
  • Watt density optimization.
  • Packaging advice.


Their help provides high performance, precise fit, and extended heater life.


The pressure to produce new devices that offer greater efficiencies, compactness, and production is always present. Each item in the precedent design undergoes scrutiny and transitions to a contemporary fit, form, or function. New components are needed to meet the new design requirements. By choosing an experienced custom electric heating element design partner, the OEM gets the precision they need, plus scores of other benefits derived from the heater vendor's tacit knowledge and past experiences.


BCE

+1 510-274-1990