Showing posts with label custom thermal systems. Show all posts
Showing posts with label custom thermal systems. Show all posts

BCE Tackles Complex Thermal and Vacuum Challenges for Critical Industries

Complex Thermal and Vacuum Challenges for Critical Industries

Since 1952, BCE (Belilove Company‑Engineers) has quietly built a reputation as the team you call when you need thermal and vacuum solutions no one else will attempt. While others offer standard catalog parts, BCE thrives on custom engineering challenges, transforming complex heating and vacuum-feedthrough concepts into reliable, precision-crafted solutions for critical industries, including space, aerospace, semiconductors, OEMs, and university research.


A Company Rooted in Practical Engineering


At its core, BCE embodies hands-on engineering. Operating from its ISO 9001:2015-certified facility in Hayward, California, BCE engineers don’t shy away from a design just because it doesn’t fit into a neat box. They dig into the customer’s challenge, study the constraints, and engineer a practical, manufacturable solution that meets tight performance, environmental, and space requirements.

Whether the task involves designing a heater that can survive extreme temperatures in orbit or a vacuum feedthrough that must handle complex signals and power transfers without leaks, BCE combines deep thermal and mechanical engineering experience with advanced testing to deliver what others say is impossible.


Why BCE Takes on the Hard Projects


Many companies prefer the safety of off-the-shelf designs and high-volume manufacturing. BCE takes a different path. They excel in low-to-medium volume custom projects, where the demands of advanced research, space hardware, and semiconductor tools require a unique solution.


Customers approach BCE with ideas and needs that often lack a clear roadmap. BCE listens, refines the concept, and engineers a design that meets the exact operating conditions—whether it’s a specific watt density, vacuum rating, or geometric constraint.


This willingness to take on nonstandard, high-precision thermal systems has allowed BCE to become a trusted partner to companies and laboratories that require problem-solving, not just parts.


Expertise Spanning Critical Industries


Space and Aerospace


In space and aerospace, hardware must function reliably for the first time and continue to operate effectively in harsh environments. BCE engineers understand these stakes, developing systems that perform under vacuum and thermal extremes while meeting NASA outgassing requirements. Their work supports satellite systems, propulsion testing, and aerospace instrumentation without cutting corners.


Semiconductor and Advanced Manufacturing


In the semiconductor sector, BCE develops thermal systems that integrate seamlessly into demanding manufacturing environments, where thermal uniformity, precision, and cleanliness are non-negotiable. BCE’s engineering team collaborates with clients’ design teams to align the thermal system with the process goals rather than forcing a standard solution.


University Research and OEM Innovation


For university labs and OEM innovators, BCE enables cutting-edge research and prototyping by providing engineered solutions that match experimental setups and new technology platforms. Their flexible approach allows rapid iteration while maintaining performance and reliability.


The BCE Approach


BCE’s process emphasizes collaboration, iterative prototyping, and precise testing. They analyze thermal profiles, material properties, and mechanical tolerances to ensure that each custom solution will function reliably in the field. Every unit is tested for thermal, vacuum, and electrical performance before it leaves the facility.


BCE also prioritizes practical manufacturability during the design phase, ensuring that even the most advanced custom designs can be produced cost-effectively while maintaining strict quality standards.

Their engineers remain closely involved from initial discussions through delivery, ensuring the final system accurately meets the customer’s requirements and is ready to perform under real-world conditions.


A Trusted Engineering Partner


BCE succeeds because it embraces challenges others avoid. Their engineering-led culture and practical experience in thermal systems and vacuum technologies allow them to take on projects where precision, performance, and reliability are critical.


Companies, researchers, and innovators who need thermal and vacuum systems that operate under extreme conditions—and who want to partner with engineers who will engage deeply with their problems—trust BCE.


With more than six decades of applied engineering and a willingness to tackle the unusual and complex, BCE stands as a cornerstone partner for industries and researchers pushing the boundaries of what is possible.


If you need a thermal or vacuum system for a mission-critical application—and the problem seems too complex for standard options—BCE is ready to help you build it.


BCE’s Vacuum Ring Heater: Defying Boundaries in Degassing Chambers

BCE Vacuum Ring Heater
BCE Vacuum Ring Heater

Providing uniform heat to semiconductor devices in degassing chambers is essential in extracting impurities. This can only be achieved if a heating device has the proper fit and temperature uniformity for a given chamber. It is for this very application that BCE was approached by a large semiconductor company from Silicon Valley. In order to heat this company’s semiconductor wafers, it was critical that the heating device be manufactured to fit precisely into a large and circular degassing chamber posing manufacturing challenges due to dimensional and application parameters. BCE was able to provide extensive design consultations, 3D CAD modeling and lean manufacturing capabilities to this semiconductor giant at a competitive price. All these services were rendered while catering to all requirements needed to successfully manufacture their products.

SCOPE


The heating apparatus needed to satisfy the following criteria:
  • Vacuum compatibility to 10-8 Torr 
  • Maximum Operating Temperature: 200°C 
  • Temperature uniformity of ±4% at 150°C 
  • Operate at 1500W, 240V 
  • All epoxies used needed to meet NASA’s Low Outgassing Spec (ASTM E595) 
  • Reduced contamination from components inside chamber 
  • Temperature sensing capability 
  • Circular configuration between 34 and 36 inches in diameter 
  • Height of part was not to exceed 1 ft. 
  • Effective heat transfer from heating device with reduced machining cost 
OUTCOME

BCE’s Vacuum Ring Heater proved to be the ideal product for this application. Its strong aluminum ring construction ensured effective heat transfer to the circular wafers while keeping manufacturing costs low. Furthermore, its strategically embedded heater with stainless steel sheath allowed the device’s temperature uniformity to remain at ±2% at 150°C, greatly exceeding customer requirements. Moreover, BCE’s proprietary epoxy meeting NASA’s low outgassing spec was used as the primary sealant and KAPTON insulated leads were provided for the heater and integrated thermocouple to reduce contamination. In fact, the integrated thermocouple type K further served to monitor the temperature supplied to the chamber. Finally, all electrical, vacuum and dimensional requirements were met to provide the most optimal thermal environment.

Visit this link for more information on the Vacuum Ring Heater, or call (510) 274-1990.

Rapid Response Electric Heaters Designed for Clean Gases and Liquids

Mini Clean Flow Heater
Mini Clean Flow Heater
In advanced technologies such as analytical, biomedical, pharmaceutical, aerospace, electronics and laboratory applications, special purpose electric heating elements are required for heating high purity fluids and gases. These applications require rugged design, fast heat-up, tight control, high temperatures and the ability to withstand exposure to harsh solvents and corrosive gases. They also must be constructed in a way to prevent contamination of the process media.

The use of standard screw plug immersions heaters, screwed into a stainless steel welded vessels (known as circulation heaters) are almost always a misapplication for these unique requirements. Circulation heaters create more problems due to leaks, material compatibility, poor controllability, and bulky size.

BCE, a northern Californian manufacturer of custom heating elements offers it's Mini Clean Flow Heater specifically for these applications. These heaters are designed for heating "clean" liquids and gases normally found in fuel cell, bio-med, laboratory, food, semiconductor and pharmaceutical applications.

The Mini Clean Flow Heater operates in a liquid or gas stream providing very fast response times and accurate control capability.

The heating elements in the Mini Clean Flow Heater are isolated electrically from the process media, protecting them from contaminants and providing long life.

Summary:
  • Designed for heating of clean gases or liquids
  • Gas flow passes over an enclosed heated body; not exposed to resistive elements (Nichrome)
  • All parts exposed to gas flow are constructed of 304 stainless (other material available)
  • High temperatures
  • Custom wattages, voltages, inlet and outlet fittings (NPT, SAE, BSP &VCR) are available.
  • Made in U.S.A.

For more information, visit http://heater.belilove.com

Thermal Solutions Designed for Aerospace

Advanced electric heating elements and thermal systems designed and manufactured for application-specific requirements in the harsh operating environment of outer space.

Experience, precision, and reliability. BCE.

http://heater.belilove.com | (510) 274-1990

BCE Flanged Gas Heater (Custom Electric Heating Element)

Here is an example of BCE's custom heating element design and manufacturing capabilities. This is their flanged gas heater.

Some of the design features are:

  • Heat gasses to 400°C - 450°
  • Body welded to pass 10⁻⁸ vacuum
  • All 304 SST materials (other available).
  • RoHS compliant parts and components.
  • Embedded thermocouple probe.
  • Can be used in gas chromatography and other applications.
  • Wire length/type are customer specified.




For more information visit http://www.belilove.com or call (510) 274-1990.

Experience is Key When Applying Custom Electric Heating Elements

Electric Heater Design Expert
Heater design expertise is
readily available from your
Technical Sales Rep
Designing and applying custom electric heating elements are best completed and accomplished through the proper application of the right resources. One of the most available and important sources of high level technical knowledge is a vendor's local Technical Sales Rep. Their assistance is readily available and their consultative value is very high.  Bringing in a Technical Sales Rep will have a big bearing on a successful task or project completion.

Many Technical Sales Reps are degreed engineers. If they don't have an engineering degree, you'll find they have years of empirical application knowledge from working on many, many projects. You'll also find that many have worked at manufacturer's factories and know the in's and out's of production as well as anyone.

Consider these elements the Technical Sales Rep brings to your thermal system design project:

Custom heating element
Watt densities? Thermal profiles?
Distributed wattage?
There's a lot to know.
Product and Application Knowledge: Your Technical Sales Rep has probably seen hundreds, if not thousands, of custom heating requirements. They deliver a mental encyclopedia of product offerings, application insights, and broad spectrum of capabilities. They also have information regarding what products are in development that can give you the competitive edge. Much of this information resides in the Reps head, and is not generally accessible to the public via the Internet.

Experience: As a project engineer, the selection and incorporation of a new heater design may be all new to you. You may be treading on fresh ground with little or no experience in the nuance of electric heaters. There can be real benefit in connecting to a knowledgeable source, with years of past design and application experience, that will save you time, money, and effort.

Access: Technical Sales Reps work closely with a variety of manufacturers, and may even have in-house prototyping or manufacturing capabilities at their own companies. This gives you, the design engineer, a connection to “behind the scenes” manufacturer contacts with essential information not publicly available. The technical sales rep knows people, and makes it his/her business to know the people that can provide answers to your electric heating and custom thermal system application questions.

So, in this age of doing your own research and self-educating on the Internet, let's not forget the importance of a face-to-face visit with someone who can really help - your Technical Sales Rep. You'll be very pleased with the information they can provide to make your job easier and the quality of your product better.

Have a custom heater job? Contact BCE now!
www.belilove.com(510) 274-1990

Attending MD&M West and the Value of Exhibitions

medtech world
Visit BCE at booth 2184
This week BCE is exhibiting at MD&M West (Medical Design and Manufacturing West) in Anaheim, CA. While the title implies medical equipment design, the exhibition also includes packaging equipment and other related equipment. The show runs Feb. 9, 10 and 11.

MD&M is the world's largest medical design and manufacturing exhibition. It "offers three days of technical presentations, hands-on design workshops, demonstrations and ticks and tricks to help you stay ahead of the game in 2016."

Representatives from many well-know "Medtech" companies will attend and a full 3 days of presentations are planned. Some of the more interesting titles are "The Creative Keys: How to Turn a Thought Into a Thing with Ease and Grace", "New Product Development Technologies and NexGen Applications", and "Leading the Smart Manufacturing Revolution".

BCE's Applied Resistance Group will showcase its thermal system design capabilities, advanced ceramics machining, laser machining, and thick film circuits and heaters. BCE is quickly developing a nation-wide reputation as an excellent partner for these products.

BCE Applied Resistance
BCE is exhibiting their
years of experience in
thermal system design,
thick film, laser machining,
and advanced ceramics.
BCE has decades of hands-on experience with thermal systems and advanced ceramics. The result is a strong expertise in analytical instrumentation, semiconductor equipment, photovoltaic devices, medical equipment, plastics processing machinery, foodservice equipment, packaging machinery, aerospace technologies, and laboratory R&D.

Exhibitions and trade shows are great places to network and build business relationships. Face-to-face contact with prospective customers and vendors provide an opportunity for strong business relationship foundations. Meeting with someone in person is far better than meeting online.

One huge benefit of attending an exhibition is the ability to meet large numbers of helpful people in one place. When attending an exhibition, it's best to plan ahead and utilize your time efficiently. Set up appointments in advance so that you don't waste time wondering. Make a list of booths and people you really want to get to know. And please, stop by the BCE booth (2184) - you'll be glad you did.

Engineered Thick Film Heating Elements

Thick film heating elements were developed as an outcropping of long-time technology used for production of printed circuit boards and hybrid circuitry. The term “thick film” refers to the resistance circuit (or heating element) that is deposited by a screen printing process, typically 0.0005” thick and deposited on a ceramic or metal substrate.

A thick film heating element provides precise layout of the resistance element exactly where the heat is required. Additionally, intimate contact of the heating element to the substrate is guaranteed delivering maximum heat transfer by eliminating any air gap there between between the heating element and the substrate.

Thick film heaters give engineers broad design flexibility of the heating circuit itself. Designers can precisely distribute heat where its required and also dictate the uniformity in temperature distribution. This design flexibility can be applied to curved and irregular shapes, as well as flat, to accommodate custom heating applications.

Highly machined ceramic parts, with intricate designs, high dielectric properties,  and smooth surfaces are ideal for thick film heating elements. Advanced ceramic's chemically inert, non-porous properties facilitates the careful and exact control of the trace pattern and trace dimensions, thus providing a “heated part” approach to equipment design.

Features of Ceramic Thick Film Heaters:
  • High dielectric
  • High thermal efficiency
  • Very rapid heating
  • Uniformity of heated area / pattern
  • High watt densities
  • Chemically inert
  • Custom shapes and sizes
  • Custom wattages and voltages
  • Embedded temperature sensors
Thick film heating elements are used in many industries today, particularly in advanced technologies such as analytical instruments, medical equipment, aerospace, semiconductor, and research & development.

BCE, located in the San Francisco Bay Area, has decades of experience in consulting, designing, and applying thick film heaters. Their reputation has grown nationally as a premier custom thermal solutions provider.  For more information, contact:

BCE
21060 Corsair Blvd
Hayward, CA 94545
Phone: (510) 274-1990
Fax: (510) 274-1999
E-mail: sales@belilove.com
www.belilove.com

Custom Heating Elements and Controls

custom heating element
Custom heating element.
Many types of industrial and manufacturing equipment, including analytical instrumentation, semiconductor, photovoltaic, medical, plastics processing, foodservice packaging, and aerospace equipment require some kind of custom electric heater, controller, and sensor.

For instance here, in semiconductor processing, you can find a need for electric heating in all these areas:  Bake platen heaters, bake/chill pedestal & platen heaters, hot chuck heaters, high temperature platen heaters, standard pedestal heaters, vacuum chamber heaters, and aluminum pedestal heaters.

A well engineered thermal system considers overall heat load, maintenance power requirements, control method, and sensor location. Working with a vendor who has the experience and background in this kind of product development is critical. Careful consideration of form, fit, and function requires the guidance an experienced applications engineer to avoid wasted time and money. 







Electric Heating Element Technical Reference Guide

Carnot engine diagram
Carnot engine diagram
(courtesy of Wikipedia)
Here’s a very handy reference document (courtesy of Hotwatt) for the application of electric heating elements in industrial and OEM applications such as extruding, vulcanizing, laminating, curing, bonding and thermoforming.

The heater application guide provides all the important technical look-up tables required to properly apply electric heaters, such as wattage calculation formulas and examples, properties of metals properties of non-metallic solids, properties of liquids and gases, suggested watt densities, estimates of wattage required, guide for heat losses, suggested sheath materials, installation,  Ohms Law, and typical wiring diagrams. The reference document is also very helpful when designing custom electric heating elements and designing a thermal system.

Designing a Process Control Loop? Or maybe a Custom Thermal System? Call a Sales Engineer.

Tech Sales Engineer
Sales Engineers are a valuable,
readily available resource.
Are you an engineer tasked with designing a new control loop for a manufacturing line? Or perhaps you're an engineer at an OEM designing a new piece of equipment requiring an electric heater, control and sensor?

Call a sales engineer to make your job easier.

Projects and tasks are best completed and accomplished through the proper application of the right resources. There exists an access point to high level technical knowledge and assistance that can be easily tapped and brought to bear on your successful task or project completion.

Local distributors and representatives for process equipment and control manufacturers provide services that may help you save time and cost, while also achieving a better outcome for the entire project. Consider a few elements the technical sale rep brings to your project:

  • Product Knowledge: Sales engineers will be current on product offerings, proper application, and capabilities. They also have information regarding what products may be obsolete in the near future. This is an information source at a level not generally accessible to the public via the Internet.
  • Experience: As a project engineer, you may be treading on fresh ground regarding some aspects of your current assignment. There can be real benefit in connecting to a source with past exposure to your current issue. 
  • Access: Through a technical sales engineer, you may be able to establish a connection to “behind the scenes” manufacturer contacts with essential information not publicly available. The rep knows people, makes it his/her business to know the people that can provide answers to your  application questions.

Certainly, any solutions proposed are likely to be based upon the products sold by the representative. That is where considering and evaluating the benefits of any proposed solutions become part of achieving the best project outcome.

Develop a professional, mutually beneficial relationship with a technical sales team. Their success is tied to your success and they are eager to help you.