YOUR WORLD LEADING PARTNER IN INTELLIGENT HEATING & CONTROL

HEATER + MEASUREMENT = COMPLETE & CONTROL SOLUTION

PRODUCT DEVELOPMENT

We work together in a gate model to make sure we reach target in cost and production SOP

Evaluation / Approval to Prototype Production Design / Testing & start: development: development: Pre-production Development: validation First serial (B-SAMPLES) (C-SAMPLES) (A-SAMPLES) delivery

• Specification work • Initial testing • Production work / • Functional testing and • DVP Work • Project management • Feasibility • Verification and Final design evaluation • PPAP • Final report • First proposals analysis of A samples • Documentation and • Production engineering • Final design • Design preparation preparation • Prototype design

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 process including sales, product development, manufactur-

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

2 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 a supplier, but your preferred partner. Customized solutions 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 , 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, APPLICATIONS and as one of the largest suppliers of rear-view mirror heating Vision systems concepts, we have a vast knowledge of the demands of the trans- Fluid systems portation business. We keep your thumbs warm when operating Rear-view mirrors a snowmobile or keep tanks from freezing on trains. We heat the Seat heaters handlebars for ATVs and the floors in trams. With a product range Floor heaters from lens and sensor heaters to heating batteries. Windshield wipers The possibilities are endless. Filters Alco locks

HEATING SOLUTIONS

CAMERA HEATER Backer Calesco provides heat for different types of sys- tems, for example, front-view, side-view, rear-view & park- ing 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 heat- ing 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 APPLICATIONS and analytic industry where precise heat and maintaining exact Magnetic stirrers temperatures are important in many processes. We recognize Autoclaves the importance of technological advancements and are develop- Surgery beds ing and designing heating solutions that will work in the medical Incubators field. Our knowledge and expertise in heating products will allow Fluid heaters (Infusion) us to produce a heater that meets your heating specifications. We can fit , temperature fuses and sensors of the DNA Analysis thermo-element type, thermistors and resistance sensors directly Laboratory research equipment on elements in accordance with customer specifications. This Respirators helps to ensure reliable control. 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 ap- plications 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 opti- mize 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 APPLICATIONS industry for decades. Our foil is approved for high-tech, weight- Floor heating systems management applications. A space-saving efficient alternative to Couplers be used in, for example, as floor heating, frost protection, rear- Steps view mirror heating and seat heating. The flexible foil is supplied Windshield wipers in various materials such as PVC, Polyester, Silicon and Mica. 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 , 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 APPLICATIONS for more efficient batteries both for Hybrid and Electrical cars. Lead-acid When batteries are exposed to cold weather the temperature of the Nickel Metal Hydride battery drops and the chemical reactions occur more slowly, so the Lithium Ion battery cannot produce the same amount of current that it can at Sodium Ion . When decreasing below -20°C in some situations, Zebra the chemical reactions will happen so slowly and generate so little 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 heat- ers 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 . 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. APPLICATIONS Our heaters are found in applications such as waterbeds, floors Mirrors for housing or RVs, bathroom mirror demisters, panel heaters and Waterbeds towel heaters. Our domestic products offer you great solutions Floors for easy and safe heating. We give you warmth where it’s needed Infrared Panels most for enhanced comfort. 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 . 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 heat- ers 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 rether- APPLICATIONS malization. The heaters are easy to design for custom needs, with Heating cabinets space-saving solutions that can also be produced in different Espresso machines power densities. The heating systems are cost efficient, hygienic Professional kitchen equipment and can be designed for easy cleaning. You can use our heaters for Defrosting anything from cup warmers in espresso machines to professional Cooking tables cooking equipment like griddles and cook-serve systems. 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 bet- ter 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 life- time 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 meas- uring the resistance of the foil to regulate temperature.

16 RELIABILITY, ENERGY EFFICIENCY & TEMPERATURE CONTROL 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 Innovations 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. POLYESTER - PTC PRINTED POLYMER - ETCHED FOIL Self-regulating, robust and corrosion resistant

Superior heat transfer and uniform heat with PTC characteristics. output. Fast warm up with long life cycle. Max. power density: 0.3W/cm²

Max. power density: 0.6W/cm² Max. temperature: +70°C

Max. temperature: +105°C Rear-view mirrors / Lens heaters / Waterbed

Mirror heaters / De-icing equipment / heaters / Low temperature applications /

Hand grip heaters / Rear-view mirrors / De-icing

Battery heaters

- PRINTED POLYMER PEN

Low power, constant wattage with a large span PEN is similar to PET but has higher chemical, of resistivity. Insensitive to small damage. thermal, mechanical and electrical properties.

Max. power density: 0.1W/cm² More cost effective compared to polyimide.

Max. temperature: +70°C Max. power density: 1W/cm²

High voltage, small area applications / Max. temperature: +160°C

Waterbed heaters / IR targets / Floor heating Electronic devices / Radiators / DNA Analysis /

High power standard elements

POLYIMIDE SILICONE

Thin and semi-transparent with excellent Excellent temperature properties. Can be

dielectric strength. vulcanized to metal parts.

Resistant to chemicals. Max. power density: 1.3W/cm²

Max. power density: 1.3W/cm² Max. temperature: +230°C

Max. temperature: +200°C Food service equipment / Medical respirators

Military and aerospace / Medical diagnostic / Ultrasonic cleaners / Freeze protection and

instruments / LCD displays / Lens heaters / condensation prevention

Laboratory research

MICA PVC

High power density. Fast warm up and high Very flexible, waterproof and acid resistant

working temperatures. with high mechanical strength.

Max. power density: 5W/cm² Max. power density: 0.1W/cm²

Max. temperature: +600°C Max. temperature: +70°C

Food service appliances / Semiconductor Waterbed heaters / Water heaters / Military

industry / DNA analysis / Radiators, heating equipment / Slim blankets / Surgery beds

panels / Packing/strapping/sealing equipment WE ARE WITH YOU ALL THE WAY!

Idea

Shipping Specification

Manufacturing SOLUTION Development

Approval 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 cir- cuit 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 Circuit 600°C. Several circuits may be arranged on the same heater. A foil element provides even heat Insulation material distribution over the entire surface. It is also 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 · Light weight · Low energy consumption

· Multiple temperature zones · Simple assembly · High quality

· Flexibility · Quick heating

· Thin · Efficient heat transmission

CUSTOMIZED MULTIPLE CIRCUITS FLEXIBLE

Foil heating elements are designed according Elements can generate different heat levels Elements can be attached to products to customer needs and requirements. on the same surface area. with many different shapes.

EVEN TEMPERATURES PRECISE SENSOR LOCATION MULTIPLE VOLTAGES

Elements can be designed with varying out- Sensors can be added in any location on An element can combine 220V/12V to put to compensate for heat loss at the edges. the same level as the heating circuit. standardize one element for different voltage products.

21 TECHNICAL INFORMATION

Element type PVC Polyester Polyimide Silicone Mica PEN

Max. element temp. 70°C 105°C 200°C 230°C 600°C 160°C (depending on application)

Min. element temp. -40°C -60°C -60°C -50°C -50°C -60°C

High voltage resistance 15 220 200 17 32 ? at 20°C as per ASTM KV/mm

Thermal conductivity 0.17/70°C 0.16 0.17 0.24 0.30 0.16 at 100°C W/(m x K)

Moisture absorption as per ASTM D-570-63 0.2% 0.8% 2.9% 0.1% 1.0% 0.8% 24h immersion at 23°C

Moisture resistant yes yes yes yes yes yes as per IEC 335-1 sect. 15-16

Waterproof yes yes - yes - yes as per IEC 335-1 sect. 15-16

Constant of dielectricity 5-9 3.3 3.5 2.9-3.6 4-5.5 ? at 25°C 50Hz

Constant of dielectricity - 3.7 3.1 - 6.2 ? at 150°C 50Hz

UV radiation resistance limited limited limited good very good ?

Solvent resistance very limited limited limited limited limited ?

Bending radius, min. 20 mm 1 mm 1 mm 10 mm - 1 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 ?

Resistance 0.01 ohm/cm² to 6000 ohms/cm² Resistance tolerance As standard, ±10% of nominal. Tolerance down to ±2% available to special order. Rated voltage 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

2 Temperature rise 0.60 W/cm 2 140 0.50 W/cm 140 The following information will assist in the design of

2 elements and rough calculation of data. Optimum ef- 120 0.40 W/cm 120 fect and temperature conditions for specific applica-

100 100 tions are usually determined experimentally. 2 0.30 W/cm 2 The diagram shows temperature rise as a function 0.25 W/cm 80 80 of time for certain applications and various types of 2 0.20 W/cm elements with different surface ratings. Surface rat- 60 2 60 0.15 W/cm ing is defined as the total power divided by the ef-

40 2 40 fective area of one side of the element. The figures 0.10 W/cm refer to elements suspended horizontally in free air. 2 20 0.05 W/cm 20

0 0 0 10 20 30 40 Sec

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 °C

5.0 W/cm2 4.0 W/cm2 3.5 W/cm2 340 340

320 320 3.0 W/cm2

300 300

280 280

2 260 2.5 W/cm 260

240 240

220 220 2.0 W/cm2

200 200

180 180 1.5 W/cm2 160 0.75 W/cm2 160 1.0 W/cm2 140 140

2 120 0.5 W/cm 120

100 1.0 W/cm2 100

2 80 0.3 W/cm 80

2 60 0.5 W/cm 60

2 40 0.2 W/cm 40 0.1 W/cm2

20 0.05 W/cm2 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.

Weight of material (g) x spec. heat (Ws/(g °C)) x temp. rise (°C) P = W Time sec.

Specification of heat and density for common materials:

Density Material Spec. heat Ws/(g °C) g/cm3

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 (single-sided) max (cm2) 0.380 mm 0.190 mm 5000 Electrical insulation and 0.300 mm calculating leakage current

When a foil element is fitted on a metal surface, 4000 leakage current must be taken into account.

0.125 mm In industrial and low-voltage (<48V ~) applications there are no limitations regarding leakage current, 3000 0.200 mm while strict limitations apply to household appli- ances. The basic standard for heating appliances is 0.075 mm laid down in the test rules IEC 6605, on which vari- 2000 ous national standards (SEMKO, NEMKO, DEMKO,

0.050 mm VDE, etc.) are based. The maximum level of leakage current for Class I 1000 0.025 mm (grounded) appliances is 0.75 mA/kW while for Class II (double insulated) appliances it is 0.25 mA/kW. Medical appliances are subject to special leakage 0 0 1 2 3 II(mA) current restrictions as per IEC 601.

Polyester Silicone Polyimide Micanite

24 PTC Heating Elements

The Backer Calesco self-limiting heating foil with PTC effect element. Even though metals also increase resistance with (Positive Temperature Coefficient) is based on a special temperature, the effect is not as dramatic as for the PTC/ carbon filled polymer material that increases resistance polymer element. with temperature and hence automatically limits the power The nature of polymer PTC heaters makes them the most generated by the heater. suitable for low temperature applications with operating The resistance increases gradually from room temperature temperatures below 30°C. up to 80°C by about 5–6 times. When 80°C is reached the Due to the variable nature of the resistance in the element, power decreases 80–85% from the initial value. The benefit it is rather difficult to predict the exact heating power. It is with this type of PTC heater is the decreased risk for over- highly dependent on the heat dissipation of the heat sink it heating, compared with a traditional resistive metal heating is attached to.

1,6 8 C 1,4 7

1,2 6

1 5

0,8 4

0,6 3 0,4 2

0,2 to related Effect PTC at 20°C Resistance 1

Power related to Power at 20° Power to related Power 0 0 - 40 - 20 0 20 40 60 80 100 - 40 - 20 0 20 40 60 80 100 Temperature °C Temperature °C

Temperature control to minimize element temperature and accept a deviation from the ideal working temperature. The final decision on In conjunction with Backer Calesco foil heating elements temperature settings and location can often be it is usually necessary to arrange some form of control to made only after practical tests. ensure that the desired temperature is maintained. A foil 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 sen- sors 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

For best results, working temperature should be over 15°C. Metals and glass Clean thoroughly Ensure exclusion of air pockets. Pressing from center outwards.

As above. Note that plastics containing Plastic Clean thoroughly 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 • 8000 employees and 60 production units on 4 continents Backer develops, produces and sells customized solutions and components

for electric heating, measurement and control. The original technology was • 70 years of accumulated competence stainless steel tubular elements. However, the constant growth of the Group, and experience in the industry both organically and through acquisitions, has enabled the integration of • International organization with local several new technologies. Today the Group offers a far wider product range, presence with a vast number of technologies for several industry sectors and a large variety of applications. • Many specialized R&D departments to bring new innovative solutions to BACKER TECHNOLOGIES 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

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