Electrical Ceramic Heater Parts

The range of ceramic heater part produced at Jyoti are Steatite Ceramic Interlocking Insulating Beads in various shapes and sizes, Steatite and Jyalox End Sealing Bushes for sealing the ends of tubular type electrical heaters

Steatite and Cordierite Ceramic Band Heater Insulators with single and multibores for manufacture of Electrical Band Heaters for plastic moulding machines.

Ceramic Tubes and Formers with single and multibores in various patterns and sizes in Steatite, Cordierite and Aluminium Oxide materials. Jyalox High Alumina Ceramic stress relieving interlocking insulators for electrial Pre-and-Post-Heating mats.

Electrical Ceramic Heater Parts |	Ceramic Band Heater Insulators | Ceramic insulator

The use of ceramic insulating components has become an absolute necessary in order to meet with today's requirements in the field of Electrical Heating Engineering Technology, due to importance of high temperatures, insulation, size limitations and safety standards.

Ceramic heater parts are produced from the proprietary developed ceramic recipes formulated from the most selected quality raw materials to ensure that the components possess all the necessary physical, chemical and electrical properties as per the international quality standards.

Most of the ceramic heater components are produced from the company's owned moulding tools, however we welcome your enquiries for specific type components. We suggest before designing your end product, please consult us, to discuss about the component material, its geometry etc. to offer the components at an economical cost made from most suitable ceramic.

We have established separate modern tool room facilities equipped with CAD, CAM, CNC machine tools and EDM to design and fabricate intricated moulding tools to meet with customers requirements for tailormade components. Also full fledged state of art R&D Laboratory is established for research and development of new ceramic materials as well as to conduct testing physical, chemical and electrical properties of ceramic materials, so that we can offer most appropriate material, for construction of required ceramic components.

We provide all the necessary services required for developing suitable ceramic components for your application.

Properties Units Steatite HF-82 KER-221 Jyalox 92W C-786 Jyalox 95P/W C-795 Cordierite Dense C-410 Cordierite Porous C-511
Color OFF WHITE WHITE PINK/WHITE OFF WHITE GREY/BROWN
Content MgO SiO2 Al2 O3 92% Al2 O3 95% 2MgO
2Al2 O3
5SiO2
MgO
Al2 O3
SiO2
Density gm/cm3 2.70 3.70 3.75 - 3.8 2.4 - 2.5 2.1 - 2.15
Porosity % 0 0 0 0.10 - 0.50 15 - 20
Co-Efficient of Thermal Expansion
(25-1000 °C)
10-6 K-1 8.5 7.5 - 8.0 8.8 3.0 - 3.5 3.0 - 4.5
Thermal Shock Resistance
(Down Shock)
°c 180 170 160 300 350
Thermal Conductivity (25 °C) WM-1 K-1 2.3 22 24 3.0 1.5 - 2.0
Max Temperature of Operation °C 1050 1200 1400 1000 1000

All Dimensions are in mm :

  • Tolerances for Width and Height ± 0.3 mm OR 2% which is Greater.
  • Tolerances for Holes and Slots ±0.15 mm
  • Tolerances for Length ± 0.2 mm OR 1% which is Greater.
  • Bow Allowance 0.15 mm OR 0.5% of the Length

Steatite Ceramic Band Heater Insulator

All Dimensions are in mm :

  • Tolerances for Width and Height ± 0.3 mm OR 2% which is Greater.
  • Tolerances for Holes and Slots ±0.15 mm
  • Tolerances for Length ± 0.2 mm OR 1% which is Greater.
  • Bow Allowance 0.15 mm OR 0.5% of the Length

All Dimensions are in mm :

  • Tolerances for Width and Height ± 0.3 mm OR 2% which is Greater.
  • Tolerances for Holes and Slots ±0.15 mm
  • Tolerances for Length ± 0.2 mm OR 1% which is Greater.
  • Bow Allowance 0.15 mm OR 0.5% of the Length

Steatite and Cordierite Band Heater Insulators LS (Large Size)

Typical Properties of Cordierite Material
Nominal Composition : 2Mgo, 2A12 O3 , 5SiO2
Colour : 2Mgo, 2A12 O3 , 5SiO2
Nominal Composition : White
Density : 2.35 - 2.40 gm/cc
Water Absorption : 0.5 %
Flexural strength : 800 Kg/cm2
Compressive strength : 5000 Kg/cm2
Hardness on Vicker’s scale : 300 - 320 Hv10
Hardness on Moh’s scale : 6.0
Co-effcient of liner thermal
Expansion (20-1000 °C)
: 3.0 - 3.5 X-10 -6 / °C
Thermal conductivity (20 °C) : 3.0 W/M0 K
Thermal Shock Resistance
(Down shock)
: 300 °C
Dielectric Constant (20 °C, 1MHz) : 50
Dissipation factor (20 °C, 1MHz : 0.004
Volume resistivity (20 °C) : 1011 Ω
MATERIAL CODE
STEATITE ALS
CORDIERITE LSBC

All Dimensions are in mm :

  • Tolerances for Width and Height ± 0.3 mm OR 2% which is Greater.
  • Tolerances for Length ± 0.2 mm OR 1% which is Greater.
  • Tolerances for Holes and Slots ±0.15 mm
  • Bow Allowance 0.15 mm OR 0.5% of the Length

Steatite End Sealing Beads

PATT. NO Ø D Ø D1 Ø d H h Ref. Fig No
ESB - 1 06.75 05.70 05.70 10.80 04.45 [1]
ESB - 2 07.00 06.00 02.70 11.00 04.50 [1]
ESB - 3 06.86 04.95 02.80 10.92 04.75 [1]
ESB - 4 08.20 06.40 04.50 11.00 05.00 [1]
ESB - 5 08.40 06.50 04.20 11.20 04.80 [1]
ESB - 6 08.00 06.30 03.40 10.20 04.00 [1]
ESB - 7 08.00 05.30 03.80 07.75 02.50 [5]
ESB - 8 08.00 05.75 04.00 08.00 03.00 [5]
ESB - 9 08.50 05.75 04.40 08.00 03.00 [5]
ESB - 10 07.90 05.80 03.30 07.00 03.95 [4]
ESB - 11 10.65 05.95 03.50 04.00 02.00 [6]
ESB - 12 06.50 04.50 03.30 09.00 02.40 [3]
ESB - 13 08.15 06.30 04.35 11.00 05.00 [1]
ESB - 14 06.90 05.30 03.60 10.00 04.50 [2]
ESB - 15 10.60 08.00 04.35 12.25 05.00 [2]
ESB - 16 08.20 06.38 03.20 11.00 04.48 [1]
ESB - 17 07.70 05.60 03.20 09.00 04.00 [2]
ESB - 18 06.30 04.70 02.80 08.00 03.00 [2]
ESB - 20 08.00 05.80 03.30 10.00 04.00 [2]
ESB - 21 10.65 05.95 03.50 04.00 02.00 [6]
ESB - 22 06.50 04.50 03.30 08.50 02.40 [3]
ESB - 23 08.70 06.00 03.50 07.20 04.20 [4]
ESB - 24 06.90 05.25 03.50 10.00 05.00 [5]
ESB - 25 15.00 11.00 05.80 15.50 05.00 [5]
ESB - 26 10.60 08.00 04.90 12.70 05.70 [5]
ESB - 27 11.50 09.50 05.50 12.25 05.00 [5]
ESB - 28 09.50 06.00 01.50 17.00 10.00 [7]
ESB - 29 06.30 04.30 02.75 07.00 02.50 [5]
ESB - 30 07.62 05.82 02.20 10.90 07.90 [7]
ESB - 31 07.60 05.80 02.20 13.85 08.00 [7]
ESB - 32 07.30 05.70 04.00 12.00 04.50 [5]
ESB - 33 08.00 05.50 03.20 07.00 02.00 [1]

All Dimensions are in mm :

  • Tolerances for Width and Height ± 0.3 mm OR 2% which is Greater.
  • Tolerances for Holes and Slots ±0.15 mm
  • Tolerances for Length ± 0.2 mm OR 1% which is Greater.
  • Bow Allowance 0.15 mm OR 0.5% of the Length

Steatite Ceramic Interlocking Insulating Beads

DEMO HEAD

PATT. NO Ø D Ø d H Approx Nos.Per Kg Approx Per Kg
1 03.50 01.40 03.50 14925 52.20
2 04.30 01.90 04.90 8403 33.60
3 05.30 02.50 05.70 5435 27.20
4 06.75 03.40 07.30 2625 15.00
5 08.30 03.50 08.50 1239 08.30
6 10.3 04.10 10.30 682 06.00
7 11.10 04.50 10.80 536 05.00
8 12.70 05.50 12.70 390 03.70
9 13.60 06.00 13.60 320 03.60

FLAT HEAD

10 06.80 04.35 07.30 3115 17.5
11 08.70 05.50 08.70 1412 10.60
12 10.50 06.30 10.50 1197 06.70
13 11.00 07.00 10.50 857 09.00

FISH SPINE

3 05.00 02.20 05.35 6250 26.00
4 06.50 03.50 06.50 3705 18.00
5 08.00 03.80 07.70 2000 11.00
Quantity Variation in Nos. per Kg = ± 5%

All Dimensions are in mm :

  • Tolerances for Width and Height ± 0.3 mm OR 2% which is Greater.
  • Tolerances for Holes and Slots ±0.15 mm
  • Tolerances for Length ± 0.2 mm OR 1% which is Greater.
  • Bow Allowance 0.15 mm OR 0.5% of the Length

95% Al2O3 Pink Aluminium Oxide Ceramic Stress relieving interlocking heatermat beads

Stress Relieving Interlocking Insulators for Pre and Post-Heating


In welding large structures, pipe works and reaction vessels etc. it is a common practice to locally employ electrical heating devices to raise the temperature of the metal sections prior to welding and to control the sudden fall in temperature after the area is welded.

Stress Relieving Interlocking Insulators for Pre and Post-Heating

Jyalox ceramic has excellent electrical properties such as insulation and heat dissipation which ensure safe operation, quick and proper heating of area at the elevated temperatures.

The electrical device is in the form of flexible heater mat, constructed with alumina ceramic interlocking beads. The electric heating elements are supported by ceramic beads which insulate the device from the structure being welded.

Jyalox ceramic bead insulators available for construction of stress relieving flexible electrical heater mats

Flexible electrical heating mats find the widest use in stress relieving applications, as the interlocking pattern of ceramic beads allow maximum flexibility to the mat, to cover the heating element properly from exposure to the area required to be heated up, such as concave, convex and flat surfaces of vessels, pipes etc. Several mats can be connected together to cover large surface areas of vessels, pipes etc required for stress relief treatment.

Jyalox ceramic stress relieving bead insulators are mechanically tough, strong and wear resistant to withstand abuse of rough handling of heater mats commonly experienced while in use in heavy construction industry.

Flexible electrical heating mats find the widest use in stress relieving applications, as the interlocking pattern of ceramic beads allow maximum flexibility to the mat, to cover the heating element properly from exposure to the area required to be heated up, such as concave, convex and flat surfaces of vessels, pipes etc. Several mats can be connected together to cover large surface areas of vessels, pipes etc required for stress relief treatment.

Jyalox ceramic stress relieving bead insulators are mechanically tough, strong and wear resistant to withstand abuse of rough handling of heater mats commonly experienced while in use in heavy construction industry.

Jyalox-95P Ceramics Physical Properties

Nominal Composition : 95% Al2O 3
Colour : Pink
Specific Gravity : 3.70 - 3.75
Flexural Strength : 3250 kg/cm2
Coefficient of linear
thermal expansion (20-4000°C)
: 8.8 x 10-6/°C
Thermal shock resistance
(Down shock VT)
: 160°C
Thermal Conductivity (20O°C) : 24 W/M°K

Jyalox-95P Ceramics Chemical Properties

A O 3 : 95.00%
SiO2 : 1.41%
MgO : 1.35%
CaO : 1.16%
Cr2 O3 : 0.75%
Na2 O : 0.16%
BaO : 0.07%
Fe2 O3 : 0.04%
TiO2 : 0.03%
Others : 0.03%

Our design engineers are always at your service to assist you for use of Ceramic Insulator from the standards range. We can also develop custom design Ceramic insulator for your applications if the required quantities are substantially large for economically viable production. All the above features coupled with good mechanical qualities make Jyalox beads an ideal carrier of the heating element.

JYALOX 95 P-W (Pink - White) Aluminium Oxide End Sealing Bushes

PATT NO. Ø D Ø D1 Ø d H h
ESB - ALP - 101 06.10 04.40 02.65 05.90 02.70
ESB - ALP - 102 06.10 04.40 02.92 05.90 02.70
ESB - ALP - 103 06.50 04.80 02.65 06.20 02.70
ESB - ALP - 104 07.90 05.60 03.25 06.70 02.70
ESB - ALP - 105 10.50 08.00 04.70 08.00 03.70

All Dimensions are in mm :

  • Tolerances for Width and Height ± 0.3 mm OR 2% which is Greater.
  • Tolerances for Holes and Slots ±0.15 mm
  • Tolerances for Length ± 0.2 mm OR 1% which is Greater.
  • Bow Allowance 0.15 mm OR 0.5% of the Length

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