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Etched Foil Resistivity

Last post 01-30-2009, 2:19 PM by Vitreous Humor. 3 replies.
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  •  02-20-2008, 7:38 PM 1632

    Etched Foil Resistivity

    Hi All, 

    Does the etched foil used in the heaters have a standard resistivity? I am thinking of a design where the etched foil heating element is extended and used as the connector to the heater. I need to determine the width of the heater element 'tracks' to achieve an accepatble temperature rise at 2.5A.

    Thanks, Justin.

  •  01-11-2009, 10:46 AM 1665 in reply to 1632

    Re: Etched Foil Resistivity

    Jusitn,

    I just finished the calculations for a 0.001 thick copper nickel alloy.  The resistivity was quoted as 225.5 ohms for a one foot long circular mil.  That was a bit esoteric for me so I recalculated the resistivity to 3.74877965 x 10^-7 per meter^3.

     I hope that helps.

    --Steve Rines,

    Ludwigslust, Germany

  •  01-11-2009, 10:49 AM 1666 in reply to 1665

    Re: Etched Foil Resistivity

    Regarding the temperature rise at 2.5A I have a related question:

    I am designing a flex circuit to sit between fields of neodymium magnets.  The circuit will be attracted/repelled by the magnets based on changes in voltage applied to the flex circuit.  I have designed the trace layout to take advantage of the flux fields of the magnets.  The circuit requires a minimum trace resistance to match the impedance of the operational amplifier.  I intend to use CuNi as the trace material to achieve the necessary resistance.  At the moment I defined a 2.7 meter trace of 1 mil CuNi 2.7mm wide to achieve the requisite resistance (15 ohms).  The flex circuit is a double-sided circular disk 80mm across, in a circular frame but moving axially in the open air.   My goal is no more than 45deg temp rise at 150W. How do I determine the temperature rise of the flex circuit based on voltage/current in?

    Regards,

    --Steve

  •  01-30-2009, 2:19 PM 1672 in reply to 1632

    Re: Etched Foil Resistivity

    Etched foils used in heater manufacturing do have standard resistivities that reflect the properties of the metal alloy. Lower resistance heaters will be made commonly of different thicknesses of 70-30 Copper-Nickel Alloy which has a resistivity of 180 ohm-square-mil/foot (same as 225 ohm-circular-mil/foot used in another example). Higher resistance heaters will commonly be designed in different thicknesses of Inconel which has a resistivity of 490 ohm-square-mil/foot. Both of these alloys have a common property that they have a low TCR, i.e. resistance is relatively stable across temperature.

    There are other foils used to make heaters that may have desirable properties for other applications. In fact, it is possible that the heater could be made of all copper materials with a fine pattern where you want heat and larger traces where you want it to act like a flexible circuit.  Copper has a resistivity of 9.2 ohm-square-mil/foot and is much more temperature sensitive than the other alloys. So if the heater resistance is low enough, it could be designed on copper.

    If you are using copper, calculate the current that will be flowing through the traces and design the flex lead per the conductor nomograph charts in the flex circuit design guide for the conductor temperature rise that you can allow. If you are using another alloy, the power density in the enlarged trace must be the equivalent of the power density in the copper trace used in the nomograph.

    For a 1 oz copper, the trace width needs to be near 0.15" for a 10 dC rise at 2.5 amps. At 1/2 oz copper, the trace width increases to near 0.35".


    Vitreous Humor
    "Eye can see clearly now..."
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