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Traditional Wire Wound Heater/Resistors
Large and bulky 3-dimensional shapes cause issues for designers. These designs use excessive amounts of space to accommodate the wire, central core and mounting hardware. Heat transfer is poor due to the difficulty in thermally coupling the cylindrical shape to standard heat sinks. High resistances can only be achieved through excessively long wires or through extremely thin wires-neither of which is desirable. The majority of wound resistors are spiral wound and add inductance to the circuit that may be unacceptable. Inductance be reduced by special winding techniques but this adds cost to the resistor.
Thick Film Heaters and Resistors.
Thick film heaters and resistors are generally flat 2-dimensional shapes as thin as 0.010” thick, which offer a low profile. This minimizes the space requirements and is inherently better for thermal coupling to flat heat sinks, circuit boards and bulk heads. The thick film pastes come in a variety of resistance values so resistors from less than 1 to many Giga Ohms can be produced. This variety also allows tailoring of the resistance traces to accommodate the surface area available and optimize the amount of thermal coupling to transfer heat. The printed pattern allows opportunities to reduce/eliminate added electrical inductance inherent in wound resistors that may be unacceptable.