The Science Behind Thermik’s Temperature Protection Systems

Thermik Gerätebau has revolutionized thermal protection technology through its innovative approach to temperature-sensitive components. Understanding the science behind these life-saving devices reveals why Thermik has maintained its position as a world market leader in thermal protectors and thermistors for decades.

At the core of Thermik’s product line are two primary technologies: thermal protectors and PTC thermistors. Both serve critical functions in temperature regulation and safety, but they operate on different principles and are designed for distinct applications.

Thermal protectors, also known as temperature limiters or thermal cut-offs, are safety components that automatically disconnect electrical appliances when there’s a risk of overheating. The basic principle is straightforward: when a predefined temperature threshold is reached, the protector interrupts the flow of electricity, shutting down the device and preventing further heating that could lead to damage or fire. Once the device cools down sufficiently, the protector reconnects the circuit, allowing the appliance to function again.

The technology behind Thermik’s thermal protectors utilizes bimetals—materials composed of two different metals with differing thermal expansion coefficients. When heated, these metals expand at different rates, causing the component to bend or deform. In Thermik’s devices, this property is harnessed to create a mechanical switch with two or more internal contacts. One contact remains stationary while the other is movable. As temperature rises to the maximum permissible level of the bimetal, the movable contact separates from the static one, interrupting the circuit. When cooling occurs, the bimetal returns to its original shape, reconnecting the contacts and allowing current to flow again.

What sets Thermik’s thermal protectors apart from competitors is their precise engineering and innovative design. The company’s flagship innovation, first introduced in 1973 with the W1000 model, featured a 2-disc design that was flatter than competing products and solved numerous problems associated with other geometries, particularly the issue of current self-heating in bimetallic switches. This breakthrough established Thermik as an industry leader and laid the foundation for decades of subsequent innovations.

PTC thermistors, the other major component in Thermik’s portfolio, function differently from thermal protectors. While thermal protectors are safety components that prevent overheating, thermistors are primarily used for temperature measurement and regulation. The acronym “PTC” stands for “Positive Temperature Coefficient,” indicating that the resistance of these components increases as temperature rises, thereby reducing the current flow through the thermistor.

This property makes PTC thermistors extremely sensitive to even minor temperature changes, making them ideal for applications requiring precise temperature measurement. Thermik’s thermistors are deployed in a vast array of devices, from fire detectors and ovens to refrigerators, as well as in food industry equipment, medical electronics, and machinery manufacturing. Compared to conventional alternatives, Thermik thermistors are distinguished by their minimal mass combined with maximum temperature sensitivity.

The company’s commitment to precision and reliability is evident in its production processes. Thermik uses high-quality materials in its manufacturing, including bi-metal switching mechanisms with a high proportion of precious metals in the thermistors. Compared to cheaper metals, these materials react more precisely and reliably, enabling Thermik to meet the exacting specifications required by the electrical industry. This commitment to quality materials is a key factor in the company’s unique market position, as no other manufacturer can match these high standards.

A significant aspect of Thermik’s success lies in its comprehensive approach to product development and production. The company maintains control over the entire product cycle, from development to production, all conducted in-house. This integrated approach provides substantial benefits to customers, enabling customized development from the outset and facilitating easier individual adaptations. For clients in the electrical industry, the reliability, durability, and precise function of these components are paramount, particularly given their typically long product lifecycles exceeding 20 years.

Beyond customized solutions, Thermik also offers standardized products designed to meet general market needs. These thermal protectors are available in various technologies to accommodate different requirements and budgets, with flexible out-of-the-box solutions featuring numerous series, nominal response temperatures, and cable lengths to suit diverse applications.

Through its scientific expertise and commitment to innovation, Thermik Gerätebau continues to advance the field of thermal protection technology. Its products not only safeguard countless electrical devices but also contribute to energy efficiency and sustainability, making them increasingly relevant in today’s environmentally conscious marketplace. As electrical components become more prevalent in everything from household appliances to renewable energy systems, Thermik’s science-based solutions will remain essential for ensuring safety and reliability across multiple industries.