Electronic – Right kind of resistance wire for near-skin heater

heatlow-voltageresistancesafety

I'll be up-front and say I know jack squat about electrical engineering aside from "conductors heat up when you run current through them."

I'm looking in to building a low-voltage (~12-24 volts) personal heater that I can attach to the inside of a jacket; basically a small battery-powered electric blanket with no control system other than just unplugging the battery when it gets too hot and plugging it back in when it gets too cold. I'm not sure how possible this is to do safely though.

My main question is, what should I use for the heating coil? I was hoping to have a long wire that zig-zags over most of the back of the inside of the jacket. Kanthal wire is really cheap right now 'cos of all the people wanting to build vaporizers; is that an appropriate material? If so, what specific mixture and gauge should I be going for?

Looking at the specifics it seems like it's meant for extremely high temperatures, whereas I want something that stays around 30-40 degrees Celsius on low voltage. I can't seem to find anything that says it's designed for that kind of application, though. Am I barking up entirely the wrong tree?

Is this a practical idea at all?

Best Answer

It probably is feasible.

But: you need to realize that even for electricity, conservation of energy applies! So if you want to produce 10,000 Ws (wattseconds) = 10 kJ of heat, you need to have that much energy in your battery.

So, in your place, I'd start by calculating what amount of heat you want to produce. That's really easy. Calculate the amount of material (ie. flesh) you want to heat up, multiply that by the specific heat of the material (use the specific heat of water, flesh is mostly that stuff), and then you know how many Joule you need. One Joule is 1 W · 1 s.

Then divide that by the time (in seconds) you want to allow the heating to heat up that much material, and you've calculated the power (in Watt) necessary to heat up that amount of material that fast.

Now, I don't believe you know nothing. You've probably heard of 1 W = 1 A · 1 V. So if you have a 12 V battery, in order to produce 1 W, needs to make \$\frac1{12}\text{ A}\$ current flow. If you need 120 W, you'll need 10 A. It's that simple.

Now that you know how much current you need to spend, you can calculate two things:

  1. how long your warmer should last with a single charge. Most batteries are rated in "Ampere hours", Ah, so take one battery that you think would be of acceptable weight and size, and figure out how long it will be able to source that current.
  2. how much resistance your wire needs to have, because, Ohm's law, U = R · I -> R = U / I (the resistance is the ratio between voltage U=12V and the current I). Heater wire has a fixed resistance per length. You can thus calculate the length of wire necessary.

This doesn't address things like maximum power impedance matching etc, but it does in theory give you a good idea of what your system needs to look like.