A leading Brazilian manufacturer of precision measurement instruments faced a recurring reliability issue:
condensation and micro-frost formation inside their high-accuracy instruments—especially during sudden humidity changes common in Brazil’s coastal and tropical regions.
Even tiny moisture droplets caused:
Sensor drift
Inaccurate readings
Corrosion of internal components
Calibration failures
Increased service and warranty costs
To ensure stable performance, the customer needed an internal heating solution that could:
Prevent moisture buildup
Keep internal temperature and humidity stable
Operate silently 24/7
Require zero maintenance
Fit inside compact instrument housings
Never overheat or damage sensitive electronics
The client initially used traditional resistance heaters, but these created new problems:
Uneven heating
Risk of overheating
Need for external thermostats
Short lifespan in humid environments
Sudden temperature spikes affecting sensor accuracy
After researching alternatives, they discovered the advantages of PTC (Positive Temperature Coefficient) heaters, and specifically Tiancheng, due to:
32 years of PTC engineering experience
Extremely stable, maintenance-free heating
Proven anti-frost solutions for instrumentation & medical applications
Consistent temperature behavior within ±5–10°C
Excellent aging performance under humidity and thermal cycling
Compact aluminum-shell modules ideal for embedded designs
Tiancheng provided a miniature aluminum PTC heater that could be integrated directly into the instrument’s internal air chamber.
Self-regulating temperature — no external controller required
Uniform heating to prevent localized hot spots
Constant low-power heating to maintain stable humidity and temperature
Silent 24/7 operation
Excellent moisture resistance & insulation
Compact structure suitable for small instrument housings
Safe anti-frost performance even during rapid environmental changes
The heater was positioned along the inner wall of the instrument casing to create a gentle thermal buffer—keeping the environment above dew point, regardless of outside humidity.
The Brazilian manufacturer reported immediate and measurable improvements:
Condensation completely eliminated
No frost formation even during rapid temperature drops
Instrument internal humidity kept stable
Power consumption significantly lower compared to resistance heaters
Calibration remains stable for longer periods
Fewer sensor errors
No internal corrosion
No hot spots or overheating incidents
24/7 maintenance-free operation
No need for manual moisture checks
Reduced warranty cases and service cost
Increased instrument lifespan and customer satisfaction
PTC technology’s natural advantages played a key role:
Automatically adjusts power based on temperature
Cannot exceed its designed temperature
Ideal for small enclosed spaces
Perfect for humidity-sensitive applications
Reliable even in tropical climates like Brazil
For this client, Tiancheng’s PTC heater became an invisible but critical component that ensures precision, stability, and reliability in their advanced instruments.
