Flexible heaters are designed to generate the heat level required for the application at hand. They may be attached to various sizes of curved, flat, or bulky equipment for a range of functions. Choosing the correct flexible heater helps ensure stable, consistent, heat without damage or failure to the particular application. At JenTer Technologies, we are your source for various flexible heater solutions that fulfill the requirements of various industry applications.
Let’s review some of the most frequently used flexible heaters. Manufacturers of these heaters often produce polyimide heaters, silicone heaters, polyester heaters, and mica heaters.
Polyimide Flexible Heaters
Flexible heaters made with polyimide have two layers of polyimide film that encase one layer of etched foil element. This polyimide film is often referred to as Kapton®®. A number of different adhesives may be applied to secure etched foil elements in position such as acrylic and silicone.
The benefits of flexible heaters made with Kapton®® include:
- Small profile makes them perfect for 2D applications
- Facilitate quick heating and cooling
- Ideal in moderate/high temperature environments
- Resistant to radiation, chemicals, and fungi
- Resistant to cracking and tearing
- Stable, uniform thermal distribution
- Allows good thermal transfer
- Minimal outgassing in vacuum environments
Applications for Polyimide Flexible Heaters
These heaters are lightweight and thin in nature, and therefore ideal for use in applications in which it is beneficial to keep weight to a minimum on working components. It is also ideal for use where space restrictions are an issue. The flexibility of polyimide makes it a common choice for cylindrical and irregular surfaces.
When durability and ruggedness are needed, polyimide is often used. These flexible heaters are often found in applications for the medical, aerospace, military, and food service industries.
Silicon Rubber Flexible Heaters
Flexible heaters made with silicone rubber are ideal for general purpose applications. These elements include wire wound or etched foil that has undergone vulcanization between two insulating materials of silicone rubber.
Silicone rubber flexible heater solutions have the following applications and benefits:
- Embedded easily into cut-offs, thermal switches, and sensors
- Applicable within a temperature range of 40°C to 200°C (392°F)
- Ideal for 3D applications
- Works in outdoor environment, high temperature, and humid conditions
- Thickness of the silicone material resists abrasion and mechanical damage, and adds dimensional stability and durability
- When vulcanized on surfaces, provides exceptional thermal efficiency and bonding
- Ideal for outdoor and wet environments, acting as a barrier to moisture
- Usable when multiple watt densities are required
- Applicable for flat surfaces
Polyester Flexible Heaters
Polyester flexible heater solutions are customized for applications that require a low level of heat transfer. They consist of elements manufactured from wire wound, etched foil, or indium titanium oxide inks. The elements are applied between polyester layers that provide transparency for some applications.
The benefits of polyester flexible heaters include:
- Transfer heat uniformly
- Ideal for low temp applications
- More economical (at times) than silicone heaters
- Lightweight and flexible
Applications for Polyester Flexible Heaters
Polyester heaters are routinely used for smaller applications in which a lower temperature is needed. Manufacturers often use these heaters in cases where damage might occur to the application under moderate or high heat. These heaters are also used in cases where an ice or moisture buildup can accumulate on parts, such is warming batteries, warming cups in coffee makers, maintaining the temperature of ingredients in restaurants, de-icing mirror surfaces, and warming fish aquariums.
The lightweight and flexible characteristics of polyester flexible heaters make them ideal for applications in which irregular curved surfaces and increased weight are an issue.
Mica Flexible Heaters
Mica heaters have two layers of mica on each side of an etched foil element. They offer the following features and benefits.
- Ideal for high watt density applications
- Operations in a temperature range of -150°C to 600°C
- Provide excellent heat transfer and quick recovery times
- May be customized for a quick thermal response
Applications for Mica Flexible Heaters
Common applications for mica flexible heaters include processing and packaging equipment, enclosure systems, air heaters, and food service equipment. These heaters may be used on various components, such as thermocouples, thermostats, thermistors, thermal fuses, specialty wiring harnesses, and RTDs.
Choosing the Right Flexible Heater
Applications for flexible heaters may vary depending on the surface structure, size, operation, or environmental conditions of the application. In order to select the appropriate flexible heater, manufacturers must conduct a complete review, testing, and validation of the equipment. This will help in the process of matching the right flexible heater to the requirements of the application.
For information about the custom flexible heater solutions we offer at JenTer, call us today at 920.928.2022 or complete our contact form.