The performance of certain industrial processes relies on effective and efficient localized heating. To achieve localized heating, manufacturers apply different types of heater elements, which are manufactured from various materials and are customizable to fulfil the thermal transfer requirements of an industrial application. Some of the commonly used materials today for electrical heating elements include aluminum foil, polyimide, silicone rubber, and mica. At JenTer Technologies, we are your trusted source for various types of custom heating elements.
Custom flexible heating elements are available in two predominant configurations – wire-wound elements and etched foil elements. The various options available can make choosing the right heating element a challenge, but the information provided below should offer some information to make your decision an easier one.
It is important to understand the differences between the various flexible heater solutions in order to choose the right one. Let’s first look at the two major types of heater elements.
Heater Elements
Wire-Wound
This type of electric heating element includes a resistance wire having a designated diameter and consisting of one or multiple strands. If the element includes more than one strand, those strands are woven together and installed on a fiberglass core. They are wound in a set pattern on each layer of the substrate, evenly spaced apart. Dynamic applications often utilize wire-wound heaters because they can handle abrasive forces and can be sized much bigger than etched foil heaters.
Etched Foil
The popularity of flexible etched foil heaters has increased over recent years. They do not include wire and have the appearance of printed circuit boards with thin alloy metals that are acid etched onto the substrate. The widths of these etched foil heaters range from 0.005” to 0.10”. The thinness of the foil results in an extremely lightweight and thin etched foil heater.
You will generally find etched foil heaters in static applications in which weight and size carry greater importance. However, they can be manufactured with more density to meet the demands of an application. Etched foil heaters have high watt densities, and they heat up and cool down quickly.
Materials
Silicone Rubber
Silicone is commonly used in custom heating elements for various industrial and general-purpose applications. The various benefits afforded by silicone rubber heaters include:
- Flexible heaters manufactured from silicone rubber can handle higher temperatures that are often present in outdoor environments.
- They may be utilized within a substantial temperature range of -40°C (-72°F) to 200°C (360°F).
- These silicone heaters can be made very thin, down to 0.050 inches thick.
- These flexible rubber heaters can be built into sensors, thermal switches and cut-offs with ease.
- These flexible custom heating elements, when vulcanized onto a surface, provide exceptional bonding and thermal efficiency.
- They can also be cured to conform to 3D applications.
Mica
Mica electric heaters may have a heating element located in-between each layer of mica. The reason mica custom flexible heating elements are popular for various industrial applications is the following:
- They may be used within a broad temperature range from -150°C (-270°F) to 600°C (1080°F).
- They are ideal for applications involving high watt densities.
- They may be custom produced to achieve a fast thermal response.
- They have quick thermal recovery time capability and ensure excellent heat transfer.
Polyimide
These flexible heaters often have a thin heating element positioned in between two polyimide film layers. Particular adhesives, such as FEP Teflon® or acrylic, are used to keep the etched foil element in place. Kapton®®, a special polyimide film created by DuPont, is also used with these heaters. Some of the reasons these polyimide heaters are commonly used include:
- They have a small profile; they are an effective option for 2D applications.
- They facilitate rapid cooling and heating.
- They are chemical and water resistant.
- They are effective in environments that are subject to extreme temperatures.
When choosing the best flexible heater solutions for your applications, knowing the differences between the various types of heater designs and material is helpful, but it is just as important to source these heating elements from a trusted source.
When it comes to finding the best electric heating elements, manufacturers with a track record of experience, backed by resources and know-how, can help provide the flexible heater solutions needed for various applications. At JenTer Technologies, we are your dependable source for mica, silicone rubber, and Kapton®® flexible heaters. To learn more about the custom heating elements we offer, give us a call today at 920.928.2022 or send us a message by using our contact form.