RTD temperature sensors are widely used in silicone rubber heaters because they deliver stable, repeatable, and accurate temperature feedback. This is especially important in systems that rely on controlled heating rather than simple warming. When an RTD is integrated into a silicone heater, the heater becomes more precise, reacts more consistently, and maintains a more uniform surface temperature. In real projects, this means fewer failures, safer operation, and longer service life.
This article provides a clear and practical explanation of how RTDs work, how they are placed inside silicone heaters, what mistakes must be avoided, and why manufacturers like Danyu Electronics are trusted for advanced heater builds.
An RTD temperature sensor is a device that measures temperature by tracking the change in electrical resistance of a metal element. When users search for RTD Temperature Sensor meaning, they are often looking for a simple explanation: the core sensing material—often platinum—changes resistance in a predictable way as it heats up. Because platinum behaves very consistently, the readings remain accurate over time and across wide temperature ranges.
The most recognized standards are PT100 and PT1000. A PT100 element has 100 Ω resistance at 0°C, while PT1000 has 1000 Ω at the same point. These fixed starting values make calibration and temperature conversion very straightforward.
RTDs are valued for three things engineers care about most: accuracy, stability, and long-term repeatability.
An RTD temperature sensor diagram usually shows the basic layers that make up the sensing element. The structure is simple but designed to keep the resistance stable during temperature changes. Although structures vary by manufacturer, most diagrams include:
Below is a typical RTD temperature sensor diagram:
This structure must remain stable under thermal cycling. When integrated into a silicone heater, the RTD must be thin enough to react quickly but durable enough to survive bending and pressure during use.
The primary purpose of an RTD is to give the control system a reliable temperature reference. Without a sensor, the heater can only run blindly. With an RTD, the controller can:
In industries such as medical equipment, outdoor electronics, optics, and battery heating, this level of control is essential.
Silicone rubber heaters often operate on curved surfaces, metal housings, or structural components that require stable heat control. RTD Temperature Sensors provide the accuracy and consistency necessary for these applications.
1. High Accuracy
RTDs can reach ±0.1°C accuracy—critical for:
2. Fast Thermal Response
When laminated to the heater, the RTD reads temperature almost instantly.
3. Uniform Temperature Control
Controllers can regulate the heater more precisely, reducing hot spots.
4. High Durability
RTDs tolerate mechanical flexing, vibration, and silicone’s thermal expansion.
5. Temperature Stability Over Time
RTDs drift far less than thermocouples, making them ideal for applications where calibration stability matters.
In a silicone heater, the RTD is typically embedded between silicone layers close to—but not touching—the resistance wire circuit. This placement allows the RTD to sense the true operating temperature without being exposed to electrical noise or mechanical stress.
Heat generated by the heater spreads through the silicone sheet. The RTD senses the change, and the controller translates that resistance into a temperature reading. When the reading reaches the target temperature, the controller reduces output. When the temperature falls, the system raises output again. This constant adjustment produces smooth heating rather than sharp fluctuations.
Well-designed heaters position the RTD in the most representative thermal zone, which depends on the heater geometry, power density, and actual installation surface.
1. Pt100 (100 Ω at 0°C)
2. Pt1000 (1000 Ω at 0°C)
RTD Wiring Options
| Type | Accuracy | Cost | Best Use |
| 2-wire | Lowest | Low | Short cables |
| 3-wire | Medium | Medium | Industry standard for silicone heaters |
| 4-wire | Highest | High | Laboratory or aerospace |
3-wire RTDs are the most common in silicone rubber heaters because they:
Sensor bonding is critical. A poor bond leads to slow response, drift, or even sensor failure. Quality heater manufacturers typically use one of these methods:
A proper bond provides excellent thermal contact, mechanical stability, and moisture protection.
Best Practices for Safe Integration
RTDs work with three wiring formats:
The controller sends a small current through the RTD and measures the resulting voltage. With the known relationship between resistance and temperature, the controller calculates the real temperature. Stable wiring and clean bonding help deliver consistent readings.
Incorrect installation can create multiple issues:
These problems are often invisible to end users but can cause early failures in real applications. A trusted supplier avoids these risks with stable production methods.
Danyu Electronics has been in the flexible heater field for nearly ten years, supporting custom heating solutions for industrial, medical, optical, and outdoor systems. Our production site covers over 3,000㎡, equipped with clean bonding lines and dedicated temperature-sensor processing areas. We develop silicone rubber heaters, polyimide heaters, transparent heaters, and custom-shaped heaters with embedded RTDs. A strong engineering team reviews every design to confirm heat density, sensor placement, wiring style, and long-term stability before production.
If you are preparing a project and need a heater with accurate RTD temperature sensing, our team would be pleased to assist. You may send your drawing, target temperature, voltage, and power needs. We will review your requirements and return with a clear solution and quotation.
1. Can I embed more than one RTD in a silicone heater?
Yes. Dual RTDs are common—one for control, one for safety redundancy.
2. Are RTDs better than thermocouples for silicone heaters?
Yes, for accuracy and stability. Thermocouples are better for high-temperature applications (>260°C).
3. Can I replace an embedded RTD?
No. Only surface-mounted RTDs are replaceable.
4. What temperature range can RTD Temperature Sensors handle?
5. Is Pt100 or Pt1000 better?
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