Ultra-thin flexible heaters are precision-engineered heating solutions developed to deliver consistent and uniform temperature in compact devices. For medical portable diagnostic devices, maintaining an accurate temperature range is critical to secure reliable test results.
These heaters are built using polyimide (Kapton), PET film, or silicone rubber substrates. Their ultra-thin profile, typically 0.05mm–0.2mm, integrates easily into handheld analyzers, point-of-care systems, and compact PCR equipment.
| Parameter | Specification Range |
| Thickness | 0.13mm – 0.4mm |
| Voltage Range | 3V – 24V (customized available up to 220V) |
| Power Density | Up to 1.5W/cm² |
| Operating Temp. | –40°C to 200°C (Kapton material) |
| Materials | Polyimide (Kapton), PET, Silicone, ITO |
| Options | Adhesive backing, embedded sensors, connectors |
| Certifications | RoHS, ISO13485 for medical-grade production |
Ultra-thin flexible heaters are widely used across different medical portable diagnostic devices and related industries. Below are detailed application examples:
The standard heater thickness starts from 0.13 mm, which is thin enough to fit compact diagnostic housings while maintaining structural strength. This thickness also prevents delamination during frequent sterilization cycles.
Medical devices often run on rechargeable batteries. Heaters are typically designed at 0.5–1.2 W/cm², which provides rapid heating without draining battery life. For instance, a 20 cm² heater running at 0.8 W/cm² consumes only 16 W, suitable for portable analyzers.
Diagnostic devices require accurate heat levels. For example, blood analysis units often need 37 °C ±0.5 °C to maintain sample viability. Precision control is achieved by integrating thermistors or RTDs.
Heaters must comply with ISO 13485 and RoHS requirements. Adhesives and substrates must be biocompatible to prevent risks during patient interaction.
Medical instruments are exposed to disinfectants and cleaning agents. Polyimide heaters provide strong chemical resistance and can operate reliably after >10,000 thermal cycles between room temperature and 100 °C.
A client developing a portable PCR analyzer required a thin, low-power heater to maintain reagents at controlled temperatures. The challenge was ensuring accurate results without compromising battery life.
Danyu designed a custom polyimide ultra-thin flexible heater with a built-in thermistor. The heater achieved uniform heating of 37°C ±0.5°C, consumed only 3.8W, and was just 0.1mm thick. After integration, the device performed reliably in both laboratory and field environments, improving diagnostic turnaround time.
Q1: What temperature range do ultra-thin flexible heaters support?
They typically operate from –40°C to 200°C, depending on material selection.
Q2: Can heaters be customized for specific diagnostic devices?
Yes. We design heaters with custom shapes, voltages, resistance values, and even transparent options.
Q3: Do you provide heaters with integrated temperature sensors?
Yes. Thermistors, RTDs, or thermocouples can be embedded for accurate monitoring.
Q4: Are these heaters compatible with sterilization processes?
Polyimide-based heaters withstand autoclaving and chemical sterilization, making them suitable for medical use.
Q5: How fast do these heaters reach stable temperature?
They can reach operating temperature within seconds, depending on power density and design.
Danyu enables to offer one-stop customized heating solutions according to your specific requirements.
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