Have you ever struggled with batteries losing power in the cold, or delicate instruments overheating in the wrong conditions? Have you wondered how engineers keep devices at just the right temperature, no matter the environment? Danyu electronics offer 24V circular silicone heaters that can solve this problem.
From keeping batteries warm in freezing climates to ensuring precision in medical devices and industrial equipment, these heaters do more than provide heat—they deliver consistent, reliable performance in places where traditional heating methods fall short.
A 24V circular silicone heater is a flexible electric heater designed for applications that demand uniform heating across round or cylindrical surfaces. The “24V” refers to the operating voltage, which is common in battery-driven systems, mobile equipment, and industrial sensors.
These heaters are constructed from a thin resistive heating element—either etched foil or wound resistance wire—encapsulated between layers of silicone rubber. The circular format allows them to wrap around pipes, tanks, or cylindrical batteries, delivering steady heat where it’s needed most.
The silicone material provides elasticity, dielectric insulation, and excellent resistance to moisture and chemicals. The heater’s lightweight nature means it can be installed easily with adhesive backing or clamping rings, making it suitable for both permanent and removable applications.
The process of making a silicone heater combines precision electrical engineering with material science. Every layer is optimized for both performance and durability. Here’s a detailed look into the manufacturing process.
1. Designing the Heating Circuit
The first step involves designing the electrical pattern that defines how heat is distributed. Engineers use software tools to calculate watt density (W/cm²) across the heater’s surface. A common design formula is:
Where:
For example, if a 24V heater has a resistance of 12 ohms, its power output is:
This determines the total heat generated. Engineers adjust resistance paths to balance heating uniformity.
2. Selecting the Heating Element
Two main heating element types are used:
Etched foil is often preferred for circular silicone heaters because it supports tighter tolerances and faster warm-up times.
3. Lamination with Silicone Rubber
Once the circuit is patterned, it’s placed between two layers of uncured silicone rubber. The layers are pressed together and heat-cured to form a single vulcanized unit.
This encapsulation process creates a waterproof, electrically insulated, and mechanically resilient structure. The thickness typically ranges from 0.5 mm to 3 mm, depending on voltage, wattage, and application.
4. Vulcanization and Finishing
During vulcanization, the heater is cured under controlled temperature and pressure to solidify the silicone and eliminate air pockets. After curing, leads or connectors are attached—commonly silicone-insulated wires with crimped or soldered terminals.
For battery heaters or pipe wraps, the heater may also include built-in sensors such as NTC thermistors, RTDs, or thermostats for temperature feedback and control.
Finally, the assembly is die-cut or laser-cut into its circular shape, ensuring perfect fit and dimensional stability.
The performance of a 24V circular silicone heater depends on several engineering parameters:
| Parameter | Typical Range | Description |
| Voltage | 12V–48V DC | Defines power input |
| Watt Density | 0.5–3.0 W/cm² | Determines heat intensity |
| Temperature Range | -60°C to +230°C | Operational limits |
| Thickness | 0.5–3 mm | Depends on circuit type |
| Resistance Tolerance | ±10% | Affects heat distribution uniformity |
Heat Transfer Mechanism
Silicone heaters work primarily through conduction and radiation. Once current passes through the resistive element, electrical energy converts to heat. That heat transfers outward through the silicone layer and into the contact surface.
The rate of heat transfer depends on:
Where:
This formula helps engineers optimize heater thickness for specific heat requirements—thin layers yield faster heat transfer but lower dielectric strength.
Batteries—especially lithium-ion types—are sensitive to temperature. When exposed to cold conditions, their chemical reactions slow down, internal resistance increases, and capacity drops sharply.
A 24V battery heater addresses this by maintaining the battery pack at an ideal operating temperature (typically 20–40°C). Circular silicone heaters can wrap around cylindrical cells or adhere to battery housings. They prevent freezing, stabilize output, and improve charging performance.
Common use cases include:
These heaters are often integrated with temperature controllers to prevent overheating, extending both battery life and reliability.
The typical working temperature of a silicone rubber heater spans from -40°C up to about 280°C, depending on the material formulation and manufacturing process. For continuous or long-term usage, the recommended upper limit is approximately 250°C. Within this range, the silicone maintains its flexibility, insulation strength, and dielectric properties without signs of hardening or discoloration.
When temperatures approach 300°C and above, the silicone rubber begins to undergo gradual thermal degradation. Prolonged exposure beyond this limit causes the material to lose elasticity and may eventually lead to surface cracking or carbonization. Therefore, while short bursts near 280°C may be tolerable, continuous exposure to 400°C is far beyond the safe operating threshold for standard silicone heaters.
| Feature | Silicone Heater | Kapton Heater |
| Max Continuous Temperature | 230°C | 260°C |
| Flexibility | Very high | Moderate |
| Thickness | 0.5–3 mm | 0.1–0.3 mm |
| Moisture Resistance | Excellent | Moderate |
| Mechanical Durability | High | Fragile |
| Cost | Moderate | Higher |
| Applications | Batteries, pipes, outdoor devices | Aerospace, cleanrooms, electronics |
Silicone heaters excel in rugged environments, offering mechanical toughness and weather resistance. Kapton heaters, however, win in precision thermal applications where space is limited and cleanliness is vital.
For most 24V battery and circular heating designs, silicone remains the practical and cost-effective choice.
1. Determine the Power Requirement
Use the equation:
Adjust resistance to achieve desired power output without exceeding temperature limits.
2. Choose Appropriate Watt Density
Typical watt density for silicone heaters ranges from 0.5 to 2.5 W/cm². Higher values accelerate warm-up but require efficient heat dissipation.
3. Account for Thermal Insulation
Adding insulation layers improves efficiency but increases warm-up time. Balance both for stable operation.
4. Use Temperature Control
Integrate a thermostat, thermistor, or PID controller to prevent overheating and extend lifespan.
5. Match Heater Shape to Surface Geometry
Circular or ring-shaped heaters ensure full contact on curved surfaces, reducing hot spots.
At Danyu electronics, we combine advanced flexible PCB engineering with thermal design expertise to deliver custom silicone heater solutions tailored to your application.
We support OEM and ODM projects across automotive, medical, and energy sectors—whether you require a 24V battery heater, a flexible printed heater with sensor integration, or a rigid-flex PCB assembly for advanced control modules.
In addition to this, we offer various voltage like 12V, 48V, 120V and shapes silicone rubber heater, whatever you want, we can make for you! If you are searching for a reliable thermal solution for rubber silicone heater or polyimide Kapton heaters, you are welcome to reach us at any time!
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