Silicone Heating Film Supplier | Silicone Rubber Heater

Introduction to Silicone Rubber Heaters

We offer a variety of heating elements for silicone rubber heaters, including stainless steel 304, CuNi44, and Inconel600. These elements exhibit excellent dielectric properties and can operate in environments ranging from -70°F (-56.6°C) to 392°F (200°C). Now, let's delve into the different types of heating elements, their respective functions, and application scenarios in detail.

Types of Flexible Silicone Rubber Heaters:

Etched Foil Heaters:

Etched foil heaters utilize chemically etched circuits sandwiched between thin layers of silicone rubber to enhance the heat transfer performance for applications that require precise temperature control. Although etched foil circuits require wider traces to achieve equivalent resistance compared to wire elements, the traditional printing/etching process used in circuit board manufacturing allows for strict spacing control, enabling trace spacing as close as 0.004". Our design team ensures precise circuit geometries to ensure uniform heat distribution and consistent repeatability throughout the production process.

Silicone rubber heaters utilizing etched foil circuits can provide twice the output power compared to older wire-wound technologies. This technology allows for the integration of multiple heating zones on a single heater, making it suitable for designs that require power densities greater than 5 W/in². The foil thickness of the circuit ranges from 0.0005" to 0.004".

Wire-Wound Heaters:

Wire-wound heaters employ wire elements wound between layers of silicone rubber. This structure ensures even heat distribution and provides excellent physical strength. Wire-wound heaters are typically used in applications that require larger sizes or lower production volumes. They can adapt flexibly to different shapes and sizes without the need for holes or notches.

silicone rubber heater

Please note that the information provided here covers a range of commonly used resistance wire materials in wire-wound flexible heaters. The specific selection of wire materials depends on the requirements and operating conditions of the application. Here are some applications of wire-wound flexible heaters using different types of resistance wire:

Nickel-Chromium (NiCr) Alloys: These alloys, commonly referred to as nickel-chromium wires, are the most widely used materials in silicone rubber heater applications. They possess high resistivity, good oxidation resistance, and can operate at temperatures up to 1,250°C (2,280°F).

Copper-Nickel (CuNi) Alloys: CuNi alloys have moderate resistivity and an extremely low temperature coefficient of resistance. They are typically used in flexible heater applications with a maximum operating temperature of up to 600°C (1,110°F).

Iron-Chromium-Aluminum (FeCrAl) Alloys: FeCrAl alloys are high-resistance materials that exhibit excellent shape stability, thereby prolonging the heater's lifespan. These alloys are used in applications with a maximum operating temperature of up to 1,400°C (2,550°F). Compared to traditional nickel-chromium alloys, silicone rubber heaters made with FeCrAl alloys can accommodate higher surface load capacities, higher resistivity, and lower density. As a result, these heaters can be designed using less material, reducing weight.

The etched or wire circuits are then soldered to lead wires and vulcanized between two layers of silicone rubber, forming a fully uniform unit. The silicone layer acts as a protective barrier, preventing physical damage such as scratches or abrasions, serving as a moisture barrier for operation in wet and outdoor environments, and exhibiting resistance to most chemicals.

Compared to etched foil heaters, the wire-wound design allows for concentrated heat distribution in specific sections of the heater, overcoming the limitations of etched foil technology. Etched foil heaters can be made from various alloys such as aluminum, stainless steel, non-magnetic nickel-chromium alloys, copper, and constantan. Our rich experience in these different materials ensures that we can design and provide the best solutions tailored to your specific application requirements.

Applications and Industry Advantages:

Flexible silicone rubber heaters exhibit excellent heating efficiency. They employ advanced technologies and materials, allowing for rapid heat transfer and quick attainment of the desired temperature. This means that they can deliver heat to the heated product faster, effectively enhancing heating efficiency and saving time and energy. The heating capabilities of customized flexible silicone rubber heaters offer numerous advantages across various industries, including but not limited to medical, aerospace, defense, and food services. These heaters find extensive application in different industries, enhancing the functionality and performance of heating-related processes.