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Flexible Flat Heating ElementsDownloadsInquiry Form

These flexible flat heating elements are available. Use the selection table to find the most suitable product easier.

Selection table for Flexible Flat Heating Elements
Selection table
  Silicone Kapton Polyester
Continuous temperature resistance 200 °C 200 °C 90 °C
Continuous temperature resistance with self adhesive foil 180 °C 180 °C 90 °C
Short term temperature resistance 230 °C 200 °C 100 °C
Recommended max. watt density 0,8 W/cm² 2,0 W/cm² 0,2 W/cm²
Power tolerance +10 / -5% +10 / -5% +/-10%
max. dimension 950 x 3000 mm 285 x 550 mm 600 x 1000 mm
min. dimension 30 x 30 mm 25 x 25 mm 25 x 25 mm
min. height 0,8 mm 0,2 mm 0,2 mm
Dimension tolerance +/- 1 mm +/- 1 mm +/- 1 mm
Quantities from 1 piece from 1 piece from 25 pieces
min. bend radius 15 mm 1 mm 10 mm
max. IP-protection IP65 IP64 IP64
Adhesive foil possible yes yes yes
UL possible yes no yes

Silicone heating mats

Silicone Heater Mats [1 / 9] Silicone heaters are resistant to permanent temperatures up to 200 °C, with self-adhesive foil 180 °C should not be exceeded. Higher temperatures of 230 °C is possible for a short time without destroying the heater. The temperature that will be reached within the application, generally is not easy to predict, as there are many influencing factors. In addition to the power, resp. surface load, this also includes mass and type of the material to be heated (thermal conductivity, surface quality, etc.) installation / assembly situation (bonded, vulcanised, clamped, etc.), ambient temperature, air movement and, of course, the control technology used.

limiter 1/2'' [1 / 4] As an aid to orientation you will find here a table showing the temperature that can occur at the heater depending on the watt density in an unregulated state.

Surface Temperatures of Silicone Heater Mats

Test conditions:

download pdf
  • Silicone heater mat, vulcanised to a 1,5 mm aluminium plate
  • Ambient temperature 20 °C
  • Still air
  • Heating element in a horizontal position
  • Measured in a steady state condition
Watt density of heating element [W/cm²] Surface temperature on mat [°C]
0,05 40
0,075 60
0,1 70
0,125 80
0,15 90
0,2 105
0,25 121
0,3 135
0,35 150
0,4 164
0,45 176
0,5 188
0,55 200
0,6 210
0,65 220
0,7 230
0,75 238
0,8 247
0,85 253
0,9 259
0,95 265
1,0 270
1,1 280
1,2 290
1,3 300
1,4 310
1,5 320
1,6 330
1,7 340
1,8 350
1,9 360
2,0 370

As a rule of thumb: the lower the surface load, the longer the life of the heater. In order to avoid overheating, we recommend not to exceed a watt density of 0.8 W/cm2. Some of our customers have applications in which heating elements with 2 W/cm2 or more are used without any issues. This is mainly dependant on the thermal conductivity of the material being heated, the higher the thermal conductivity the higher the power density can be so the applications in which this is possible, can only be found out by testing. Because of the large number of temperature influencing variables that cannot be influenced by us, we do not offer warranty for overheated heating elements with a surface load of more than 1.3 W/cm2.

Application examples for silicone heater mats include: canteen kitchen technology / catering, anti-fog and anti-freeze applications, tool or plate heating in machines, 3D printers, laboratory equipment, composite materials repair, joint curing and much more.

When designing silicone heaters, the designer has almost unlimited degrees of freedom. This applies to the minimum and maximum dimensions within wide limits, as well as for shapes and cut-outs or holes and bushings of any kind. The excellent shape flexibility of silicone heaters enables heating of cylindrical, conical or rounded surfaces. It is also possible to preform the heating element during production for diameters as small as 12 mm. This is practiced, for example, for pipes, bodies with shape transitions or small deflection radii. The ability to pre-form the heater will also depend on the length of the tubular part. The following applies here: the longer the more rigid, the more effective the preforming is. Spiral wrap silicone heaters are also available for flexible pipes down to 6mm diameter.


Flyer silicone heating mats

Flyer silicone heating mats

Flexible heating elements made from silicone or Kapton insulation are thin and lightweight so can be installed where space is limited, and due to their low mass they have a fast response to temperature control. The self-adhesive foil option allows for a quick and uncomplicated fixing. The operating temperatures range from -60 °C to 200 °C (180 °C with adhesive backing).

download pdf

Applications in the plastics industry

  • Preheating Station / Heating Plates
    • Easy attachment to existing sheets or plates due to self-adhesive foil
    • Easy to clean with water or isopropyl alcohol
    • With direct control continuous operation up to 200 °C
  • Granulate Dryer
    • Heaters can be produced in funnel shape, direct bonding possible
    • Optionally with thermal insulation on the outside (PU or silicone foam)
  • Blister Packaging Machines
    • Direct contact with foil or cardboard possible
    • IP 65 - Cleaning with water / cleaning agent possible
  • Hot Presses
    • Direct application to the press plate
    • Low weight - fast heating - low energy consumption
  • 3D Printer
    • Adaptable to any print bed geometry
    • Homogeneous temperature profile due to even heat transfer

10 Advantages of our silicone heating mats

  • Low weight
  • Easy installation
  • Moisture proof
  • Easy cleaning
  • Minimum space requirement
  • Integrated temperature sensors
  • Integrated temperature switches / fuses
  • From single pieces to large series
  • Every shape possible
  • Short heat up times

Geometry

  • Shapes / cut-outs / holes Can be provided according to your wishes
  • If necessary, a cutting tool must be created (e.g. for a particularly large number of holes or narrow position tolerances)
  • Between two holes and to the edge we need at least 10 mm insulation distance, otherwise the area remains unheated

Preformed heaters

  • useful for Ø as small as 12 mm and up to Ø 100 mm
  • not possible with self-adhesive foil
  • Spiral wrap heater suitable for Ø as small as 6 mm
  • The spiral wrap is suitable for both, tubes and sleeves

Production process

There are two different manufacturing techniques for silicone heaters, which have different benefits depending on the number of units, geometry, layout of heating tracks, thermal load and the application.

  • wire wound

For lot sizes below 50 pieces silicone heaters are usually manufactured using resistance wire laid manually in a meandering pattern with the help of a pin board. If necessary, a special heating wire can be used, which withstands mechanical stresses by thermal expansion even better. This wire is used especially in very large heaters, or heaters which are moved more frequently. Since a pin board is sufficient as a tool, only low design costs are incurred, which makes this manufacturing process interesting for individual production with low volumes.

  • etched foil

For larger batch sizes or heaters with many holes and complex layouts, the heating tracks are produced by vulcanising a special alloy foil to the silicone and then printing and etching the foil to create the circuit. The heat distribution in these heaters is more homogeneous than wire wound, as the foil tracks are flat and the distances between the tracks are smaller than with wire. Furthermore, the degree of automation in this process is higher, which increases reproducibility and, not least, cost-effectiveness for larger quantities. Varying power densities across the surface of the heater can easily be designed using etch foil technology.


Mounting options

There are many different ways to attach silicone heaters. Which is the best solution depends primarily on the application, but also on the shape and size of the heater. In the case of a high surface load on the heater, for example, a good heat transfer is particularly important and fastening with silicone straps is not recommended.

  • self-adhesive foil
    • not removable
    • good heat transfer
    • temperature resistant up to 180 °C
    • suitable for any shape and size
    • not applicable for self-adhesive mats
    • download bonding instructions here
  • Press-fit
    • Removable
    • temperature resistant up to 200 °C
    • termination area and attachments such as limiters and the connection area must be left out in the pressure plate
    • screw-on pressure plate required
    • risk of partial overheating due to inhomogeneous contact pressure
    • risk of mechanical damage of the heater by burrs or sharp edges on the metal plates
  • vulcanising
    • not removable
    • temperature resistant up to 200 °C
    • Ideal heat transfer
    • Can only be made in the factory by the manufacturer
  • Bonding with silicone adhesive
    • Not removable
    • temperature resistant up to 200 °C
    • Very good heat transfer
    • alternative to vulcanisation, which can also be carried out by the customer
    • download bonding instructions here
  • Silicone straps
    • removable
    • for cylindrical or rounded contact surfaces
    • suitable for preformed heaters up to Ø 250 mm
    • wears quickly when used regularly
    • width: 12 mm (25 mm for larger heaters)
    • temperature resistant up to 180 °C
  • Velcro
    • removable
    • for cylindrical or rounded contact surfaces
    • sewn direct or indirect on heater
    • area around Velcro is not heated, when sewn on direct
    • width: 15 / 20 / 25 / 50 / 100 mm
    • Velcro resistant up to 80 °C
  • „hooks & springss
    • removable
    • Variable clamping elements (hooks, eyes, straps, springs)
    • Under hooks / eyelets and in the clamping area unheated
    • Also suitable for conical shapes
    • Springs suitable from Ø 100 mm

Sensors

The silicone heaters can be equipped with sensors, limiters and fuses of all kinds. In the following we present the most common variants, which are usually available in production. However, it is also possible that you provide parts that we apply to the heaters.

In your design, you should note that these components usually cannot be installed flush with the surface.

  • Pt 100 / PT 1000 / thermocouple type J / NTC / PTC
    • For temperature reading and further processing by a controller
    • Can be placed anywhere on the heater (if the position is not defined, the sensors are placed near the connection area)
  • It is not possible to fit SMD parts

Temperature limiters / fuses

  • Uchiya
    • 50 – 140 °C in 10 °C-steps
    • Overtemperature protection
    • Bimetal switch
    • Encapsulated design - low overall height
    • Appr. 10,000 switching cycles
    • Suitable for 230V AC / max. 10A
    • Hysteresis 30 – 40 °C
  • 1/2" Disk
    • 5 °C, 13 °C, 20 – 200 °C in 10 °C-steps
    • Overtemperature protection
    • Bimetal switch
    • Open design – must be covered with silicone hat
    • Appr. 100.000 switching cycles
    • Suitable for 230V AC / max. 10 A
    • Hysteresis 10 – 20 °C
    • Can be installed in leads for anti-freeze applications
  • Diverse fuses
    • Single Shot Over temperature protection
    • When the fuse is tripped, the circuit is interrupted until the heater is replaced or the fuse is reset (depending on the type of fuse)
    • Typical models are NEC/Schott SF-R andMicrotemp G4
  • Various special components
    • Pockets for capillary thermostats and sensor probes, available in Ø 3,4, 6 und 8 mm
    • Length as required
  • Pockets, hats and enclosures for all kinds of components

Leads

You are free to choose the type, length and position of the connection cable. Please note that the connection area is always slightly thicker than the rest of the heater. You can see this very well on the following pictures, which show the most common options. If you do not specify any special requirements, we generally assume 1000 mm PTFE leads in the middle of the short side. The length and type of the connection cable can be easily changed for subsequent orders of an existing design; a new design / tool must be created to change the position.

  • PTFE-leads (standard)
    • Low construction height
    • Resistant up to 190 °C
    • Flexible and robust
    • Max. IP62
  • Silicone leads
    • Low construction height
    • Resistant up to 180 °C
    • Very flexible but less robust than PTFE leads
    • Max. IP64
  • Silicone cable
    • Resistant up to 180 °C
    • Robust
    • No single wires (i.e. solid single wire)
    • 5adrig with PT 100 available
    • IP64 standard
    • IP65 Possible
  • Ground lead
    • Has to be contacted on site as silicone mats do not have metal parts on the outside
  • Various other leads and cable
    • (HO7RN-F cable)
    • PVC

Protection sleeve

In the case of silicone heaters, leads are less often fitted with protective hoses than is the case with most other types of heaters. Thermal protection in particular plays only a subordinate role due to the comparatively low operating temperatures. For mechanical protection, however, there are options such as silicone/fiberglass sleeve or heat-shrinkable tubing.

The use of a protective conduit above the leads is recommended as a second insulation and in order to be able to lay the leads better. Fixing the hose under the connection pad is advisable, but also leads to a thicker termination area.

  • Silicone/Fibre glass sleeve
    • Ø 3 – 12 mm
    • Resistant up to 235 °C

Silicone foam

Silicone foam can be applied to the heating elements for thermal insulation. A main field of application for such insulated silicone heaters is e.g. semiconductor production. Here, vacuum piping systems are heated and insulated in this way.

  • Heating mats insulated with silicone foam
    • Shore-hardness: 42 +/- 5
    • Density: 250 +/- 40 kg/m3
    • Resistant up to 230 °C
    • UL
    • Thickness:
      • 3 mm (also adhesive)
      • 5 mm (also adhesive)
      • 8 mm
      • 12 mm
  • For thermal insulation
  • As protection for termination and sensors etc.
  • Insulation and heating for piping systems
    • Tubular forms for pipes, cuboid forms for pumps, valves etc.

Conformities & standards

Our flexible silicone heating elements are manufactured according to the strictest test criteria and meet all relevant standard requirements and safety specifications as far as these are applicable due to the nature of the product. General certificates of conformity relating to organizations or product groups can be downloaded in our Downloadcenter under Service > Quality. Product-specific confirmations are available on request.

  • certifications
    • CE
    • RoHS
    • UL/CSA (Optional with surcharge, only possible with UL-CSA approved accessories)
    • VDE (Optional with surcharge, only possible with VDE approved accessories)
CE RoHs UL CSA

Printig

  • Inkjet printing
    • black
    • Used for Low volume orders
    • Without additional costs
    • Can include different details on different batches (serial number)
    • Cannot include logo
    • Semi-permanent (can be rubbed off)
  • Silicone ink screen printing
    • White
    • Used for high volume orders
    • Can include logos (in a single white colour)
    • Additional costs for printing screen (usually included in tooling costs for etch foil heaters)
    • Requires a new tooling when details change
    • permanent
  • Silver label on cable or leads
    • for heaters that are difficult to position under inkjet printer or very small heaters where there is not enough space

Different silicone materials are used, depending on whether the heater is frequently moved in the application, must be particularly thin or must meet fire behaviour regulations. Normally, you describe your requirements and the application to us and we will then select the appropriate material.

silicone heating mats - materials

Kapton Foil Heaters

Kapton Foil Heaters Kapton is resistant up to 200 °C as insulation material and up to 180 °C with self-adhesive foil.
In general, Kapton heaters are always more expensive than silicone or polyester heaters. Where the chemical resistance or the weight of the heater plays an important role, this material is the preferred solution.

Here, too, an acceptable service life at high temperatures can only be ensured by quickly controlling the temperature with the measurement as close as possible to the heater.

Kapton's resistance to fungi, bacteria, ozone, weather, aging and most chemicals, acids and solvents is very good, making Kapton heaters an ideal solution for many critical applications. In addition, they are silicone-free and are known for their even heat distribution. The high voltage resistance of Kapton is very good and so the heating can become very thin. Due to the low thickness, heat transfer to the workpiece is improved and higher surface loads are possible. Typical applications are: Laboratory technology, aircraft electronics, printing technology, diagnostic instruments, vacuum chambers, Medical equipment, Military applications.

It is generally difficult to predict which temperature a heating element will reach in the application, as there are many influencing factors. In addition to the power or surface load, this includes the mass and type of material to be heated (thermal conductivity, surface quality, etc.), the installation/assembly situation (glued, clamped, etc.), the ambient temperature, air flows and, of course, the control and regulation technology used.

As a rule of thumb, the lower the surface load, the longer the service life. We recommend a maximum surface load of 0.8 W/cm2.

Unlike silicone heaters, Kapton heaters are always manufactured with etch foil. There are tooling costs for each new design. For pre-series or very small quantities, however, it is possible to use a temporary tool, which is cheaper, but is not suitable for high volume production.

95% of our Kapton heaters are supplied with adhesive foil. The subsequent application of an adhesive is not possible. Therefore, the only application possibilities are a self-adhesive film, which is already produced with the Kapton heater, or pressing on the material to be heated.

Generally, it would be possible to fit thermocouples or other sensors on the heater. However, these would then have to be attached to the heater with silicone, which in turn is not permitted for Kapton heaters in many applications.

Kapton Foil Heaters
Kapton Foil Heaters
Kapton Foil Heaters
Kapton Foil Heaters variants

Mounting options

  • self-adhesive foil
    • not removable
    • good heat transfer
    • temperature resistant up to 180 °C
    • suitable for any shape and size
    • download bonding instructions here
  • Strapping or taping to tubular forms
    • removable

Polyester Foil Heaters

Polyester Foil Heaters consist of a conductive ink between two insulation layers of polyester. With a max. size of 950 x 600 mm, their height averages to 0.2 mm. As you can see in the pictures almost every outline and all kind of holes are feasible. Naturally we can integrate safety- and controlling devices such as limiters, cutouts, thermocouples, and resistance sensors.

Regarding temperature profile, electromagnetic compatibility and immunity to failure, polyester foil heaters are clearly superior to heater mats with wound wire or etched heating circuits due to their plane heating ink.

Another advantage of the used ink is the simple realization of differential power: for this either the composition of the ink is varied or blanks are integrated in the design (see picture of the foil heater on the left, with dotted edges).

The heater can be pressed on or fixed with a self-adhesive foil. Wrapped in PVC, the use in liquids is possible as well.

Typical applications are e. g. mirror heaters, water bed heaters, or low temperature room heaters. For terrarium and aquarium heaters we offer standard elements as well.

Polyester Foil Heaters Polyester Foil Heaters
Polyester Foil Heaters
Polyester Foil Heaters
Polyester Foil Heaters


Downloads:

  • Chapter Flat Heating Elements
    Chapter Flat Heating Elements

    Multifunctional use, uniform heating: Contact heating of flat surfaces. We manufacture flat heating elements in several materials, customised to your application.


  • Flyer Silicone Heater Mats
    Flyer Silicone Heater Mats

    Flexible heating elements made from silicone or Kapton insulation are thin and lightweight so can be installed where space is limited, and due to their low mass they have a fast response to temperature control. The self-adhesive foil option allows for a quick and uncomplicated fixing. The operating temperatures range from -60°C to 200°C. (180°C With adhesive backing).

  • Surface Temperatures of Silicone Heater Mats

    It is generally impossible to predict which temperature can be reached by a heater mat as there are plenty of influencing factors. Among them are beside the power, also weight and type of the material to be heated, ambient temperature, air flow and, naturally, the process control. The table shows which temperature will be reached on a mat in relation to the watt density and without temperature control.

  • Operating Instructions Silicone Heater Mats

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