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
|temperature resistance||200 °C||200 °C||110 °C|
|recommended max. watt density||0,8 W/cm²||2 W/cm²||0,2 W/cm²|
|max. size||5000 x 950 mm||550 x 300 mm||1000 x 1000 mm|
|min. size||30 x 30 mm||25 x 25 mm||25 x 25 mm|
|min. height||0,8 mm||0,2 mm||0,2 mm|
|lot size||from 1 piece||from 1 piece||from 50 piece|
|min. bend radius||15 mm||1 mm||10 mm|
|self-adhesive foil possible||yes||yes||yes|
Silicone heater mats consist of heating wire or an etched heating foil, which is encapsulated and insulated between two silicone mats strengthened by textile glass fibers. They are suitable especially for applications requiring precise temperature and homogeneous heat distribution. Due to their low thermal mass they distinguish by quick response and an excellent controllability. Their low mass and small construction height (from 0,8 mm) make them interesting for many aerospace applications. Their resistance against moisture and humidity (IP 65) recommends them for laboratory equipment, catering appliances and frost or condensation protection especially of electronic components.
Silicone heater mats are temperature resistant up to 200 °C, with adhesive foil a maximum of 180 °C should not be exceeded. Short-term higher temperatures (230 °C) can be reached without destroying the heating element. 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 power, also weight and type of the material to be heated, ambient temperature, air flow and, naturally, the process control. Here can see a table which shows which temperature will be reached on a mat in relation to the watt density and without temperature control.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]|
As a rule of thumb it can be said the lower the watt density the longer the lifetime. We recommend a maximum watt density of 0,8 W/cm². Some of our customer have applications in which mats with 2 W/cm² or more are operated without issues. In which applications this is possible can be found out only by tests. We do not assume any liability for overheated mats with a watt density of more than 1,3 W/cm².
Fitting for your application, silicone heater mats can be build in nearly every dimension and geometry with numerous extra-components, e. g. thermocouples, limiters and thermal fuses.
Especially for larger quantities we recommend to use heating mats with etched heating foil. In regard to forms, dimensions and complexity of heat distribution they are as variable as heaters with heating wire. Through shorter distances and larger surface of etched strip conductors they reach an even higher watt density and a more homogeneous heat distribution.
For easy installation we recommend silicone heating mats with self-adhesive foil. This foil fixed in a special procedure on the heater, meets most requirements even at max. permissible operating temperature. The latest progress in adhesive technique replaced the conventional vulcanising nearly completely.
All Silicone heater mats also VDE and UL rated available.download pdf
Applications in the plastics industry
Pre-Heating / Hot Plates
- easy installation on existing metal sheets or plates with adhesive foil
- easy cleaning - silicone and Kapton are separating agents
- with direct control continuous operation up to 200 °C
- funnel shaped mats available, direct bonding possible
- optional thermal insulation on the outside (PU or silicone foam)
Blister Packaging Machines
- direct contact with foil or cardboard possible
- IP 65 cleaning with water / detergent possible
- direct bonding to press plate
- low weight - quick heating up - low energy consumption
Kapton (Polyimide) is a semitransparent and flexible insulation material. Its superb insulation properties allow to produce very thin heating Elements. The resulting efficient heat transfer permit high watt densities. The temperature resistance of these heating elements is 200 °C.
Kapton foil heaters are always manufactured customized. The mats can be designed to any shape. Multiple circuits and areas having different power density can also be designed to suit specific requirements. They can be supplied with surface mounted temperature sensors.
The resistance against fungus, bacteria, ozone, weather and age is excellent so that the heating elements are suitable for a number of critical applications.
The self-adhesive foil is a quick and simple fixing method which provides superb bonding results.
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.
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.
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