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Flexible heaters
Customizable
Product Catalog
Flexible Heaters
ELEKHEAT offers flexible heating solutions designed for precise, efficient heating on flat or irregular surfaces, ensuring reliable performance in diverse applications.
Flexible heaters use resistive elements like etched foil or wires, embedded in materials such as silicone rubber or polyimide, ensuring durability and efficient heat transfer. They provide uniform heating with precise temperature control, compatible with external controllers and sensors for safety. Highly customizable in shape, size, and watt density, they suit diverse industrial and commercial applications.
Flexible Heater Applications
1.Food and Beverage
- Food storage heaters
- Drum heaters
- Laminators
- Packaging machinery
2.Automotive
- Battery warmers
- Heated mirrors
- Heated seats
- Engine pre-heaters
3.Medical and Laboratory
- Incubators
- Laboratory instruments
- X-ray devices
- Optical equipment
4.Medical and Laboratory
- Incubators
- Laboratory instruments
- X-ray devices
- Optical equipment
5.Industrial and Commercial
- De-icing systems
- ATM machines
- Vending machines
6.Aerospace and Aviation
- Aircraft comfort heaters
- Propeller de-icers
- Gyroscopes
- Guidance systems
- Aviation instruments
7.Electronics and Semiconductor
- Memory planes
- Circuit boards
- Semiconductor equipment
- Outdoor antennas
8.Other
- Autoclaves
- copy machines
- refrigeration units
- heated presses
Flexible Heater Structure
Product Lines
Etched Foil Heaters
ELEKHEAT’s Etched Foil Heaters use advanced etched foil technology for rapid, uniform heating, offering high watt density and customizable designs for precise industrial applications.
Polyimide Heating Membrane
Silicone Rubber Heaters
Contact Elekheat today by dialing 008618914757574 or use our contact form ,We are happy to answer any questions. Elekheat is your best partner for heating element solutions!
How do polyimide heating membranes compare to silicone rubber heaters in cost?
Polyimide Heating Membranes
- Lower material costs due to thin-film construction.
- Cost-effective for low-power and precision applications.
- Typical cost per unit: $5–$50 (varies with size and customization).
Silicone Rubber Heaters
- Higher material and production costs due to robust construction.
- Ideal for high-power and rugged industrial applications.
- Typical cost per unit: $20–$150 (varies with watt density and size).
Long-Term Value
- Polyimide heaters are cost-efficient for precision applications where energy consumption is low.
- Silicone rubber heaters provide greater durability, reducing replacement and maintenance costs in harsh environments.
Flexible Heaters: General Specifications
| Parameter | Specification Range | Details |
|---|---|---|
| Voltage | 12V to 600V (AC or DC) | Wide compatibility for low-voltage electronics to high-power industrial systems. |
| Length | 1″ to 120″ (customizable) | Supports compact devices to large-scale equipment applications. |
| Width | 1″ to 36″ (customizable) | Designed for narrow, intricate spaces or broad surfaces. |
| Thickness | 0.1mm to 3mm | Ultra-thin for polyimide (0.1–0.3mm), robust silicone rubber (1.5–3mm), or etched foil heaters (0.1–0.2mm). |
| Heating Element | Etched foil resistive pattern | High-precision, uniform heating with rapid thermal response. |
| Lead Wire | Teflon-insulated or custom options | High-temperature, chemical-resistant, and reliable for varying environments. |
| Operating Temperature | -200°F to 450°F | Polyimide: -200°F to +200°F; Silicone Rubber: -50°F to +450°F; Etched Foil: Highly stable at varying ranges. |
| Wattage Density | 0.1 to 50 W/in² | Low for precision applications, high for industrial use, with etched foil offering enhanced uniformity. |
| Wattage Tolerance | +5%, -10% | Precision wattage control ensures stable and uniform heat distribution. |
| Attachment Method | PSA adhesive, vulcanization, or mechanical | Flexible installation options for different applications. |
Why Partner with ELEKHEAT?
- Global Reach: Trusted by clients in over 40 countries, we bring international expertise to every project.
- Proven Expertise: Established in 1997, we have nearly three decades of experience in delivering high-performance heating solutions.
- Custom Solutions: Tailored designs to meet the specific needs of high-temperature and corrosive environments.
- Reliable Quality: ISO-certified manufacturing ensures durability and consistent performance in demanding conditions.
- Technical Support: A dedicated team of engineers providing end-to-end assistance, from concept to deployment.
Have a Question?
At ELEKHEAT, we’re here to provide the answers you need. Whether you’re looking for product information, technical specifications, or need assistance with maintenance, our team of experts is ready to help. Don’t hesitate to reach out—we’re committed to ensuring you get the support you need for the best heating solutions.
- Selection Guide
- Installation Guide
- Resource Center
1. Determine Your Application Needs
Precision Heating
Use polyimide heating membranes for applications requiring precise and uniform heat in confined spaces (e.g., medical devices, semiconductor manufacturing).
Rugged and Harsh Environments
Opt for silicone rubber heaters for outdoor, moisture-prone, or heavy-duty industrial uses (e.g., tank heaters, de-icing systems).
2. Voltage and Wattage Requirements
Voltage: Match the heater to your system's power supply (12V–600V, AC or DC).
Watt Density:
Low (<5 W/in²): For delicate heating tasks.
Medium (5–15 W/in²): General-purpose applications.
High (>15 W/in²): Demanding industrial tasks.
3. Size and Design
Length and Width:
Compact devices: Short heaters (1″ to 12″).
Industrial systems: Large heaters (up to 120″ long and 36″ wide).
Thickness:
Polyimide: Ideal for ultra-thin, space-constrained designs.
Silicone Rubber: Best for durability and high-power density.
4. Environmental Factors
Moisture and Chemicals: Silicone rubber heaters provide superior protection.
Temperature Extremes:
Polyimide: For controlled environments (-200°F to 200°F).
Silicone Rubber: For extreme conditions (-50°F to 450°F).
5. Installation and Attachment: Flexible Heaters
Here is a detailed guide for the installation and attachment of flexible heaters, presented in a structured format with descriptions, specifications, and recommended models.
Clamping Mechanisms
Mechanism Type | Description | Specifications | Model Recommendations |
Spring-Loaded Clamps | Provides consistent pressure and adapts to thermal expansion, suitable for curved or cylindrical surfaces. | -Material: Stainless steel- Tension: 1–15 lbs- Diameter: 1"–18" | - ELEKHEAT F-SL101 (Small heaters)- ELEKHEAT F-SL202 (Medium heaters) |
Hook-and-Loop Straps | Lightweight and adjustable, ideal for temporary or portable installations. | -Material: Nylon or silicone-coated straps- Width: 1"–2"-Length: Adjustable (12"–36") | - ELEKHEAT HLS-100 (Standard use)- ELEKHEAT HLS-200 (Heavy-duty use) |
Attachment Methods
Attachment Type | Description | Specifications | Model Recommendations |
Pressure-Sensitive Adhesives (PSA) | Provides quick, clean, and semi-permanent installation on smooth surfaces. | -Adhesive Type: High-temperature silicone-Operating Temp: -40°C to 200°C-Thickness: 0.005"–0.010" | - ELEKHEAT PSA-101 (Standard adhesive)- ELEKHEAT PSA-202 (High-temp adhesive) |
Vulcanization | Permanently bonds the heater to a surface for rugged and harsh environments. | - Bonding Material: High-temp silicone rubber-Cure Temp: 150°C–200°C-Bond Thickness: 0.010"–0.050" | - ELEKHEAT VUL-300 (Standard bonding)- ELEKHEAT VUL-500 (Industrial-grade bonding) |
Mechanical Fasteners | Secure attachment using bolts, screws, or clamps for reusable and adjustable applications. | -Material: Stainless steel brackets-Fastener Size: M3–M6 bolts- Thickness: 0.5"–1" | - ELEKHEAT MF-101 (Small heaters)- ELEKHEAT MF-202 (Heavy-duty heaters) |
Additional Notes:
Spring-Loaded Clamps: Best for flexible heaters on cylindrical surfaces, such as pipes or tanks, where some expansion is expected during operation.
Hook-and-Loop Straps: Ideal for temporary setups or portable heaters that require frequent repositioning.
Pressure-Sensitive Adhesives: Ensure the surface is clean and free of debris before application for optimal adhesion and heat transfer.
Vulcanization: Recommended for high-stress environments where permanent bonding is necessary, such as in industrial or aerospace applications.
Mechanical Fasteners: Provide secure and adjustable mounting, especially useful for large, custom-shaped heaters.
This structured guide ensures you select the most appropriate installation and attachment methods for your flexible heater applications. For customized solutions or expert assistance, contact ELEKHEAT for a consultation.
Proper installation is critical to ensure the performance, safety, and longevity of flexible heaters. Follow these detailed steps to install flexible heaters correctly:
1. Pre-Installation Checklist
Inspect the Heater: Check for any visible damage to the heater or lead wires. Do not use a damaged heater.
Clean the Surface: Ensure the mounting surface is clean, dry, and free of debris, oil, or contaminants that could affect adhesion.
Recommended cleaning agents: Isopropyl alcohol or a similar solvent.
Verify Compatibility: Confirm that the heater's voltage, wattage, and dimensions meet the requirements of your application.
2. Tools and Materials Required
Isopropyl alcohol or cleaning solvent
Lint-free cloth
Roller or squeegee for uniform adhesion (if using PSA backing)
Mounting adhesive (if not pre-applied)
Fasteners (if mechanical installation is required)
Temperature controller (recommended for precise operation)
3. Installation Methods
Flexible heaters can be installed using one of the following methods, depending on the application:
A. Adhesive Backing (Pressure-Sensitive Adhesive - PSA)
Position the Heater: Align the heater on the desired surface without removing the protective liner.
Peel and Stick: Gradually peel off the adhesive liner while pressing the heater firmly onto the surface.
Apply Pressure: Use a roller or squeegee to press the heater evenly, ensuring maximum contact and eliminating air bubbles.
Cure Time: Allow the adhesive to cure (typically 24 hours) for optimal bonding.
B. Vulcanization
Prepare the Surface: Ensure the surface is clean and compatible with the vulcanization process.
Apply Vulcanization Adhesive: Spread a thin layer of adhesive on both the heater and the surface.
Press and Bond: Press the heater onto the surface and cure it according to the adhesive manufacturer’s guidelines (temperature and time).
C. Mechanical Fastening
Drill and Mount: Use pre-drilled holes or edge fasteners to attach the heater securely to the surface.
Add Insulation: If required, add thermal insulation to improve efficiency and protect the heater.
4. Electrical Connection
Check Compatibility: Verify the voltage and current ratings of the power supply match the heater's specifications.
Connect Lead Wires: Securely attach the heater's lead wires to the power source or controller using appropriate connectors.
Grounding: Ensure proper grounding to prevent electrical hazards.
Test the Circuit: Before full operation, perform a low-power test to check functionality.
5. Operational Guidelines
Temperature Control: Use a thermostat or controller to prevent overheating and maintain desired temperatures.
Periodic Inspection: Regularly check for wear, damage, or adhesive degradation.
Avoid Excessive Flexing: While flexible heaters are designed to bend, repeated sharp flexing may reduce their lifespan.
6. Safety Precautions
Do Not Overlap: Ensure the heater is installed flat and does not overlap itself, as this can cause overheating.
Monitor Temperature: Use a temperature sensor to prevent exceeding the heater's maximum temperature range.
Avoid Liquid Exposure: While silicone rubber heaters are moisture-resistant, avoid immersion unless specified.
7. Troubleshooting Tips
Uneven Heating: Check for poor surface contact or air gaps under the heater.
Adhesion Failure: Ensure the surface was cleaned thoroughly before installation.
No Heat Output: Verify electrical connections and power supply compatibility.
8. Maintenance and Removal
Maintenance:
Inspect regularly for damage or signs of wear.
Clean gently with a damp cloth; avoid abrasive materials.
Removal:
For adhesive-backed heaters, slowly peel off the heater while applying heat (e.g., with a heat gun) to soften the adhesive.
Clean any residual adhesive from the surface with an appropriate solvent.
By following this guide, you can ensure a successful installation that maximizes the performance and lifespan of your flexible heater. If you have further questions or need technical support, contact us today!
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