Blue Ink is member of Ultimheat Alliance Controls and heating equipments

Blue Ink is member of Ultimheat Alliance Controls and heating equipments

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Controls, Components, Heating equipments

ULTIMHEAT Technology Flat Heaters : Flexible Rectangular Silicone Heaters

Rectangular heaters

Main Feature

ULTIMHEAT silicone heating elements are made of laminated silicone rubber sheets, vulcanized together through heat and high pressure on both sides of an embedded wire wound heating element. Fiberglass-reinforced silicone rubber gives heater dimensional stability without sacrificing flexibility. Silicone is used because of its high temperature resistance (permanent temperature up to 200°C (390°F), high thermal conductivity (~7 10-4 W/cm.K) and good electrical insulation properties (~12KV/mm) A fiberglass grid, which is visible under the surface, reinforces the silicone rubber sheets. The wire wound heating element web covers the entire surface of the heater. This web could be designed such that holes and cut-outs are incorporated on the heater. This construction makes silicone rubber heaters an ideal solution to the requirements of many low and medium temperature applications, which do not conform to the shapes, sizes and dimensions of band, strip, cartridge, tubular and coil heaters.

Other general particularities of these heaters are:
- Precise heating and lightweight
- Not affected by vibration or flexing,
- Comply to UL94-VO (flame retardant) and ROHS
- Low Smoke and Low Toxicity
- Silicone is non-toxic, and moisture and chemical resistant

Main Applications

Some examples of silicone flexible rectangular heaters applications:
1.Prevent condensation in motors or instrument cabinets
2.Anti freeze or condensation in of electrical enclosures like: traffic signal boxes, automatic teller machines, temperature control panels.
3.Mirrors defrost and dew removing
4.Catering equipment heating
5.Airplane engine heaters and aerospace industry
6.Medical equipment: blood analyzers, medical respirators, test tube heaters, etc.
7.Curing of plastic laminates
8.Computer peripherals such as laser printers, copy machines
9.Medical and massage heating pads
10.TV and radars parables deicing

Technical Features

Length: in standard 100 to 400 mm (4 to 16"), on special order up to 1000 mm (40")
Width: in standard 100 to 400 mm (4 to 16"), on special order up to 1000 mm (40")
See our band heaters page for width less than 100 mm (4")

Dimensional tolerances:
  • 0 to 150 mm (0 to 6 inches): +/- 1.5 mm (+/- 1/16 inch)
  • 150 to 500 mm (6 to 20 inches) : +/- 3.5 mm (+/- 1/8 inch)
  • 500 mm to 1000 mm (20 to 40 inches): +/- 5 mm (+/- 3/16 inch)

Tighter tolerances are available on custom designs if needed

Standard heater thickness without adhesive, leads output thickness not included: 1.60 mm +/- 0.15 mm (0.065 inch +/- 0.005") .Add 0.1 mm (0.005") to above dimensions for foil backing.

Maximum total thickness over leads (horizontal wires output):
  • AWG 22 (0.3 mm²) 0.15" (3.8 mm)
  • AWG 20 (0.5 mm²) 0.16" (4 mm)
  • AWG 18 (0.75 mm²) 0.17" (4.2 mm)
  • AWG 15 (1.5 mm²) 0.19" (4.7 mm)

Silicone foil minimum bending radius: 0.125" (3.2 mm)

Standard Weight: 0.24 gr/cm² 240 g/m² (8 oz./ft²)

Ingress protection: IP65

Maximum operating temperature: peak 220/230 °C (446°F), continuous: 200 °C (390 °F)*

Even if silicone heaters can be used at higher temperature, we recommend for a safe and durable use that maximum permanent surface temperature on silicone should not rise more than 160°C and maximum acceptable peak temperature should not rise more than 200°C.

Minimum ambient temperature: -60 °C (-80 °F)*

*These maximum and minimum temperatures apply to silicone heaters only. Restriction will apply for controls

Voltage: 12V to 600V, AC or DC (UL rating is 600 VAC, TUV recognition is max 250 VAC)

Resistance tolerance: -5%/+10% (tighter tolerances are achievable)

Power tolerance: -10% to + 5%

Watt density: The limitation factor is the heating foil maximum acceptable temperature. This temperature is dependent upon three factors:
  - Temperature exchange with ambient or surface
  - The maximum operating temperature
  - Heater temperature control

If the element is temperature controlled sufficiently or the heat is taken away by forced air or a heat sink, the Watt density can range up to 0.8w/cm², (5.2 w/inch²). More typical designs are equal or below 0.4w/cm², (2.6 w/inch²)

Standard watt density:
  • 0.2 w/cm² (1.3 w/inch²)
  • 0.4 w/cm² (2.6 w/inch²)
  • 0.8 w/cm² (5.2 w/inch²)

Quality control routine tests: Each element is 100% tested for continuity, resistance and insulation. Tests are made according to EN 60335-1 and EN 50106 standards

Dielectric Strength: 1500V AC, 2s, 0.5 mA (single insulation models) or the typical approval agency recommendation of 2 x input voltage +1000 volts.

Insulation resistance: More than 10 Mohms

Surface temperature: Temperature that the silicone rubber heater will attain when suspended in still air at 70 °F (20°C) depends of the watt density. Below 5.2 w/inch², (0.8 w/cm²), the temperature will rise during some minutes and stabilize at a temperature below the critical 500 °F (260°C) which is the highest technically acceptable surface temperature.

Surface temperature after stabilization /watt density
W/cm² 0.05 0.10 0.15 0.20 0.30 0.40 0.45 0.50 0.60 0.70 0.8 0.9 1.0
Stabilization Temperature °C 40 70 90 105 135 165 175 190 210 230 250 260 270
W/inch² 0.32 0.64 0.97 1.3 1.9 2.6 2.9 3.2 3.9 4.8 5.2 5.8 6.5
Stabilization Temperature °F 104 158 194 221 275 329 320 347 410 446 482 500 518

Leads: Standard leads for heaters are FEP insulated, flexible stranded plated copper wire. They are UL Style 1330 rated for 180°C/ 600 volt operation. Lead types and exit locations are adaptable to application requirements. Standard length is 200 mm.

Standard wire gauges:
AWG22 (or 0.3 mm²) is standard for rating up 3.5A
AWG20 (or 0.5 mm²) is standard for rating from 3.6 to 5.5A
AWG18 (or 0.75 mm²) is standard for rating from 5.6 to 8A
AWG15 (or 1.5 mm²) is standard for rating from 8.1 to 15A

Electrical connection output: standard is wire leads horizontal output. On request we can provide vertical leads output, side output with 6.3 x 0.8 tab terminals or flat cable. Wires can be equipped with terminals on request. Built in connectors must be submitted to our engineering department for feasibility

Terminals options

Horizontal wires terminals
(standard)

Horizontal tab terminals

Vertical wires terminals

Horizontal Flat cable

Built in sensors and safety devices options

On the heaters surface it can be over-molded disc thermostats, temperature sensors, fixed setting bimetal thermostats, thermal cutouts and surface mounting adjustable bimetal thermostat.

Adjustable surface thermostat

Adjustable bulb and capillary thermostat (need at least 100 mm width)

Thermal cut out (fuses at preset temperature)

Thermocouple

pt100

disc thermostat (ambient temperature sensing)

Heater surface temperature sensing (manual or automatic reset)

high limit fixed setting bimetal strip thermostat (snap action, large differential)

Fixed setting creep action thermostat with small differential

Other Options:

- Adhesive backside for application on various surfaces such as glass, steel, plastic
- Forming and curving on curved surfaces
- Various size and dimensions to adjust heating to complicated patterns
- Heating foil can be factory vulcanized to metal parts (without adhesive), allows higher wattage levels for faster processing
- Possibility of having areas with different heating power, with two or more circuits on the same element

Warning:

Silicone rubber heaters are not suitable for: radiation, vacuum, or prolonged exposure to oil

Design Services:

Our experienced designers can assist in your design efforts to build a surface heater specifically for your application. In addition, we can look to optimize your current element designs and recommend proper watt densities, controls and element construction. We will conduct a thorough design review and present a proposal and quotation, followed by sample elements upon approval. We also provide testing services and gather agency approvals to verify and ensure that the element construction and design will be optimal for your application.

Custom designs Protection:

We protect your intellectual property in confidential fashion. Many of our large clients and ongoing projects are protected with NDA's.

Main references
Rectangular standard Heaters :

(No controls, 200 mm FEP insulated wires, horizontal output, 4 or 8 w/ cm² (2.6 and 5.2 w/inch²)

Rectangular heater main references, 0.4 w/cm² (2.6 w/inch²). (click on reference to download drawing)

Reference Width mm (A) Width inches Length mm (B) Length inches Power Watts Voltage
(AC)
Amps wire gauge
9AR0A0A08040H200 100 3,9 100 3,9 40 220/230 0,2 AWG22
9AR0A0B08080H200 100 3,9 200 7,9 80 220/230 0,3 AWG22
9AR0A0C08120H200 100 3,9 300 11,8 120 220/230 0,5 AWG22
9AR0A0D08160H200 100 3,9 400 15,7 160 220/230 0,7 AWG22
9AR0A5A08060H200 150 5,9 100 3,9 60 220/230 0,3 AWG22
9AR0A5B08120H200 150 5,9 200 7,9 120 220/230 0,5 AWG22
9AR0A5C08180H200 150 5,9 300 11,8 180 220/230 0,8 AWG22
9AR0A5D08240H200 150 5,9 400 15,7 240 220/230 1,0 AWG22
9AR0B0C08240H200 200 7,9 300 11,8 240 220/230 1,0 AWG22
9AR0B0D08320H200 200 7,9 400 15,7 320 220/230 1,4 AWG22
9AR0C0C08360H200 300 11,8 300 11,8 360 220/230 1,6 AWG22
9AR0C0D08480H200 300 11,8 400 15,7 480 220/230 2,1 AWG22
9AR0D0D08640H200 400 15,7 400 15,7 640 220/230 2,8 AWG22
9AR0A0A05040H200 100 3,9 100 3,9 40 110/115 0,4 AWG22
9AR0A0B05080H200 100 3,9 200 7,9 80 110/115 0,7 AWG22
9AR0A0C05120H200 100 3,9 300 11,8 120 110/115 1,1 AWG22
9AR0A0D05160H200 100 3,9 400 15,7 160 110/115 1,5 AWG22
9AR0A5A05060H200 150 5,9 100 3,9 60 110/115 0,5 AWG22
9AR0A5B05120H200 150 5,9 200 7,9 120 110/115 1,1 AWG22
9AR0A5C05180H200 150 5,9 300 11,8 180 110/115 1,6 AWG22
9AR0A5D05240H200 150 5,9 400 15,7 240 110/115 2,2 AWG22
9AR0B0C05240H200 200 7,9 300 11,8 240 110/115 2,2 AWG22
9AR0B0D05320H200 200 7,9 400 15,7 320 110/115 2,9 AWG22
9AR0C0C05360H200 300 11,8 300 11,8 360 110/115 3,3 AWG22
9AR0C0D05480H20 300 11,8 400 15,7 480 110/115 4,4 AWG20
9AR0D0D05640H200 400 15,7 400 15,7 640 110/115 5,8 AWG18

Rectangular heater main references, 0.8 w/cm² (5.2 w/inch²). Attention these heaters must be used on a power dissipation surface or a heat sink.
(Click on reference to download drawing)

reference Width mm Width inches Length mm Length inches Power Watts voltage amps wire size
9AR0A0A08080H200 100 3,9 100 3,9 80 220/230 0,3 AWG22
9AR0A0B08160H200 100 3,9 200 7,9 160 220/230 0,7 AWG22
9AR0A0C08240H200 100 3,9 300 11,8 240 220/230 1,0 AWG22
9AR0A0D08320H200 100 3,9 400 15,7 320 220/230 1,4 AWG22
9AR0A5A08120H200 150 5,9 100 3,9 120 220/230 0,5 AWG22
9AR0A5B08240H200 150 5,9 200 7,9 240 220/230 1,0 AWG22
9AR0A5C08360H200 150 5,9 300 11,8 360 220/230 1,6 AWG22
9AR0A5D08480H200 150 5,9 400 15,7 480 220/230 2,1 AWG22
9AR0B0C08480H200 200 7,9 300 11,8 480 220/230 2,1 AWG22
9AR0B0D08640H200 200 7,9 400 15,7 640 220/230 2,8 AWG22
9AR0C0C08720H200 300 11,8 300 11,8 720 220/230 3,1 AWG22
9AR0C0D08960H200 300 11,8 400 15,7 960 220/230 4,2 AWG20
9AR0D0D08A28H200 400 15,7 400 15,7 1280 220/230 5,6 AWG18
9AR0A0A05080H200 100 3,9 100 3,9 80 110/115 0,7 AWG22
9AR0A0B05160H200 100 3,9 200 7,9 160 110/115 1,5 AWG22
9AR0A0C05240H200 100 3,9 300 11,8 240 110/115 2,2 AWG22
9AR0A0D05320H200 100 3,9 400 15,7 320 110/115 2,9 AWG22
9AR0A5A05120H200 150 5,9 100 3,9 120 110/115 1,1 AWG22
9AR0A5B05240H200 150 5,9 200 7,9 240 110/115 2,2 AWG22
9AR0A5C05360H200 150 5,9 300 11,8 360 110/115 3,3 AWG22
9AR0A5D05480H200 150 5,9 400 15,7 480 110/115 4,4 AWG20
9AR0B0C05480H200 200 7,9 300 11,8 480 110/115 4,4 AWG20
9AR0B0D05640H200 200 7,9 400 15,7 640 110/115 5,8 AWG18
9AR0C0C05720H200 300 11,8 300 11,8 720 110/115 6,5 AWG18
9AR0C0D05960H200 300 11,8 400 15,7 960 110/115 8,7 AWG15
9AR0D0D05A28H200 400 15,7 400 15,7 1280 110/115 11,6 AWG15

Adhesive backside: replace the last character (0) by A

Download Flexible rectangular silicone heaters catalog