Horizontal wires terminals
ULTIMHEAT Technology Flat Heaters : Flexible Rectangular Silicone Heaters
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
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
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")
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):
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:
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|
|Stabilization Temperature °C||40||70||90||105||135||165||175||190||210||230||250||260||270|
|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
Horizontal wires terminals
Horizontal tab terminals
Vertical wires terminals
Horizontal Flat cable
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)
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
- 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
Silicone rubber heaters are not suitable for: radiation, vacuum, or prolonged exposure to oil
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.
We protect your intellectual property in confidential fashion. Many of our large clients and ongoing projects are protected with NDA's.
(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
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|
Adhesive backside: replace the last character (0) by A