Silicone Rubber Heater

Silicone rubber heater from Fullchance makes it possible to achieve extremely flexible and energy efficient heating solutions. By flexible we mean two things. Firstly, you will get fully customized heaters where you can specify the input voltage, the power consumption, the dimension or even 3D geometry, the means of installation, the thermal insulation, temperature control method, etc. Heat will be transferred to the intended devices efficiently at your will. On the other hand, you can order as less as one heater for test. It costs you nothing more if you need to change the design later on.

 

Silicone rubber heaters provide dependable performance under rigorous conditions.  These heaters can be designed and fabricated to fit your industrial application.

We use custom software to calculate the configuration of the heating element of the silicone rubber heater, given the voltage, wattage and resistance.

Heating Element

Silicone rubber heater can be made with etched foil heating elements or wire wound heating elements.

Etched foil heating elementEtched foil silicone rubber heaters are made with thin metal foils (0.02mm), usually nickel based alloy, as the resistance element. The resistance pattern to be etched is designed in CAD and transferred to the foil, which is laminated to the insulation substrate. The element substrate is then processed through acid spray to produce the desired resistance pattern.

Wire wound elements for silicone rubber heaters are relatively old technology. They are wired manually according to certain patterns.  The wiring accuracy can hardly be controlled, especially for small sized heaters. Unless for irregular shaped 3D heating applications, wire wound technology has been phased out by Fullchance. 

The etched foil silicone rubber heater has exceptional heat transfer compared to wire wound elements, due to its large flat surface area. It can deliver more uniform heat profiles with higher watt densities, providing longer service time. It can also be zoned with distributed wattage or separate heating circuits to accommodate for load variations. Edge compensation for the temperature can also be realized.
 

Etched Foil Silicone Rubber Heaters

The etched element provides superior heat transfer and exceptionally uniform heat output, which results in a faster warm-up cycle and longer life. The heaters operate in ambient temperatures from -80°F to 500°F.

etched foil silicone rubber heaters

Advantages over wire wound silicone rubber heaters:

  • Higher watt densities
  • Distributed wattages
  • Elimination of edge loss compensation
  • Greater element area over heater sheath
  • Complex heat distribution with a rating of about 200°C (392°F)
  • Economical mass production
  • Reproduction of complex circuits

 


 

Dual Voltage, Zoning and Three Phase

Dual Voltage, three phase input for silicone heaterdual voltage silicone rubber heaterlaboratory heater

Due to the flexibility in circuit design of silicone rubber heaters, multiple heating circuits can be designed to accommodate dual voltage and multiple zones. On dual voltage heaters, three leads, including a common in a different color, are provided for wiring the heater in series for the higher voltage and parallel for the lower voltage. 120/240 Vac or 240/480 Vac can be achieved. Multiple circuit areas can be zoned to achieve different heating effects. Three-phase circuits can also be designed for high current applications.

 

Waterproof Silicone Rubber heater

water proof silicone rubber heater We have developed leak tight silicone rubber heaters which can be permanently immersed into water. This is very useful for high humidity environment or fluid heating where conventional immersion heaters can't be used due to space or mounting limit. The applicable fluid includes some corrosive chemical solution. For example, our silicone rubber heaters have been used for SCR (Selective Catalytic Reduction) tank Adblue heating for exhaust gas control of diesel vehicles. Please consult us for chemical compatibility if you have similar demand.

 

Specification of silicone rubber heaters

Electrical Characteristicssilicone rubber heater
Voltage rating:                                0-480V, AC or DC
Watt density:                                  up to 5.0W/cm2
Watt tolerance:                               +/-5%
Insulation resistance:                       1000M
Dielectric strength:                          1500V/min
Ground mesh:                                  optional

Temperature:
Max operation temperature:              250°C
Continuous operation temperature:    ≤200°C
Temperature control:                       optional

Dimension:
Minimum size:                                  25mm x 50mm
Maximum size:                                 800mm x 3000mm
Thickness:                                      0.8mm - 1.5mm

Others

HS code:                                          8516800000
Termination:                                    Teflon cable, silicone cable, PI cable
Mean lifetime:                                  ≥100,000 hours
Thermal insulation:                          optional, silicone sponge of different thickness

 

Factory Vulcanization

silicone rubber heaterfactory vulcanization of silicone rubber heaterpipe fitting of silicone rubber heater

Factory vulcanization of the silicone rubber heater is recommended for the following permanent installations:

  • heater to be installed inside or outside of a drum (mug heater)
  • heater to be installed on complicated shaped objects, like bent or T pipes
  • applications which have high requirement on temperature distribution 

With our special tools, the silicone rubber heaters will be preformed to a certain shape and easily attached to your equipment without extra work. Minimum temperature variation will be ensured.pipe heater assembly

We delivery standard heating pipe assembly (with power plug) as well. Please consult us for your application.

 

Temperature rise curve

This figure illustrates the surface temperature of a 1.5mm thick silicone rubber heater with different watt density over time. The heater is hanged vertically in 20°C free air. The data is supposed to be a reference for 1.5mm thick silicone rubber heater of standard structure. This is to give you an idea how fast the heating can be. In reality, among other parameters, attachment with different objects will result in different rise curve and stablized temperature.

 

 

Wire Wound Silicone Rubber Heaters

The excellent dielectric properties of silicone rubber and the strength of fiberglass combine to produce a unique heater. First, fine nickel-chromium alloy wire is spiraled onto a center core of fiberglass twine, producing a strong, flexible heating element.  Electronically-controlled precision winding equipment ensures consistency. 

Circuits are then hand-wound on permanent tooling providing repeatability of resistance and pattern. Parallel circuits are utilized where possible, permitting continued operation should a single circuit be damaged.

When the heating element is positioned, a second layer of silicone rubber is laid over the wire. The layers are then vulcanized to permanently position the circuits.

Using these versatile and flexible heaters, the ability to apply heat exactly where required is limited only by imagination — and a maximum continuous operating temperature of about 200°C (392°F).

Read more:
installation of silicone rubber heaters

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Specifications:
Material
Maximum Operating Temperatures
Maximum Watt Densities
°F
°C
W/in2
W/cm2
Silicone rubber 
500
260
80
12.5

Operating temperatures up to 500°F (260°C)
Watt densities up to 80 W/in2 (12.5 W/cm2), dependent upon application temperature
Wire-wound element thickness — 0.055 in. (1.4 mm)
Etched foil element — 0.022 in. (0.56 mm)  

Applications:

  • Freeze protection and condensation prevention for many types of instrumentation and equipment
  • Medical equipment such as blood analyzers and test tube heaters
  • Computer peripherals such as laser printers
  • Curing of plastic laminates
  • Photo processing equipment
  • Semiconductor processing equipment
  •  

Features & Benefits:

Features

Benefits

Designed to the exact shape and size needed

·                               Conforms to your component and/or equipment

More than 80 designs available immediately from stock

·                               Reduces downtime

Constructed with wire-wound or etched foil elements

·                               Delivers a thin, lightweight heater

·                               Provides the desired flexibility for many dynamic applications

·                               Delivers low mass and easily repeatable distributed watt densities

Moisture and chemical-resistant silicone rubber material

·                               Provides longer heater life

Vulcanizing adhesives or fasteners

·                               Allows heaters to be easily bonded to the part


 

The following grades of Silicone rubber heater are available from Fullchance. Please follow the links below for more information.
Compound suitability chart: click here for a comparison of Silicone rubber heater.  This may help to select your rubber type.
 
Standard Grade Silicone Rubber Heaters

Silicone heating dehumidifier

Silicone heating blanket

Heating schemes

Silicone heating band

etching silicone heater

explosing proof silicone heater

Hot plate silicone heater magnetic silicone heater

silicone heating plate

 Please visit the pages below to learn about the many options available. There are normally no engineering or set up fees for even the most complex designs. Many of these options can be added to stock heaters for immediate delivery.
 

  • Unusual Shapes -One of the advantages of silicone rubber heaters are the variety of shapes in which they can be manufactured.

  • Terminations - Silicone rubber heaters can be manufactured with various types of lead wires and other terminations.

  • Temperature Control - Temperatures can be controlled using thermostats or thermocouples.

  • Drum heaters - Silicone rubber heaters are ideal for heating liquid containers. Fullchance stocks heaters for 55 gallon drums and 5 gallon pails.

  • Enclosure Heaters - Another good application for silicone rubber is freeze protection of electrical enclosures. There are several sizes in stock and custom sizes are available.
     

  • Insulated Heaters - Silicone rubber sponge insulation is available in several thicknesses to keep heat on the part, not the surroundings.

Mounting Options:

  • Flat Surfaces - Mounting on a flat surface involves one of several bonding methods.

  • Cylinders - Mounting normally requires a fastening option.

We also supply a range for chinese specification silicone sheet.  Please follow the links below for our most common types:

 

 

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