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Wire-Wound Element Construction
Silicone Rubber heaters with wire-wound elements provide excellent physical strength capable of withstanding repeated flexing without compromising the life and performance of the heater. They are also very effective for manufacturing geometrically challenged shapes, including three dimensional ones. The wire-wound process is recommended and preferred for small to medium size quantities, medium to large size heaters, and to produce prototypes to prove out the design parameters prior to entering into large volume production runs when using etched foil.
the wire-wound element process consists of resistance wire wound on a fiberglass cord for added support and flexibility. The wire-wound element is laid out in a special designed pattern to ensure uniform heat profile and to conform to the size and shape of the silicone rubber heater, avoiding holes and cutouts, or to concentrate the heat profile in a specific section(s) of the heater as the application dictates. Power lead wires or cord sets are attached to the heater windings with solder and firmly secured in place through a vulcanizing process, ensuring that the assembly becomes homogenous. Key Facts
Advantages Of Wire Wound Flexible Heaters
Silicone rubber has low thermal mass and provides superb electrical insulation properties allowing for high power densities with fast response to temperature control.
Wire wound heater mats and pads are manufactured using evenly spaced resistance wires laminated between flexible, lightweight sheets of silicone and can be made in any size or shape to suit individual client requirements.
Silicone heater mats or pads can be made to suit temperatures ranging from -60ºC to 230ºC and can be provided with a range of temperature control devices including thermocouples, platinum sensors and limit switches.
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Thermal control pockets and housing can also be catered for to allow a client to utilise their own control devices if required.
Wire wound silicone heater mats can also be provided with a self-adhesive backing to provide a quick and simple method of securing heater mats to the required surface.
Alternatively a non-adhesive mat can be fitted with a range of fixings such as hooks and springs, buckles and straps or Velcro - contact T&D for further information.
Wire Wound Silicone Heater Mat / Pad Application Examples
Industrial Catering
Battery Warming
Environmental Control
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