Factory Vulcanization
Simultaneously with the vulcanization of the two silicone layers for the heating element, Fullchance can vulcanize (attach) the heating element to the customer's part. Factory vulcanization offers superior heat transfer due to the intimate and consistent bond. Factory vulcanization also offers the customer reduced manufacturing time, thereby increasing production velocity. Depending on part geometry, Fullchance uses several proprietary vulcanization methods to complete the process.
Pressure Sensitive Adhesive
Fullchance silicone rubber heaters can be furnished with pressure sensitive adhesives. These heating elements feature a removable liner to protect the adhesive before installation by the customer. Depending on the substrate material and the operating temperature, Fullchance engineers will select either an acrylic based pressure sensitive adhesive or a silicone based adhesive to best satisfy these requirements. Customer parts should be clean and free from oil and grease before attachment.
Silicone RTV
Fullchance silicone rubber heaters can also be attached with silicone RTV (room temperature vulcanizing). RTV can achieve a highly reliable bond and is suitable for high temperature operation. Two-part RTV may be required for large heating elements as one-part RTVs require humidity to cure properly. Consult Fullchance for installation assistance.
Attachments for Removable Heaters
For silicone rubber heaters that need to be easily removed from the part being heated, Fullchance has available a variety of attachment options. Most any attachment method that is available for fabric can also be utilized on silicone rubber heaters. These include grommets for lacing, grommets with springs and/or buckles, Velcro, Nylon or silicone straps with "D" rings, and straps in conjunction with ITW Nexus style two-part buckles. Consult Fullchance engineering to discuss the most appropriate option.
MOUNTING METHODS
Maximum Temperature: 200°F / 93°C
Maximum Watt Density: 1 W/in2 (0.16 W/cm2)
Maximum Width: 24" (610 mm)
Recommended Maximum Pressure: 40 PSI
MOUNTING METHODS
PSA (and PSA Plus)
For ease of attachment, specify PSA. Installation is simple: just peel off the protective liner and apply. It will adhere to most clean smooth surfaces. Care must be taken when installing to attain a smooth, consistent, uniform bond to achieve maximum results.
Maximum Temperature:
Continuous – 300°F (149°C)
Intermittent – 500°F (260°C)
Recommended Watt Density:
Under 5 W/in2 (0.78 W/cm2)
Maximum Temperature:
Continuous – 300°F (149°C)
Intermittent – 500°F (260°C)
Recommended Watt Density:
Under 5 W/in2 (0.78 W/cm2)
PSA Plus
A layer of aluminum foil is vulcanized to the back of the heater for added
heat dissipation prior to the application of PSA.
A layer of aluminum foil is vulcanized to the back of the heater for added
heat dissipation prior to the application of PSA.
Factory Vulcanizing
Flexible heaters can be factory vulcanized to bare or anodized aluminum, Stainless Steel, Marble, or other hard surfaces for permanent attachment and excellent heat transfer.
The uncured silicone rubber heater is placed on the metal part and placed in the vacuum oven where the heater vulcanizes and adheres to the part in one operation. This procedure forms an extremely strong permanent bond with most metals due to the fact that the silicone rubber flows into and fills the micro structure in the surface of the metal. The metal part can be manufactured by Fullchance or supplied by the customer. Consult Fullchance for other materials including granite.
Magnetic Mounting
A flexible magnetic material can be attached to the back of a silicone rubber flexible heater. Will adhere to many varieties of steel. Ideal for those situations were you need to "Slap On" some heat! Specify when requesting a quote.Maximum Temperature: 200°F / 93°C
Maximum Watt Density: 1 W/in2 (0.16 W/cm2)
Maximum Width: 24" (610 mm)
Field Applied Adhesive
For a field applied permanent bond, a room temperature and ambient humidity curing silicone rubber adhesive is recommended. Fullchance offers two types that will retain physical and electrical properties up to 500°F (260°C).
When using RTV adhesive, cover the heater completely with a thin layer of RTV, position the heater in place, and use a small roller to remove air bubbles, which could cause hot spots and lead to premature failure of the heater.
D-Rings and Straps
Mechanical fasteners are available for applications where flexible heaters must be detachable from cylindrical parts.
Velcro Straps
Mechanical fasteners are available for applications where flexible heaters must be detachable from cylindrical parts.
Boot Hooks and Springs
Mechanical fasteners are available for applications where flexible heaters must be detachable from cylindrical parts.
Boot Hooks and Lacing Cord
Mechanical fasteners are available for applications where flexible heaters must be detachable from cylindrical parts.
Grommets and Lacing Cord
Mechanical fasteners are available for applications where flexible heaters must be detachable from cylindrical parts.
Heavy Duty Spring Clamps
Mechanical fasteners are available for applications where flexible heaters must be detachable from cylindrical parts.
Snaps
Mechanical fasteners are available for applications where flexible heaters must be detachable from cylindrical parts.
Clamping
Flexible heaters may be applied by clamping or compression between two rigid materials. The plate surfaces must be ground reasonably smooth. Care must be taken not to damage the heater or pierce the insulation. Mill out an area or cutout in the top plate for the added thickness of the lead exit area.Recommended Maximum Pressure: 40 PSI
Outside Diameter Mounting
Mechanical fasteners are available for applications
Fullchance has developed the techniques necessary to permanently mount silicone rubber heaters to the outside diameters of pipes and medium size vessels. This technique is particularly useful for heated drums and air or gas heating.
Minimum Diameter: 0.5" (12.7 mm)
Maximum Diameter: 6" (152.4 mm)
Maximum Length: 20" (508.0 mm)
where flexible heaters must be detachable from cylindrical parts.Maximum Diameter: 6" (152.4 mm)
Maximum Length: 20" (508.0 mm)
3-D Configurations
Dimensional silicone rubber heaters can be vulcanized to fit a shaped outline. This technique is particularly useful for wrapping Silicone Rubber heaters around pipes or small vessels. Custom tooling or special forms may be required.
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