Silicon Rubber Heaters - Flexible Silicon Rubber Heaters
 Silicone rubber heaters consist of many layers of silicone rubber sheets that are bonded together through heat and high pressure. A fibreglass grid (which is visible on the surface) reinforces the silicone rubber sheets. It is possible to make the surface of the heaters smooth (i.e. make the grid invisible) by covering the fibreglass with a thin layer of silicone. A uniformly spiralled resistance wire web that covers the entire surface of the heater is embedded within the layers of silicone rubber. This web could be designed such that holes and cut-outs are incorporated on the heater. When silicone rubber heaters are made with a pressure sensitive adhesive backing, a thin layer of aluminium is added prior to the adhesive layer, in order to improve heat transfer and maintain its uniformity. 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 standard shapes, sizes and dimensions of band, strip, cartridge, tubular and coil heaters.
Silicone rubber heaters are rugged, moisture and chemically resistant and are easily bonded or cemented to heat sinks or other parts to be heated. Temperatures from -80 to 390°F (-62 - 200°C) in a wide range of watt densities are regularly supplied. The thin profile transfers heat quickly because the actual resistance element is so close to the heated part. Silicone rubber heaters can be insulated with silicone sponge rubber bonded to one side. Another way to lower radiated and convected heat losses is to apply an aluminized foil surface to the heater back. Very little is added to the overall thickness. A common application of Silicone rubber heaters is wrap around drum heating.
 Silicone rubber heaters are available with built in thermocouples, thermistors, thermostats and very high temperature cutoffs. Silicone rubber heaters are also available vulcanized to parts or could be fastened with spring loaded clamps, eyelets for lacing up or by clamping or compression.
Silicone rubber heaters are devices which can conform to the surfaces they are heating. There are many varieties of flexible heaters which include silicone rubber heaters, Kapton heaters, heating tapes, heating tapes with thermostats, rope heaters, wrap around tank heaters, gas cylinder heaters and custom sizes.
Silicone rubber heaters are rugged, reliable, accurate, and moisture and chemical-resistant. They can be easily bonded or adhered to other system parts. Flexible heating elements have a wide range of industrial, commercial, and military applictions where reliability, cost of effectiveness, minimum cross section, resistance to deterioration and basic flexibility are critical.
Silicone Rubber Heaters - Features:
Flexible and bendable to right angles Moisture resistant Direct bonding to part being heated Thin and light weight construction Can be designed and shaped to your imagination (holes notches etc.) Fast heat up and quick cool down High watt densities possible
Silicone Rubber Heaters - Applications:
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Heating of Electronic Components- ATM's and Photocopiers
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Heating of Aerospace Instrumentation-Satellites and Spacecraft
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Semiconductor Wafer Processing
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Autoclaves, Incubators and Sterilizers
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Medical Imaging, Medical Diagnostic Instruments and Analyzers
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Applications requiring a flexible shape or design Heaters Controls And Sensors Ltd., supplies silicone rubber heaters for many different applications such as industrial catering, battery warming, environmental control or electronics (particularly telecommunications), laboratory equipment and anti-condensation. The uses for silicone rubber flexible heaters are infinite as they can suit any application requiring surface heating up to 200°C. Their suitability for arduous conditions has been proven in applications from polar expedition to space exploration.
Silicone
Rubber Heaters - Attachment Methods:
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RTV Adhesives In the field, a strong bonding to application surfaces could be achieved by using room temperature adhesive pastes. Red colored RTV 106 and transparent RTV 116 are the two types of adhesives available. Both these RTV materials are adequate for temperatures up to 5000F.
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Pressure Sensitive Adhesive Silicon rubber heaters could be made with a thin layer of high temperature (3250F) adhesive backing. This adhesive, which can easily bond to practically any surface, is supplied with a protective cover, which can be easily removed before applying the heater to any surface. The watt density of a heater should not pass 5 watt/in2 when a PSA is used.
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Factory Vulcanization This is the most efficient method to bond a heater to a surface. Using high temperature and pressure, Silflex heaters can be vulcanized to a surface. However, bonding through this method can be carried out only in the factory.
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Mechanical Fasteners When a silicon rubber heater is wrapped around an application, the ends of the heater can be fastened by attachments used on fabrics. Eyelets with lacing cords, Velcro hook and loop, metallic fasteners with springs, and independent straps are the most commonly used fasteners.
Silicone
Rubber Heaters - Lead Wire Styles:
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Silicon rubber heaters come only with lead-wire terminations. Two styles are available:
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Teflon or Silicone wire leads These leads are sandwiched between the silicon layers, and a small patch is placed on the point of exit to provide extra protection. This causes the formation of a slight bump at the point where the wires are attached. To eliminate this problem, the attachment between the internal resistance wire and the lead wire could be made at an external tab.
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SJO Power Cables When silicon rubber heaters are used independently in an industrial application, they can be made with power cables that exit from a silicone transition box attached to the heater. Proper electrical plugs are available with the power cables.
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Silicon rubber heaters can accommodate pre-set or adjustable thermostats, thermal cut-offs and external "J" type thermocouples. Each has a specific temperature range and maximum amperage capability; the factory should be consulted for their availability.
Silicone
Rubber Heaters - Specifications & Design Capabilities:
Flexibility - Min Radius Kapton 1 /32" 0.8 mm, Min Bend radius Silicon 1 /8" 6 mm Temperature Range - Silicon - 80ºF to 500ºF, Kapton - 60ºF to 550ºF, Neoprene - 40ºF to 250ºF, HT Foil Semi rigid max 595ºF Thickness - Silicon .018" to .070", Kapton .006" Ultra Thin, Neoprene .050" to .125", HT Foil .025" Maximum Length - Wire wound 150" Longer lengths available, Etched foil 36", Consult HCS for long heaters Maximum Width - Most Heaters 36", Consult HCS for wide heaters Maximum Voltage - 600 VAC 2 Watt Densities - 35 watt/ inch in controlled conditions Sensors - Thermocouples, RTD, Thermistors, Thermostats
Silicone Rubber Heaters
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