Your guide to flexible heaters
August 12, 2024Flexible heaters are made from ultra-thin polyimide film, polyester (PET), silicon rubber, mica, transparent film and fabric. Each offers unique properties and delivers precision, versatility and efficiency to meet many heating application requirements, from medical and industrial processes to wearable technology.
Figure 1: Flexible heaters are made from ultra-thin polyimide film, polyester (PET), silicon rubber, mica, transparent film and fabric. Source: Pelonis Technologies
Polyimide heating elements can be used in low to high temperature environments and are widely used in industrial, electrical, automotive and medical applications. For instance: Temperature range: -240° C to 310° C (-400° to 590° F).
PET can be applied with double-sided adhesive backing and are as flexible as polyimide heating elements. Translucent PET is the most economical and least expensive flexible heating element.
They can be used in temperature ranges of -25° C to 120° C (-13° F to 248° F).
Silicon rubber heaters can heat up rapidly with an even temperature and can be applied with an adhesive backing. They are appropriate for temperature ranges of -200° C to 300° C ( -328° F to 572° F).
Mica heaters have a high tensile strength and can withstand high temperatures. They are in compliance with insulation testing of a high voltage resistance and can be integrated with a metal mold. They are appropriate for temperature ranges of -200° C to 1,000° C (-328° F to 1,832° F).
Transparent film heaters heat up quickly and evenly with no harmful effects from glare. They are appropriate for temperature ranges of -25° C to 120° C (-13° F to 248° F).
Fabric heaters can be safely integrated directly into fabrics, textiles or flexible materials to provide warmth and comfort.
Features and specifications
- Fast heat conduction and fast cooling
- Lightweight and flexible, can be wound and bent
- AC/DC 1 V to 1,000 V
- Withstand 3,000 V test
- Heating pads can be custom made to match any size
- Can be pierced with holes or the center may be removed to allow the heating pads to conform to different shapes
- Can be divided into many areas with different power specifications and temperatures on a heating pad
- Can be installed with temperature controllers such as NTC, temperature sensors and temperature fuses
- Safe and reliable with long service life
Applications
- Aviation equipment
- Medical equipment
- Industrial equipment
- Fittings or traffic equipment
- Electrical appliances
- LCD displays
- Bathroom mirror defogger
- Automobile electronics
- Food warmers
- Laboratory equipment
Ultra-thin flexible heaters
Ultra-thin flexible heaters outperform other conventional heating elements and feature excellent physical and electrical properties that result in thermal stability over a wide temperature range.
Figure 2: Ultra-thin flexible heaters. Source: Pelonis Technologies
- Lightweight, flexible
- Ultra-thin (less than 0.22 mm) heater
- Continuous operation from -240° C to 310° C (-400° F to 590° F)
- Available in 1.5 V AC/DC to 600 V AC/DC
- Efficient heat transfer to all types of parts
- EMF-free
- More than 5,000 standard UL recognized models in round and rectangular shapes
- Optional adhesive and thermostat
- The heating element can be wound and bent. The minimum bending radius is about 0.2 mm
cUL recognized
Ultra-thin flexible heaters have more than 5,000 cUL recognized standard rectangular and circular shaped heaters for selection and complex customized two-dimensional shapes. Sizes, voltages and wattages can also be designed to meet an exact application.
Uniform heating
Ultra-thin flexible heaters feature excellent physical and electrical properties that result in thermal stability over a wide temperature range. Uniform part temperatures are assured by matching power.
Quick heat-up
Ultra-thin flexible heaters’ built-in nano technology heating elements create strong bonding, which makes them more flexible than typical flexible heaters. This allows heat to transfer more efficiently and evenly than foil imprinted heaters. Ultra-thin flexible heaters' high temperature capability with thin construction and low mass design allow higher wattage for faster heat-up and warm-up time.
Light and space saving
The thickness of ultra-thin flexible heaters is less than 0.22 mm (0.0087 inches) and they typically weigh only 0.04 g/cm² (0.009oz/in2). They are ideal heaters for applications with limited space such as defense electronics, aircraft, portable medical instruments, laboratory research, optical and photographic equipment, LCD displays, computer equipment, high density electronic devices and many more.
PET heating elements can be applied with back adhesive and the polyimide film heating element can be used in a frigid environment and is widely used in electric appliances, industrial, automotive, electronics and medical applications.
Polyester (PET) heaters
Figure 3: PET heating elements are translucent elements. Source: Pelonis Technologies
PET heating elements are translucent elements that can be applied with double-sided adhesive backing and are as flexible as polyimide heating elements. They are the most economical and least expensive flexible heating elements and provide remarkable flexibility, rapid heating capabilities and unmatched efficiency.
- Temperature range: -25° C to 120° C (-13° F to 248° F)
- Waterproof and moisture proof
- Can be wound and bent
Safe and cost-effective
These elements are designed with features like overheat protection and durability against extreme conditions. Their durability and energy efficiency contribute to cost savings over time. They save energy due to their rapid heating and cooling capabilities, resulting in lower operational costs.
Flexible and uniform heating
PET heating elements are highly flexible, allowing them to conform to various shapes and surfaces. This flexibility makes them ideal for applications where traditional rigid heating elements are impractical. These heating elements also provide even and consistent heating across their entire surface, ensuring precise temperature control.
Low thermal inertia and chemical resistance
PET heating elements heat up quickly and cool down rapidly, reducing energy consumption and improving efficiency. They are resistant to a wide range of chemicals, making them suitable for use in harsh environments.
Long life expectancy
PET heating elements have a long operational life, reducing the need for frequent replacements.
Customizable
They can be tailored to fit specific project requirements and can be customized in terms of size, shape and wattage to meet specific heating requirements. PET heating elements can be used in automotive applications for defrosting and de-icing applications, medical devices including for patient warming and fluid heating, food processing for temperature control and curing processes, and industrial equipment for process heating and temperature maintenance.
Silicon rubber heaters
Figure 4: Silicon rubber heating elements are engineered to deliver uniform heat distribution. Source: Pelonis Technologies
Silicon rubber heating elements are engineered to deliver uniform heat distribution, rapid heating and exceptional durability. They can be customized for complex shapes to provide consistent warmth for industrial processes, or reliable temperature maintenance for critical applications. The silicon rubber heating elements heat up rapidly with an even temperature and can be applied with an adhesive backing. They are primarily composed of super conductive heating alloy sheets and high temperature silicon rubber insulation cloth.
- Temperature range: -200° C to 300°C (-328° F to 572° F)
- Acid resistance
- Waterproof, insulating and oil environment resistant
Safe and cost-effective
Designed with safety in mind, they often include features like overheat protection and resistance to electrical hazards. Their rapid heating and uniform heat distribution contribute to energy savings by reducing heat loss and operational costs.
Flexibility and uniform heating
Silicon rubber heaters are highly flexible and can conform to a wide range of shapes, making them suitable for irregular surfaces and complex geometries. These heaters provide even and consistent heating across their entire surface, ensuring precise temperature control.
Rapid and precision heating
Silicon rubber heaters heat up quickly, reducing startup times and improving operational efficiency. They offer precise temperature control, ensuring that critical processes are maintained within specified parameters.
Durability and long life expectancy
Silicon rubber heaters are robust and can withstand harsh environments, including exposure to chemicals, moisture and mechanical stress and have a long operational lifespan, reducing the need for frequent replacements.
Customizable
They can be tailored to specific sizes, shapes and wattages to meet unique heating requirements. Silicon rubber heating elements can be used in the medical industry for patient warming and diagnostic equipment, de-icing and cabin heating, food processing facilities for temperature control during cooking and curing processes. Additional applications include automotive mold heating and engine preheating, and process heating and equipment maintenance.
Mica heaters
Figure 5: Mica heating elements are crafted from mica sheets. Source: Pelonis Technologies
Mica heating elements are crafted from mica sheets, a naturally occurring mineral known for its excellent electrical and thermal insulation properties. They are designed to provide rapid, uniform and reliable heating, The ultra-thin film heating pad is constructed to have a high tensile strength and withstand high temperatures. It is in compliance with insulation testing of a high voltage resistance and can be integrated with a metal mold. With their high heating efficiency, mica heating elements replace conventional heating elements and heating pipes.
- Temperature range: -200° C to 1,000° C (-328° F to 1,832° F)
- Applicable to various high temperature resistant insulation materials such as electrical appliances and industrial equipment
Safety
These heaters are designed with safety in mind and often include features like overheat protection to prevent damage.
High thermal efficiency
Mica heating elements are renowned for their exceptional thermal efficiency. They convert electrical energy into heat with minimal losses, ensuring that energy is used effectively and reducing operational costs.
Flexibility and uniform heating
Mica heaters are flexible and can be easily formed into various shapes and sizes, making them ideal for applications with curved or irregular surfaces. They have excellent heat transfer properties that results in even heat distribution across the entire surface of the heating element. This uniformity ensures consistent and precise temperature control.
Rapid and precision heating
These elements heat up quickly, reaching the desired temperature in a short amount of time. This rapid heating is crucial in applications where quick response times are essential. The uniform heat distribution ensures precise temperature control, making them suitable for applications where maintaining specific temperatures is critical.
Chemical and moisture resistance
Mica is inherently resistant to moisture and many chemicals, making mica heating elements suitable for use in demanding environments where exposure to harsh substances is a concern.
Durability and long life expectancy
Mica heaters are robust and have a long operational life, reducing the need for frequent replacements.
Easy installation
Their flexibility and customizability simplify the installation process, reducing downtime and installation costs.
Customizable
They can be tailored to specific wattages, voltages and shapes to meet the unique heating requirements.
Transparent film heaters
Figure 6: Transparent film heating elements consist of a thin, flexible and optically clear film. Source: Pelonis Technologies
Transparent film heating elements consist of a thin, flexible and optically clear film that can be applied to transparent or translucent surfaces. With the construction of an ultra-thin film heating element, the transparent film heating element will not affect any sight line with high performance or common double-sided adhesive backing stuck onto both sides.
- Temperature range: -25° C to 120° C (-13° F to 248° F)
- Heats up quickly and evenly
- The visible transparency is up to 85% higher than that of conventional glass
- No harmful effects from glare
Safety and energy efficiency
These elements are designed to meet safety standards and often include features like temperature sensors and overheat protection. They offer energy-efficient heating, minimizing heat loss and reducing operational costs.
Transparency
The defining feature of transparent film heating elements is their ability to maintain transparency even when activated. This property makes them ideal for applications where both heating and visibility are required, such as automotive windows, display screens and architectural glass.
Flexibility and uniform heating
Transparent film heating elements are highly flexible, allowing them to conform to curved or irregular surfaces without compromising their heating efficiency and they provide even and consistent heating across their surface, ensuring that the entire area is heated uniformly.
Rapid heating
Transparent film heating elements are known for their quick heating response, reducing the time required to achieve the desired temperature.
Durability
Transparent film heating elements are designed to withstand environmental factors such as moisture, UV exposure and temperature fluctuations, ensuring a long operational life.
Easy installation
Transparent film heating elements’ flexibility and thin profile make them easy to install without adding significant weight or altering the appearance of the surfaces they are applied to.
Customizable
These heating elements can be customized in terms of size, shape and wattage to suit specific heating requirements, making them adaptable to various applications.
Transparent film heating elements offer a unique combination of transparency and efficient heating, making them ideal for applications where visibility, energy efficiency and customization are paramount.
Fabric heaters
Figure 7: Fabric heaters can be integrated directly into fabrics, textiles or flexible materials. Source: Pelonis Technologies
Fabric heaters can be integrated directly into fabrics, textiles or flexible materials to provide warmth, comfort and functionality while being lightweight, flexible and customizable. Fabric heaters find applications in clothing, outdoor gear, medical devices, automotive interiors and numerous other fields.
Safety and energy efficiency
Fabric heaters can incorporate temperature sensors and overheat protection and are designed for energy efficiency, minimizing power consumption and operational costs and extended battery life in battery-powered applications.
Moisture resistance
Some fabric heaters are water-resistant or moisture-wicking, making them suitable for outdoor and wet environments.
Portable and lightweight
They add minimal weight and maintain warmth and comfort without sacrificing mobility or convenience.
Flexible and uniform heating
Fabric heaters are highly flexible, allowing them to conform to various shapes and contours, making them suitable for apparel, medical wraps and other products requiring flexibility. These heating elements offer even and consistent heating across the fabric surface, ensuring uniform warmth and comfort.
Rapid heating
Fabric heaters heat up quickly, providing instant warmth and comfort to users.
Durability
These elements are often engineered to withstand repeated bending, washing and exposure to environmental factors, ensuring a long lifespan.
Customizable
Fabric heaters can be tailored to specific sizes, shapes and wattages to meet the unique heating requirements of different applications.
Fabric heaters are a versatile and innovative heating solution that combines comfort, flexibility and energy efficiency. Their ability to be seamlessly integrated into various products has led to widespread adoption in multiple industries, enhancing user comfort and functionality in a wide range of applications. They are well suited for applications including apparel (heated jackets, gloves), medical (warming blankets, heated wraps), automotive (heated seats) and outdoor gear (heated tents, sleeping bags).
Figure 8: Heater insulation materials. Source: Pelonis Technologies
Figure 9: Application references: Source: Pelonis Technologies
Figure 10: Customization guide. Source: Pelonis Technologies
For additional information or for assistance with a flexible heater application, visit the Pelonis Technologies website or contact them at sales@pelonistech.com.
