When designing flexible heaters, you must consider the power requirements. The wattage of the heater must be calculated according to Ohm’s law, which states that current and voltage are proportional. One watt is equivalent to one joule per second, or the work performed by one ampere when one volt is applied to it. You must also consider warm-up power, which is measured in watts. This is the power required to warm up the heater before it starts to perform useful work.
The flexibility of a polyimide-based flexible heater element can be a great benefit for certain applications. Its thin structure makes it ideal for heating irregular and curved surfaces. These heaters are available in a wide range of thicknesses, including 0.007-inch versions. They are made with an FEP adhesive that is pressed between two layers of polyimide. This material is resistant to most chemicals and is extremely resilient.
The tensile strength of a flexible heater element is largely determined by the type of polyimide used in its construction. A polyimide flex heater element can withstand high temperatures and bends up to 0.0007-inches without cracking or breaking.
A chemically etched flexible heater element provides superior heat transfer and a consistent heat output at low operating temperatures, resulting in a shorter warm-up time and a longer life span. These elements are also extremely lightweight, and are available in polyimide (kapton), a durable organic polymer that flexible heater element provides high tensile strength and tear resistance. This material also has excellent electrical and physical properties, making it suitable for use in vacuum and other harsh environments.
Flexible heating elements can be made from several types of materials. These materials are highly flexible, and may be wire-wound or etched to conform to a shape or pattern. These elements are available in many sizes and shapes, and may also be thermowelded onto an aluminum foil, resulting in a longer, thinner design that is more flexible.
Wire wound elements are one type of flexible heater that uses wire as a heating element. These elements have excellent electrical and physical properties and are also suitable for use in vacuum environments. They are also resistant to most chemicals and can be bonded to other metals. The wire wound heaters are ideal for applications where their size is limited.
Wire wound elements are the most common type of flexible heating elements. They are made from silicone rubber and are reinforced with fiberglass or a similar material. These heaters work by creating heat via resistance to electrical current. Wire wound elements are thin and can be placed in long patterns.
Flexible heater mounting involves attaching the flexible heater element to a hard surface with a pressure-sensitive adhesive (PSA). Once the adhesive is applied, the flexible heater is placed on the component, and the protective backing is removed. Flexible heaters may have a single or double-sided adhesive coating. PSA mounting is ideal for clean, smooth, or slightly curved surfaces. This is the most economical mounting option for flexible heaters.
Flexible heaters are great for use anywhere, and are typically capable of operating at 200degC or higher. They are specially designed with custom software to determine the optimal configuration for the heating element. The etched element has exceptional heat transfer and uniformity, resulting in a shorter warm-up cycle and longer life. In addition to being flexible, these heaters are highly effective in an ambient temperature range of -80degF to 500degF.