High temperature heater
Electrical Features
Voltage input: 1.5V~ 440V can all be designed.
Power consumption: 0.01W~15W/C㎡.
Dimensions: The maximum width is 1.2M.
The maximum length (unlimited) can be depending on your demand.
The minimum thickness is 0.4mm±10%.
It is very fast and safe for the heating curve on the surface of the whole heating object with a construction of an ultra thin film heating element, tensile strength resistant and high temperature resistant, and also achieves an excellent heating result even in a severe environment. This product can complete the voltage resistant test of insulation, and can integrated with the metal mould with a better heating effect.
POLYIMIDE (KAPTON) HEATER
Polyimide (Kapton®) heaters manufactured by Sinomas are widely adopted for precision instrument heating up to 260°C. The versatile heater films have been the ultimate solution for many performance demanding applications.
Polyimide (Kapton®) film is an organic material with very high dielectric capability, thin flexible profile and low thermal mass, while providing superior resistance to most solvents, acids, and radiation. Being transparent, Polyimide (Kapton®) heater allows easy visual inspection of the internal foil circuit structure. In connection with these features, Polyimide (Kapton) heaters are very ideal for applications:
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- space and weight demanding instrument heating
- be exposed to chemicals or oil
- in vacuum environment requiring low out-gassing
- fast and precise heating
- low voltage low ohm value heater film, e.g. 5V, 12V, 24V
- high performance heating for consumer appliance
Foil Element
Polyimide (Kapton) heaters make use of very thin (e.g. 50μm) etched metal (usually nickel based alloy) foil as resistance element. The resistance pattern to be etched is designed in CAD and transferred to the foil, which is then processed through acid spray to produce the desired resistance pattern.
Taking advantage of the etched foil technology, complicated thermal profiles and wide range of resistance can be realized. Bifilar circuit meander arrangement is possible, which is often required to eliminate the parasitic inductance in the circuit.
Technical Specification
| Electrical |
Thermal |
Others |
| Input volatge |
12V - 400V |
Max Temperature |
260°C (note 3) |
Min width |
8mm (note 1) |
| Watt density |
≤ 3.0 W/cm2 |
Min Temperature |
-50°C |
Max width |
500mm (note 2) |
| Watt tolerance |
≤ ±5% |
Aluminum foil backing |
optional |
Thickness |
≤0.2mm |
| Insulation |
> 100M |
Insulation overlayer |
optional |
Bending radius |
≥0.8mm |
| Dielectric |
> 1000V/min |
|
|
|
|
| Temperature Sensor |
RTD / film pt100, thermistor / NTC, thermocouple, thermal fuse, thermal switch |
| Adhesive backing |
optional with acrylic, silicone, teflon, polyimide based PSA |
| Circuit design |
dual input voltage, multiple heat zone, low inductance design, etc. |
| Lead wires |
Teflon, silicone rubber, PI insulated cables, different plug set / termination available |
Notes:
- The minimum width of ployimide / kapton heater is 8mm for one side leads exit, 5mm for two side leads exit
- The maxmimum width of polyimide / kapton heater is only limited by the incoming roll of polyimide film. Henece there is no limit on one dimension. We can make wider heaters if the volume of demand is considerable.
- The maximum operation temperature depends on many factors. 260°C applys to Aluminum plated polyimide heaters without adhesive backing.
Aluminum / Copper Plated Polyimide Heater
Aluminum foil backing on polyimide heaters can improve the heat distribution and allows for higher watt density. For even high operation temperature and ems supression, Aluminum or copper plating of the polyimide heaters are recommended. The maximum operationtemperature of the heater can be up to 260°C. The technology has been used successfully on polyimide heaters for medical CT scanners, particle accelerators, etc.
Applications:
The film heating element is very fast and safe for the heating curve on the surface of the entire heating object of a product with the construction of an ultra thin film heating element. It won’t affect any sight line with the high-performance or common double sided adhesive backing stuck onto both sides. The penetrability is above 70%~80%.
Common terms: Transparent film heating pad, film heating pad, flexible heating element, super conductive flexible heating pad and other such terms.
Estimating Power Requirements of Etched-Foil Heaters
Introduction Etched-foil heaters have gained significant popularity due to their flexibility, uniform heat distribution, and rapid response times. These heaters consist of a resistive heating element etched onto a thin foil substrate, providing excellent thermal conductivity. Accurate estimation of power requirements is essential for designing the electrical circuitry and ensuring optimal performance of the heating system. Abstract When specifying a new etched-foil heater design, the first and often most formidable parameter to determine is heater wattage. How much power is needed to bring a part to temperature in a given time and how much to maintain it there? You can determine your heater needs by experiment or by calculating a theoretical value. The experimental approach gives the best answer, but a wattage estimate should be done before embarking on experiments. This white paper presents some numerical methods for you to use in estimating heater wattage. It is not perfectly accurate, as it is impossible to take into account all the variables acting upon a thermal system. What it does provide is an estimate to serve as a basis for ordering prototypes or starting lab experiments. Basic Heat Transfer Theory Two values must be calculated to determine wattage requirements: warm-up and operating heat. Assuming no lost heat, the power required to warm up a block of material is a linear function of the material’s mass and specific heat, the degree of temperature rise and the desired warm-up time: P = Where: P = Heater power (W) m = Mass of material (g) Cp = Specific heat of material (J/kg·K) from Table 1 Tf = Final Temperature of material (°C) Ti = Initial temperature of material (°C) t = Desired warm-up time (min) This formula will serve as a shortcut for power estimation if warm-up requirements are the dominant heat demand of the system and losses are small. The figure it gives is a minimum. Add at least 10% for unknown heat losses. For best accuracy, you can estimate heat loss during operation and warm-up. Loss occurs in three forms; conduction, convection, and radiation. Conduction transfers heat from a warmer object to a cooler one, usually through a solid medium. When speaking of etched-foil heaters, conductive loss generally refers to loss through insulation layers or heat sink mounting hardware. Conduction is a function of the temperature difference between the heater and its surroundings, the distance between hot and cool areas, and the cross-sectional area and conductivity of conductive paths. Convective loss occurs when the fluid medium surrounding the heater flows in currents and carries heat with it. For purposes of this white paper, the fluid is air. The two types of convection are natural, when heated air rises and creates air currents, and forced, when fans or wind drive air past the heater
Convective loss depends on the heat sink temperature relative to ambient, the shape and surface area of the heat sink, and the velocity of forced air. Radiation is heat emitted as infrared energy. Radiant loss varies with temperature difference between the heater and ambient, heater surface area, and the nature of the surfaces radiating and absorbing the heat (emissivity). Warm-up heat is the heat required to bring the heat sink to temperature in the desired time, plus extra heat to compensate for conductive, radiant, and convective losses during warm-up. Operating heat equals the sum of steady-state loses and process heat. Process heat represents work done by the heater to thermally process some material, for example, to melt a plastic film placed over the heat sink. The total minimum heat required for an application is the larger of two values: 1. Warm-up heat, or 2. Operating heat including process requirements.
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