However different the industries are, the task of a flexible heater can almost always be traced back to one of three basic functions. It keeps an assembly at operating temperature, it prevents condensation and icing, or it brings a medium to a defined processing temperature. The following examples show what that looks like in practice.
Medical and laboratory technology
In medical technology it is usually a matter of narrow temperature windows: samples and media must be held at a defined temperature, and analysis equipment must not fog up. Flexible heaters control the temperature of containers and transport systems, keep measuring cells at operating temperature and prevent condensation on optical assemblies. Close to the patient they are also used in heating pads, neck rolls and therapy couches – where low weight, flexibility and an even surface temperature without hot spots are what count.
Machine and plant engineering
Many production processes only deliver reproducible results once the tool is already up to temperature. A typical example is plastic welding: if the work table or tool is preheated, the joining temperature is stable from the very first part, scrap at the start of a shift is avoided and cycle time drops. Because flexible heaters can be laid out across a surface and in several zones, the temperature also stays even across larger working areas.
Laser and optical technology
Laser diodes only operate with stable wavelength and output power within a narrow temperature window. A flexible heater brings the diode up to operating temperature before switch-on, so the system runs within specification from the very first pulse instead of having to warm up first. The low mass of Kapton heaters is particularly favourable here, as it allows short heat-up times and fast control.
Defence and security technology
Equipment has to work immediately, even in frost. Flexible heaters preheat equipment carriers, housings and assemblies so that mechanics remain operable, electronics start within their permitted temperature range and optics stay free of fogging. What is required here are robust versions with a reliable termination and integrated over-temperature protection.
Rail and transport technology
Cameras and sensors in outdoor areas lose their function as soon as the lens fogs up, ices over or is covered with snow. Surface heating behind or around the optics keeps the surface permanently above the dew point and melts off adhering snow. The same principle protects outdoor displays from frost and keeps them readable across the entire operating temperature range.
Food technology and catering
Many masses can only be processed within a narrow temperature window. In chocolate and mass processing plants, flexible heaters keep pipes, containers and tools at a constant processing temperature without local overheating – decisive for consistent product quality. In catering and the home they keep food and plates at temperature.
Measurement, sensor and research technology
Sensitive sensors and measuring instruments only deliver reliable values when their temperature is stable. Flexible heaters control the temperature of measuring heads, keep reference assemblies at a constant level and protect equipment in cold environments from condensation and icing. In research setups, Kapton heaters are particularly popular because they are thin, light and vacuum-compatible.
E-mobility and vehicle technology
Batteries deliver considerably less current when cold. A flexible heater preheats the cells before starting and thus improves cold-start current, charging capability and service life. Further typical applications in the vehicle are heated mirrors as well as heated sensor and camera housings.
Three questions that decide every design
- Which target temperature is to be reached and maintained – and how precisely?
- How quickly must the target temperature be reached? This determines the required power density.
- How is it controlled? Everything from a simple thermal fuse to an integrated miniature controller is possible.
Your application is not listed? That is the rule rather than the exception – the majority of our heaters are built to customer specification. Describe your task to us and we will find the right design.
