The carrier material determines what a flexible heater can do: how hot it may become, how thin it builds, how much power it delivers per unit area, and how large it can be manufactured. We use four materials which together cover the range from –200 °C to +400 °C.
| Carrier material | Temperature range | Min. thickness | Max. power | Max. size |
|---|---|---|---|---|
| Mica | –150 to +400 °C | approx. 2.00 mm | 5 W/cm² | 1000 × 1000 mm |
| Kapton (polyimide) | –200 to +200 °C | approx. 0.10 mm | 4 W/cm² | 550 × 1000 mm |
| Silicone | –50 to +200 °C | approx. 0.80 mm | 4 W/cm² | 550 × 2000 mm |
| Polyester | –50 to +100 °C | approx. 0.25 mm | 1 W/cm² | 500 × 2000 mm |
Silicone heaters
Silicone is the workhorse among carrier materials: permanently flexible, mechanically robust and usable up to +200 °C. With dimensions up to 550 × 2000 mm it is particularly suited to large areas and to curved components such as vessels, pipes and tanks, because the heater follows the contour. Silicone heaters are usually supplied with a self-adhesive film.
Kapton heaters (polyimide)
Where installation space is tight, there is hardly a way around Kapton: from approximately 0.10 mm thick and with very low mass, yet rated from –200 °C to +200 °C. The low thermal capacity results in very short heat-up times – an advantage wherever fast, precise control is needed, such as in optics, sensor technology and vacuum applications.
Mica heaters
Mica is the only material to reach +400 °C and withstands the highest power density at 5 W/cm². In return it is rigid rather than flexible and can only be mounted mechanically – by pressing, clamping, tensioning or screwing. A self-adhesive film is not an option, because the organic adhesive bond would volatilise above approximately +175 °C.
Polyester heaters
Polyester is the economical solution for the lower temperature range up to +100 °C at up to 1 W/cm². With dimensions up to 500 × 2000 mm and low thickness it is the first choice wherever large areas only need gentle heating and unit cost matters.
Selection in three steps
- Define the target temperature – it rules materials out immediately. Above +200 °C only mica remains; below +100 °C polyester becomes economically attractive.
- Check installation space and bending radius – if the heater has to be thin or follow a contour, Kapton or silicone is the answer.
- Determine area and power density – the required heating power divided by the available area gives the power density in W/cm² that the material must carry.
Whichever step you are unsure about: give us a call. Five minutes on the phone usually settles which material fits.
