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Introduction |
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Flat Heating Elements are used wherever a flat side has to be heated symmetrically and effectively.
Constructed of winded heating wire and two shifts of insulation, custom-made adaption to nearly any surface
dimension is possible. Simultaneously an optimal heat allocation over the heated flat side is achieved.
Working temperatures up to 450°C (exceptions up to 600°C) and surface load up to 5 W/cm² are possible at
optimal heat transition.
| selection table |
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Silicone |
Kapton |
Polyester |
Micanite |
Nomex |
| temperature resistance |
200°C |
200°C |
110°C |
450°C (600°C) |
250°C |
recommended
max. watt density |
0,8W/cm² |
2W/cm² |
0,2W/cm² |
5W/cm² |
1,5W/cm² |
| max. size |
5000 x 950 mm |
550 x 300 mm |
1000 x 1000 mm |
2000 x 1000
mm |
800 x 800 mm |
| min. size |
30 x 30 mm |
25 x 25 mm |
25 x 25 mm |
30 x 30 mm |
30 x 30 mm |
| min. height |
0,8 mm |
0,2 mm |
0,2 mm |
1,3 mm |
1,3 mm |
| lot size |
from 1 piece |
from 1 piece |
from 50 piece |
from 1 piece |
from 1 piece |
| min. bend radius |
15 mm |
1 mm |
10 mm |
100 mm
(only metal sheathed) |
15 mm |
| max. IP-rating |
IP65 |
IP64 |
IP65 |
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self-adhesive foil
possible |
yes |
yes |
yes |
no |
no |
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8.1 Flexible Flat Heating Elememts |
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8.1.1 Silicone Heater Mats |
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SILICONE heater mats consist of heating wire or an etched heating foil,
which is encapsulated and insulated between two silicone mats strengthened
by textile glass fibers. They are suitable especially for applications
requiring precise temperature and homogeneous heat distribution.
Due to their low thermal mass they distinguish by quick response and an
excellent controllability. Their low mass and small construction height (from 0,8 mm)
make them interesting for many aerospace applications. Their resistance
against moisture and humidity (IP 65) recommends them for laboratory
equipment, catering appliances and frost or condensation protection especially
of electronic components. The only restriction of this versatile heater:
its max. continuous operating temperature of 200°C (up to 230°C for short
periods).
Fitting for your application, silicone heater mats can be build
in nearly every dimension and geometry with numerous
extra-components, e. g. thermocouples, limiters and thermal fuses. |
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Especially for larger
quantities we recommend to use heating mats with etched heating foil. In
regard to forms, dimensions and complexity of heat distribution they are
as variable as heaters with heating wire. Through shorter distances and
larger surface of etched strip conductors they reach an even higher watt
density and a more homogeneous heat distribution.
For easy installation we recommend silicone heating mats with self-adhesive foil. This foil fixed
in a special procedure on the heater, meets most requirements even at max.
permissible operating temperature. The latest progress in adhesive technique
replaced the conventional vulcanising nearly completely. |
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| All Silicone heater mats also VDE and UL rated available. |
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8.1.2 Kapton Foil Heaters |
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Kapton (Polyimide) is a semitransparent and flexible insulation material. Its superb insulation properties allow to produce
very thin heating Elements. The resulting efficient heat transfer permit high watt densities. The temperature resistance of
these heating elements
is 200°C.
Kapton foil heaters are always manufactured customized. The mats can be designed to any shape. Multiple circuits
and areas having different power density can also be designed to suit specific requirements. They can be supplied with surface mounted temperature sensors.
The resistance against fungus, bacteria, ozone, weather and age is excellent so that the heating elements are suitable for a number of critical applications.
The self-adhesive foil is a quick and simple fixing method which provides superb bonding results.
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8.1.3 Polyester Foil Heaters |
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Polyester Foil Heaters consist of a conductive ink between two insulation layers of polyester.
With a max. size of 950 x 600 mm, their height averages to 0.2 mm. As you can see in the pictures almost every
outline and all kind of holes are feasible. Naturally we can integrate safety- and controlling devices such as
limiters, cutouts, thermocouples, and resistance sensors.
Regarding temperature profile, electromagnetic compatibility and immunity to failure, polyester foil heaters are clearly superior to heater mats with wound wire or etched heating circuits due to their plane heating ink.
Another advantage of the used ink is the simple realization of differential power: for this either the composition of the ink is varied or blanks are integrated in the design (see picture of the foil heater on the left, with dotted edges).
The heater can be pressed on or fixed with a self-adhesive foil. Wrapped in PVC, the use in liquids is possible as well.
Typical applications are e. g. mirror heaters, water bed heaters, or low temperature room heaters. For terrarium and aquarium heaters we offer standard elements as well.
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8.2 Drum Heaters |
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8.2.1 HSSD - Silicone Side Drum Heater |
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Application
The HSSD silicone side drum heater is a simple and effective method of applying heat to drums. It has a higher watt density than the HISD side drum heater but provides no
thermal insulation. Multiple units up to a maximum of three can be used to give quicker warm up times and higher product temperatures. The HSSD side drum heater is available
in four standard sizes (25 / 50 / 105 / 200 Litre) or can be manufactured custommade.
HSSD silicone side drum heaters are specifically designed for the melting or reducing the viscosity of soaps, fats, varnishes and oil based type of products.
They can also be used in conjunction with the HBD base drum heater to increase product heat up.
Construction
The heating element of the HSSD side drum heater is PTFE coated and sandwiched between multiple layers of silicone coated glass fabric to give a double insulated
construction for added safety. Attachment to the drum is by a quick and simple spring & clip arrangement that ensures good surface contact with the drum.
Technical Data
All HSSD side drum heaters come complete with 2 metres of high temperature rubber insulated power cable, a 0 to 120°C capillary thermostat plus neon indicators for power and load on. They are available in 230V (special voltages possible).
| drum size |
power |
length |
width |
| 25 litre |
300 W |
800 mm |
125 mm |
| 50 litre |
500 W |
940 mm |
125 mm |
| 105 litre |
800 W |
1300 mm |
125 mm |
| 200 litre |
1000 W / 1500 W |
1665 mm |
180 mm |
Health and Safety
All HSSD Silicone Side Drum Heaters are manufactured to conform to the EEC low voltage and EMC directives and CE marked accordingly.
Additionally for safety, it is advised that power to the drum heater be disconnected when drum is either empty or being filled,
or upon installation or removal of the heater itself. It is recommended that the unit be operated in a dry environment with the
drum vented to avoid build up of internal pressure.
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8.2.2 HISD - Insulated Side Drum Heater |
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Application
The HISD silicone side drum heater is a simple and effective method of applying heat to drums. It is available in four standard sizes (25 / 50 / 105 / 200 Litre) or can be
manufactured custommade. HISD side drum heaters are specially insulated to aid thermal efficiency.
The HISD is specifically designed for use with plastic drums but can be used on any containers where delicate materials require gentle warming.
It can also be used in conjunction with the HBD base drum heater to increase product heat up.
Construction
These low powered double insulated heaters are constructed to Class II for added safety. The heating element of the HISD range is stitched
into an insulated jacket made from a waterresistant, teflon coated polyester, insulated with glass filament blanket insulation complete with
quick release buckles for ease of installation and removal.
Technical Data
All HISD side drum heaters come complete with 3 metres of power cable, either a -5° to +40°C or 0° to 90°C capillary thermostat and are
available for 110V or 230V supply (special voltages possible).
| drum size |
power |
length |
width |
| 25 litre |
200 W |
1020 mm |
400 mm |
| 50 litre |
250 W |
1250 mm |
440 mm |
| 105 litre |
400 W |
1650 mm |
440 mm |
| 200 litre |
450 W |
1950mm |
450 mm |
| 200 litre* |
1200 W |
1950 mm |
800 mm |
*suitable only for steel drums
Health and Safety
All HISD/HTSD Drum Heaters are manufactured to conform to the EEC low voltage and EMC directives and CE marked accordingly.
Additionally for safety, it is advised that power to the drum heater be disconnected when drum is either empty or being filled,
or upon installation or removal of the heater itself. It is recommended that the unit be operated in a dry environment with the drum
vented to avoid build up of internal pressure.
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8.2.3 HTSD - Insulated Side Drum Heater |
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Application
The HTSD range of side drum heaters is based on the HISD design but has a higher operating temperature (up to 220°C). It is available in four standard sizes (25 / 50 / 105 / 200 Litre)
or can be manufactured cus-tom-made. HTSD side drum heaters are specially insulated to aid thermal efficiency.
HTSD silicone side drum heaters are specifically designed for the melting or reducing the viscosity of soaps, fats, varnishes and oil based type of products.
The HTSD 200L-heater can also be used in conjunc-tion with the HBD base drum heater to increase product heat up.
Construction
The heating element of the HTSD side drum heater is stitched into an insulated jacket made from a silicone insulated glass cloth.
The insulating outer jacket is made up of a needle mat of silica-glass filaments com-plete with quick release buckles for ease of installation and removal.
Technical Data
All HTSD side drum heaters come complete with 3 metres of power cable, a 20° to 200°C capillary thermo-stat and are available for 110V or 230V supply (special voltages possible).
| drum size |
power |
length |
width |
| 25 litre |
380 W |
1020 mm |
400 mm |
| 50 litre |
450 W |
1250 mm |
440 mm |
| 105 litre |
700 W |
1650 mm |
440 mm |
| 200 litre |
1250 W |
1950 mm |
800 mm |
Health and Safety
All HISD/HTSD Drum Heaters are manufactured to conform to the EEC low voltage and EMC directives and CE marked accordingly.
Additionally for safety, it is advised that power to the drum heater be disconnected when drum is either empty or being filled, or upon installation or
removal of the heater itself. It is recommended that the unit be operated in a dry environment with the drum vented to avoid build up of internal pressure.
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8.2.4 HBD - Base Drum Heater |
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Application
The HBD heater is specifically designed for the melting or reducing the viscosity of soaps, fats, waxes, varnishes and oil based type of products.
The diametre of the base enables use on all sizes of drums up to 200L, although the efficiency is limited for smaller drums. The HBD is manufactured with
a 900W silicone rubber insulated heater mat which provides an even distribution of heat to the platen.
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HIJD - unheated insulation jacket
» to be used in conjunction
with HBD base drum heaters
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In order to reduce the heat-up time, the HBD can be used in conjunction with other drum heaters (HSSD/HISD/HTSD) or with an unheated insulation jacket. |
Construction
The HBD is made from 2 mm thick mild steel for extra rigidity on uneven surfaces with tapered edges for safe ease of drum location and is protected by
a resilient high temperature coating. Temperature adjustment is afforded by a rear aperture in the control unit, with neons indicating power on and load
switching, all viewed through a window in the control unit top.
Technical Data
The HBD base drum heater is controlled by a capillary thermostat, with a temperature range of 20 to 150°C, with neon indicators for power and load on. It is available in 110V or 230V (special voltages possible).
Health and Safety
HBD Base Drum Heaters are manufactured to conform to the EEC low voltage and EMC directives and CE marked accordingly.
Care should always be taken to ensure the drum is adequately ventilated before applying heat
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8.2.5 IBC - Bulk Container Heater |
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| IBC/A |
IBC/B |
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Application
The IBC container heaters are designed to heat products stored in 1000L intermediate bulk containers.
Two types of heater are available: The IBC/A is a silicone mat heater for placement below the container liner before filling.
An insulation jacket covering the four sides and the lid is also available to aid warm up time. The second type is the IBC/B, an insulated heater jacket,
which covers all four sides of the container and has an optional insulated lid.
Construction
The IBC/A silicone mat heater comprises of a high temperature resistance wire element laminated between
silicone/glass sheets. A PTC temperature sensor is also embedded between the sheets. This connects to an electronic temperature controller
via the heater power cable and provides accurate measurement and fast response to temperature changes at the bottom of the IBC liner.
This makes the heater suitable for both high-energy absorbing products and highly viscous, temperature sensitive materials.
The heating element of the IBC/B heater is stitched into an insulated jacket made from a water resistant, teflon coated poyester,
insulated with a stitched blanket of needled silica glass. This comes complete with release buckles for ease of installation and removal.
The jacket has two separate heating circuits for its up-per and lower halves. Each circuit is controlled by an integral capillary thermostat.
Technical Data
All IBC container heaters come complete with 2 metres of power cable and an electronic controller with digi-tal readout (IBC/A) or two capillary thermostats (IBC/B) (see table).
| type |
power |
controller |
heat-up time
(without insulation lid) |
heat-up time
(with insulation lid) |
| IBC/A |
2700 W |
0 - 90°C
(electronic) |
water from
15°C to 70°C: 42 h |
water from
15°C to 70°C: 30 h |
| IBC/B |
2 x 1000 W |
-5 - 40°C or 0 - 90°C
per circuit |
water from
15°C to 55°C: 56 h |
water from
15°C to 80°C: 56 h |
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8.3 Micanite Flat Heating Elements |
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MICANITE is a kind of insulation paper which is impregnated with a heat resistant
binder and afterwards pressed in several shifts under heat and high pressure
to plates. This material is heat resistant up to 450°C (as special construction
up to 600°C) and is used for the wire wound formers as well as for the
encapsulating cover plates. Because of the typical "sandwich"-construction
of Micanite Flat Heating Elements and their high watt density it is necessary
to use a platen to press the element onto the surface to be heated.
Established on the market for round Flat Heating Elements
are some standard dimensions (Æ 58 / Æ 65 / Æ 80 / Æ 100 / Æ 160 / Æ 260 mm). But normally Micanite Flat Heating Elements
are constructed on customer’s request.
Micanite Flat Heating Elements can be metal sheathed for higher mechanical stability. This makes the heater flexible, so that
it is also possible to build a band heater. |
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8.4 Nomex Band Heaters |
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| NOMEX Band Heaters are an economic solution for those applications where a
flexible heater with low watt density (max. 1,5 W/cm²) and for max. operating
temperatures up to 250°C is needed. The application range covers baby bottle
heaters as well as motor stoppage heaters. The reachable surface load depends
on the contact pressure at the body to be heated. |
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8.5 Ceramic Flat Heating Elements |
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| CERAMIC Flat Heating Elements are suitable for high temperature applications exceeding
450°C. They are also brought into action where a heat storage capacity is needed. |
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