Silicone Rubber Heaters
Durex Industries' custom silicone heaters take advantage of the unique properties of silicone rubber to provide flexible heating elements of unparalleled performance. Silicone rubber is calendared onto fiberglass cloth in a variety of thicknesses and constructions which serve as the basis for Durex's flexible silicone heaters. Generally, two layers of material containing an etched foil element or a precision wire wound element are vulcanized together to form a basic silicone heating element.
Although most silicone heaters are manufactured in a flat flexible heater shape, Durex regularly manufactures silicone rubber heaters in a variety of formed shapes. Forming can provide superior heat transfer, and ease of installation by the customer. A typical design would be a cylindrically shaped heating element that "snaps" onto a pipe of the same diameter. Using proprietary techniques, Durex can form silicone rubber heaters into more complex shapes depending on the customer's requirements.
- Custom flexible heater prototypes
- A collaborative process that optimizes both your technical and business requirements
- Efficient in-house upfront FEMA process to assess application risks
- In-house circuit design and photo tool production
- CNC controlled state of the art cutting machine that eliminates the need for most steel rule cutting dies
- Agency Approvals and years of experience with approval navigation
- Components and sub-assemblies designed to increase your production line velocity
- Built-in standard quality checks with customer specific attributes included if desired
- Rigid document control system to lock down the prototype outcome
- Flexible delivery systems that adapt to your company’s enterprise system
- ISO 9001 certified system
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- Custom flexible designs
- High dielectric strength and resistance to dielectric fatigue
- Ozone, weather, and chemical resistant
- Flame retardant and non-toxic
- Low outgassing with no sulfur or nitrogen to create hazardous compounds that are prevalent in organic rubbers
- Proven thermal stability
Etched Foil Elements
Starting with a Durex engineered photo tool, Durex photo develops and then chemically etches a highly precisioned, resistive foil circuit, to be vulcanized internally into a silicone heating element. Durex's silicone etched foil elements can have internal element coverage of greater than 50% of the entire flexible heating element area. This coverage lowers the internal heating element temperature providing longer heater life. Etched foil heaters are superior for high watt density and higher temperature operation. In addition, because the circuit trace width can be varied in the design and manufacturing process, etched foil elements are ideal for distributed watt densities within the same heating element. Durex's efficient production methods result in etched foil being the better choice for low cost, high volume runs of smaller size heating elements.
Wire Wound Elements
Beginning with a computer designed, dedicated, winding pattern and tool, Durex manufactures precision wire wound silicone rubber heaters. Durex engineers select various combinations of resistance wires to be combined or stranded together to produce the optimal result. In many cases the resistance wire is wound around a fiberglass core for added strength and flexibility. Durex's silicone heating elements may incorporate parallel redundant circuits depending on the application and electrical requirements. Wire wound silicone heaters are generally most suited for larger heating elements, low watt densities, and smaller production runs.
Durex can provide its flexible silicone rubber heaters with a variety of thermal insulation in varying thickness and material types. For silicone rubber heating elements, silicone sponge form ⅛" to ½" is commonly provided. Kapton® heaters can be provided with silicone or engineered insulations depending on the requirements of the environment. Due to the efficiency of silicone rubber and Kapton heating elements, insulation is most often desired to reduce heating element surface temperature.
Heater Agency Approval
Durex offers flexible heating element component recognition for both UL and Canada under UL file number E110394. Durex is continually increasing its product offerings and options under component recognition. Please call Durex for the latest inclusions. In addition, Durex product support can be a valuable resource in seeking approval for UL listing on OEM equipment as it relates to issues with heating elements as Durex has helped many OEMs with certification issues.
Flexible Heaters - Silicone Rubber & Kapton® 08-04-14 1.6MB