Flexible Heaters - Electric Heating ElementsFax-Back Data Sheet
Our heater products warm batteries in telecommunications cabinets, dry the ink in silk screening machines, cure the film on airplane windshields, heat laboratory samples, or maintain an animal's body heat during veterinary operations, to name just a few applications.
Flexible Heaters - Silicone Rubber Heaters
These heaters can be designed and fabricated in many types of configurations to fit the size and shape required in your application.
Etched Foil  Our designers use custom software to calculate the configuration of the heating element, given the voltage, wattage and resistance.
The etched element provides superior heat transfer and exceptionally uniform heat output, which results in a faster warm-up cycle and longer life. The heaters operate in ambient temperatures from 500°F to -80°F. Advantages over wire wound heating elements:
Wire Wound  The excellent dielectric properties of silicone rubber and the strength of fiberglass combine to produce a unique heater. First, fine nickel-chromium alloy wire is spiraled onto a center core of fiberglass twine, producing a strong, flexible heating element. Precision electronically-controlled winding equipment ensures consistency.
Circuits are then hand-wound on permanent tooling providing repeatability of resistance and pattern. Parallel circuits are utilized where possible, permitting continued operation should a single circuit be damaged. When the heating element is positioned, a second layer of silicone rubber is laid over the wire. The layers are then vulcanized to permanently position the circuits. Using these versatile and flexible heaters, the ability to apply heat exactly where required is limited only by imagination—and a maximum continuous operating temperature of about 200°C (392°F). Silicone rubber heaters resist:
Flexible Heaters - Polyester Film Heaters Fax-Back Data Sheet
Etched Foil  The etched element has superior heat transfer and exceptionally uniform heat output, which results in a faster warm-up cycle and longer life. Use this heater to cover large areas with even heat, for flat or gently curved surfaces. Polyester is UL recognized with 105° C (221° F) surface temperature in the application.
Etched foil polyester heaters can be designed and fabricated in many types of configurations to fit the size and shape required in your application. Due to the resistance limits of the foil materials, as circuits become larger the economics of foil versus resistance wire become less attractive. Our designers use a custom computer-aided design program to calculate the design, given the voltage, wattage and resistance. Advantages of the etched foil versus wire wound heating elements are:
Wire Wound  Polyester film heaters have a maximum service temperature of 105° C (221° F). They are used to cover large areas with even heat, for flat or gently curved surfaces. Polyester film heaters can be designed and fabricated in many configurations to fit the size and shape required in your application.
Reliable Heating Elements Circuits are hand-wound on tooling patterns custom-designed for the appropriate resistance. Parallel circuits are utilized as possible, permitting continued operation should a single circuit be damaged. The precision wound resistance element is then positioned between two layers of polyester. Vulcanization permanently encapsulates the wire. The polyester heaters are characterized by the following:
Flexible Heaters - Catalog Heaters
Flexible Heaters - Enclosure Heaters
Depending on the application, enclosure heaters can be manufactured with wire wound or etched foil heating elements, and insulated for more efficiency. Heaters can be manufactured to be applied with adhesive or factory vulcanized to an aluminum mounting plate. We can customize the delivery in a forced air or static system. Many enclosure heater assemblies include thermostats, cords and plugs, insulation and built in controls.
Flexible Heaters - Mica - Etched Foil
Flexible Heaters - Kapton® Polyimide Heaters
These low thermal mass heaters have fast warm-ups and quick response because the elements run cooler, they have longer life as well. Polyimide’s properties and the moisture resistant construction make these heaters the preferable product in high humidity areas, wash down zones and in applications requiring repeated sterilizations. They are also ideal for service in harsh environments. Etched foil polyimide heaters can be fabricated in an unlimited range of shapes, sizes and wattages. Their thin, lightweight design (0.005" thick) allows close thermal contact for maximum heating efficiency, and also permits close adaptation to the contours of the part. Hi-Heat Industries designs these heaters with distributed wattages, eliminating edge loss compensation. Superior heat transfer and exceptionally uniform heat output result in a faster warm-up cycle and longer life. Kapton® is a registered trademark of DuPont™. Polyimide has excellent:
Flexible Heaters - Thermostats & Thermal Fuses
Temperature Sensors Mechanical Thermostats Creep Action | Snap Action
Both are based on a bimetal expansion-contraction principle and nearly all are pre-set to a specific temperature (non-adjustable). If the application requires very close temperature control an electronic controller with sensor is suggested over the mechanical thermostat. Freeze protection, enclosure temperature and high limit protection are the applications best suited for the low cost mechanical thermostat. Creep Action Snap Action
Thermal Fuses  Thermal fuses open the circuit if the heater exceeds the selected fuse temperature. They are a one time over temperature protection device that can prevent heater runaway in the event that a control device has frozen in the on position. Testing is suggested to select the location and temperature setting of the fuse to protect your product most effectively.
Fuses are preset with a range of 150°F to 460°F. Electrical ratings are 120/250 VAC and 15 amp maximum. They must be covered or enclosed because the outer case of the fuse is electrically live. Thermocouples & Resistance - Temperature Devices (RTD) These devices are most commonly very small and can be attached to the heater with a patch of silicone rubber/fiberglass. Almost any type thermocouple can be used. Type ”J” is most commonly employed. RTDs are either 100 Ohm or 1000 Ohm two conductor type. Special sensors can be provided to your specifications and we can mount customer-supplied sensors. Design Variations
Mechanical Fasteners  For applications on cylindrical parts or where the installation is temporary, eyelets with springs or snap fasteners are utilized to mount heaters. Spring fasteners allow for variations in circumference while providing close contact with the part to be heated. Many types of fasteners used for canvas or leather can be built into the sheath of the heaters.
Leads  Standard leads are eight inches long, silicone rubber insulated, flexible, plated copper wire. They are UL Style 3135 rated for 200°/600 volt operation. Location of exit is centered along the narrow side of rectangular heaters.
Lead types and exit locations are adaptable to application requirements. Perimeter exit (standard) or surface exit do not present design limitations.
Heaters Bonded to Metal Parts  Silicone rubber can be bonded to metal parts to create complete thermal sub-assemblies. Since a perfect fit between heater and part is a vital factor in heater efficiency, customers normally supply metal parts so we can bond or vulcanize the heater to the part in our factory, and thus assure optimum contact. Temperature sensors or thermostats may be integrated into these heaters, along with provisions for temperature controllers.  Three-Dimensional HeatersWe offer 3-dimensional heaters, which can be designed and built to fit perfectly around the complex contours of your part. This results in efficient heating and lower heating costs, because there are no “dead” areas. Our designers are happy to work with you to satisfy these complex design challenges. Bonding Methods Factory Vulcanization Silicone Rubber Adhesive (RTV) Pressure Sensitive Adhesive (PSA) - Polyester Pressure Sensitive Adhesive (PSA) – High Temperature Silicone
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Southeast Thermal Systems offers designs of heating elements that are either wire wound or etched foil, depending on the application and the heater’s requirements. Our products are Silicone Rubber, Polyester Film, Kapton® Polyimide, High Temperature Mica, Ceramic and Enclosure Heaters. We manufacture drop-in subassemblies with sensors, thermostats, fuses, cords and plugs. A combination of insulating materials is used.
Silicone rubber heaters provide dependable performance under rigorous conditions. Ambient temperatures down to –80°F and up to 500°F do not diminish performance.
In addition to custom-designed industrial heaters, Hi-Heat Industries manufactures standard sizes of silicone rubber heaters. These flat, flexible heaters range from 25 to 1500 watts. Pre-set or adjustable thermostats are optional. Contact us to discuss the electrical heating element that will work for you. 
Enclosures protecting electronic equipment require heaters for freeze protection and prevention of humidity and moisture accumulation. Hi-Heat Industries has developed a core competency in the protection of telecommunications hardware, networking equipment, high-tech security systems and control systems. We can lend our expertise for your application whether it is for OEM requirements or retrofitting existing enclosures.
This unit is constructed with two layers of high temperature mica with the etched foil element between layers. The heater is rigid and must be clamped in place, between two plates for good heat transfer and support during operation. Very high temperatures of up to 1100°F (595°C) can be achieved with correct application. Mica is a hydroscopic material and should not be used in high moisture areas. Watt densities in excess of 40 watts per sq. in. are possible, depending on the operating temperature of the process. Power lead exits are covered with ceramic and the lead exit area needs to be supported.
Kapton®, polyimide is a lightweight flexible film that maintains outstanding mechanical, chemical and electrical properties over extreme temperature ranges. Polyimide has more than 35 years of proven performance as the flexible material of choice in applications involving high, 200°C (392°F), and very low, -195°C (-319°F), temperatures.
Heaters can be fabricated with thermostats, thermal fuses, thermocouples and resistance temperature detectors (RTD) as an integral part of the heater.
There are two basic types of mechanical thermostats: Creep Action and Snap Action.
The creep action units are constructed with a bimetal strip that curves with the temperature excursions to provide the mechanical action of make and break for the contacts. This provides a close differential between on/off, but can cause radio frequency interference in enclosures that have sensitive electronics. The temperature setting is factory preset and has the range of between 40°F and 300°F, +/- 5°F. Maximum amperage of these units is 8 amps at 120 volts. These small thermostats are commonly used as motor protectors or over temperature protectors in appliance applications. 
Holes, Cutouts and Notches