Flexible heaters are the most reliable and effective type of industrial heating often used in a specific industrial setting. Typical applications include specific and general industrial settings like food service equipment, lab equipment, incubators, credit card scanners, and automotive. The high accessibility of custom heaters is proof that the heating system does its intended function without failure.
They come in different materials to match the requirements of the application and client. Common materials include:
Polyester heater,
Silicon rubber heater, and
Kapton heater.
How does it work?
The process itself is very straightforward. The flexibility of the film heaters enables taking any shape of the surface when used inside or outside products. Usually, this flexibility delivers adequate heat for a particular application and in a specific area without compromising any function.
The flexible heating elements work on the principle of temperature control to ensure the heat needed is enough to prevent damaging the application, circuitry, or heater materials. Nonetheless, the control system differs from how the heater is customized and priced.
The control system also works using the following:
Thermostat: This temperature sensor monitors and controls the amount of heat around the silicon heater. It senses heat through the line and ambient sensing. The thermostat uses a bimetallic strip to connect the electrical circuit and the heating system. The heater turns on when electricity passes through the strip, making one metal piece bend. The heater shuts down, i.e. turns off, when bending is too much.
Thermistor: This is a temperature sensor, also known as a thermal resistive resistor. A thermistor provides higher resistance levels than the conductor and lower resistance than the insulator. The function of a thermistor decreases when the temperature increases. The controllers in the flexible heaters pick the thermistor resistance and adjust it according to the set point. Plus, the thermistor material will detect and control the temperature curve.
Here are the control systems for the industrial silicone rubber heaters:
On/Off Switching
This is the most basic type of custom temperature control. When the temperature is below the desired point, you switch it on and allow it to stay that way until it reaches the set point; then, it goes off.
However, this control system is unstable. The on-and-off cycle fluctuates depending on the rise and fall of the temperature.
Proportional Controller
Usually, the proportional controller lowers the power of the flexible Kapton heater when it gets to the set point. Because there’ll be remaining heat in the heater’s wire or etched foil heating, this controller will use the low energy output to push the flexible heater to the desired set point.
Several proportional controllers use a timed system where the on/off switching wavers. Still, this controller can slightly allow the temperature to pass the set point.
Proportional Integral Derivative Controller
This advanced control system uses an advanced digital algorithm to prevent the dropping and wavering of the on/off switching.
PIDs feature regulating methods for ideal control. The sensors can make particular decisions using factors besides temperature feedback.
Hi-heat heaters are the perfect investment for your industrial processes. Here’s how custom heaters can benefit your facility;
Efficiency
A significant advantage of flexible heaters is enabling system efficiency. Consider significant factors like insulation, airflow, coverage area, and climate to make the most of your rubber heaters.
These are vital components of efficiency. This way, it becomes easy to install the custom heater and know which type and size would be ideal for particular facility requirements. Thus, you can prevent the risk of using excess power and prolong the flexible heater’s life.
Control
Each industrial space has to keep up with specific standards that enable successful operations. So, despite the technology and equipment of your facility’s system, it’s essential to ensure you have complete control of the processes.
A polyimide heating solution provides complete control. You can adjust or maintain all vital factors like temperature, airflow, climate, and more.
Design
A significant benefit of custom heaters is getting a solution that comes in a specific design. In hi-heat industries, you have control over aesthetics allowing you to choose a particular shape, form, and installation area.
This way, you choose to display your flexible silicon heater or build it in the ceiling, walls, or machinery. Better still, you can tell the manufacturer to customize your heater to match the surrounding area.
Easy Specialized Processes
If your industry requires unique processes, opting for a flexible Kapton heater is your best bet. This works for facilities that expect unique processes to enable efficient manufacturing and maintain a particular in-house setting.
Specialization put facilities ahead of the competition. You get everything working systematically in a unique way, just meant for your facility.
Works Better Than Standard Equipment
Between standard and custom heaters, the latter comes on top. Flexible heaters are uniquely built to meet specifications that are particular to the industry requirements. Standard heaters cannot compete with such settings.
Generally, standard equipment can’t care for every facility’s needs. Conversely, unique custom heaters are easily adjusted to fit or complement the needs.
Lifespan
Choosing high-quality custom-designed silicone rubber heaters enables you to prolong the lifespan of the heating elements. By properly customizing your heating system, you can easily adjust the system to work optimally in particular environments and conditions without overloading the system.
Several standard heating solutions are not suitable for large spaces or tedious processes. Some tend to overheat or stop when overworked. Fortunately, custom heating elements prevent the risk of premature damage and breakdowns to allow adequate unit control.
Long-Term Investment
In the long term, integrating polyimide heaters into your industry processes is cost-effective. Standard heating systems require constant repairs and alterations caused by a conflict between the system and facility needs.
These are not common problems with custom heaters. You can easily adjust your polyimide Kapton heater to work best with your particular conditions.
Final Thoughts
Do you need a custom heater? The above guide answers you profoundly to ensure you make the right choice.
A custom heater is a go-to solution for industrial processes, whether solely or partly. The best part is choosing what works for you and where to put it. Most importantly, flexible heaters are safe because they never exceed the desired temperature. Eventually, the benefits speak for themselves.
