Silicone-Rubber-Heaters

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Element Construction

Wire-Wound Element Construction

Silicone Rubber heaters with wire-wound elements provide excellent physical strength capable of withstanding repeated flexing without compromising the life and performance of the heater. They are also very effective for manufacturing geometrically challenged shapes, including three dimensional ones. The wire-wound process is recommended and preferred for small to medium size quantities, medium to large size heaters, and to produce prototypes to prove out the design parameters prior to entering into large volume production runs when using etched foil.

Etched Foil Element Construction

The etched foil heater has exceptional heat transfer compared to wire wound elements, due to its large flat surface area. It can deliver more uniform heat profiles with higher watt densities, providing longer operating heater life. It can also be zoned with distributed wattage or separate heating circuits to compensate for load variations. The etched foil process is recommended for small size heaters in large quantities.

Lead Exit Locations

Lead Exit A

Exit together, centered on heater width

Lead Exit B

Exit together, to one side of the heater width

Lead Exit C

Exit together, to one side of the heater width

Lead Exit D

Exit opposite ends, centered on heater width

Lead Exit E

Exit opposite ends, to one side of the heater width

Lead Exit F

Exit together, centered on heater length

Lead Exit G

Exit together, to one side of the heater length

Lead Exit H

Exit together, to one side of the heater length

Lead Exit J

Exit opposite ends, on the same side of the heater length

Lead Exit K

Exit together from the center of the heater surface

Lead Exit L

Exit together the edge of a round heater

Lead Exit M

Exit together at a corner

Customer Specified

Lead exit specified by customer. Please include drawing when submitting to Tempco.

Electrical Terminations

Teflon® Coated Lead Wire

Tempco's standard leads are 10" long, Teflon® insulated, flexible, stranded, plated copper wire. Stripped: 1/4"

UL1180 rated 300V 200°C
UL1199 rated 600V 200°C

The lead connections are insulated with vulcanized silicone rubber, which also acts as a strain relief.

HPN Cord

For portable heaters, a two-conductor neoprene cordset can be vulcanized to the heater in any desired length.

HPN Cord and Plug

A two-conductor neoprene cord and plug set can be vulcanized to the heater.
Standard Length: 6 ft. (1.83 M), 7 ft. (2.13M), or custom length as specified.
Supplied with standard straight blade ungrounded plug, or grounded plug. 120Vac only.

2-Pole 2 wire non-grounding (NEMA 1-15P)
2-Pole 3 wire grounding (NEMA 5-15P)

SJO Cord

For industrial applications, SJO heavy duty power cords can be attached to the heaters in any desired length.

SJO Cord and Plug

SJO heavy duty power cord and plug set can be attached to the heaters. Standard Length: 6 ft. (1.83 M), or custom length as specified. Supplied with standard straight blade ungrounded plug, or grounded plug. 120Vac only. (For 240Vac see page 15-15 for optional plugs)

2-Pole 2 wire non-grounding (NEMA 1-15P)
2-Pole 3 wire grounding (NEMA 5-1

Silicone Rubber Leads

Ensures a moisture seal on the heater. Due to the similarity in material, the heater will fuse to the leads during the vulcanization process. Silicone rubber leads are more flexible, but are not as abrasion resistant as Teflon® leads.

Termination Options

Crimp connectors

Crimp Connectors: insulated or non-insulated

Ring Terminal
Spade Terminal
1/4" Female Straight Disconnect
1/4" Female Right-Angle Disconnect
Miniature Connectors: example – Molex

Plugs

Standard 120 or 240 Vac – straight blade
Twist locking plugs, 120 to 480 Vac
Specify NEMA or manufacturer's part number

Built-Up Molded Lead Exit

Used to encase lead exit and optional snap action thermostat.

Shown with SJO cord rated -50°C to 105°C.

Sleeving

Various materials can be put over Teflon® or Silicone Rubber leads to provide mechanical or abrasion protection. The leads exit the heater as a single unit.

Silicone Rubber/Fiberglass Sleeving (356°F/180°C)
Heat Shrink Sleeving

Mounting Methods

PSA (and PSA Plus)

For ease of attachment, specify PSA. Installation is simple: just peel off the protective liner and apply. It will adhere to most clean smooth surfaces. Care must be taken when installing to attain a smooth, consistent, uniform bond to achieve maximum results.
Maximum Temperature:
Continuous – 300°F (149°C)
Intermittent – 500°F (260°C)
Recommended Watt Density:
Under 5 W/in2 (0.78 W/cm2)

PSA Plus
A layer of aluminum foil is vulcanized to the back of the heater for added
heat dissipation prior to the application of PSA.

Factory Vulcanizing

Flexible heaters can be factory vulcanized to bare or anodized aluminum, Stainless Steel, Marble, or other hard surfaces for permanent attachment and excellent heat transfer.

The uncured silicone rubber heater is placed on the metal part and placed in the vacuum oven where the heater vulcanizes and adheres to the part in one operation. This procedure forms an extremely strong permanent bond with most metals due to the fact that the silicone rubber flows into and fills the micro structure in the surface of the metal. The metal part can be manufactured by Tempco or supplied by the customer. Consult Tempco for other materials including granite.

Magnetic Mounting

A flexible magnetic material can be attached to the back of a silicone rubber flexible heater. Will adhere to many varieties of steel. Ideal for those situations were you need to "Slap On" some heat! Specify when requesting a quote.
Maximum Temperature: 200°F / 93°C
Maximum Watt Density: 1 W/in2 (0.16 W/cm2)
Maximum Width: 24" (610 mm)

Field Applied Adhesive

Products Temporarily Unavailable for Individual Purchase

For a field applied permanent bond, a room temperature and ambient humidity curing silicone rubber adhesive is recommended. Tempco offers two types that will retain physical and electrical properties up to 500°F (260°C).

When using RTV adhesive, cover the heater completely with a thin layer of RTV, position the heater in place, and use a small roller to remove air bubbles, which could cause hot spots and lead to premature failure of the heater.