Screen-Printed Flexible Heaters: Innovative Heating Solutions

July 5th, 2024 Printed Heaters

Introduction

Screen-printed flexible heaters, utilizing the printed electronics method, are revolutionizing the field of heating technology. These heaters are developed through precision screen printing to apply conductive or resistive inks on flexible substrates. The inks consist of materials such as functional carbon, silver, or positive temperature coefficient (PTC) elements. Commonly used substrates include polyester (PET), polycarbonate, and polyimide, such as Kapton RS conductive films.

Advantages and applications of screen printed flexible heaters

Applications

These flexible printed heaters find applications in various industries, including food service, aerospace, consumer products, medical and healthcare, as well as electronic and electrical sectors.

Screen-printed heaters, in contrast to traditional wired heaters, provide significant benefits. They are lightweight, thin, and easily conform to different shapes, providing superior flexibility and comfort. Their excellent bend radii depend on the chosen materials and heater thickness. Printed heaters enable applications that were previously unattainable with wired heaters.

Industrial Controls and Transportation Industries

Printed heaters have a wide range of applications in industrial controls, including floor heating, lab heaters, and heating systems for manufacturing and industrial machinery. In the transportation and automotive sectors, they are utilized for battery warming, spacecraft temperature regulation, defrosters, defoggers, and floorboard warmers.

Advantages

These screen-printed flexible heaters offer versatile and efficient heating solutions across diverse industries, providing lightweight, conformable, and reliable performance.

These heaters offer numerous advantages and have a wide range of applications. Here are some details about these innovative heating solutions:

Customizability:

One of the key benefits of screen-printed flexible heaters is their ability to be customized according to specific requirements. The screen-printing process allows for precise control over the configuration, dimensions, and resistance values of the heaters. This customization enables their use in various applications across different industries.

Energy Efficiency:

Printed heaters are designed to provide efficient heat transfer. The use of conductive or resistive inks on flexible substrates ensures uniform heating distribution. This efficient heat transfer not only saves energy but also enhances the overall performance of the heating system.

Lightweight and Thin:

Compared to traditional wired heaters, screen-printed flexible heaters are lightweight and thin. This characteristic makes them ideal for applications where weight and space constraints are significant factors. They can be easily integrated into products or systems without adding bulk or compromising design aesthetics.

Conformability:

The flexibility of these heaters allows them to conform to various shapes and contours. They can be bent, curved, or wrapped around objects without affecting their performance. This conformability makes them suitable for applications where heating elements need to follow complex shapes or fit into tight spaces.

Wide Temperature Range:

Depending on the materials used and construction techniques, screen-printed flexible heaters can operate within a wide temperature range. From low-temperature applications like mirror defoggers to medium-temperature industrial processes, these heaters can be tailored to meet specific temperature requirements.

Rapid Heating Response:

Printed heaters offer fast and responsive heating capabilities. They can reach the desired temperature quickly and efficiently, reducing the warm-up time for applications.

Durability:

The materials used in screen-printed flexible heaters, such as silver or carbon inks, are highly durable and resistant to wear and tear. This durability ensures a longer lifespan and reliable performance, even in demanding environments.

Safety:

Printed heaters are designed with safety in mind. These heaters eliminate the risks associated with exposed wires or hot surfaces, making them a safer heating solution.

Cost-Effective:

The manufacturing process of screen-printed flexible heaters allows for cost-effective production, especially for large-scale or customized orders. This affordability, combined with their energy efficiency, makes them an economical choice for various industries.

Overall, screen-printed flexible heaters offer a versatile, efficient, and reliable heating solution for a wide range of applications. Their lightweight design, conformability, and customizability make them an attractive choice of industries such as aerospace, automotive, medical, consumer products, and more.

Marathon’s Flexible Printed Heaters

Marathon specializes in the production of flexible printed heaters.

Silver Ink Printed Heaters

The Silver Ink Printed Heaters are developed through a screen-printing process that deposits a silver-based conductive ink on thin sheets of polyethylene terephthalate (PET). The heaters are designed with specific configurations, where the width, length, and thickness of the silver ink line dictate the resistance value. These heaters are ideal for base metal surface plate heating, reaching temperatures of up to 80°C.

Carbon Ink Printed Heaters

Carbon Ink Printed Heaters, also manufactured by Marathon, are produced using a screen-printing process that deposits carbon ink on a flexible and thin PET substrate. These heaters are commonly used in battery warming systems.

PTC (self-regulated) Printed Heaters

PTC materials exhibit an increase in electrical resistance as temperatures rise. With printed heaters, this characteristic limits current flow as the temperature of the heating element increases. PTC printed heaters find their main applications in mirror defoggers and electronic products.

Kapton RS Heaters

Kapton RS heaters are designed for industrial applications requiring higher temperatures and where flexibility is less critical. They are commonly utilized in aerospace applications, automotive interior heating, laboratories, and wind turbine deicing.

Medical Laboratory Applications

In medical laboratories, flexible printed heaters, such as those offered by Marathon, play a crucial role in warming blood and fluids, ensuring optimal conditions for various procedures.

Conclusion

Screen-printed flexible heaters utilizing the printed electronics method are revolutionizing the field of heating technology. These innovative heaters offer numerous advantages over traditional wired heaters, including lightweight and thin designs, conformability to various shapes, and customizability to meet specific requirements.

With their versatility, efficiency, and durability, screen-printed flexible heaters provide reliable heating solutions across diverse industries. They not only offer improved performance but also enhance safety and cost-effectiveness. As technology continues to advance, these heaters will undoubtedly play a crucial role in meeting the evolving heating needs of various sectors.

Explore more about industrial heaters at Marathon Heater and experience the innovation in heating and sensing technologies.