Introduction

In today’s fast-paced industries, the demand for efficient and versatile heating solutions is on the rise. Silicone rubber heaters have emerged as a go-to option for various applications, offering flexibility, rapid heating, and durability. This blog post delves deep into the world of silicone rubber heaters, exploring their benefits, applications, and installation tips.

Understanding Silicone Rubber Heaters

Silicone rubber heaters are flexible heating elements that consist of a heating wire enclosed in a silicone rubber sheet. These heaters operate on the principle of converting electrical energy into heat energy, providing a uniform distribution of heat across their surface. The flexibility of silicone rubber heaters allows them to conform to complex shapes and contours, making them ideal for a wide range of applications in different industries.

Their thin design and direct bonding to the application facilitate efficient and rapid heat transfer, resulting in faster heating and lower wattage requirements. Silicone rubber heater offer a very high watt density, and their versatile design permits higher or lower heat concentration zones to meet distributed wattage requirements. They can be pre-formed to complex shapes and can withstand mechanical shock and vibration. They can also accommodate thermostats or RTDs for precise temperature controls.

Marathon Silicone rubber heaters are available in two types:

Wire wound 

This elements consist of the resistance wire wound on a fiberglass cord for support and stability. Wire wound is recommended and preferred for all large and small-sized heaters.

Etched foil heaters 

Etched foil heaters are made with a thin metal foil (.001”) as the resistance element. The etched foil heater provides 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.

Applications of Silicone Rubber Heater

Silicone rubber heaters find extensive use across various industries:

Automotive Industry:

From defrosting applications to engine heating, silicone rubber heaters play a crucial role in maintaining optimal operating conditions in vehicles.

Medical Sector:

In medical sector, silicone rubber heaters are employed for patient warming, maintaining incubator temperatures, and other vital applications.

Food Processing:

Industrial ovens, heated rollers, and other equipment in the food processing industry benefit from the uniform heating provided by silicone rubber heaters.

Electronics:

PCB heating during manufacturing processes and battery warming in electronic devices are some common applications of silicone rubber heaters in the electronics industry.

Benefits of Silicone Rubber Heaters

Silicone rubber heater offer a host of advantages:

• Flexibility and Adaptability: Their ability to conform to irregular shapes makes them versatile for a wide range of applications.
• Rapid and Uniform Heating: Silicone rubber heaters heat quickly and distribute heat evenly, ensuring efficient performance.
• Energy Efficiency: These heaters are energy efficient, helping to reduce operational costs.
• Resistance to Harsh Conditions: Silicone rubber heaters are resistant to moisture, chemicals, and extreme temperatures, ensuring durability and longevity.

Installation and Maintenance Tips

Proper installation and maintenance are essential for maximizing the performance and lifespan of silicone rubber heaters.

Installation Guidelines:

Follow manufacturer instructions for correct installation to ensure safety and efficiency.

Mounting method:

1. Pressure Sensitive Adhesive:

An easy mounting method is to peel and stick. PSA is attached directly to one side of the heater. Just peel away the protective liner and attach the heater to the desired tool. It is not recommended for curved surfaces. The heater should be installed within 6 months of manufacture.

2. Factory Vulcanizing:

Another method of installation is to send your tool to the Marathon Heater factory. The tool is placed in a vacuum cable and the SRH is vulcanized directly to the tool. This is the strongest bond available.

3. Field applied adhesive:

SRH may also be attached with field applied adhesive; Marathon Heater will supply the required RTV to adhere the heater to the desired surface. We offer a room temperature curing adhesive. Apply a thin film of RTV on the entire bottom of the heater. After positioning the heater on the part, use a roller to remove all air trapped between the heater and the part. Allow the RTV to cure for 24 hours.

4. Safety Precautions:

Always adhere to safety guidelines when installing or handling silicone rubber heaters.

5. Maintenance Practices:

Regular maintenance, such as cleaning and inspection, can help prevent issues and extend the heater’s lifespan.

Case Studies

Case Study 1: Enhanced Efficiency in Automotive Defrosting Applications

In a leading automotive manufacturing plant, the challenge of efficiently defrosting vehicle windshields during cold weather conditions was tackled with the implementation of silicone rubber heaters. Traditional defrosting methods were often slow and energy-intensive. By integrating custom-designed silicone rubber heaters into the defrosting system, the plant experienced a significant improvement in efficiency and performance.

The silicone rubber heaters were strategically placed along the windshield edges, ensuring uniform heating across the surface. This led to faster defrosting times and improved visibility for drivers, enhancing safety on the roads. The flexibility of silicone rubber heaters allowed them to conform to the curved shape of the windshield, providing an optimal heating solution without compromising aesthetics or functionality.

Moreover, the energy efficiency of silicone rubber heaters resulted in cost savings for the automotive manufacturer. By efficiently converting electrical energy into heat and distributing it evenly, the silicone rubber heaters reduced overall energy consumption compared to conventional heating methods. The durability and resistance of silicone rubber heaters to harsh environmental conditions further contributed to their long-term reliability in automotive applications.

Case Study 2: Advancing Patient Care with Silicone Rubber Heaters in Medical Services

In a renowned medical facility focused on neonatal care, maintaining precise and stable temperatures within incubators is crucial for the well-being of premature infants. The facility faced challenges with maintaining consistent heating levels due to fluctuations in ambient temperatures and inadequate heating solutions. To address this issue, silicone rubber heaters were introduced as a reliable and efficient heating solution for the incubators.

By customizing silicone rubber heaters to fit the interior walls of the incubators, the medical facility achieved precise and uniform heating throughout the incubator space. The flexibility of silicone rubber heaters allowed for seamless integration without compromising the available space or obstructing medical procedures.

The rapid heating capabilities of silicone rubber heaters ensured quick response times to temperature adjustments, providing a controlled and stable environment for the infants. The energy-efficient nature of silicone rubber heaters also contributed to reduced power consumption, aligning with the medical facility’s sustainability goals.

Customization and Design Options

Silicone rubber heater can be customized to meet specific requirements:

Tailored Solutions:

Marathon offers customization options for wattage, size, shape, and other specifications to suit individual needs.

Marathon Design Option:

There are several design options:

Ground Mesh: For grounding purposes, a second layer of insulating material and a conductive grid can be added to the heater. The heater comes with a ground wire.

Silicone Rubber Sponge Insulation: To improve heater efficiency, 1/16”, 1/8”, 1/4”, 3/8”, or 1/2” insulation can be bonded to the outside of the heater. Closed-cell silicone sponge is extremely flexible.

Round Heaters: Round shapes are also available. Round heaters are best attached to tooling with PSA.

Silicone Rubber Enclosure Heaters: Enclosure heaters are used to maintain temperature in any type of electrical box. Typical applications include ATMs.

Conclusion

Silicone rubber heaters have revolutionized the heating industry with their versatility and efficiency. As industries continue to evolve, the demand for reliable heating solutions like silicone rubber heaters is expected to grow. Explore the possibilities that silicone rubber heaters offer and stay ahead of the curve in adopting this innovative heating technology.

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

Contact us at enquiry@marathonheat.com for your requirements for any industrial heater.