Printed Heater
Printed Heater
Resistor or conductor paste is screen printed on top of a substrate to create printed heaters. It can be printed directly onto the surface that has to be heated, greatly increasing the heating efficiency. The user application and design specifications are taken into consideration while choosing inks and substrates. There are various types of printed heaters, including thick film heaters on metal and ceramic surfaces and flexible printed heaters.
1. Flexible Printed Heater
Flexible Printed Heaters are directly printed on polyester (PET), polyimide (PI), polycarbonate, etc. according to user requirements and specific operating parameters. Flexible printed heaters are based on positive temperature coefficient (PTC) materials that enable the heater to control its desired temperature or on fixed resistance heater designs that require a control circuit to control the temperature.
The heater can be easily mounted using pressure-sensitive adhesive, field-applied adhesive, Velcro, etc., according to the requirement.
It has advantages over conventional heaters such as being light weight, flexible to take place, providing uniform heat distribution, etc.
2. Thick Film Heater on Ceramic and Metal
Thick film heaters are developed using thick film materials such as conductive, resistive, and dielectric on alumina, aluminum nitride, stainless steel, and aluminum. These heaters offer fast response time and uniform heat distribution in a low-profile heater design.
Thick film heaters are widely used in high-performance, high-reliability, energy-efficient, limited-space, and high watt density applications. They can be applied to complex shapes to produce targeted heat.
Thick film heaters are divided into two types according to production:
- Printed on metal substrate
- Printed on ceramic substrate
Substrate: Alumina / Stainless Steel / Aluminum Nitride etc.
Features of Flexible Printed Heater
- Uniform and fast heating
- Low out-gassing
- Flexible, lightweight, durable, safe and reliable
- Water and acid resistant
- Minimal material waste, resulting in lower production costs compared to etched heaters, where sheets are chemically etched to create the circuit
Features of Thick Film Heater
- High operating temperature up to 600°C (932°F)
- Low thermal mass – fast temperature ramp-up and cool-down
- Excellent control over heat distribution and temperature uniformity
- Uniform and quick temperature rise
- Easy assembly and disassembly – cost savings
- Temperature sensors and controls can be incorporated
- No outgassing with inorganic systems and chemical resistant
- Vibration and shock resistant
1. Technical Specifications of Flexible Printed Heater
| Parameter | Specification |
|---|---|
| Max Length | ~ 25 inches |
| Max Width | ~ 20 inches |
| Thickness | 0.056" standard, other thickness available |
| Watt Density | 0.2 W/cm² |
| Wattage Tolerance | +5%, -10% |
| Maximum Temperature | Permanent up to 90°C (100°C for short periods) |
| Voltage | 1 V to 240V AC or DC |
| Heating Element | Silver / Carbon / PTC |
2. Technical Specifications of Thick Film Heater
| Material | Alumina | Aluminum Nitride | Stainless Steel |
|---|---|---|---|
| Thermal Conductivity (W/m·K) | 20 | 170 | 15 |
| Watt Density (W/m²) | 23 | 150 | 75 |
| Max Temperature (°C) | 600 | 450 | 350 |
| Coefficient of Thermal Expansion (×10⁻⁶/°C) | 7 | 4.6 | 12–15 |
| Voltage (V) | 240 | 240 | 240 |
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