Silicone Rubber Heater
- Lightweight, thin, flexible - as thin as 1.0 mm
- Custom shapes including cutouts, slots and irregular profiles
- Etched foil resistive element, uniform heating
- -50°C to 200°C continuous operating temperature
- Moisture and chemical resistant, optionally IP67
- Multiple installation methods available
- Built-in temperature sensors
- Thermal insulation or thermally conductive overlayer
- UL & CE approvals
Why Choose Silicone Rubber Heaters#
Flexible Heaters come in several forms — polyimide (Kapton), silicone rubber, mica, and Teflon being the most common. Each has its strengths, but silicone rubber stands out in two areas that matter most for demanding OEM applications.
True 3D conformability. Polyimide Heaters are flexible, but their flexibility is essentially two-dimensional — they bend, but do not stretch. Silicone rubber, by contrast, is elastic and can conform to compound curved surfaces, irregular housings, and complex 3D profiles that no other flexible heater can match.
Unmatched customizability. Silicone rubber heaters can be custom-manufactured across virtually every dimension: surface finish, fiberglass or reinforcement-free construction, factory vulcanization onto metal profiles, integrated sensors and thermostats, custom connectors, and waterproof press-molding up to IP67. This depth of customization is simply not available with Teflon or mica heaters.
The result is a heating element that doesn’t just fit your device — it becomes part of it.
Etched Foil vs Wire Wound Silicone Heaters#
Silicone rubber heaters are available with etched foil elements or wire wound elements. Wire wound elements are wired manually according to a pre-defined meander via the guide pins on the pattern board. Except for irregular-shaped 3D profiles or long silicone heating tapes , wire wound technology has been phased out at SINOMAS.
The etched foil silicone rubber heater has exceptional heat transfer compared to wire wound heaters due to its large flat contact surface. It can deliver more even heat profiles with higher watt density, providing longer service life. Besides chemical etching, for quick prototyping or large sized heating blanket, we can also manufacture the foil element by laser cutting.
Factory Vulcanized Silicone Rubber Heaters#
Through a controlled process of heat and pressure, silicone rubber heaters can be factory vulcanized onto plain or black anodized aluminum, stainless steel or other metal profiles / panels. The silicone rubber actually flows into the microstructure of the metal profile forming a permanent bond and allowing the most efficient heat transfer.
Factory vulcanized heated metal profiles have superior performance compared to any field installation. Factory vulcanization allows silicone rubber heaters to be designed at higher watt density and increases heater life. While the max watt density for standard silicone heater is 0.8 watts per cm2, factory vulcanization onto aluminum can support up to 3.0 watts per cm2 if the operation temperature is controlled.
By a similar process but without a heat sink, silicone rubber heaters can be factory vulcanized / pre-formed into a shape (mostly cylindrical or spiral) permanently. The preforming greatly facilitates the installation of silicone rubber heaters on pipes, cylinders of small diameter and inside fitting in metal drums.
Waterproof Silicone Rubber Heaters (IP67)#
Silicone rubber heaters are generally moisture-proof. Additional edge sealing will be enough for occasional water spray. If the heater pad is to operate under water for extended periods, the whole heater has to be press-molded to prevent moisture ingress through the fiberglass-reinforced edges. In this case, the thickness of heater pad will increase to about 2.6mm. Integrated temperature sensors are also possible.
The waterproof silicone rubber heaters are very useful for humid environments or even fluid heating where conventional immersion heaters can’t be installed due to space or mounting constraints. For example we have delivered silicone heating elements (2W/cm2) for portable hot water kettles, and heating blankets to maintain the temperature in greenhouses.
Silicone Foam Insulation#
Silicone foam insulation can be bonded to silicone rubber heaters to minimize heat loss and improve efficiency. Its closed-cell structure traps air, acting as a thermal barrier that directs heat toward the target surface instead of dissipating it into the surroundings — allowing faster heat-up and lower energy consumption.The foam layer also cushions the heater against mechanical shock and vibration, adds a degree of electrical insulation, and protects nearby components from excessive heat. Retaining silicone’s natural flexibility and temperature stability (typically -40°C to 150°C), it conforms easily to curved or irregular mounting surfaces — making it ideal for pipes and valves heating.
Installation Methods#
Silicone rubber heaters can be installed in the following ways:
- PSA adhesive backing
- RTV Adhesive Paste
- Clamping or Compression Plates
- Hooks and Springs
- Hook & Loop Fasteners (Velcro)
- Lacing/Tying
Temperature Rise Curve#
The graph below illustrates the surface temperature rise of a standard silicone rubber heater at different watt densities. In the test the samples were hung freely in an enclosed space.
The graph is supposed to give you an idea of how fast the heating can be. It cannot replace engineering calculations and testing for your specific application. The temperature in the real situation will be related to many different factors.
