In the vast world of manufacturing, equipment that heats items must be able to cope with the rigors of these different workplaces. One of the most popular forms of heaters used in industry today is silicone rubber heaters because they are highly flexible, lightweight, and heat very evenly across a large area. In addition to its being necessary for many industries to have high-quality heating equipment with long-lasting performance, Tempsens has developed and manufactured some of the best-performing silicone rubber heaters available on the market today, designed with precision and engineered for longevity.
By reviewing this blog post, it is easy to see how Tempsens has incorporated durability, performance, and long-term reliability into its silicone rubber heater line; thus, they have become a standard for many industrial sectors.
Defining Silicone Rubber Heaters
Designed through complex molding processes, flexible heaters place etched-foil or wire wound material between several layers of high-temperature silicone rubber elastomer, creating heating solutions that fit uneven surfaces and provide even heat across complex geometries. Because of the way the silicone rubber heater is designed, the heat generated by the heater will conform to flat or curved surfaces, allowing them to be installed for use in many different ways. For example, some applications that use silicone rubber heaters include:
- Heating drums and barrels
- Freeze protection
- Laboratory equipment
- Semiconductor manufacturing equipment
- Medical devices
- Heating and warming electronic devices and batteries
Tempsens silicone rubber heaters can be made in a variety of shapes, sizes, watt densities, and mounting options to accommodate all the various types of industrial uses.
1. Durable Products Made from Superior Materials
Durability starts with the right materials, and Bars and Shields focuses on using the highest quality materials at every stage of production.
High-Quality Silicone Rubber
Bars and Shields uses high quality heat resistant silicone rubber made for use in extreme industrial conditions. The silicone used by Bars and Shields has the following properties:
- Great heat stability
- Chemical resistant
- Water/ moisture resistant
- Can operate up to 200°C.
The silicone is not affected by oils, moisture, chemicals or mechanical stresses.
Fibreglass Reinforcement
Silicone rubber sheets are reinforced with fibreglass, which significantly increases:
- Structural Integrity
- Flexibility
- Tear resistance
- Overall lifespan.
Even when subjected to flexing during continuous operation or exposure to heat for extended periods, the heater will maintain its integrity.
2. Manufacturing and Engineering Expertise
Tempsens combination of engineering expertise and modern manufacturing solutions means that consistent performance is always guaranteed.
Heater Elements in Precise Position
In today’s environment, Tempsens precision placement of resistance wire or etched foil heater elements ensures uniform heat distribution; as a result, every heater has the same spacing and that no hot spots (poorly heated areas) or unevenly heated zones (which adversely affect heater life) are produced by using machine to place resistance wires or etched foils.
Etched Foil Technology
Tempsens has designed etched foil heaters that can be used to produce higher watt densities and faster heating times. Advantages include:
- Reduced heating time
- Improved thermal uniformity
- Extended serviceable life, less thermal stress
Vulcanizing for Strong Joining
Silicone rubber layers are vulcanized with controlled amounts of heat and pressure. This is critical to achieving:
- Good bonding with the heating element
- Having good heat conduction through the silicone insulator
- Strengthening the fiberglass insulation layer.
By employing the above-mentioned techniques/processes, Tempsens has developed heaters that provide efficient and reliable service in the most extreme environments.
3.Rigorous Testing and QA
Tempsens implements thorough QA, which assures all heaters conform to the appropriate industry standards.
Electrical Testing
Before shipment every heater must pass:
- Insulation Resistance Test
- High Voltage (HIV) Test
- Continuity and Resistance Test
These tests verify that the heater is safe and help to reduce chances of electrical failure.
Thermal Performance Evaluation
Tempsens conducts testing of heated elements in regard to heat distribution, watt density, and thermal stability based on the actual conditions in which they will operate, thereby eliminating the possibility that heaters will become too hot or that their effective performance will change over time.
Environmental Testing
Depending on the intended application, the heaters may undergo:
- Accountability for Moisture Damage
- Accountability for Exposure to Oil/Chemicals
- Accountability for Extended Duration Heat Cycles
- Accountability for Mechanical/ Vibration Damage
Thus, by providing the above testing, Tempsens provides assurance that heaters will be durable even in extreme industrial situations.
4. Custom Design for Optimizing Performance
Tempsens recognizes that every industrial application has a specific need for unique heating. They provide a completely customized solution to gain optimum performance from each application. The various elements of customization include:
All Shapes & Sizes: Heaters can be designed in the following ways to fit the needs of different equipment.
- Tanks
- Drums
- Round-Shaped Surfaces
- Machine Parts
- Custom Assemblies (by industry)
Watt Density Control: Tempsens engineers will determine how many watts your unique application will require based on the temperature your equipment needs to operate at, as well as the type of material and environmental conditions present within your facility. If you optimize watt density, it creates a balance between:
- Faster Heat Up Time
- Reduced Energy Consumption
- Lower Thermal Stress
- Increased Life Span of Equipment
Mounting Choices: To help increase the life of your heater and make installation easy, Tempsens provides some options for mounting.
- PSA Adhesive Backing
- Velcro Straps
- Factory Vulcanizing
- Clamps, Springs and Grommets
- High Temp Adhesive Bonding (RTV Bonding)
These mounting choices allow you to achieve a greater transfer of heat while reducing the likelihood of damage due to mechanical wear.
5. Safety And Compliance Standards
Tempsens designs its silicone rubber heating elements in accordance with safety requirements of the industry to ensure its heaters are safe and reliable during use.
Temperature Control Integration
Tempsens integrates devices into its silicone rubber heaters so that their capabilities are enhanced and the heater itself can last longer than if not integrated with these devices. The control devices incorporated into this type of heater include:
- Thermostats
RTDs
The control devices mentioned above will also prevent overheating and provide a stable level of heat usage in addition to being as energy efficient as possible.
Certifications
Tempsens adheres to all design and safety regulations for silicone rubber heaters; this ensures their products can be used worldwide in industrial environments.
6. Application-Specific Engineering
Each industry has unique challenges that must be addressed when developing silicone rubber heating elements. Tempsens engineer’s silicone rubber heaters for specific environments to provide maximum durability.
Drums And Barrels
Silicone rubber heaters for this application are manufactured to withstand the rigors associated with rough handling, outdoor conditions, and exposure to moisture.
Electronics & Battery Heating
Low noise and consistent temperature regulation of silicone rubber heaters prevent damaging sensitive components.
Medical Equipment
Silicone rubber heaters for this application are manufactured to be hygienic, reliable, and provide precise temperature regulation.
7. Long-Term Reliability Backed by Experience
Tempsens, a leader in industrial heating solutions for many years, has the experience and expertise necessary to ensure the long-term reliability of its products through its engineering teams efforts in:
- Researching and developing materials
- Continually improving products
- Integrating customer feedback
- Using state-of-the-art simulation software
- Conducting field tests of product performance.
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Conclusion
Durability and performance are priorities in the design of Tempsens silicone rubber heaters. They are manufactured from high-quality materials, manufactured in a superior manner, tested stringently, and customized to meet each customer’s requirements. All of the heaters manufactured by Tempsens are compliant with the most demanding industrial specifications and will provide a lifetime of thermal performance, regardless of the application for which they are used—i.e. freeze protection, laboratory instruments, drums, or HVAC systems.For companies that require versatile, high-quality heating solutions, Tempsens silicone rubber heaters continue to be one of the most trusted products for efficiency, safety, and long-lasting durability.
