Custom Heating Solutions

Flexible heaters give you design options that other conventional heaters can not match. Keenovo's custom heating solutions include Element Design and Integrated Components & Accessories.

Element Design

Insulation Type: Fiberglass reinforced silicone rubber or polyimide (e.g. Kapton™).
Heating Element Type: Wire wound or etched foil.
Wire Wound element uses a round resistance wire(wire harness) while Etched Foil uses a chemically etched thin & flat metal track much like a printed circuit board.

Silicone heater or Kapten Heater?

Kapton heaters(Etched foil) are ideally
suited for applications with space and
weight limitations, or where the heater
will be exposed to vacuum, oil, or
chemicals for long time.

Silicone heaters (Wire Wound ) are ideal
for small quantities and low cost sampling,
or where repeated flexing is required.
Element Patterns: Dual Voltage, 3-phase,Zoning and profiling.
Multiple heating circuits can be designed to achieve dual voltage and multiple zones. On dual voltage heaters, three leads, including a common in a specific color, are provided for wiring the heater in series for the higher voltage or parallel for the lower voltage. 120/240 Vac or 240/480 Vac can be specified.

Multiple circuit areas can be zoned to compensate for various heating effects desired.

Three-phase circuits can also be designed for large high current applications. A profiled foil element offers Distributed
Wattage and levels out temperature gradients by providing extra heat where losses occur, such as along edges or around mounting holes.

Outline Shapes: With a 3-dimensional approach, heater shapes are only limited to imaginations.
Holes, cutouts, and notches can be designed so the heaters accurately fit to the part.

Silicone heater with irregular shape 1 Silicone heater with irregular shape 2

Leads Exit and connection tab: Heater's power leads can be configured and an unheated lead exit tab can be added to the heater to eliminate cold sections or when used in a compression application to remove the bulge at lead exit area from between the plates.

Leads Exits from Center of Long Side Leads Exits/Center Long side wiht Tab Leads Exits from Center of Short Side Leads Exits/Center Short Side with Tab Leads Exits/One End Long Side Leads Exits/End Long side wiht Tab Leads Exits/One End Short Side
Leads Exits/One End Short Side with Tab Leads Exits/Two Corners Leads Exits/Two Ends Long Side Leads Exits/Round Leads Exits/Round with tab Leads Exits/Ring Leads Exits/Ring with tab

Integrated Components and Accessories

A) Heater Installation (PSA, Field Applied Adhesive, Vulcanized silicone rubber,Laminated polyimide heaters, Mechanical Fasteners:)

Versatile flexible heaters allow a variety of mounting methods. Proper installation is crucial to heater performance. The heater must be in intimate contact with the heat sink, as any gaps can block heat transfer and cause a hot spot incurring premature heater failure.

Pressure Sensitive Adhesive (PSA): The simplest mounting method, with factory-applied PSA, you just remove the backing paper and press the heater in place.
Presure Sensitive Adhesive Backing

Field Applied Adhesive: Room temperature vulcanizing (RTV) silicone rubber adhesive is used for a superior permanent bond.
After applying a thin film between the heater and the surface, a roller should used to remove any air bubbles, and then allowed to cure for 24 hours.

Factory Vulcanization ( for Silicone heaters) and Lamination( for Kapton heaters): Silicone heater and kapton heater can be factory bonded to its mating metal without adhesives for permanent attachment and excellent heat transfer. Metal parts(heat sinks) can be manufactured by Keenovo or supplied by the customer. Enclosure heater is a typical example of factory vulcanization.

Mechanical Fasteners: Mechanical Fasteners are applied where heater installation is temporary.
The most common mechanical mounting methods are : spring hooks, Velcro, buckles and straps, boots hook and lacing, snap fastener.

Spring Hooks Grommets

B) Thermal Insulation

To increase heater efficiency, silicone sponge rubber or EPDM insulation can be bonded to the top side of the heater. Typical thermal insulation thicknesses are 5mm, 8mm, 10mm.

Heater with silicone sponge Silicone Heater With EPDM Thermal Protection


C) Temperature Control and Thermal Management(Preset Built-in Thermostat, Adjustable Thermostat, Built-in temperature sensors(k,J thermocouples, RTD-PT100, digital controller)

Thermostats, temperature sensors, digital temperature controller and thermal fuses can be fabricated as an integral part of the heaters.

Pre-set Mechanical Thermostats: Snap action and creep action are two different types of pre-set Mechanical thermostats. Both are based on a bimetal expansion-contraction principle and are pre-set to a specific temperature non-adjustable. Typical applications are freeze protection, enclosure temperature and high limit protection.They provide a low cost means temperature control. The thermostat is normally built in by wiring directly into the heater and enclosed in a molded silicone rubber/fiberglass housing on the heater permanently.

Electronic controller with sensor is suggested over the mechanical thermostat for precise temperature control applications.

Adjustable Mechanical Thermostats: Adjustable Mechanical thermostats allow the user to set a specific temperature and attain a desired result. The thermostat is encapsulated in a silicone rubber overmold. Typical Adjustment Ranges Available are: 0~80 Deg C, 30~150 Deg C, 50~250 Deg C.

Buit-in Temperature Sensors: Thermocouples, RTDs, and thermistors can be located to monitor temperature of either  the heat sink (part being heated) or the heater surface itself. For silicone heaters, temperature sensors are held in place with a protective patch or probe pocket of silicone rubber/fiberglass vulcanized to the heater body while for Kapton® heaters they are affixed to the surface with epoxy.

Thermocouples: Almost any type thermocouple can be applied at almost anywhere on the heater surface. Type ”J” and "K" are most commonly employed.

Resistance Temperature Devices: The RTD’s resistance changes in a very linear relationship with its temperature and is considered the most accurate and stable sensor. Thin film PT100 or PT1000 are commonly used. They can also be encased in probes.

Thermistors: Thermistors are also resistive-based temperature sensors but as they do not respond in a linear style, they are only used in a limited temperature range or at a specific single temperature.

Thermal Fuse: Thermal fuses are a one time over temperature protection device that can prevent dangerous temperatures in the event of a control device failure. Testing is suggested to select the location and temperature setting of the fuse to protect your product most effectively.

Digital Temperature Controller: Recommended for applications where precise temperature control is desired. A complete control option, ready to be used with plug and sensor fitted. NO MORE tedious wiring before precise temperature is possible. Check now for its User's Manual.

Keenovo Digital Controller Box C Keenovo Digital Controller Box F

Start your custom design or ask us for more info now.