Ultra Thin Flexible Heater FAQ

KLC - Ultra Thin Flexible Heaters

Taiwan KLC Corporation, a leading designer and manufacturer of heaters, offers precise heating solutions with MUTEX Ultra-Thin Flexible Heater that outweighs other conventional heating elements. MUTEX Ultra-thin flexible heaters features excellent physical and electrical properties which result in thermal stability over a wide temperature range. If you are looking for flexible heaters for your application, please contact us on +886-4-25330456 or email: info@ptc-heater.com.tw right now!

FREQUENTLY ASKED QUESTIONS

Q1. Do I need temperature controller?
Q2. Which attachment method should I use?
Q3. Can Ultra-thin Flexible Heater be used suspended in air?
Q4. What is the difference between Ultra-Thin Flexible Heater and PTC Heater?
Q5. What should I know before installing Ultra-Thin Flexible Heaters?
Q6. Can I trim an Ultra-Thin Flexible Heater to the size and shape I need?

Q1.  Do I need Temperature Controller?

If you require the flexible heaters with higher heat-up rate or higher power density (>0.8W/cm2), make sure temperature sensor or thermostat is installed to prevent overheating, causing damage to products. Place temperature sensor close enough to the heater to sense heater temperature.

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Q2.  Which attachment method should I use?

To ensure longer heater life, proper attachment to contact surface is critical. With exception to heaters with lower power density(<0.4W/cm2), Ultra Thin Flexible Heaters must make intimate contact over the entire contact surface and ensure the surface is clean without any fingerprints or oil sludge for successful applications. For heaters with higher power density (>0.8W/cm2) or surface temperature >150℃, it is recommended to attach the flexible heaters by clamping to the object to be heated and make sure thermostat is connected to prevent overheating. On the other hand, it is optional for lower temperature heaters to use either self adhesive or clamping method for mounting. 

>>Self Adhesive: Ultra Thin Flexible Heaters are available with self-adhesive. Installation is made easy by simply peeling off the protective liner and rolling the heater in place on a clean surface (free of oil sludge or fingerprints). Best to apply the heater with soft rubber roller to ensure the entire heater is in contact with the contact surface of the item to be heated without any air pockets.

Important Notes:

!Maximum temperature of flexible heater when using self-adhesive method:150℃
!Heaters with self-adhesive will need to be installed within 6 months of purchase.

>>Clamping: To allow Ultra Thin Flexible Heaters to be detached and reapplied for other applications, Ultra Thin Flexible Heaters can be clamped to metal surfaces by using a metal plate held in place by fasteners. Because Ultra Thin Flexible Heaters are so thin it is a good idea to use a silicone pad or insulation layer between the heater and the pressure metal plate to cushion the heater to ensure complete contact to prevent air pockets as well as directing the heat towards the item to be heated.

Important Notes:
!The contact surface must be clean and free of chemicals or foreign materials that could affect the heater and free of sharp projections that could pierce the heater.
!When clamping, make sure the metal plate covers the entire heating area without touching the terminal and lead wire. Ensure the metal plate maintain even pressure across heater surface and is not tilted or has air gap, else the heater will not be able to dissipate heat properly and cause the heater to overheat.

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Q3.  Can Ultra Thin Flexible Heater be used suspended in air?

Because the mass of an Ultra Thin Flexible Heater is very small, they are generally not suitable for heating in air. Ultra Thin Flexible Heaters are best utilized when mounted to an object that can be heated by conduction rather than convection or radiation. For air heating, we recommend using PTC Heaters Series for various heating options.

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Q4. What is the difference between Ultra-Thin Flexible Heater and PTC Heater?

There are several major differences between Ultra-Thin Flexible Heaters and PTC Heaters, as shown in table below:

  PTC Heaters Ultra-Thin Flexible Heaters
Inrush Current Yes No
Power (W) High Power applications Low Power applications
Ohm's Law No Yes
Heating Air heating & Conductive heating Conductive heating
Constant Temperature Voltage change will have little affect on heater temperature and power(W). Voltage change will affect both heater temperature and power(W).
However, if low power is maintained (<150℃), temperature will remain consistent under stable heat dissipation rate.
Defining Wattage Exact heater wattage cannot be defined, wattage will change according to the ambient temperature and heat dissipation rate. Constant heater wattage, will not change with ambient environment.
Advantages Stable temperature; safe to use; with wide applications Light, small and flexible; with wide applications
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Q5. What should I know before installing Ultra-Thin Flexible Heaters?

Please read the following carefully before installing Ultra-Thin Flexible Heaters to prevent misuse and ensure longer heater life.

  1. DO NOT let the lead wires hang loosely. Make sure the lead wires are mounted in a fixed position to prevent pulling of lead wire causing heater breakage.
  2. DO NOT immerse heaters in liquids or expose heaters to steam and corrosive gas.
  3. DO NOT operate heaters at a voltage higher than the specified or rated voltage.
  4. DO NOT cut, punch holes, disintegrate heaters or attempt to repair damaged heater and avoid contacts with sharp objects. Damaged heaters will become unusable.
  5. DO NOT leave heaters operating unattended unless adequate controls are installed to insure safety.
  6. DO NOT overlap heaters.
  7. DO NOT attempt to repair damaged heaters.
  8. AVOID exposing heaters to substances that could ignite or cause damage to the heaters.
  9. Heaters can be bent around curved surfaces; however, DO NOT exceed minimum bending radius (R0.5mm).
  10. When connecting across two joining surfaces, make sure the joining corner is blunt to prevent heater surface been damaged or pierced.
  11. Heaters must be attached to an appropriate heat sink when power density is greater than 0.4W/cm2 and should NOT be mounted free-standing in air, especially for heater with high power density, it would require effective heat conduction or connect to thermal controller.
  12. Exercise care in attaching heaters to flat or curved surfaces. Heaters can be attached by mechanical clamping, by using factory applied pressure sensitive adhesive (PSA), or with a thin layer of conductive epoxy. Make sure that the entire heater is in contact with the surface with no air pockets trapped underneath. This is especially important for high watt density heaters, i.e. heaters with a watt density of 10W/cm2, to prevent heater failure. Also make sure terminals and lead wires do not come into contact with metal plate (when clamping) and surrounding conductive metals.
  13. If air pockets are found within heaters before or after installation, contact our sales team immediately. This could be caused by overheating due to voltage applied is above the voltage in the heater specification or due to inappropriate installation of heaters.
  14. Before removing heaters, please make sure the power has been turned off and all components have cooled down before removal.
  15. For heaters with high power density(>0.8W/cm2), make sure adequate measures are taken to control heater temperature and install heaters together with metal plates and recommended silicone pads or silicone adhesives.
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Q6. Can I trim an Ultra-Thin Flexible Heater to the size and shape I need?

No. Ultra Thin Flexible Heaters cannot be cut or trimmed. The element conductor covers the entire area to maximize the heat spreading effect. Cutting into this would create an electrically open circuit and expose the electrically live element.

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