Heaters Engineered to Operate Under Harsh Conditions
Flexible heaters are typically single layer flexible circuits that utilize copper or resistive alloys, such as Inconel and Cupro-nickel, to form conductive paths. As electrical current is driven through the higher resistance conductors, heat is generated. Conductor width and thickness are selected to provide the desired resistance value based on the supply voltage. Dielectric materials are selected based on operating temp and heater power density.
Our custom-engineered flexible heaters provide reliable, uniform heating in a wide range of applications, especially where traditional rigid heaters fall short. Designed to conform to complex and irregularly shaped devices, our solutions deliver efficient thermal performance in compact, low-mass packages.
Flexible heaters are engineered to operate under harsh conditions. We work closely with you to design your flexible heater to best fit your applications – from selecting the right materials to thermal profiles, we’re with you every step of the way.
Flexible Heater Webinar
Thermal Precision Meets Flexibility: The Technology Behind Heater Circuits
Join internationally recognized flexible circuit design experts for an in-depth look at the game-changing world of flexible heaters. From medical devices to diagnostic equipment to cutting-edge automotive applications, discover how these ultra-thin, lightweight flexible heaters deliver exceptional heat transfer in even the most compact, irregular spaces. Don't miss this chance to see real-world applications and innovative solutions in action.
- Discover the benefits of flexible heaters for a variety of applications
- Explore the advantages and limitations of flexible heaters
- Compare the merits of adhesive and resistive foil selections
- Examine the cost drivers of flexible heaters
Benefits
Flexible heaters offer very good heat transfer to the heat sink in a very low profile and low mass package. Because they are flexible, they can also conform to, and heat, irregular surfaces that other types of heaters cannot. TCR (Temperature Coefficient of Resistance) of custom heater alloys provide minimum resistance change when temperature changes.
Each design can be tailor to your needs:
- Size and shape
- Installation options -flat or curved surfaces
- Watt density
- Profiled heating
- Addition of temperature sensors
- Thermal protection
- Multiple termination options
Customizable Designs: Tailored to fit your exact size, shape, and power needs, our flexible heaters are available in polyimide or silicone rubber constructions.
Even Heat Distribution: Minimize hot spots and maximize efficiency with uniform surface heating.
Lightweight: Ideal for space-constrained applications without sacrificing performance.
Applications
FCT’s flexible heaters perform reliably across a wide range of applications and industries.
- Automotive: battery warming, seat heaters, sensors, mirror defoggers
- Medical Devices: diagnostics, fluid warming, wearable tech
- Industrial Equipment: sensors, enclosures, process tools
- Consumer: wearables, outdoor devices, kitchen appliances
Materials
- Heater element – Inconel 600, Cupronickel 715, Constantan, Copper
- Insulation – Polyimide film/epoxy adhesive, polyimide film/acrylic adhesive
- Heat spreading material – Aluminum, Copper
- Pressure sensitive adhesives – 3M 467, 3M 468, 3M 6035, 3M 9077, 3M 9460, 3M 9469, TESA 8853, TESA 8854
Supplemental Information
Flexible Heater Webinar
- Multiple foil alloys and thicknesses to choose from to provide a large range of custom resistance values.
- Custom heater element layout services to provide heater resistance that will provide the desired power output based on voltage input.
- Assembly capabilities to add thermistors, connectors, lead wires, potting, etc.
- A wide variety of pressure sensitive adhesive backings to choose from
- Custom mounting of heaters to heat sinks with either pressure sensitive or thermosetting adhesives
- Fabrication of customer specified heat sinks
Selectively copper plated conductors to eliminate heating in leads and other areas (cupronickel/Constantan)
- Aluminum or copper heat spreader layers to help transfer heat to heatsink.
- Assembly of thermistors, lead wires, and connector.
- Epoxy potting or assembled components and wires.
Pressure Sensitive Adhesive (PSA) with release liner applied to heatsink side of heater for easy “peel and stick” application.
