Resistor or conductor paste is screen printed on top of a substrate to create printed heaters. It can be printed directly onto the surface that has to be heated, greatly increasing the heating efficiency. The user application and design specifications are taken into consideration while choosing inks and substrates. There are various types of printed heaters, including thick film heaters on metal and ceramic surfaces and flexible printed heaters.
Flexible Printed Heaters are directly printed on polyester (PET), polyimide (PI), polycarbonate, etc. according to user requirements and specific operating parameters. Flexible printed heaters are based on positive temperature coefficient (PTC) materials that enable the heater to control its desired temperature or on fixed resistance heater designs that require a control circuit to control the temperature. The heater can be easily mounted using pressure-sensitive adhesive, field-applied adhesive, Velcro, etc., according to the requirement.
It has advantages over conventional heaters such as being light weight, flexible to take place, providing uniform heat distribution, etc.
The thick film heaters are developed using thick film materials such as conductive, resistive, and dielectric on alumina, AIN, stainless steel, and aluminium. The thick film heaters have a fast response time and uniform heat distribution in a low-profile heater. It is widely used in high-performance, reliability, energy efficiency, limited space, and high-wattage density applications. The heaters can be applied to complex shapes to produce targeted heat. The thick film heaters are also divided into two types (according to production): 1. printed on a metal substrate; 2. printed on a ceramic substrate.
Substrate: Alumina/ Stainless Steel/ Aluminum Nitride etc.
| Max Length | ~ 25 inches |
|---|---|
| Max Width | ~ 20 inches |
| Thickness | 0.056" standard, other thickness available |
| Watt Density | 0.2 W/cm² |
| Wattage Tolerance | +5%, -10% |
| Maximum Temperature | Permanent temperatures of up to 90°C (max. 100°C for short periods) |
| Voltage | 1 V to 240V AC or DC |
| Heating Element | Silver/Carbon/PTC |
| Material | Alumina | Aluminum Nitride | Stainless Steel |
|---|---|---|---|
| Thermal Conductivity (W/m·K) | 20 | 170 | 15 |
| Watt Density (W/m²) | 23 | 150 | 75 |
| Max Temperature (°C) | 600 | 450 | 350 |
| Coefficient Of Thermal Expansion (×10⁻⁶/°C) | 7 | 4.6 | 12-15 |
| Voltage (V) | 240 | 240 | 240 |
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