Large Format Flex Heaters
Epec Engineered Technologies designs and manufactures custom oversized flexible heaters for applications requiring heat across large surfaces. Available with silicone rubber or polyimide encapsulation, these heaters are built to your required shape, footprint, supply voltage, and thermal performance.
Our etched foil and wire-wound constructions provide options for complex heater patterns and large dimensions. Designs can include rear pressure-sensitive adhesive, temperature sensors, power leads, and plugs to simplify integration into your equipment.
At a Glance: Large Format Flex Heaters
- Custom oversized flexible heaters are available in silicone rubber or polyimide constructions, with etched foil designs up to 480 mm × 1,800 mm and wire-wound designs up to 1,000 mm × 3,000 mm.
- Engineered to your exact dimensions, shape, voltage, watt density, and thermal requirements, with options for adhesives, temperature sensors, power leads, and plug configurations.
- Supports large-area heating applications with watt densities of 20 W/in² and higher, plus multi-heater assemblies for installations that exceed individual heater size limits.
Oversized Heater Sizes and Construction Options
Heater size and encapsulation options depend on the element construction. Etched foil supports more complex element patterns, while wire-wound construction accommodates our largest individual heaters.
For installations extending beyond these individual heater dimensions, Epec can support kitting and subassemblies that combine multiple heaters into a larger heating solution.
Custom Shapes and Heating Patterns
An oversized heater must fit the equipment while delivering heat where it is needed. Epec designs custom outlines, cutouts, and element layouts around the available mounting surface and surrounding components.
Etched foil construction provides flexibility in element geometry, allowing the heating pattern to be tailored to the application. Wire-wound construction offers an option for larger silicone rubber heaters where coverage area is a primary requirement.
Our engineers review the heater footprint, heated area, mounting conditions, and temperature requirements to select the appropriate construction.
Watt Density and Supply Voltage
Epec supports oversized heater designs with watt densities of 20 W/in² and higher, subject to application and construction requirements. Selecting the appropriate watt density involves evaluating heat transfer, operating temperature, encapsulation material, and how the heater contacts the surface being heated.
For large heaters, total power is an important design consideration. Increasing the heated area at a given watt density increases the required wattage, which affects supply current, lead sizing, connections, and temperature control.
Heaters can be designed for supply voltages including 12 VDC, 28 VDC, 120 VAC, and 240 VAC. Each design is matched to its specified voltage and power requirements.
Adhesive and Mounting Options
Oversized flexible heaters are available with or without rear pressure-sensitive adhesive, or PSA. Epec uses 3M brand adhesives, including 3M 467 and 3M 468, with adhesive selection based on the mounting surface, temperature, and installation requirements.
A properly applied adhesive helps maintain contact between the heater and the heated surface. On larger installations, surface preparation and application techniques are particularly important to reduce trapped air and support consistent heat transfer.
Heaters without PSA can be supplied for applications requiring another mounting method.
Temperature Sensors and Thermal Management
Epec can integrate thermocouples, resistance temperature detectors, or RTDs, and other thermal management devices into the heater assembly. These components provide temperature feedback or support temperature limiting when connected to the appropriate control system.
Sensor placement should reflect the application’s heating requirements. For oversized heaters, our engineers can help evaluate sensing locations based on the heated surface, expected temperature variation, and areas most susceptible to overheating.
Power Leads and Plug Options
Power connections can be configured to support the equipment and installation. Available plug options include NEMA 1-15, NEMA 5-15, and NEMA 6-20.
Plug selection is matched to the heater’s supply voltage, current requirements, and equipment grounding needs. Lead routing and connection locations can also be incorporated into the custom design.
UL Markings and Electrical Testing
Most designs can be supplied with existing UL markings applicable to the heater construction under UL 499. Epec reviews the proposed configuration to confirm the applicable marking and approval coverage.
Every heater receives electrical continuity and high-potential, or hipot, testing. These checks verify the electrical path and dielectric integrity before shipment.
Frequently Asked Questions
Quick Links
- What is the largest flexible heater Epec can manufacture?
- How do I choose between etched foil and wire-wound heater constructions?
- What voltages are available for large format flexible heaters?
- Can temperature sensors be integrated into the heater?
- Are large flexible heaters available with adhesive backing?
What is the largest flexible heater Epec can manufacture?
Maximum heater size depends on the construction method. Etched foil heaters can be manufactured up to 480 mm (19 in) wide by 1,800 mm (71 in) long, while wire-wound silicone rubber heaters can reach 1,000 mm (39 in) wide by 3,000 mm (118 in) long. For larger installations, multiple heaters can be combined into a custom assembly.
How do I choose between etched foil and wire-wound heater constructions?
Etched foil heaters allow for more intricate heating patterns, custom shapes, and precise heat distribution. Wire-wound heaters are typically selected when very large dimensions and broad heating coverage are the primary requirements. Epec reviews the application requirements to determine the best option.
What voltages are available for large format flexible heaters?
Large format heaters can be designed for a range of supply voltages, including 12 VDC, 28 VDC, 120 VAC, and 240 VAC. Each heater is engineered to match the specified voltage, power requirements, and operating conditions.
Can temperature sensors be integrated into the heater?
Yes. Epec can integrate thermocouples, RTDs, and other thermal management devices directly into the heater assembly. These components provide temperature feedback and help support accurate temperature control and overheating protection when used with the appropriate control system.
Are large flexible heaters available with adhesive backing?
Yes. Oversized heaters can be supplied with 3M pressure-sensitive adhesives, including 3M 467 and 3M 468, or without adhesive if another mounting method is preferred. Adhesive selection is based on the mounting surface, operating temperature, and installation requirements.
Need a Custom Oversized Flexible Heater?
Send us your required dimensions, shape, supply voltage, target temperature, and mounting details so we can review your oversized flexible heater application. Include any requirements for adhesives, temperature sensors, power plugs, or UL markings so our engineering team can review the complete assembly.
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