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Kapton Heaters

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Kapton heaters, often known as Polyimide heaters, are constructed using Kapton polyimide film. Kapton heaters have the lowest profile of any flexible heater, have high tensile strength, and distribute heat evenly; they work well in hot environments and confined spaces. Read More…

Kapton Heaters A Kapton heater is a type of electronic heater that uses polyimide film to encapsulate heating circuits. This thin, ultra-flexible and lightweight material makes Kapton heaters a great solution for compact applications.
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Leading Manufacturers

Danvers, MA  |  978-777-0070

Backer Hotwatt is a superior designer & manufacturer of electric heaters and related heater accessories for various OEM & industrial applications.

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Backer Hotwatt, Inc. $$$

Columbus, IN  |  812-372-0281

For more than 70 years, Ulanet™ has been engineering and manufacturing electric heaters, cartridge heaters, immersion heaters, tubular heaters, miniature strip heaters and bolt hole heaters, as well as industrial heaters and appliance thermostats.

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Ulanet™ $$$

Rochester Hills, MI  |  888-852-3611

Working in the production of infrared heating products since 1965, Combustion Research is sure to be able to meet the infrared heater needs for your application. Our products (Reflect-O-Ray®, Omega II® and Synergy® brands) are known for their "big three" — comfort, efficiency and economic operation.

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Combustion Research Corporation $$$

Fortville, IN  |  905-664-8274

Superior Radiant Product is the global innovation champions in the heating industry, saving energy for future generations. SRP offers a complete range of low and high-intensity energy efficient infrared heaters for industrial, commercial, agricultural and residential applications worldwide.

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Superior Radiant Products $$$

Houston, TX  |  800-460-5200

Process industries have relied on Gaumer since 1962 for the design and manufacture of industrial heaters, electric heaters, heating systems plus controls. Circulation heaters, component heaters (radiant heaters, strip heaters, cartridge heaters), comfort heaters and immersion heaters are the offerings.

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Gaumer Process Heaters, Systems & Controls $$$

Charlotte, NC  |  800-438-4936

Space-Ray is an international manufacturer of infrared radiant gas heating products. We are a division of the Gas Fired Products Group of companies which manufactures energy efficient overhead radiant heating, space heating, infrared heaters and process heating systems in the UK and USA. We design and manufacture energy efficient gas heating products that will stand the test of time.

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Space-Ray, Inc. $$$
placeholder image Backer Hotwatt, Inc. Ulanet™ Combustion Research Corporation Superior Radiant Products Gaumer Process Heaters, Systems & Controls Space-Ray, Inc.

During manufacturing, a pattern is cut onto the thin foil to disperse heat across a surface. Copper and constantan are some materials used to make this ultra-thin film or foil. Kapton heaters are also unusual because they can withstand radiation and resist harsh chemicals, making them ideal for industrial applications.

Polyimide film can have holes cut into it to fit around other electrical components, and specific heat sensors can be glued to the film's surface. In addition, Kapton heaters can be equipped with thermostats, thermal fuses, and specialized wire harnesses. These flexible heaters come in various forms, sizes, and wattages.

Kapton Heater

Features of a Kapton Heater

  • They have outstanding physical and electrical qualities, resulting in thermal stability over a wide temperature range.
  • They have outstanding physical and electrical qualities, resulting in thermal stability over a wide temperature range; various opaque variants are available.
  • Kapton heaters have radiation and fungal resistance, allowing for use in various applications.
  • They may be readily glued or attached to numerous surfaces or other system parts, and they are rugged, dependable, accurate, and moisture/chemical-resistant.
  • They have a wattage tolerance of 10% and a maximum watt density of 50 W/in2.
  • Kapton heaters have a 1000 VAC dielectric strength.

Materials Used in Kapton Heaters

  • The heating element is laminated inside a Kapton heater, and thin polyimide sheets are used as insulation.
  • Its enhanced circuit imaging and printing allow designers to disperse watts and generate various heat patterns in the exact location.
  • Heaters can be built for low-voltage heating or numerous heating zones when different wattages are required in other film parts.
  • Adhesive tape can be used to help with the installation of other components.
  • To increase heat dispersion, aluminum foil can be utilized as a backing.
  • Kapton heaters can be terminated in various ways, including leads, connectors, solder terminal pads, and card-edge-ready.
Laminated Heating Element

Construction of Kapton Heaters

Kapton heaters may be customized to fit several industrial and commercial electrical applications.

  • A typical design includes an etched foil element between two films of Kapton and FEP glue.
  • The lead wires exit from the heater's breadth side's upper-right corner.
  • For broad heaters only, leads exit centrally from the width side.
  • The lead wires on circular heaters emerge radially.
  • A pressure-sensitive adhesive option is offered. The user can also mechanically clamp the heaters or epoxy install them.
Kapton Heater Lead Wires

Working of Kapton Heaters

  • The resistance element in Polyimide (Kapton) heaters is a thin etched metal (typically nickel-based alloy) foil.
  • The etched resistance pattern is created in CAD and then transferred to foil, acid sprayed to generate the appropriate resistance pattern.
  • Its slim and light profile and high watt density allow for precision heat distribution at a cheap cost of operation.

Benefits of Kapton Heaters

  • A Kapton heater can direct heat where it's required, including heat profiles that can be regulated.
  • Kapton heaters' thin structure allows them swift thermal transfers, resulting in faster heat.
  • Kapton heaters can withstand extreme temperatures from -328 °F to 329 °F (-200 °C to 165 °C) due to the Kapton film's thin profile and versatile capabilities.
  • Kapton heaters use polyimide films, which are thin and lightweight, solvent resistant, dimensionally stable, and have excellent tensile strength and tear resistance. They also offer a high level of vibration resistance in industrial applications.
  • Kapton heater heating components are polyimide, which has minimal outgassing qualities.
  • Kapton Heaters are suited for situations requiring a lightweight solution or quick heat-up time.

Applications of Kapton Heaters

  • This cutting-edge technology has analytical test equipment, LCD screens, and military equipment applications.
  • Even crucial aircraft electronics are safeguarded by these specific heaters, ensuring that the aircraft's electrical systems are not harmed during a power outage.
  • Electronics that may need to operate in cold temperatures, such as ATMs or laptops, nearly usually include an incorporated Kapton heater to maintain all of the other parts at a functioning temperature.
  • Kapton heaters are used in medical diagnostic tools such as heat sample trays, reagent bottles, and CPAP ventilator humidifiers, among other things.
  • Optoelectronic components are stabilized using Kapton heaters.

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