Our product range of flexible heating systems

For more than 50 years, we have been developing and producing flexible heating systems on a silicone basis for operating temperatures up to 240 ° C. The applications range from industrial applications, measurement and control technology to energy systems and medical engineering up to the aerospace engineering. Today, over 5 million HORN silicone-based heating systems are in use worldwide. Experience you can build on.

Due to challenging assignments of tasks by our customers from different industries, we have oriented our production towards customer-specific solutions. We manufacture both, single pieces and high volume. Highest quality standards and no need for maintenance characterize our products.

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Technical informations
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Useful information for designing silicone heaters

Temperature: -60 bis +240°C (please note the restrictions under the header fastener types)
Operating voltage: 6 – 400V, AC/DC (single- or three-phase), up to 750V on request
Heating output: 0.05 – 3 W/cm² (from 0.45 W/cm² we recommend a temperature controller)
Maximum length: 3000mm
Maximum width: 1000mm
Thickness: 1,5 – 6mm
Electrical connection: Single cores, cable, plug-in contacts
Temperature controller: Depending on design
Installation, fasteners: Depending on design
High-voltage resistance: Approx. 24 KV/mm (with standard material)
Protection against moisture: On request splash proof XP X4, higher safety classes on request
Series test: In accordance with DIN EN 60335-1 (VDE 0700-1) and DIN EN 50106 (VDE 0700 Part 500)
Approvals: In accordance with DIN EN 60335-1 (VDE 0700-1) 2007-02, UL File E24820

Physical properties

Temperature resistance: -60 to + 240°C
Thermal conductivity ISO 8301: approx. 0.27 W/m K (with standard material)
Weathering and aging resistance: Very good
Ozone resistance: Very good
Steam resistance: Good to approx. 130°C or 2.5 bar

  • Compressive load on the heater: max. 50 N/cm² two-dimensional pressure
  • With container heaters with changing levels the temperature controller or temperature sensor must be attached to the upper side of the heater (= hottest position when the level drops)
  • Depending on the heater design, the minimum bending radius is 30 mm
  • Silicone heaters must not be bent
  • The heaters must not be cut or mechanically damaged
  • The heaters may only be operated with the prescribed voltage
  • Incoming goods inspections are not carried out for materials that are provided, because we assume that these parts are supplied in a perfect condition. Materials must be provided not less than three weeks before the confirmed delivery date for the heaters, so that this date can be complied with.

Maximum temperature loads

  • The maximum temperature load for silicone heaters is 240°C
  • The maximum temperature load for silicone heaters with self-adhesive foil is 150°C

To make sure that the heater element does not overheat a suitable temperature controller is suggested during the planning stage, or supplied on request. With power densities > 0.45 W/cm² we recommend additional security using a thermal cut-out.
The temperature that can be reached with a heater element depends on the following factors:

  • Ambient temperature
  • Thermal conductivity of the medium/material to be heated
  • Insulation of the heater element and the heated medium
  • Radiant emittance (heat loss through eternal influences)
  • Thermal conductivity of the heater carrier
  • Flow rate of the medium to be heated

see also Temperature diagrams

The connection between the specific heating output and the surface temperature that results from this can be seen in the following two diagrams. Because the achieved temperatures are also influenced by insulations and ambient conditions, with power densities > 0.45 Watt/cm² we recommend the use of a temperature controller that ensures that temperatures > 240°C are not reached.
Measuring conditions:
Silicone heater 300×200 mm, flexible and vulcanised on 1.5 mm aluminium sheet
Heater in horizontal position (sheet on top)
Unmoved air at RT=23°C


Flexible silicone heater

Flexible silicone heater

Silicone heater vulcanised on 1.5 mm aluminium sheet

Silicone heater vulcanised on 1.5 mm aluminium sheet

Vulcanising

Connections: Aluminium, Stainless steel, Steel, Various metals
Installation surface: Any (depends on tool)
Temperature range: -60 to + 240°C
Bonding times and installation instructions: Attached in the factory

Self-adhesive foil

Connections: Metals, Various plastics, Ceramic
Installation surface: Flat or cylindrical
Temperature range: 0 to + 150°C
Bonding times and installation instructions: Instructions for using self-adhesive foil

Sticking with silicone cold vulcanisation

Connections: Metals, Various plastics, ,Galss, Ceramic any
Installation surface: Any
Temperature range: -60 to + 180°C
Bonding times and installation instructions: Instructions for using silicone adhesives

Pressing on using pressure plates

Connections: Any
Installation surface: Flat
Temperature range: -60 to + 240°C
Bonding times and installation instructions: Place the flexible heater between the function part and the pressure plate.
Alternative: vulcanise the heater on the pressure plate.
Instructions for use

Clamping with tension springs, tying on

Connections: Any
Installation surface: Cylindrical
Temperature range: -60 to + 240°C
Bonding times and installation instructions: Simple installation on site, above all if the heated function parts has to be replaced.

Safety information

Installation, maintenance, repair and connecting require qualified skilled personnel (electri-cians) and may only be carried out using original spare parts. Before the start-up of the appliance, the heater or the installation a test must be carried out in accordance with the valid safety regulations and statutes (e.g. VDE 0700-500, CE, German Accident Preven-tion Regulations (UVV)
The heater element is an electrical component with basic insulation without a protection class.
The safety measures must be carried out by the operator on site. We recommend the use of an RCCB so that dangerous shock currents can be prevented.

Instructions for using silicone adhesive

  1. Clean the metal surfaces thoroughly and degrease (use acetone or carbon tetrachloride) and leave to dry for about 30 minutes.
  2. Spread silicone adhesive (use a fine-toothed spatula) on the silicone heater and the metal surface.
  3. After applying the adhesive, leave the parts to dry in the air for about 3 minutes.
  4. Now place the heater on the metal body in such a way that it can be kneaded from the centre. Press down heavily with stroking movements towards the edges to remove any air bubbles.
  5. Remove any silicone adhesive that has emerged.
  6. Leave the adhesion position for about 2 hours under slight pressure (weight).
  7. Let the adhesion bond for 24 hours.
  8. After bonding, heat the heater up to check if bubbles form. If bubbles cannot be seen, the heater’s perfect functioning capacity is guaranteed.

Instructions for using self-adhesive foil

  1. Clean the metal surfaces thoroughly and degrease (use acetone or carbon tetrachloride) and leave to dry for about 30 minutes.
  2. Pull the protective foil off the back of the heater element.
  3. Now place the heater on the metal body in such a way that it can kneaded from the centre. Press down heavily with stroking movements towards the edges to remove any air bubbles.
  4. Leave the adhesion position for about 2 hours under slight pressure (weight).
  5. After bonding, heat the heater up to check if bubbles form. If bubbles cannot be seen, the heater’s perfect functioning capacity is guaranteed.

Installing the heater systems

Before you connect the silicone heater element to the supply, check that the mains voltage conforms to the data on the ratings plate or the label.
Wrap the heater element (heating mat) around the part that is to be heated and fasten in accordance with the instructions (fastener types). The base for the installation must not have any points, burrs and edges and welds must be ground flat. The standard heater element can be bent up to a radius of 30 mm.
If the heater element is to be stuck on (with silicone adhesive or self-adhesive foil), prepare the base beforehand.
When installing the heater element make sure that the heater fits tightly on the function part.
The heater element must not overlap. With poor dissipation there is a risk of overheating and the maximum temperature is exceeded without control.
Do not insert any foreign bodies (needles, nails, screws or similar) into the heater element; this can destroy the heating circuits.
If this information is ignored this will lead to damage to the heater element or to its destruction through overheating.

Start-up

Safety notice

During the specified operation, the temperature of the silicone heating element can rise to levels which can lead to serious injury. The operator must take suitable measures for protection of persons.
It must be ensured that the maximum permissible temperature is not exceeded, also in the case of additional external heating. The characteristics of the medium to be heated must be taken into consideration in controlling the temperature of the silicone heating element.
Limiting of the max. temperature of the heating element must be taken into consideration.

Stresses and faults in the operation of the heater

If there is a danger that the heater can no longer be operated without danger, shut the heater element / installation down immediately and secure it against switching on again.
This procedure is also necessary if the following occurs:

  • the heater element has visible signs of damage (e.g. cracks)
  • the installation/controller no longer works in the range of the specifications
  • if there has been a mechanical overload through pressure, tension, incorrect storage or transport
  • the heater element is or was exposed to welling liquids<
  • mechanical changes (cutting, additional drill holes, etc.) were made to the heater element

Explosion-protected installations and rooms

Explosive media that release potentially explosive gases when the temperature increases may not be heated up with the silicone heater. The silicon heater element may only be used outside potentially explosive areas.
Exception: if the operator has carried out the installation in accordance with the valid explosion protection regulations and carried out appropriate tests.

Your contact persons

Harald Knobelspies
Harald Knobelspies
Sales director

knobelspies@horngmbh.com
+49 (0)7731 7803-14


Harald Knobelspies
Sales director +49 (0)7731 7803-14
Peter Abele
Peter Abele
Technical sales

abele@horngmbh.com
+49 (0)7731 7803-15


Peter Abele
Technical sales +49 (0)7731 7803-15
Petra Schieke
Petra Schieke
Sales administration

schieke@horngmbh.com
+49 (0)7731 7803-17


Petra Schieke
Sales administration +49 (0)7731 7803-17
Elona Siebold
Elona Siebold
Sales administration

siebold@horngmbh.com
+49 (0)7731 7803-16


Elona Siebold
Sales administration +49 (0)7731 7803-16

Contact

Please write to us or call us.

ADDRESS

Gewerbestr. 14, 78244 Gottmadingen

PHONE

+49 7731 78030