Birk Manufacturing is the only heating manufacturer that produces and supplies butyl heating solutions. Our butyl heating solutions are manufactured with high-quality, waterproof materials that can withstand a multitude of hazardous environments. They are highly flexible and durable and are best used for environments that are not typically conducive for typical flexible heaters. Butyl heaters have a standard thickness of around 2mm and can come with integrated thermostats. Integrated thermostats help with the self-regulation of heater assemblies that are completely waterproof. An additional benefit of butyl heaters is that they require minimal maintenance and their service life is enhanced because of their advanced design features. Based on your heating requirements, you can combine and integrate these heaters with RTDs, fuses, thermostats, thermocouples, wiring harnesses, thermistors or any other similar hardware.

Birk Manufacturing is a leading thermal partner throughout the heat processing industry. Birk’s cartridge heaters are known for their extremely high surface loading that allows large power to be delivered where space is extremely limited. A cartridge heater is a tube-shaped heating element that can be inserted into drilled holes. Cartridge heaters provide localized and precise heating. A cartridge heater is manufactured with a resistance coil wound around a ceramic core. This core is then surrounded by dielectric and encased in a metal sheath. Powered heat transfer through the coil to the sheath causes the sheath to heat up. This heat transfer then heats the inside metal part that requires an elevated temperature.

If purchasing one of Birk’s 1/8” swaged in-stock cartridge heaters, the fit/drilled hole size for a cartridge heater is integral to the overall operation and heater lifespan. In a low or medium temperature application (315°C (660°F) or below), holes can be drilled to .008” over the nominal size of the drill, resulting in fits of .014”. While this fit will be looser and does not permit optimal heat transfer, it aids in the installation and removal of the cartridge heaters, especially those with longer sheaths. At high watt densities, a close fit is much more critical. The holes should be drilled and then reamed. With a tighter fit, the heater will run cooler and have a longer life span.

Birk’s cartridge heaters are a great solution for reaching elevated temperatures. This in turn suggests that incorporating a temperature sensor and controlling feature would be best for the overall application. Birk has a vast temperature sensor product offering along with direct access to design engineers who will be able to advise customers whether or not to integrate a surface mount or bolt-on RTD or thermocouple.

In some applications, an embedded temperature sensor or higher watt density is required. This can be achieved with a custom cartridge heater solution. Custom cartridge solutions allow Birk’s customers to achieve their thermal needs even in the most challenging applications.

Flexible heaters are often utilized by design engineers because their applications require even heat distribution in a highly specific area. Etched-foil flexible heaters are also used in applications where surface-mount heat is required due to physical constraints. Custom shapes, build-ups, thicknesses, multiple circuits and shaded watt densities allow for fully customizable flexible heaters, meeting the exact requirements of any application while offering a robust product that will stand the test of time. Birk's flexible heating elements are made using materials such as silicone rubber, Kapton®, mica and butyl. Birk's Kapton® flexible heaters are thin flexible heaters that are highly customizable and allow for rapid thermal recovery. Each material has its own features and benefits, but they all cover wide temperature ranges. Depending on your application requirements, specific materials can be utilized to resist chemicals, UV rays and moisture. There are many ways to achieve temperature control in addition to flexible heaters. As one of the leading flexible-heater suppliers, Birk can incorporate sensors, controllers and thermostats directly into heaters to provide customers with a full turn-key solution while ensuring stability in critical applications.

Birk's silicone rubber heaters are rugged, flexible and chemical-resistant. Our rugged flexible heaters can be combined with many components. Thermostats, fuses, thermocouples, RTDs, thermistors, connectors, heat sinks, wiring harnesses, motors and any other desired hardware are available upon request. Birk manufactures both resistance-wire and etched-foil circuits in our silicone rubber heaters. There are advantages to both circuit types. Resistance wire is more robust in dynamic applications that require a silicone heater, and foil circuits are a perfect match for applications requiring extremely even heat distribution. Wire-round silicone heaters and etched-foil silicone rubber heaters can be designed with varying watt densities, dual voltages and multiple heated zones. In order to successfully achieve the most efficient heat transfer, custom flexible silicone heaters can be vulcanized to metal surfaces. The proprietary processes Birk has developed for vulcanization can ensure superior bonding between surfaces and silicone heaters. Through our commitment to quality and advanced development technologies, Birk continues to be recognized as one of the leading manufacturers of silicone rubber heaters in the world.

Birk Manufacturing specializes in designing and manufacturing customized thermal solutions for flexible heating applications. However, we find it beneficial to offer our customers a standard heating solution for their flexible heater application needs. Quick prototyping, small-quantity orders, no tooling and multiple resistance availabilities are just some of the benefits of selecting a standard Birk heater for your flexible heater applications. Birk's standard heaters have proven effective in research, development and testing phases. However, once these phases are complete, customized solutions are recommended to ensure that the overall assembly and application requirements are met. Custom solutions have full integration capabilities with connectors, RTDs and thermocouples for ease of installation. Custom heater solutions reduce the need to source multiple delivery-system components by supplying a single cohesive thermal delivery system to the customer. Custom solutions can be incorporated into higher-level assemblies, allowing for a turn-key solution for the customer. Our highly trained design and engineer team members are available to discuss your flexible heating application needs and to provide you with a customized thermal solution backed by Birk's warranty.