How to Test Polyimide Heaters for Reliability and Durability?

Polyimide heaters are known for their flexibility, durability, and precise heating capabilities. They are crucial components in various industries, including aerospace, medical devices, and electronics. Ensuring their reliability through rigorous testing is essential to meet the demanding standards of these applications. In this blog post, we will delve into the various reliability tests that Polyimide heaters undergo, highlighting both standard and optional tests as required by customers.

1. Dielectric Strength Test (If not specified by the customer)

The dielectric strength test for Polyimide heaters typically involves applying AC1200V, 5mA for 60 seconds without any abnormalities. For silicone rubber heaters and epoxy resin heaters, the test involves AC1500V, 5mA for 60 seconds without any abnormalities. This test aims to evaluate the electrical insulation performance of the heater under high voltage conditions, ensuring there is no risk of electric shock or short circuit.

Test Process:

• Apply AC1200V voltage to the Polyimide heater, with a test current of 5mA, for 60 seconds.

• Observe for any abnormalities such as breakdown or leakage.

• For silicone rubber and epoxy resin heaters, conduct the same test at AC1500V.

  

2. Insulation Resistance Test (If not specified by the customer)

The insulation resistance test checks the electrical insulation performance of the heater, ensuring it provides adequate insulation protection under high voltage. The test voltage is usually DC1000V, and the resistance should be greater than 100MΩ.

Test Process:

• Apply DC1000V voltage and measure the heater’s resistance.

• Ensure the resistance value is greater than 100MΩ, indicating good insulation performance.

3. Thermal Shock Test (As required by the customer)

The thermal shock test evaluates the reliability of the heater under extreme temperature changes. The test typically ranges from -25°C to 125°C, with each cycle lasting 4 hours.

Test Process:

• Place the heater in a -25°C environment for a certain period, then quickly transfer it to a 125°C environment and maintain it for a specified time.

• Repeat the cycle for 4 hours.

• Observe the heater’s performance during temperature changes, ensuring no abnormalities such as material cracking or electrical  performance degradation.

4. Wire Pull Test (As required by the customer)

The wire pull test evaluates the mechanical strength of the heater’s connection wires, ensuring they do not break under external forces. The pull test standard is set according to the wire diameter.

Test Process:

• Set the pull standard value according to the wire  diameter.

• Apply tension to test the mechanical strength of the wires.

• Ensure the wires do not break or loosen when tension is applied.

5. High-Temperature and High-Humidity Test (As required by the customer)

The high-temperature and high-humidity test evaluates the performance stability of the heater in high-temperature and high-humidity environments. The standard test conditions are 60°C and 95% relative humidity for 240 hours.

Test Process:

• Place the heater in an environment with 60°C  temperature and 95% relative humidity.

• Conduct the test for 240 hours.

• Observe the heater’s performance under high-temperature and high-humidity conditions, ensuring no abnormalities      such as moisture absorption or electrical performance degradation.

Kapton heaters undergo a range of reliability tests to ensure they meet the high standards required for their applications. These tests include standard procedures for dielectric strength and insulation resistance, as well as optional tests for thermal shock, mechanical strength, and high-temperature/high-humidity conditions. By rigorously testing these heaters, manufacturers can ensure their products are robust, reliable, and ready to perform in the most demanding environments.

At HRX Heaters, we pride ourselves on our comprehensive testing protocols, ensuring that our Polyimide heaters exceed industry standards for reliability and performance. Trust HRX Heaters for your critical heating needs, where quality and dependability are our top priorities.