Thermrup® Silicone Rubber Heating Technology

Thermrup® Silicone Rubber Heating Technology

Semi-conductive, planar heat generator with far-infrared radiation

In the market for electrical heating solutions, so-called silicone rubber heating elements are usually understood as flexible heating mats in which metallic heating conductors (e.g., nickel-chromium wires or etched resistance tracks) are embedded in silicone.
The silicone layer primarily serves a mechanical protective and insulating function – it is not itself an active heat generator.

The technology developed by Thermrup®, however, follows a fundamentally different approach:
The silicone rubber material itself becomes an electrical and thermal functional material.

Material Principle: Semi-conductive Silicone Rubber

Thermrup® uses a specially formulated silicone rubber-graphite composite matrix, in which finely dispersed carbon-based fillers are homogeneously distributed within the elastomer.

This material structure creates a semiconducting network with the following properties:

defined electrical resistance

uniform current distribution across the entire surface

volumetric heat generation ("Bulk Heating")

temperature-dependent resistance characteristic (quasi-PTC behavior)

Unlike wire or foil-based heating systems, heat is not generated locally along a conductor, but over the entire surface of the material.

Planar and Homogeneous Heat Generation

Since the entire silicone rubber acts as a resistance element, significant advantages arise:

• no hotspots due to concentrated heating conductors
• very high temperature homogeneity
• uniform heat dissipation even on curved or irregular surfaces
• excellent mechanical flexibility and adaptability

These properties are particularly crucial for close-contact, large-area, or safety-critical applications.

Far-Infrared Radiation (FIR)

A particular technological advantage of the Thermrup® material solution lies in the natural emission of Far-Infrared Radiation (FIR).

Carbon-based materials like graphite are physically efficient FIR emitters.
The Thermrup® heating element typically radiates in the wavelength range of approx. 6–14 µm, which is particularly well absorbed by water, organic molecules, and biological tissue.

Compared to classic metallic heating conductors:

Property	Conventional Heating Conductors	Thermrup®  Heating Element
Heat Generation	point/linear	planar
Heat Transfer	mainly conduction	conduction + radiation
Far Infrared	negligible	significant
Thermal Comfort	local	uniform & deep-acting

 

Self-stabilizing Temperature Characteristic

Due to its semiconducting material structure, Thermrup® silicone rubber exhibits self-limiting thermal behavior:

increasing temperature → increased resistance

reduced current flow with local heating

significantly lower risk of overheating or material damage

In many applications, this allows for:

simplified or even dispensable external temperature control

increased operational safety

exceptional longevity of the heating element

Distinction from Conventional Silicone Heaters

The essential difference to conventional silicone heating technology available on the market is not evolutionary, but fundamentally technological:

> Thermrup® has not just encased a heating element in silicone – Thermrup® has transformed silicone itself into an active heating element.

This material science approach places higher demands on:

raw material selection

particle dispersion

aging stability

electrical reproducibility

However, it opens up application areas that are only limitedly or not at all feasible with classic heating wire solutions.

Typical Application Areas

Medical and therapeutic heat applications

Wellness and regeneration systems

large-area low-temperature heating

safe contact heat

applications with increased demands for homogeneity and comfort

Conclusion

The Thermrup® technology represents a material-based paradigm shift in electrical heating.
By combining semiconducting silicone rubber, planar heat generation, and natural far-infrared radiation, a heating solution is created that clearly differs from conventional silicone-based heating systems – technically, functionally, and physically.