8
Heraeus Noblelight Infrared Modules for Industrial Processes
Heraeus Noblelight
Infrared Modules for Industrial Processes
Car
bon
Twin
Infra
red
Em
itter
s C
IR
Fast
Res
pons
e, M
ediu
m W
ave
Infra
red
Em
itter
s
Car
bon
Rou
nd T
ube
Infra
red
Em
itter
s C
IR
Sho
rt W
ave
Infra
red
Em
itter
s
Infrared radiation transfers heatdirectly and at high efficiency. Infrared heating technology meansheat only where it is needed, at theoptimum wavelength for the materialand in line with the process.
Carbon Infrared Emitters CIR®
CIR® emitters combine a medium wavespectrum with fast response times and highpower outputs. These emitters are produ-ced as round tube- or twin tube emitters, in lengths up to 3m, with maximum poweroutputs of 100 kW/m2 for round tube or150 kW/m2 for twin tube emitters.
Medium Wave Infrared EmittersStandard emitters with a medium wavespectrum, solid, flexible in construction,lengths (up to 6.5m) and power output (max. 60 kW/m2), especially suitable for continuous processes.
Fast Response, Medium Wave Infrared EmittersEmitters, with an improved output in themedium wave (2-4micron). Response timesas fast as short wave, with a maximumpower output of 150 kW/m2 and lengthsup to 6.4m
Short Wave Infrared EmittersInfrared emitters in the short wave region.Twin tubes with lengths of up to 6.4m andhigh maximum power output of 200 kW/m2.
Infrared Halogen Emitters NIRHalogen infrared emitters with a spectrum in the near-infrared region, a maximumpower output of 1000 kW/m2 and very fast response times.
Emitters for Targeted Heatmeet all requirements in finishing processes, where only very small or curved faces,edges, borders or defined contours of theproduct need heating. For this HeraeusNoblelight has developed purpose builtproducts such as contoured emitters, small surface emitters, Omega emittersand emitters for heating hot rivets.Common to all of these emitters is theirfocus in shape, size and spectrum to thedesired process. Heat is produced in atargeted fashion exactly where it is needed.Consequently energy losses to thesurrounding area are very small. Infrared emitters are produced as roundtube or twin tube. Twin Tube InfraredEmitters have a high mechanical stabilityand can be produced in every requiredlength up to 6.3mA Gold Reflector on the IR emittersreflects the IR radiation; the effective radi-ation onto the object is therefore roughlydoubled.
The Right Wavelength to Optimize the Result
Med
ium
Wav
e In
frare
d E
mitt
ers
Infra
red
Hal
ogen
Em
itter
s N
IR
Infra
red
Hal
ogen
Em
itter
s N
IR
Different wavelengths are more suitableor less suitable for a particular processaccording to the absorption propertiesof the material and the practical require-ments of the production process.Heraeus Noblelight is a specialist incustom-built infrared emitters andassists in the selection of the optimumemitter. Heraeus Noblelight creates thebasis for solutions, which are matchedprecisely to the requirements of theuser. The development of emitters aredirected at the needs of customers andthe latest state of the art technology.
Heraeus Noblelight infrared modulescomprise one or more infra red emittersmounted in a suitable housing andusually wired into a terminal boxmounted on the back of the unit.System solutions comprise modulesand a control panel designed to meetthe requirements of the individualprocess.
Modules – designed for the processThe great strength of Heraeus Noblelightlies in the tailor-made solutions it offerscustomers. Experienced personnel inGermany, Belgium, Great Britain and theUSA construct modules to meet customerrequirements. The latest technology, such as three-dimensional CAD techniques,is available.Modules can be built from all infraredemitters to dimensions that suit customer’splant with outputs necessary for the specificprocess. The selection of the optimumemitter for the material to be heated ismade with reference to the process data.
Heraeus Noblelight modules are tailoredsolutions offered with or without ventilationand designed to meet all issues suchas emitter type, thermal and mechanicalstability, air movement and operatingenvironment.They are designed to be fitted into anexisting plant or for installation into newlines.
Systems – for the complete heating processOn Request infrared modules can beprovided as part of a complete solution. This can provide simple on off control ofemitters through to full closed loop controlwhere substrate temperature is measuredand emitters regulated to maintain therequired heating profile.The control panel provided will be a wallmounted or floor standing enclosureequipped with all the necessary electronicand electrical equipment.
The Right Wavelength to Optimize the Result
Modules can come in various forms –to suit the process. Depending on theprocess parameters, the product webwidths or special temperature profiles,flat large heating fields, individuallyshaped modules, tunnels or ovens canbe designed and built.
Plastic drawing with infrared modulesInfrared modules arranged in flat heatingfields are best suited for heating processeson product webs. However, many processesrequire further consideration. Tubular profiles need to be evenly heatedall round, as consistent heating is importantto obtain constant foil thickness.Consequently, the plastic tubes are heatedto a given temperature and then stretched.The advantage of IR radiation over warmair is that the heat is concentrated in a verysmall space. As a result the heating zoneis reduced. IR modules can be controlledvery accurately and reliably heat plasticmaterials to the required temperatures.
Module OvensModules in oven form facilitate the heating of continuous plastic tubes orfibres. They also allow the vulcanisation ofrubber as the heat is evenly concentratedonto the product from all sides.A quartz glass safety tube allows aircooling of the emitter surface withoutcooling the product.
All Kinds of Modules
Plastic drawing with IR heat IR Module in oven form
Bending of plastic componentsThermoplastic components are heated by infrared before forming. Compact,controllable modules ensure that only theproduct, and not the surrounding environ-ment, is heated. Modules can be hinged to facilitate loading of components.The product temperature is measured with a pyrometer and, at a given temperature,the plastic components, such as tubes, are removed and formed as desired.
Operations in vacuumIn the production of thin film solar cells, float glass sheets are heated so that theycan be coated. This takes place in vacuumplant. Infrared emitters, which generateheat directly in the vacuum chamber, heatthe float glass sheets very effectively.Heraeus modifies its emitters for operatingin vacuum with special sockets and leadsand also manufactures emitters withspecial voltages. Infrared modules are alsomodified for operation in vacuum, so thatall current conducting parts are built forvacuum conditions.
Bending of plastic components Vacuum plant with infrared emitters
Carbon module with zone regulationA module with Carbon infrared emitters ishelping to improve the quality of internalcarpeting of motor vehicles.This has been made possible through 15 individually controllable zones, whichallow the maintenance and control of agiven temperature profile. Car internal carpets are formed in a verycomplicated manner and are different forevery type of car. A complete module system, where eachindividual zone has its own thyristor, whichcontrols the power individually, and wherethe temperature of the carpet is controlledwith the aid of a pyrometer, leads to asignificant improvement in quality. Notleast, such a system can be adjusted tocater for the different types and shape ofcarpet. The flexible control and the fast responsetimes of the carbon emitters also allowsignificant energy savings.
Chocolates need IR heatIn the manufacture of caramel-filledchocolates, the edges of a chocolate filledmould are heated and then fused with a chocolate lid. Carbon infrared emitter’s heat thechocolate reliably and, because of theirvery fast response, can be switched offquickly in the event of a production linestoppage to prevent any over-heating ofthe chocolate. The emitters are very stableand are also fitted with an alarm system todetect any damage. The infrared modulesrequire only 25 % of the space required byceramic modules.Heraeus has developed special moduleswith a safety foil for food applications.
Relaxing textilesIn the manufacture of carpet tiles, hotbitumen is applied to the tile backingstructure. To guarantee the adhesion of the bitumen layer to the backing structurethe carpet must be ”relaxed“ as much aspossible. To do this, the carpet web isheated with infrared and stretched overrollers. The complete operation is pyro-meter controlled, which in combination with very fast response IR emitters ensuresthat changing line speeds or unexpectedproduction linestoppagesarenotaproblem.The infrared modules concentrate a lot ofenergy in a very small area, to save bothenergy and space.
Modules for all sectors
Industrial manufacturing processesneed heat for many different produc-tion stages. Infrared modules reliably and efficiently heat product webs, dry lacquers and activate adhesive,assist in the forming of plastics and areused in the production of foodstuffs.Infrared modules facilitate theapplication of infrared heat in virtuallyall sectors.
Heating chocolate Carpet web relaxed before the coatingCarbon module for car internal fittings
Making carpets with IRLatex, is applied to woven carpet to,provide stability and to bind the woventufts into the weft backing. This medium wave system with widthswitching capabilities is used to pre dry the latex coating before the carpet passesover a steam heated drum. With thisarrangement, high quality carpets can beproduced time after time, productionspeeds are increased and productivityimproved.
Drying of varnish on wood In the manufacture of furniture, woodenboards or panels are coated many times to achieve the desired shade or colour. Before the cover varnish is applied, awater-based stain coat must first be com-pletely dried. This takes place reliably andrapidly with infrared radiation. Mediumwave emitter’s dry water based coatingsvery efficiently and save energy. Coatingson temperature-sensitive products can also be dried quickly, without overheating theproduct.IR Modules require significantly less spaceand operating time than conventionalheating methods. They are simple tohandle, are easily incorporated into themanufacturing process or retrofitted intoexisting plant.
Drying PVC in the automotive industryA PLC controlled system with bodyidentification ensures that only vehicles with a PVC anti-chip compound applied are heated.Infrared is used to pre cure the PVCcoating applied to the sill area of thevehicle.Two banks of carbon emitters aredesigned to direct energy to the area ofthe sill where the coating is applied.To ensure maximum energy efficiency theemitters are cascaded to track the vehicleas it moves down the line.
Drying of latex on the backing of carpets Coating of wood parts Drying PVC anti chip compound
Tested, Checked and Proven
Know-how with traditionHeraeus Noblelight has many years’experience in infrared heating technologyand provides individual advice and service.Heraeus Noblelight offers its customersthe capability for proving trials in its in-house Applications Center or on-sitewith experienced technical assistance.Heraeus has Application Centers all overthe world.Here you can examine the effects ofinfrared and the different infrared spectralradiation on your product as well asmeasure the temperature distributionduring the heating process. From theseresults Heraeus engineers can calculatethe required power output and otherparameters needed for your new thermalprocess.In addition we offer a range of portabletest equipment which can be used for anonline appraisal of the benefits of infrared.
Areas of Application ● Heating● Drying● Coating● Laminating● Annealing
Find nearly all about infrared on our CD.Order free of charge!
Heraeus is your partner for industrial heating processes in● Glass● Plastics● Textiles● Automotive● Semi-conductor Manufacture● Food Processing● Print and Paper● Electronics● MetalsHeraeus Noblelight sales engineers use 30 years of company experience from all major industries to give you expertguidance during the initial stages of yourthermal process design.
Tests in the Application Center Tests with customer materials
Drying trials on-site with portable testequipment
Source information
Foil drawing (page 4): Windmöller & Hölscher,
D-49525 Lengerich, Vacuum plant (page 5): Roth & Rau
Oberflächentechnik GmbH, D-09358 Wüstenbrand
Heraeus Noblelight GmbHReinhard-Heraeus-Ring 7D-63801 KleinostheimGermanyPhone +49 (6181) 35-8545Telefax +49 (6181) 35-168410E-Mail: [email protected]
Heraeus Noblelight Ltd.Unit 1 Millennium CourtClayhill Industrial EstateBuildwas RoadGB-Neston, Cheshire CH64 3UZPhone +44 (151) 353 2710Telefax +44 (151) 353 [email protected]
Heraeus Noblelight, Inc.2150 Northmont Parkway, Suite LDuluth, GA 30096/USAPhone +1 (770) 418-0707Telefax +1 (770) 418-0688
E-Mail:[email protected] Reg. No. 39254
We reserve the right to change the pictures Printed in Germany HNG - B 56 E 5C 12/04/M+Tand technical data of this brochure.
