Infrared Application of the Month:
Embossing Laminates
A processor of wood grain laminates for home furniture products required an efficient and cost-effective source of process heat for embossing a wood grain finish to its products. They achieved their goals by replacing their ceramic heaters with short wave infrared heaters; these provided the required efficiency and applied targeted heat more evenly across the product surfaces.
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Infrared Application of the Month:
Booster for Metal Compressor Manufacturing
The manufacturer of metal compressors for refrigeration applications suffered from production bottlenecks. They sought greater efficiency in the powdercoating phase of the manufacturing process. By boostering the existing drying over through the addition of shortwave infrared heat lamps, the process enjoyed greater control, quicker heat-up, more even heat distribution, and a 50% increase in throughput for the powdercoating phase.
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Tech Center Spotlight: Wire Protection Screen for IR Windows
Metal mesh is an alternative method for protecting infrared modules. Its primary advantage is mechanical protection of the infrared haters. Wire screen features high open areas for maximum thermal efficiency. Typically it is constructed from welded or woven stainless steel wire with 1.5 - 2.5mm diameter.
Temperature of the wire depends on the infrared energy and airflow, and does not vary significantly among different infrared lamp types. After heat-up, temperature remains fairly stable. Metal mesh is acceptable for many different processes, but the ceramic glass window is a better solution for processes involving thin films and foils.
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Special Designs:
M Series Modular Infrared System
With the M Series Infrared Heating Module, targeted heat can be applied quickly, easily, and efficiently for all products that require surface heating or drying.
The M Series infrared heating modules feature a rugged and durable heating field that is perfect for many industrial heating applications. Available in three widths (110mm, 220mm, 330mm), the modules can be configured in any length up to 10 feet and can be combined to make larger heating fields. The heater housing is designed to accommodate 1 to 9 heaters depending on module width. The fan cooled housing keeps the exterior safe to touch while providing the necessary cooling for the internal components. Housing made from profiled aluminum. The modules are cut to length as needed, and designed to specifically fit your application. The M Series heater modules are highly customizable from stock materials, and delivery is typically only a few days.
Learn more about the M Series Modular Infrared System from Heraeus Noblelight.
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Technical Learning: Introduction to IR Technology, Part 4 (conclusion)
Developments in process heating
During World War II infrared heating became more widely recognized. The main applications were in the metal finishing fields, notably in the curing and drying of paints and lacquers on military equipment. Banks of lamp bulbs were used very successfully, and although by today's standards the power intensities were very low, the technique offered much faster drying than the fuel-fired convection ovens of the time. Production bottlenecks were overcome and military supplies to the armed forces were maintained.
After the urgency of war production had passed, the adoption of infrared heating techniques continued, albeit on a much slower basis. As industries reverted to normal peace time operations, prewar methods of production were reinstated in order to resume full output as quickly as possible, and to provide immediate employment for the returning members of the armed forces.
However, in the mid 1950s the motor vehicle industry again began to show interest in the capabilities of infrared for paint curing, and a number of production line infrared tunnels came into use. The familiar lamp bulbs were by now being complemented by a new tubular lamp of higher radiant intensity but smaller in physical size. This allowed a much higher packing density to be achieved, hence a higher power intensity over a given area of radiant emission.
With the interest in infrared heating now renewed, new types of heat sources (heaters) were developed to fill the ever widening needs of industry. There now exists a variety of types, shapes and sizes with an extensive range of intensities and operating temperatures. This flexibility enables the equipment designer to meet a vast range of process heating requirements, such as paint curing, moisture evaporation, printing ink drying and heating of solid materials. Thus the technique is not restricted to a unique heating condition but may be as powerful or as gentle as a particular process requires.
Summary of benefits
The growth in popularity of infrared systems over the past 30 years stems not only from numerous production benefits provided by this form of heating but also from more mechanized production processes and new heat setting materials being deployed in industry. Certain benefits are, of course, common to all infrared systems, but additional specific benefits are often obtained depending on the process under consideration.
In general infrared systems provide the following:
- Rapid heating of the product. In all but a few exceptional cases radiative transfer of heat is much faster than convection. A more constant rate of heating is obtained because the source temperature is normally much higher than that of the product, even at the end of the heating cycle.
- Low energy costs because of short heating times, and the ability to apply the heat only where and when it is required.
- Cleanliness in operation as the heat sources do not cause contamination.
- Elimination of atmospheric pollution due to the absence of combustion products.
- Ease of control combined with safe operation.
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That's it for this month's issue of Application Notes for IR Heating. Feel free to encourage your colleagues to subscribe. Just click HERE to send them an invitation to subscribe. It's quick, easy, FREE, and no-obligation.
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