October 2005
In This Issue...
Resources
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Welcome to the Premiere Issue
This is the first issue of Noblelight News from Heraeus. In this and future issues, we'll offer concise, relevant information about infrared and ultraviolet solutions for the specialty lighting market. In each issue we'll focus on applications and success stories; we'll help demystify technical concepts; and we'll let you know about special offers from Heraeus Noblelight. We want to make every issue of Noblelight News a resource you'll look forward to reading. Let us know how we're doing. We welcome comments, feedback and questions. [ Back to Top ]
Infrared Application of the Month:
Powder Oven for Gaskets
IR System Affords Energy- and Space-Savings
By installing an infrared oven from Heraeus Noblelight, a gasket manufacturer has been able to achieve significant savings in energy costs in the curing of powder coatings on a range of sealing gaskets at its manufacturing plant. In addition, the infrared system occupies less than half the space required by the previous gas-fired convection oven and has also allowed component throughput to be considerably increased.
The manufacturer factory specializes in the manufacture of seals and sealing systems for industry. Although some of these seals can be up to 5m in diameter, the majority are less than 1.2m diameter.
An important stage in the manufacture of metal sealing gaskets is the application and curing of an epoxy powder coating which provides in-service corrosion protection. Previously, the coatings had been cured in a gas-fired hot air oven but this had developed a number of disadvantages, the main one being the excessive energy consumption. This was primarily caused by the fact that the oven needed to be fired up at least two hours before the start of production and then had to be run continuously throughout the shift, regardless of whether product was being cured or not.
In an effort to reduce this energy consumption and to eliminate some of the other drawbacks of the hot air system, the gasket manufacturer decided to investigate alternative methods of curing the epoxy coating. As a result, tests were carried out using infrared as the curing technique and these proved so successful that a full scale, monorail medium wave infrared oven was installed.
This has a total length of 5.6m and an internal heated height of 1.3m so that it can handle gaskets up to 1.2m in diameter. The oven is split into three, consecutive 1m zones. The first zone is used to pre-heat the component and features 32, 2.75kW infrared heaters arranged on each side of the monorail conveyor which carries the components. This zone is followed by two holding zones, where the powder is heated further and allowed to flow fully. The first holding zone features 14, 2.75kW heaters arranged along one side of the oven, while the second zone has the same arrangement of heaters arranged on the other side of the oven. If required, control of the first holding zone can be effected by switching the heaters from full power to half power, while the heaters in the second holding zone are infinitely controllable by means of a thyristor.
Because the oven is now switched on only when needed, there has been a significant reduction in energy costs. In addition, curing is now much faster and output has been increased as there is now no need to wait for the oven to reach temperature before components are passed through. Moreover, the new infrared oven requires less than half the space of the convection oven.
For more information on Heraeus infrared heaters, please click HERE.
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Tech Center Spotlight:
Carbon Heaters
Infrared Heating Technology
Infrared heaters transmit large amounts of energy in a short time and at high efficiency. The wavelength of the infrared radiation has a crucial effect on the effectiveness of the heating process. Infrared heaters, which are optimally matched to the materials to be heated, provide energy savings of up to 50%. Heraeus infrared heating technology offers significant advantages: heat exactly where it is needed, with the optimum wavelength for the product and in line with the process.
High heating efficiency and rapid cool down make the mediumwave carbon heater from Heraeus the only medium-wave heater to offer you shortwave response times. Suitable for all medium-wave applications, this heater also offers the capability to match temperatures to the optimum absorption wavelength for each application. Together, these features eliminate overheating and contamination of sensitive substrates.
A particular large portion of medium wave radiation is absorbed in water, solvents and plastics and converted into heat. This allows significant benefits: carbon heaters dry printing inks, with less stress for the paper because the radiation acts more intensively on the ink. The high power heater increases print drying speed and reduces drying time. It also heats plastics in a targeted manner, with less heating of the surrounding environment.
- Various types of infrared heaters have different maximum output at different wavelengths – Halogen IR heaters at 1 µm, Carbon heaters at about 2.5 µm. Therefore at 3 µm the High Power Carbon heater provides three times the irradiance of a Halogen heater.
- Only that part of the spectrum which covers the absorption curve of water is effective for the drying process – not the whole infrared radiation. The infrared radiation of the Carbon heater is almost ideally matched to the absorption spectrum of water. In comparison, only a small fraction of short wave radiation covers the absorption curve. In other words, the greater part of the energy of short wave infrared radiation is wasted.
- The result is: A short wave heater at the same power density supplies less than 50 % of the power
of a carbon heater in drying processes. For example, at an irradiation of 120 watts/in2, the effective power density of a carbon heater is around 28 watts/m2; that of a short wave heater is around 14 watts/in2.
For more information on Heraeus carbon heaters, please click HERE.
Special Designs:
Short Wave Plug-in Heater
Heraeus offers the short wave infrared heater with a plug in connection. This design makes initial assembling as well as maintenance during production very simple. The plug in heater type helps to reduce maintenance costs.
Technical Data
- Short Wave
- Twin tube, 23 x 22 mm
- Gold reflector
- Single end connection
- Up to 10 Amp current
- 55-480 Volts possible
Advantages
- Simple installation
- Quick disconnect
- Fast replacement
- Tool-free replacement
- Reduce downtime
Click HERE to download a brochure on this product.
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Special From Heraeus
Limited time offer....until stock is gone.
Quartz T3 infrared heater 1600W/240V 16 inch heated
List price $54.73 each
fire sale @ $23.60 each
case price $19.95 each (60pc / case)
Quartz T3 infrared heater 2500W/480V 25 inch heated
List price $70.15 each
fire sale @ $31.50 each
case price $26.60 each (55pc / case)
All prices are in US dollars and freight shipped FOB Atlanta, Georgia USA. Email or call Toll-Free 800 311-8527 to order. [ Back to Top ]
That's it for this month's issue of Noblelight News. 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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