Infrared Application of the Month #1:
Curing Latex on Carpet Backs
A carpet manufacturer sought a more efficient method for curing the latex backing of their carpets. They had been using a steam-heated platen and drum. A new mediumwave IR system from Heraeus allowed a 40% increase in production line speed, and the new system eliminated the problem of latex residue on the drum. The series of eighteen heaters -- each with its own switch -- allows quick, on-demand adjustment to accomodate different carpet widths.
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Infrared Application of the Month #2:
Curing Resin Impregnated Glass Fiber Sheets
A glass manufacturer chose Heraeus carbon infrared technology for its curing process. Resin-impregnated glass fiber sheets are cured in front of an IR module that features rapid on/off temperature response. Lower power consumption is a feature of the new process, and reduced glare in the final product is a result.
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Tech Center Spotlight:
Mediumwave IR Heaters
Stable and efficient, fast response medium wave heaters can transfer high power over long lengths. The high absorption by surface layers and films makes them particularly applicable to thin materials, while the fact that they also have a penetrative effect fits them for use in plastics processing. The heaters can be switched on and off in seconds and are consequently best suited for processes with short cycle times.
Because infrared heaters can be individually matched to a particular application, heating and drying processes can be seamlessly integrated within finishing operations – and with minimum disruption to existing manufacturing lines.
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Special Designs:
Spiral Heaters
With heaters in spiral form discs, tubes or rods made of plastics, metal or glass can be heated homogeneously. Compared with conventional heating methods, spiral heaters can provide savings in energy, time and costs. Heraeus offers a wide range of heaters for special applications.
Click HERE to download a brochure on Heraeus spiral heaters.
A wide assortment of other special design heaters is available from Heraeus. Click HERE for details.
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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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