Heraeus Noblelight

Infrared Modules for Industrial Processes

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Infrared radiation transfers heat directlyand at high efficiency. Infrared heatingtechnology means heat only where it isneeded, at the optimum wavelength forthe material and in line with the process.

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.

Short Wave Infrared EmittersInfrared emitters in the short wave region.Twin tubes with lengths of up to 2.4m andhigh maximum power output of 150 kW/m2.

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 120 kW/m2 and lengths up to 6.3m

Medium Wave Infrared EmittersStandard emitters with a medium wavespectrum, solid, flexible in construction,lengths (up to 6m) and power output (max. 50 kW/m2), especially suitable for continuous processes.

Carbon Infrared Emitters CIRCIR emitters combine a medium wavespectrum with fast response times and highpower outputs. These emitters are producedas 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.

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 Heraeus hasdeveloped purpose built products such ascontoured emitters, small surface emitters,Omega emitters and emitters for heating hot rivets.

The Right Wavelength to Optimize the Result

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 6.3m

A Gold Reflector on the IR emitters reflectsthe IR radiation; the effective radiation ontothe object is therefore roughly doubled.

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Heraeus infrared modules compriseone or more infra red emitters mountedin a suitable housing and usually wiredinto a terminal box mounted on theback of the unit.System solutions comprise modules anda control panel designed to meet therequirements of the individual process.

Modules – designed for the processThe great strength of Heraeus lies in thetailor-made solutions it offers customers.Experienced personnel in Germany,Belgium, Great Britain and the USAconstruct 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 modules are tailored solutionsoffered with or without ventilation anddesigned to meet all issues such as emittertype, thermal and mechanical stability, air movement and operating environment.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.

What is a module?

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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 is a specialist in custom-builtinfrared emitters and assists in theselection of the optimum emitter.Heraeus creates the basis for solutions,which are matched precisely to therequirements of the user. The develop-ment of emitters are directed at theneeds of customers and the latest stateof the art technology.

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 heated allround, as consistent heating is important toobtain constant foil thickness. Consequently,the plastic tubes are heated to a giventemperature and then stretched. Theadvantage of IR radiation over warm air isthat the heat is concentrated in a very smallspace. As a result the heating zone isreduced. IR modules can be controlled veryaccurately and reliably heat plastic materialsto the required temperatures.

Module OvensModules in oven form facilitate the heatingof continuous plastic tubes or fibres. Theyalso allow the vulcanisation of rubber as theheat is evenly concentrated onto the productfrom all sides.A quartz glass safety tube allows air coolingof the emitter surface without cooling theproduct.

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 generate heatdirectly in the vacuum chamber, heat thefloat glass sheets very effectively. Heraeusmodifies its emitters for operating in vacuumwith special sockets and leads and alsomanufactures emitters with special voltages.Infrared modules are also modified foroperation in vacuum, so that all currentconducting parts are built for vacuumconditions.

Bending of plastic components Vacuum plant with infrared emitters

Heating chocolate Carpet web relaxed before the coating

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. Not least,such a system can be adjusted to cater forthe different types and shape of carpet. 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 the chocolatereliably and, because of their very fastresponse, can be switched off quickly in the event of a production line stoppage toprevent any over-heating of the chocolate.The emitters are very stable and are alsofitted with an alarm system to detect anydamage. The infrared modules require only25 % of the space required by ceramicmodules.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 thebitumen layer to the backing structure thecarpet must be ”relaxed“ as much aspossible. To do this, the carpet web isheated with infrared and stretched overrollers. The complete operation is pyrometercontrolled, which in combination with veryfast response IR emitters ensures thatchanging line speeds or unexpectedproduction line stoppages are not a problem.The infrared modules concentrate a lot ofenergy in a very small area, to save bothenergy and space.

Carbon module for car internal fittings

Modules for all sectors

Industrial manufacturing processesneed heat for many different productionstages. 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.

Drying of latex on the backing of carpets Coating of wood parts Drying PVC anti chip compound

Making carpets with IRLatex, is applied to woven carpet to, providestability and to bind the woven tufts into theweft backing. This medium wave system with widthswitching capabilities is used to pre dry thelatex coating before the carpet passes overa steam heated drum. With this arrange-ment, high quality carpets can be producedtime after time, production speeds areincreased and productivity improved.

Drying of varnish on wood In the manufacture of furniture, woodenboards or panels are coated many times toachieve the desired shade or colour. Before the cover varnish is applied, a water-based stain coat must first be completelydried. This takes place reliably and rapidlywith infrared radiation. Medium waveemitter’s dry water based coatings veryefficiently and save energy. Coatings ontemperature-sensitive products can also be dried quickly, without overheating theproduct.IR Modules require significantly less spaceand operating time than conventionalheating methods. They are simple to handle,are easily incorporated into the manu-facturing process or retrofitted into existingplant.

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 PVC coatingapplied to the sill area of the vehicle.Two banks of carbon emitters are designedto direct energy to the area of the sill wherethe coating is applied.To ensure maximum energy efficiency theemitters are cascaded to track the vehicleas it moves down the line.

Reg. No. 39254

Heraeus Noblelight GmbHReinhard-Heraeus-Ring 7D-63801 KleinostheimGermanyPhone +49 (6181) 35-8545Telefax +49 (6181) 35-8410E-Mail:hng-infrared@heraeus.comwww.heraeus-noblelight.com

Heraeus Noblelight Ltd.8, Caldbeck RoadBromborough, WirralMerseyside CH62 3PL/EnglandPhone +44 (151) 343 0545Telefax +44 (151) 343 9883E-Mail:hnl-bromborough@heraeus.comwww.heraeus-noblelight.com

Heraeus Amba Australia Pty. Ltd.Unit 3, 41-49 Norcal RoadNunawading, Victoria, 3131Phone +61 (3) 9874 7455Telefax +61 (3) 9874 7488

E-Mail:sales@heraeus-amba.com.auwww.heraeus-amba.com.au

We reserve the right to change the pictures Printed in Germany · HNG - B 56 E 3C 03/02/M+Tand technical data of this brochure.

Source information

Foil drawing (page 4): Windmöller & Hölscher, D-49525 Lengerich, Vacuum plant (page 5): Roth & Rau Oberflächentechnik GmbH, D-09358 Wüstenbrand

Know-how with traditionHeraeus Noblelight has many years’experience in infrared heating technologyand provides individual advice and service.Heraeus offers its customers the capabilityfor proving trials in its in-house ApplicationsCenter or on-site with experienced technicalassistance.Heraeus has Application Centers in Kleinostheim (D), Liedekerke (B),Bromborough (GB), Atlanta (USA) and Cavenago Brianza (I).Here you can examine the effects ofinfrared and the different infrared spectralradiation on your product as well as measurethe temperature distribution during theheating process. From these results Heraeusengineers can calculate the required poweroutput and other parameters needed foryour new thermal process.In addition we offer a range of portable testequipment which can be used for an onlineappraisal of the benefits of infrared.

Areas of Application in the Glass Industry● Heating● Drying● Coating● Laminating● Annealing

Heraeus is your partner for industrial heating processes in● Glass● Plastics● Textiles● Automotive● Semi-conductor Manufacture● Food Processing● Print and Paper● Electronics● MetalsHeraeus sales engineers use 30 years of company experience from all majorindustries to give you expert guidanceduring the initial stages of your thermalprocess design.

Tested, Checked and Proven

Tests in the Application Center Tests with customer materials

Drying trials on-site with portable testequipment