What is An Infrared Heater?
An infrared heater is a type of radiant heating system that emits infrared radiation to directly heat objects and surfaces within its line of sight, rather than heating the surrounding air.
Components of An Infrared Heater
Heating Element: The primary component is a heating element that converts electrical energy into infrared radiation. Common types include:
- Metal film elements – thin metal films or wires that emit IR when heated by electrical current
- Peltier elements – solid-state devices that generate heat when electrical current flows through them
- Halogen lamps – incandescent lamps with a halogen gas that allows the filament to operate at higher temperatures, emitting more IR
Housing/Casing: An outer casing or housing encloses the heating element, often with an IR-transparent window to allow radiation to pass through.
Reflectors: Reflective surfaces behind the heating element help direct and focus the IR radiation.
Types of Infrared Heaters
Heating Element Types
Electric Heating Elements
- Resistance wire heating elements: Metal resistance wires like tungsten or nichrome arranged in a coiled or meandering pattern to generate infrared radiation when heated by electric current.
- Peltier elements: Solid-state heating elements using the Peltier effect to generate infrared radiation directly from electric current.
- Carbon/graphite heating elements: Extruded and sintered carbon/graphite rods or plates that emit infrared when electrically heated.
Combustion Heating Elements
Gas-fired infrared emitters: Radiant tubes or panels heated by the combustion of gases like natural gas or propane.
Infrared Heater Configurations
Panel/Surface Heaters
- Heating elements embedded in or applied to a flat panel or surface that radiates infrared energy.
- Panels can be made of ceramic, metal, or other materials with high infrared emissivity.
Tubular Heaters
- Heating elements arranged inside a cylindrical quartz or ceramic emitter tube.
- Heat is transferred to the tube surface primarily by radiation from the heating element.
Reflector Heaters
- Heating elements mounted in a reflector housing to direct infrared radiation in a controlled pattern.
- Reflectors can have different shapes (e.g. parabolic) to focus or disperse the infrared energy.
Modular/Customized Heaters
- Infrared emitters designed as modules that can be arranged in custom configurations for specific applications.
- Modules can have convex or concave emitting surfaces to control radiation patterns.
Applications of Infrared Heater
Industrial Applications
- Curing of coatings, forming plastics, annealing, plastic welding, and print drying processes benefit from infrared heating’s ability to rapidly and efficiently heat targeted surfaces/materials.
- Soldering electronic components using infrared heating enables high speed, low thermal lag, and effective temperature profiling.
Building/Space Heating
- Infrared panel heaters can be used for heating rooms and buildings by radiating heat directly onto surfaces, walls, and occupants without significantly heating the air.
- Advantages include quick heating response, uniform radiant heat distribution, low air movement, and suitability for large/poorly insulated spaces.
Specialized Heating Applications
Deicing aircraft wings 6 by targeting infrared radiation on ice buildup.
Infrared saunas and bathrooms for heating occupants directly.
Food cooking and heating by primarily heating the food itself instead of the surrounding air.
Application Cases
| Product/Project | Technical Outcomes | Application Scenarios |
|---|---|---|
| Infrared Curing Systems | Rapid and efficient curing of coatings, inks, and adhesives, reducing energy consumption and processing time by up to 50% compared to conventional methods. | Industrial printing, coating, and laminating processes requiring high-speed curing. |
| Infrared Plastic Welding | Precise and localised heating enables strong, seamless welding of plastic components with minimal material degradation, improving product quality and durability. | Automotive, medical, and consumer product manufacturing involving plastic components. |
| Infrared Food Processing | Uniform and controlled heating of food products, enhancing flavour, texture, and shelf-life while reducing cooking time by up to 30% compared to conventional methods. | Commercial food processing plants, bakeries, and food service operations. |
| Infrared Comfort Heating | Efficient and targeted heating of occupied spaces, reducing energy consumption by up to 60% compared to traditional HVAC systems while providing consistent warmth. | Residential, commercial, and industrial spaces requiring localised heating solutions. |
| Infrared Soldering Systems | Precise and controlled heating of electronic components, enabling high-speed soldering with minimal thermal stress, improving product reliability and reducing rework rates. | Electronics manufacturing and repair facilities requiring efficient and accurate soldering processes. |
Latest Technical Innovations of Infrared Heater
Heating Element Materials and Designs
- Carbon-based heating elements made from sintered carbon-based substances and resins, with resistance-temperature characteristics adjusted through reheating in vacuum
- Wire or plate-shaped heating elements containing carbon-based substances, with internal lead wires wound around the ends
- Metallic heating conductors applied to or embedded in ceramic insulating layers
- Peltier elements assigned to the cover layer and connected in a thermally conductive manner for advantageous heating conditions
Emitter Tube and Cover Designs
- Quartz glass emitter tubes filled with inert gas, housing the heating element
- Emitter tubes with pinches at the ends, aligned with opaque tube sections
- Cover layer acting as a radiant surface, with a gap maintained in front of the emitter layer
- Covers made of materials partially transparent to infrared radiation
Advanced Heating Element Structures
- Metamaterial structures capable of emitting infrared radiation with a non-Planck distribution peak wavelength when supplied with thermal energy from the heating element
- Infrared radiators with convex first emission surfaces and concave second radiation surfaces for efficient use of infrared heating effect
Electrical and Thermal Management
- Electrical contacting of heating conductors via exterior contacts and through-contacts (vias)
- Closed air chambers adjacent to the heating chamber for improved thermal management
- Reflection plates sleeved on the side walls of infrared heating tubes, with mounting holes for the tubes
Technical Challenges
| Heating Element Material Design | Developing advanced heating element materials with optimised resistance-temperature characteristics and high infrared emissivity, such as carbon-based composites or metallic conductors embedded in ceramic insulators. |
| Emitter Tube and Cover Design | Designing emitter tubes and covers that maximise infrared transmission while withstanding high temperatures, such as quartz tubes with inert gas fillings or covers made from infrared-transparent materials. |
| Temperature Distribution and Uniformity | Achieving uniform temperature distribution across the emitter surface to prevent hotspots and ensure consistent infrared output. |
| Thermal Insulation and Heat Management | Improving thermal insulation and heat management systems to minimise heat losses and increase energy efficiency. |
| Integration of Advanced Controls | Integrating advanced control systems, such as temperature feedback loops and adaptive heating profiles, to optimise performance and energy usage. |
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