Infrared LampsMore than radiation

2 Radiation

Drying drum

3Radiation

What is Radiation?

Spot welding unit with IR Pin-type lamps

IR-A 0.78 µm – 1.40 µmshort wavelength IR

IR-B 1.40 µm – 3.00 µmmedium wavelength IR

IR-C 3.000 µm – 10.0 µmlong wavelength IR

UV 0.10 µm – 0.38 µm ultraviolet light

VIS 0.38 µm – 0.78 µmvisible light

Radi

ance

�

Wavelength �

[µm]

0 0.5 1 1.5 2 2.5 3 3.5

Colour temperature

2900 K 2400 K 2100 K 1700 K

Typical spectrum of an incan descent lampatdifferentcolourtemperatures.

Contact-free heatingAn object irradiated by a heat source with short or medium wavelength can absorb more than 92 % of the radiated energy. This radiation can be transformed into heat within the heated object. To gain the highest possible efficiencythematerialoftheheatedobjecthastohaveanabsorptioncoeffi-cient which matches the spectrum of the IR-lamp.

Invisible for human eyesIR radiation lies beyond the range of visible light and therefore it cannot be seen by the human eye. According to DIN 5031 the spectral range of IR radiationisdefinedfrom0.78µmto10.0µm.TheIRrangeisdividedintothesections IR-A, IR-B and IR-C, as shown in the diagram.

Spectrum of the IR rangeIt is customary to use the terms short wave, medium wave and long wave toclassify IR-lamps.Thesedefinitionsareeasily remembered,but fromatechnical point of view they are incorrect. Solid state or monolithic lamps, i.e. incandescent lamps, continuously emit radiation within two of the above- mentioned wavelength ranges.

ConductionTransmittance by direct contact with the heat source

ConvectionTransmittance by direct contact with the heated media

RadiationContact-free transmittance through electromagnetic radiation

Therearedifferentoptionstoheat up objects – with and without direct contact:

4 Heating technology

Heating technology at its best

• Availablefrom100Wupto16000W• Colourtemperaturefromlessthan800Kup to 3200 K• Availablewithorwithoutintegratedreflector• Radiationadaptation inaccordancewith the application by use of additional tubes or coatings• A unique feature for USHIO IR-lamps is the EasyFit technology. With this tech- nology, the exchange of lamps – even of customized ones – is extremely fast and easy. EasyFit is individually adjustable and combines convenience and functionality. The lamp is both electrically attached and at the same time mechanically mounted• The well-known quick plug-in connector (KSSV) can be assembled• Customer-specificmodificationsornewdevel- opmentsofIR-lampsonrequest

Highly efficient in performance and costs• Short IR-lamp reaction time: 1–3 seconds, i.e. very little delay during switch-on, control andswitch-off• Very important if the material supply is stopped! • IR-lamps with short or medium wavelength are available to transform more than 92 % of the total input of electrical power into IR radiation• Typical average life of 5000 hours at rated voltage • No heating of the surrounding air through short-wave radiation • Nowarm-upcostsorheat-uptime• High-qualityquartztubesguaranteemechan- ical and thermal robustness • Dimmablewithseveralelectronicdevices• IR radiation can be directed by using an integrated reflector which leads to low IR power loss• Specificareaheatingfrom1upto500kW/m²• Constructionofcompactmachinesduetothe small dimensions of the IR-lamps• Specificpowerdensityfrom10upto270W per cm heat length

USHIOInfraredlamps(IR-lamps)aremanufacturedfromquartzglassandconstructedto ensure longevity of the lamps. The product range consists of lamps for short-wave and medium-wave applications.

5Heating technology

SpotweldingunitwithIRPin-typelamps;imagebybielomatikLeuzeGmbH&Co.KG

6 Applications

Apply USHIO quality to meet your need

• GlassandPETthermoforming• Plasticwelding• Keepingfoodwarmincatering• Heating of wafers in the semiconductor industry/epitaxy• Drying of fillers and varnishes in the car industry• Humiditycontrolinthepaperindustry• Medicalapplications• Fixingoftonerincopyandprintingmachines• Releaseoftensiononmetalweldingjoints• Solderingofprintedcircuitboards• Activationofglue• Hardeningofresins• Materialtesting• Shrink-fittingofballbearings• Hardeningofcement• Heating air in halls and in public transport vehicles• Shrinkingoffoils• Evaporationofsolvents(developmentoffilms)• Evaporationofwaterinairhumidifiers

Drying of ceramic bases

7

We provide for the perfect fi t

ThroughclosecooperationoftheR&Dandproductiondepartments,USHIOisabletodevelopandproduceapplication-specificlamps.Sometimesasmallmodificationissufficienttooptimize the application.

Perfectfit

Single-tube lampsMost applications use the typical single-tube lamp.Itisavailableindifferentversions.

IR Pin-type lampsSingle-ended IR Pin-type lamp with reflectivecoating. Designed for spot heating of contours – especially in the plastic welding industry.

Bended single-tube lampsUSHIO has developed an advanced productionprocess and can therefore offer highly sophisti-cated bended lamps. The advantage of these lamps: they can be combined in a variety of ways toprovidehomogeaneaouslyheatingfields.

Twin-Tube lampsBoth tubes of the twin-tube lamps are melted together. This ensures very high stability for longer lamps. Twin-Tube lamps can be single-ended or double-ended.

8 IR-lampsockets

Ushio IR-lamp sockets

LirU

B

R7s

KSSV

Lr

G

LiR

EasyFit

LirM

R7s tube

Fa4

LidU

Lin

9Reflectors

Heat up the power with reflectors

Radialpowerdistributionin%.Lampwithoutreflector

Radialpowerdistributionin%.Lampwithreflector

0

180170160

150

140

130

120

110

100

9080

7060

50

40

3020

10 -10-20

-30

-40

-50

-60-70

-80-90

-100-110

-120

-130

-140

-150-160

-170

50

100

150

200

Relative, radial radiant power in % withandwithoutreflector

Flamesprayingonthequartztube

Integrated reflectorDue to the longitudinal dimensions of IR-lamps the radiation is radial. By using a reflector, the radiation can easily be directed, increasing usable IR power up to 170 %. Integrated or external reflectors can be used depending on the appli-cation. Integrated reflectors guarantee high quality,easyhandlingandheatprotectionoftheIR-lamps housing.

Integrated reflectors are directly flame-sprayedon the quartz tube. Inmost cases the reflectorismadeofaluminaceramic. Ithasanefficiencyof approx. 80 %. The temperature resistance of the aluminaceramic reflector is higher than theoneofthequartzbulb.Thisguarantees–evenin applications without forced air cooling – the reflectorsfunctionalityoveritslifetime.

10 Quality

How to operate USHIO IR-lamps

General hints• Clean gloves must be worn when handling IR-lamps to avoid contamination of the quartztube.• Ifcleaning isnecessary,thisshouldbedone using rubbing alcohol or another suitable alcohol. • IR-lamps may only be handled if discon nected from the power supply. • Evenafterswitchingoff, IR-lampscanbeso hot that they can cause burns. • When changing lamps, the lamp holders shouldbecheckedforcharringandifneces sary be replaced.• Itisimportanttotakecaretohavethecorrect positioning when using IR-lamps with reflectors.• Theinstructionswhichareenclosedwiththe lamppackinghavetobeobservedatalltimes.

Permissible burning positions During operations the burning position must be in accordance with the spec-ification.TheburningpositionisspecifiedforeveryIR-lamp.IftheIR-lampis operated beyond the permitted burning position, its lifetime will decrease significantly. USHIO offers IR-lamps which are especially designed for vertical use.

Safety USHIOIR-lampsaresubjecttocontinuousqualitycontrolmeasuresandaredesigned not to cause any damage when used according to the instructions.

Thelampsmaybeusedonlywithsuitablesockets.Pleaseobservethemanu- facturer‘s instructions for the maximum operation temperature and current ofthesockets.Damagedsocketsmustbereplaced.

IR-lamps generate a high amount of heat. When installing, care must be taken tomaintainadequatedistancebetween theemitterand theheatedsurface,aswellasthereflector/fixture,toavoiddamage.

MeasurementintheR&Ddepartment

11IR-lamps

Electrical designUSHIO IR-lamps are designed in a way to obtain a specific power at acertain voltage. The life span of the lamps depends directly on that. Afrequentloadchangeinthevoltageofpowercanresultinashorterlife-time of the lamp. The operation at over-voltage will decrease the lifetime significantly.USHIOcanadapttheproductionandhandlingofanIR-lampinawaythatitslifetimewillnotbeaffectedbyloadchanges.Ifyouletusknowbeforehand,wewilldesigntheIR-lampforyourspecificneeds.

Permissible temperature range Toavoidmeltingof thequartz tube, interruptionof thehalogencycleandoxidation of the molybdenum foil during operation of the lamp, care has to be takentokeeptheoperatingtemperaturesaslistedbelow.

Dimming AllUSHIOIR-lampsaredimmable.

Welded point

Leadwire

PinchTungstenfilament

Molybdenum foil

Quartz tube

Max. pinch seal temperatureMin.quartztubetemperatureMax.quartztubetemperatureOptimumquartztubetemperature

350 °C250 °C900 °C

300–600°C

Version:1703-B-IR-IR

G-EN

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