Infrared heating

Abstract

Infrared heating (1) comprising at least one IR heating element (3), which is arranged in the floor area, on the walls or on the ceiling of a room or in suitable combinations of these room areas, and has one or more electrically operated IR heating panels, characterized in that the IR heating panels are designed as IR heating modules (2) and have one or more IR heating segments (4) which are arranged on an IR radiator (5) for transmitting heat and IR radiation, wherein the IR heating segments (4) are designed as electrical resistance elements for emitting heat and IR radiation and consist partially or completely of the following components: - Graphite, - silicon carbide or other components from the group of substances “rare earths”, - additional materials such as aluminum oxide, slate and / or resins.

Description

[0001] The present invention relates to a versatile infrared heater and its IR heating modules, which are suitable for heating residential and commercial premises in a diverse and energy-saving manner.

[0002] Electric and gas-powered infrared heaters have been around for a long time and are used for various purposes.

[0003] This utilizes the heat-generating effect of infrared radiation from the electromagnetic spectrum when it hits objects and bodies. Infrared radiation, as part of the electromagnetic spectrum, is essentially emitted by every body according to its temperature, with the intensity of IR radiation increasing sharply at a body temperature above 100°C.

[0004] In addition to the well-known electric heaters, whose filament is a resistance element and is stimulated by electric current to emit infrared radiation, there are also gas heaters whose filaments are heated with flammable gas to emit heat and IR radiation.

[0005] Other infrared heaters, particularly for industrial applications such as in various drying processes on assembly lines, often use a heating coil enclosed in a quartz glass vacuum or in a protective gas, or heating wires embedded in insulating layers, which act as resistance elements and are made to glow by the flow of current.

[0006] Infrared heaters for any room and open space have the advantage over other types of heating in that the emitted IR radiation immediately acts as heat on the body of people or objects.

[0007] This isn't the case with other conventional gas or oil heating systems. Here, the heat transfer medium (water) must first heat the radiator and then the surrounding air, resulting in a slower heating response.

[0008] The infrared heaters considered here use electrical resistance elements, wires or coils through which current flows to generate infrared radiation.

[0009] These resistance bodies can have different designs and sizes, such as metallically contacted wires and strips made of carbon, metallic resistors or electrically conductive carbon fiber fleece.

[0010] In some cases, these electrical resistance bodies do not themselves serve as heating segments for the emission of infrared radiation, but transfer their entire heat to surface-shaped infrared radiators (IR radiators) to which they are technically firmly connected.

[0011] Such IR radiators, often designed as surface radiators or infrared panels, have better IR radiation characteristics and can be flexibly shaped and scaled in their dimensions according to their intended use.

[0012] However, only a part of the electrical energy used is converted into the desired infrared radiation; the rest is dissipated into the environment through heat conduction and convection.

[0013] To increase the IR radiation output of the IR heaters compared to heat conduction and convection, well-known electric infrared heaters also use specially designed and enlarged radiation surfaces or additional IR reflectors.

[0014] Numerous proposals and designs are known from the patent literature which are intended to improve the efficiency of infrared heaters and IR radiation.

[0015] The German patent DE10 2010 008 449 B4, for example, describes an infrared wall heating system with a flexible heating fabric into which carbon threads are woven as a resistance heating element and metallic electrical conductors.

[0016] The electrical conductors are arranged perpendicular to the carbon filaments at both ends of the heating element and tightly wrap around the carbon filaments. The heating element is protected on both sides by a layer of insulating foil.

[0017] The wall heating system described is very light and emits warming infrared radiation after just a short time.

[0018] However, these types of heating wallpapers operate at low voltages of up to 42 V and cannot be connected directly to the public power grid, but require additional voltage converters or inverters.

[0019] Another infrared surface heating element based on electrically and thermally conductive carbon precision fleece is known from German utility model DE20 2006 07 228 U1. It serves as a multilayer sandwich for space heating and drying. It can be operated with both alternating and direct current and behaves like a heating resistor.

[0020] The special fiber mixture of the fleece in combination with infrared-permeable special glass and an aluminum foil shielding leads to a very high emission of infrared radiation at wavelengths of 7.4 µm to 8.4 µm.

[0021] This high emission of thermal radiation is intended to significantly reduce the energy consumption of these surface heating elements.

[0022] However, the complex layer structure and its necessary isotropic structure across the surface pose a major challenge in production.

[0023] The object of the present invention is therefore to provide an electric infrared heater for rooms which can be used or integrated in a versatile and expedient manner in various infrared heater designs.

[0024] For this purpose, the proposed infrared heating system should have special IR heating modules as a replaceable assembly, which ensures a high proportion of infrared heat radiation in the total heat output.

[0025] This problem is solved by the characterizing part of the first claim in conjunction with its preamble. Further innovative and advantageous solutions are proposed in the subclaims.

[0026] The infrared heater according to the invention comprises one or more heating elements which can be flexibly designed according to the requirements and tasks, which are arranged in different designs in the floor, on the walls or on the ceiling of a room to be heated or in suitable combinations and have one or more electrically operated IR heating modules, each of which has one or more shaped bodies as resistance heating segments.

[0027] The electrical contact of the heating segments is made by a special conductive adhesive, which is part of the invention.

[0028] The IR heating modules consist of a planar infrared radiator (hereinafter IR radiator) for emitting IR radiation and convection heat to the environment, which is thermally connected to one or more heat-generating IR heating segments.

[0029] The IR heating segments are designed as block-shaped or three-dimensional resistance elements for emitting heat and IR radiation and, depending on the application, consist partly or completely of the following components: Graphite, silicon carbide or other components from the group of “rare earths”, as well as additional fillers such as aluminum oxide, slate and / or resins.

[0030] According to the invention, the components of the heat-generating IR heating segments are predominantly in powder form, which are then pressed into various three-dimensional resistance elements, hereinafter also referred to as IR heating segments.

[0031] According to the invention, the heat-generating IR heating segments are preferably firmly connected to the IR radiators to form IR heating modules and for heat transfer, which can be realized, for example, with heat-transferring but electrically insulating high-temperature adhesives.

[0032] Depending on the application of the IR heating modules, such as the temperature to be achieved, a suitable number of IR heating segments can be additionally attached to an IR radiator.

[0033] The modular design of the IR heating modules and their flexible composition from the aforementioned basic materials allows them to be used in different IR heating systems, for example by varying the resistance value and current intensity.

[0034] The invention will now be explained with reference to several embodiments and the Fig. 1 and Fig. 2 will be explained in more detail.

[0035] They show: Fig. 1 - an infrared heater 1 according to the invention with the IR heating module 2, Fig. 2 - a side view of the infrared heater 1 with five heating segments 4 on an IR radiator 5.

[0036] The representation of a flat IR heater 3 in Fig. 1 is preferably intended for wall mounting of any room to be heated with the infrared heater 1, in particular living, working or business premises or other recreation and storage rooms or outdoors.

[0037] In this embodiment of the invention, the section of an IR heater 3 with an IR heating module 2 is shown as an essential component of an infrared heater 1. The dashed outline of the IR heater 3 shows only a section of the invisible entire heater 3, which, depending on the design and use, can comprise one or more IR heating modules 2.

[0038] The IR heating modules 2 form an important structural unit suitable for various embodiments of the infrared heater 1 according to the invention, which consists of one or more IR heating segments 4 and one or more IR radiators (5).

[0039] The IR heating segments (4) are preferably secured to each other by means of an electrically conductive adhesive (11) and to the IR radiator (5) for intensive heat transfer. However, other suitable fastening methods for the IR heating segments (4) on one side of the IR radiator (5) can also be selected ( Fig. 2).

[0040] According to the invention, the IR radiator (5) is designed as a surface radiator with a different shape depending on the application for emitting radiant heat in the form of infrared radiation, wherein the IR radiation share of the total heat emission in the spatial direction should be at least 40%.

[0041] A central element of the invention are the IR heating segments (4), which are designed as one or more individual resistance elements made from a powder mixture containing the components according to the invention in various compositions. The resin component does not have to be in powder form.

[0042] The powder mixture of the components, including a resin, is pressed under high pressure into individual molded or other three-dimensional bodies 4 with any suitable dimensions, which are then individually connected to one another as IR heating segments 4 or by an electrically conductive adhesive and are installed to form IR heating modules 2.

[0043] According to the invention, the components of the powder mixture for the IR heating segments 4 essentially comprise the following substances: Graphite, silicon carbide or other components from the “rare earth” group of substances, as well as additional fillers such as aluminum oxide, slate and / or resins.

[0044] In a particularly advantageous composition, the following variable proportions of the powder mixture are provided for the production of the IR heating modules 4: Graphite, between 20% and 40%, Silicon carbide or other components from the group of substances “rare earths”, between 20% and 40%, The filling to 100% is done by additional substances or fillers, such as aluminum oxide, slate and / or resins. According to the invention, the heating segments 4 can be adjusted depending on the desired heating power in a suitable number and arrangement on an IR radiator surface, in particular on the IR radiator 5 for heat transfer.

[0045] In a further advantageous embodiment of the invention, specific temperature ranges for the emission of IR radiation from the IR radiators 5 and / or the IR heating segments 4 can be realized by the composition of the powder mixture according to the invention with resins.

[0046] Clay can also be added.

[0047] The following temperature ranges on the surface (OT surface temperature) of the IR radiator (5) can be adjusted by the composition of the powder mixture for producing the IR heating segments (4): - Low temperature range with 30 - 60 °C OT, mixture of 15 - 30 % graphite, 20 - 40 % silicon carbide or other "rare earths" and 40 - 50 % materials / fillers such as alumina, slate, clay and resins, - Medium temperature range with 30 - 60 °C OT, mixture of 25 - 45 % graphite, 30 - 60 % silicon carbide or other "rare earths" and 30 - 40 % materials / fillers such as alumina, slate, clay and resins, - High temperature range with 200 - 1200 °C OT, mixture of 40 - 75 % graphite, 20 - 50 % silicon carbide or other "rare earths" and 5 - 30 % materials / fillers such as aluminum oxide, slate, clay and resins,

[0048] In an advantageous embodiment, the shaped body of the IR heating segments 4 has, for example, the following dimensions: width: 15 mm, length 40 mm and height 2-3 mm.

[0049] With a radiation area of ​​15 cm by 15 cm, approximately four heating segments are attached / glued to the IR radiator 5 to achieve the required heating output / temperature of the IR heater 3. Due to the arrangement of the inventive IR heating segments 4, the IR radiator 5 develops an approximately six times stronger and larger IR radiation field than comparable IR radiators, with an overall smaller radiation area, resulting in significant energy savings.

[0050] The powder mixture of the individual components mentioned above for producing the heating segments 4 depends on the intended application and is variably adjustable. The composition of the powder mixture for the IR heating segments 4 allows the electrical resistance and thus also the current intensity and temperature to be determined and adjusted. The proportions of various components for producing the IR heating segments 4 are mixed and pressed according to user specifications regarding the desired temperature of the IR heating modules 2 or the size of the heating surface of an IR radiator 5 or, for example, the heating rate of an IR heater 3.

[0051] As from Fig. As can be seen in Figure 1, the power supply to the individual IR heating segments 4 of the IR heating modules 2 is provided via the contact surfaces 8 attached to the block ends, which are connected to an external voltage source via the electrical connections 7. Depending on the number and power rating, the IR heating segments 4 of the IR heating modules 2 can preferably be connected directly to the 220 V public power grid or operated via converters with 40 V DC or AC.

[0052] The individual IR heating segments 4, which are preferably connected by means of an electrically conductive contact adhesive 11, are arranged individually or as a block ( Fig. 1) arranged on a heat-insulated, non-combustible carrier plate (9) and contacted by means of conductor wires ( Fig. 2). The IR heating segments 4 are preferably attached to the carrier plate 9 using high-temperature adhesive or another suitable fastening method.

[0053] The carrier plate 9 also shields the IR heater 3 from rear heat loss and any room walls behind it, if this is desired for the application. Applications are also possible that require the release of a certain amount of heat from the rear, for example, for drying purposes. The IR heating modules 2 on the carrier plate 9 are also suitable as a common assembly to form a heater 3 for any heating arrangement according to the invention, such as a wall heater, a floor heater, or a ceiling heater with appropriate additional structures.

[0054] The insulating carrier plate (9) has no thermal or electrical contact with the IR radiator (5) and is designed to be thermally and electrically insulating.

[0055] Depending on the design and desired heat output, the inventive designs of the infrared heater 1 can, in principle, be operated with any suitable power source. However, corresponding transformers, rectifiers, or other necessary switching elements require additional effort and cost.

[0056] In a particular embodiment, numerous IR heating modules 2, here, for example, eighteen square IR heating modules 2 with an area of ​​15 cm by 15 cm, are integrated into a radiator 3 measuring 120 cm by 60 cm. The distances between the IR heating modules 2 can be kept small due to their low thermal expansion.

[0057] In this arrangement, the IR heating modules 2 are arranged approximately in three rows of six IR heating modules 2 each, one above the other. Due to the small size of the IR heating modules 2 with their IR radiators 5, the expansion of the surface of the radiator 3 caused by heating is reduced to almost zero and does not pose any technical problems.

[0058] The power supply of the IR heater 3 is preferably via a household socket with the public power grid.

[0059] The surface of the IR radiators 5 can be heated to well over 100°C to achieve higher IR heating output. With a target temperature of 80 to 100°C for the IR heating module 2 with the IR radiator 5, which the IR heater 3 reaches in less than 5 minutes depending on the power supply, the energy consumption / connected load is approximately 350 watts.

[0060] The rear area of ​​the IR heater (3) is made of a fire-resistant and highly heat-insulating material, while the front area in the radiation direction is made of IR-permeable quartz glass or a similar suitable material.

[0061] In a preferred embodiment, the rear region of the IR heater 3 is formed by one or more electrically non-conductive, heat-insulating and non-combustible support plates 9.

[0062] The front area of ​​the radiator 3 is formed by one or more highly IR-permeable front panels 10 arranged in the room or IR radiation direction in front of the IR radiator 5.

[0063] The front panel(s) 10) act as protective surfaces in spatial direction against possible overheating and burn hazards to persons and objects.

[0064] Compared to other IR heater models with similar parameters, energy consumption is reduced by about half at the same surface temperatures.

[0065] In a particular embodiment, the IR radiator 5 of the IR heating modules 2 consists of an aluminum plate which is covered with an electrically non-conductive layer which is readily permeable to IR radiation in the radiation direction.

[0066] On the other side of the IR radiator 5 (rear side), on which the IR heating segments 4 are arranged, i.e., towards the carrier plate 9, the IR radiator 5 is not IR-permeable. This does not apply to the connecting surface between the IR heating segments 4 and the IR radiator 5. Here, good IR permeability is naturally necessary ( Fig. 2). The aluminum plate of the IR emitter 5 is designed to have a thickness of 0.5 mm to 2 mm.

[0067] Depending on the design of the IR heating segments 4 for an IR heating element 3, different material thicknesses can be selected for the IR radiation surface or the IR radiator (5). The thicker the sheet metal or aluminum plate, the slower the IR heating effect and the longer the heating time. However, thicker sheets of the IR radiator 5 absorb more heat from the IR heating segments 4 and store it longer.

[0068] In this version, the carrier plate 9 for holding, thermally insulating and electrically contacting the IR heating segments 4 has no contact with the IR radiator 5.

[0069] In a preferred embodiment, the IR radiator 5 is coated on one side in the radiation direction with an infrared-active color layer, which further increases the emitted infrared portion.

[0070] A further embodiment of the invention relates to the use of the IR heating modules 2 for radiators 3 or their application in the low-temperature range, i.e. for temperatures of the IR radiator 5 of approximately 30°C to 40°C.

[0071] Here, other suitable structures can be provided as overheating protection in the direction of the room or can be omitted completely.

[0072] In the low-temperature range, the IR heating segments 4 can also advantageously be operated with lower voltages of approximately 40 V. Thus, the connection of PV systems (photovoltaics) to operate the IR heating modules 2 with 40 V direct current is also within the scope of the invention.

[0073] As already described above, the resistance values ​​of the IR heating segments 4 for constructing the IR heating modules 2 from different weight proportions of the components in the powder mixture according to the invention can be variably changed and adapted to the desired use.

[0074] By adjusting the resistance values ​​of the IR heating segments 4, current and voltage values ​​as well as the electrical power consumption in connection with the heat generation and the emitted IR radiation can also be controlled.

[0075] In a further embodiment, the IR emitter 5 has the shape of a strip with, for example, a length of 50 cm and a width of 5 cm.

[0076] Several heating segments 4 are glued to the back of the carrier plate 9 with high-temperature adhesive and are connected to electrical lines and connections 7 via the carrier plate 9.

[0077] This IR heating module 2 is suitable as an assembly for larger area heating applications.

[0078] According to the invention, the IR heating module 2, consisting of the IR radiator 5 and its attached IR heating segments 4, can have any suitable shape and dimensions depending on the application. In this context, the use of individual electrically connected heating segments of different sizes is also possible.

[0079] In further preferred embodiments, the heating assemblies according to the invention and described above, such as the IR heating modules 2 comprising IR radiators 5 and IR heating segments 4, are also intended to be used for different designs in infrared heating construction in heating panels, e.g., IR heating modules 2 or components.

[0080] In this sense, an IR heater 3 should also be understood to include various components or IR radiating surfaces.

[0081] For example, IR radiators 3 can be designed as ceiling elements, grid ceiling elements or Odenwald ceiling elements.

[0082] The IR heating modules 2 according to the invention, which consist of IR heating segments 4 and IR radiators 5, are then integrated into the ceiling or floor elements, taking into account the requirement of necessary insulating and heat-insulating installation frames.

[0083] The adapted installation of the IR heating modules 2 according to the invention in clay, gypsum or fiber cement panels and corresponding components for the wall and floor area is also possible.

[0084] The advantages of the presented invention of a novel infrared heater 1 lie particularly in the significant savings in electrical energy and the associated costs. The invention further describes extremely flexible and versatile IR heating modules 2, which are energy-saving and suitable for a wide variety of IR heating applications. The parameters of the resistance heating elements, as molded bodies of the IR heating segments 4, can be adapted to a wide range of desired applications by using different components of the powder mixtures of the starting materials.

[0085] This makes it possible to create two economical IR heating panels from IR heating modules for many conceivable applications. Reference symbol 1 infrared heater, with 2 and 3 2 IR heating modules (combination of IR heating segments 4 and IR radiators 5) 3 IR heaters, variable design, on the ceiling, floor or wall 4 IR heating segments, resistance heating elements, molded body made of powder mixture and resin, 5 IR emitters, IR beam surface, IR surface emitters 6 IR protective layer, protective grille on 5 (spatial direction) 7 electrical connections for 4 8 contact surfaces for 7 to 4 9 Support plate for IR heating segments 4 and electrical connections 7 10 Front panel in front of 5, protective surface, IR-permeable 11 electrical contact adhesive between the IR heating segments 4, 12 thermal adhesives (electrically non-conductive), between 4 and 5 QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2010 008 449 B4

[0015] DE 20 2006 07 228 U1

[0019]

Claims

[1] Infrared heating (1) comprising at least one IR heating element (3), which is arranged in the floor area, on the walls or on the ceiling of a room or in suitable combinations of these room areas, and has one or more electrically operated IR heating panels, characterized by that the IR heating panels are designed as IR heating modules (2) and have one or more IR heating segments (4) which are arranged on an IR radiator (5) for transmitting heat and IR radiation, wherein the IR heating segments (4) are designed as electrical resistance elements for emitting heat and IR radiation and consist partly or completely of the following components: - Graphite, - silicon carbide or other components from the group of substances “rare earths”, - additional materials such as aluminum oxide, slate and / or resins. [2] Infrared heater (1) according to claim 1, characterized bythat the starting materials of the components for the production of the IR heating segments (4) are predominantly in powder form, with their proportions in weight percentages varying in the following ranges depending on the application: - Graphite, between 20% and 40%, - Silicon carbide or other components from the group of substances “rare earths” between 20% and 40%, - filling to 100% is done by additional materials such as aluminum oxide, slate and / or resins. [3] Infrared heater (1) according to claim 2, characterized by that the following temperature ranges on the surface (OT) of the IR radiator (5) can be adjusted by the composition of the powder mixture for producing the IR heating segments (4): - Low temperature range with 30 - 60 °C OT, mixture of 15 - 30 % graphite, 20 - 40 % silicon carbide or other "rare earths" and 40 - 50 % materials / fillers such as alumina, slate, clay and resins, - Medium temperature range with 30 - 60 °C OT, mixture of 25 - 45 % graphite, 30 - 60 % silicon carbide or other "rare earths" and 30 - 40 % materials / fillers such as alumina, slate, clay and resins, - High temperature range with 200 - 1200 °C OT, mixture of 40 - 75 % graphite, 20 - 50 % silicon carbide or other "rare earths" and 5 - 30 % materials / fillers such as aluminum oxide, slate, clay and resins, [4] Infrared heater (1) according to claim 2 or 3, characterized by , that the IR emitter (5) is planar, and the IR heating segments (4) are designed as solid shaped bodies (4) or three-dimensional bodies, which are arranged on the IR radiator (5) and fastened for optimal heat and infrared transmission, wherein the number of IR heating segments (4) arranged on the IR radiator (5) can be variably designed depending on the application [5] Infrared heater (1) according to claim 4, characterized bythat the IR heating segments (4) designed as shaped bodies (4) consist of a pressed powder mixture of the components, the temperature and the IR radiation component of which can be varied by the composition of the powder mixture, adjusted depending on the application and is essentially adjustable via the resistance value to be achieved. [6] Infrared heater (1) according to claim 5, characterized by that one or more IR heating segments (4) are interconnected by means of an electrically conductive contact adhesive or conductive adhesive (11) and are attached to the IR rays (5) by means of electrically non-conductive thermally conductive adhesive (12), wherein a conductive adhesive (11) or another suitable contact means can also be used to form the contact surfaces (8) for the external electrical connections (7). [7] Infrared heater (1) according to claim 6, characterized bythat several IR heating modules (2), which consist of an IR radiator (5) and one or more IR heating segments (4), are arranged and combined in any desired distribution on an IR heating element (3), wherein the spaces between the IR heating modules (2) and their dimensions are designed such that only slight thermal expansion takes place. [8] Infrared heater (1) according to claim 7, characterized by that the IR heating modules (2) in the form of a structural unit comprising IR heating segments (4) and IR radiators (5) are fastened to a heat-insulating, non-combustible carrier plate (9), wherein the IR heating modules (2) are fastened by a high-temperature adhesive or another suitable type of fastening between the IR heating segments (4) and the carrier plate (9). [9] Infrared heater (1) according to claim 8, characterized bythat the IR radiators (5) of the individual IR heating modules (2) are coated or covered in the IR radiation direction with an electrically non-conductive, but IR-permeable IR protective layer (6), wherein the covering is designed as a grid-like structure or a network. [10] Infrared heater (1) according to one of the preceding claims 1 to 9, characterized by that the IR heating modules (2) are provided with an insulating and IR-permeable protective plate (10) in the IR radiation direction of the room to be heated.

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