Research & Development Guide

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Research and Development Services


W W W. C ERA MIC X. CO M

Ceramicx has over a quarter century of expertise in Infrared heating research and development. Dr Cáthál Wilson Director

We can help you with: Contract Research Services for IR heat applications Contract Testing Services – IR heaters, target materials and their interface Customised IR Oven Design and Build for new applications IR heating retrofits and upgrades to existing plant Intellectual Property (IP) development, including patent work and documentation Proof of concept(s) – heat work design to full system/ machine build Resources: When you work with Ceramicx you will find that not only do we manufacture all of the three types of IR elements in-house (ceramic, quartz and tungsten), we also formulate and manufacture all other products within our factory walls. We can supply you with manufacturing resources - in ceramic-based work (materials formulations and kiln technology); all electrical insulation work (including steatite and alumina) and also the manufacture of all heat work housings and reflectors in various metals such as steel and aluminium. Your project can thus be very tightly specified and controlled, with a fast turnaround and short lead times. We look forward to helping your manufacturing innovations.

CERAMICX I N F R A R E D F O R I N D U S T RY


RECENT R&D PROJECTS

Recent Client Successes Low temperature carbon fibre curing: Development of heating technology to debulk and curing epoxy based carbon pre-preg and dry fibre systems. Technology is capable of penetrating vacuum bags and breathers common to aerospace and automotive applications. High temperature carbon fibre: Identification and construction of oven for PEEK, PEKK, PPS organo sheets. Capable of heating materials to >450 oC for press forming and over moulding. Low temperature thermoforming: Design of a packaging thermoforming oven. Reduced energy consumption by >40% and increased production by >50% through correct tuning of IR wavelength to material characteristics. Process energy consumption reduction: Correct application of IR to process reduced time and energy consumption by >25% without increasing the capital machine cost. Adjusted heater wavelength, heat up speeds and reflector geometry to give a faster and more even heating process. Development and characterisation of optimal emitter for carbon fibre pre-preg: Development of a heater which can penetrate vacuum bag and breather materials for carbon fibre pre-preg heating. Optimisation of bread toasting process: Development of heaters reflector geometry to reduce bread toasting time by 25%. Development of a high power density IR heater: Development of a high power density IR heater: High power density heater supplying 12.8 W/cm2.

Research and Development Services


W W W. C ERA MIC X. CO M

IR HEAT SOLUTIONS

Your Custom Heat Solution Developing and Specifying the IR heating solution that is fit for your purpose and process The bulk of the R&D carried about at Ceramicx is driven by custom design and build projects; projects that typically tackle the most demanding of IR heat applications. At the beginning of the process we invite you to work through some models and ideas at our facilities and at your place of work. We then – with the help of our Herschel test instrument generate 3D heat maps, CAD files, engineering drawings and specifications together with a schedule of materials and works. The next phase involves building the prototype system inhouse at Ceramicx, fully testing and running it before shipping it to the place of commission. Many IR heat systems need to be engineered in this way in order to achieve the necessary fail-safe performance. Conveyor furnaces; walk-in industrial ovens, vertical ovens, custom infrared ovens – the construction and performance of all of these needs to be thoroughly researched and thoroughly tested and proven before shipping. Custom Build IR heating systems are the lifeblood of our company’s activities. Only through helping our customers push the envelope of heat work possibility are we able to grow our own expertise and know-how. Work with us today – and design and specify the IR heating innovations that are unique to your needs.

240 220 Target Temperature

200

TEMPERATURE (º (ºC)

180 160 140

Fig. 10

120

FQE Top surface with preheat FQE Bottom surface with preheat FQE Top surface without pre heat FQE Bottom surface without pre heat

100 80

Fig. 11

60

FFEH Top surface with pre heat FFEH Bottom surface with pre heat FFEH Top Surface without pre heat FFEH Bottom Surface without pre heat

40 20 0

CERAMICX I N F R A R E D F O R I N D U S T RY

0

30

60 90 TIME (seconds)

120

150


THE CERAMICX PROCESS

From Problem To Solution CLIENT HEAT TRANSFER PROBLEM PURCHASE ORDER MATERIALS FOR TESTING

CERAMICX PROPOSAL

CERAMICX R&D PROBLEM EVALUATION

CLIENT APPROVAL

PROPOSAL & BUDGET QUOTATION SOLUTION

END ( CONTRACT R&D ) PURCHASE ORDER

CLIENT APPROVAL

END ( CONTRACT SOLUTION BUILD )

PRELIMINARY DESIGN PROPOSAL & QUOTATION FUNCTIONAL DESIGN SPECIFICATION & PRODUCTION DRAWINGS PRODUCTION

COMMISSIONING

Research and Development Services

FACTORY ACCEPTANCE TEST


W W W. C ERA MIC X. CO M

SERVICES

A Selection of Ceramicx R&D Services Material – radiation response: Characterisation of material heating under different wavelength emitters. IR process optimisation: Determination of optimal emitter for material combinations and process characteristics. Heat flux mapping: Mapping of infrared heat energy as a function of distance. IR process development: Development of optimal heater wavelength and power combinations to make IR process as efficient as possible. Contract research services: For all IR heat applications across all three types of radiation emitter. Customised IR oven design: For new build in all manner of industries and applications. IR heating retrofits and upgrades: Across a wide variety of processing equipment. IR Oven Testing: For Cure, Adhesion, Shrinkage, Cycle Time. Intellectual property (IP) development: Including patent research work and documentation.

CERAMICX I N F R A R E D F O R I N D U S T RY


THE HERSCHEL

KTI winners with Trinity College, Dublin 2017

IR Heat Research

∙ Tools ∙ Instruments ∙ Associates ∙

In 2013 Ceramicx launched the Herschel Test Instrument – a world first; able to map and document the previously invisible IR energy field in 3D space. The Herschel has developed from strength to strength and now occupies pride of place in the Ceramicx new build laboratory and white room. It serves all manner of industries for Ceramicx – especially aerospace and automotive – in predictive IR heat and oven design and, for one thing, helps bring composite and thermoformed plastics parts to market with low energy input and low product cost and lead time. The Herschel helps us measure, map and pilot scale virtually any combination of IR heaters, materials, peripheral equipment in order to simulate, build and test any heated environment. From that point onward we are able to build customized IR ovens to client order. The R&D opportunities are extensive – from industrial furnaces to conveyor ovens, annealing furnaces, custom infrared ovens and many other infrared applications.

Ceramicx also uses an extensive academic network including Trinity College Dublin, Belfast Metropolitan, Cambridge University and The Fraunhofer Institute.

Late 2017 sees Ceramicx launching another world first this time for the composites industry. The Vector drape forming machine is an Out Of Autoclave (OOA) solution, designed to heat and cure carbon composite material whether pre-preg or dry fibre. Ceramicx meets any issues of Infrared industrial heat with a tailor made customer solution. Research and Development Services


Research and Development Services

INFRARED FOR INDUSTRY

Ceramicx Centre for Infrared Innovation. Ceramicx Ltd. Gortnagrough, Ballydehob, Co. Cork, P81 H026, Ireland. Tel. +353 28 37510 Fax. +353 28 37511 e.mail. sales@ceramicx.com www.ceramicx.com


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