Light emitting heating assembly and method of manufacturing the same

Abstract

This disclosure provides a light-emitting heating component and its preparation method, relating to the field of light-emitting heating tubes. The preparation method includes the following steps: connecting a heating wire and a fine wire to obtain a composite wire; then inserting the composite wire and a capillary tube into a base tube to obtain an assembly; partially sealing the end of the assembly to fix the composite wire to the end of the assembly, while retaining an air passage communicating with the inner cavity of the base tube; subsequently, venting and removing impurities from the interior of the assembly through the air passage to obtain a preformed tube; filling the preformed tube with a mixed gas through the air passage and performing a gas filling and pressure stabilization treatment; after the gas filling and pressure stabilization treatment is completed, sealing the air passage to obtain a sealed tube; and performing an electrostatic shaping treatment on the sealed tube to obtain the light-emitting heating component. This disclosure improves the situation where insufficient process control leads to a decrease in heat output, requiring an increase in input power, thereby reducing long-term operating energy consumption and improving the consistency of the working state of the light-emitting heating component.

Description

Technical Field

[0001] This disclosure relates to the field of light-emitting heating tubes, and more particularly to a light-emitting heating component and its preparation method. Background Technology

[0002] The typical manufacturing process of a light-emitting heating tube, also known as a halogen heating lamp tube, usually includes: winding a tungsten wire heating element into shape and connecting it with an lead wire, inserting it into a base tube, then evacuating and baking the tube to remove gas, filling it with a mixture of inert gas and trace amounts of halogen gas, sealing it, and then energizing the lamp tube to stabilize the internal state of the lamp tube, thus obtaining the finished product.

[0003] Existing manufacturing methods suffer from insufficient precision in process control during vacuum degassing, gas filling and sealing, and post-processing. This directly leads to higher input power required for the lamp to achieve the same heating output in actual use, resulting in higher energy consumption over long-term operation. Specifically, conventional vacuuming and baking processes are insufficient to completely remove impurities such as water vapor and oxygen adsorbed on the inner wall of the quartz tube and the surface of the tungsten filament. Residual impurities trigger harmful water circulation reactions during high-temperature operation, causing tungsten atoms from the tungsten filament to be continuously transported to the inner wall of the quartz tube, gradually forming a blackened film that absorbs infrared radiation. This blackened film continuously reduces the infrared transmittance of the tube wall, and the infrared radiation generated by the lamp is absorbed and lost by the blackened film itself, failing to be effectively emitted. Under the premise of maintaining the same heating effect, the input power is forced to continuously increase, directly resulting in energy waste. Meanwhile, the lack of effective pressure stabilization measures during the gas filling and sealing stage, coupled with direct sealing after filling, causes the actual gas pressure inside the tube to easily deviate from the preset value. This results in poor consistency between halogen content and filling pressure within and between batches. Some lamps, deviating from their optimal working pressure, experience decreased halogen cycle efficiency and reduced electrothermal conversion efficiency, leading to insufficient heat output under the same input power and further exacerbating the high energy consumption problem. Furthermore, the post-processing power-on process often employs simple, single-stage or roughly segmented methods, failing to establish a sufficiently uniform and stable tungsten-halogen chemical cycle equilibrium within the lamp. This results in continuous energy conversion efficiency drift during initial use after the lamp leaves the factory, with actual power consumption exceeding normal levels for a period before reaching a stable state, constituting unnecessary energy waste.

[0004] Therefore, a light-emitting heating component and its preparation method are proposed to solve the problem of insufficient process control, which directly leads to the lamp tube requiring higher input power to achieve the same heat output in actual use, resulting in high energy consumption during long-term operation. Summary of the Invention

[0005] The purpose of this disclosure is to provide a light-emitting heating component and its preparation method, which solves the problem of insufficient process control, which directly leads to the lamp tube requiring higher input power to achieve the same heat output in actual use, resulting in high energy consumption during long-term operation.

[0006] To achieve this objective, the present disclosure adopts the following technical solution: A method for preparing a light-emitting heating component, the method comprising the following steps: Step S1: Connect the heating wire and the thin wire to obtain the combined wire, and then put the combined wire and the capillary tube into the base tube to obtain the assembly. Step S2: Partially seal the end of the assembly to fix the assembly wire to the end of the assembly, and retain the air passage communicating with the inner cavity of the base tube; then exhaust and remove impurities from the inside of the assembly through the air passage to obtain the pre-formed tube. Step S3: Inject mixed gas into the preformed tube through the gas channel and perform gas filling and pressure stabilization treatment on the preformed tube; after the gas filling and pressure stabilization treatment is completed, seal the gas channel to obtain a sealed tube; Step S4: The closed tube is energized and shaped to obtain the light-emitting heating component.

[0007] Step S1 specifically includes the following steps: Step S11: Clean the base tube and capillary tube, and then preheat them. Step S12: Wind and shape the heating wire to obtain a shaped wire; Step S13: Connect the forming filament with the fine filament to obtain the combined filament, and put the combined filament and capillary tube into the base tube to obtain the assembly.

[0008] In step S11, the cleaning process involves ultrasonic cleaning in anhydrous ethanol for 5-15 minutes, rinsing with deionized water, and then drying with nitrogen gas; the preheating process is carried out at a temperature of 250-450℃ for 1-4 hours; both the substrate tube and the capillary tube are quartz glass tubes. In step S12, the heating wire is a tungsten wire; In step S13, the forming wire and the fine wire are connected by welding, the heating section of the heating wire is spaced apart from the inner wall of the base tube, the fine wire is a tungsten wire, and the base tube and the capillary tube are both quartz glass tubes.

[0009] Step S2 specifically includes the following steps: Step S21: Partially seal the lead-out end of the composite wire to fix the composite wire to the end of the base tube, and keep the inner hole of the capillary connected to the inner cavity of the base tube. The inner hole of the capillary forms an air passage to obtain a semi-finished tube. Step S22: Connect the air passage to the vacuum exhaust system, perform segmented vacuuming of the semi-finished tube through the air passage, and then vacuum bake the semi-finished tube. Step S23: Under vacuum exhaust, the combined wires in the semi-finished tube are degassed by gradation through electric current; then, inert gas is introduced into the semi-finished tube through the gas channel for replacement, and the semi-finished tube is evacuated again to obtain the pre-formed tube.

[0010] In step S21, the length of the sealing section at the end of the base tube in the combined wire is 1-5 mm; the equivalent circle diameter corresponding to the minimum flow cross-sectional area of ​​the air passage is 0.4-1.5 mm. In step S22, the segmented vacuuming includes a first vacuuming and a second vacuuming, wherein the final pressure of the first vacuuming is ≤10 Pa, and the final pressure of the second vacuuming is ≤1×10 Pa. -2 Pa; the vacuum baking temperature is 250-350℃ and the time is 60-120min; In step S23, the graded degassing includes a first degassing stage, a second degassing stage, and a third degassing stage. The first degassing stage has a power of 20-30% of the rated power and a time of 30-60 seconds; the second degassing stage has a power of 40-50% of the rated power and a time of 30-60 seconds; the third degassing stage has a power of 60-70% of the rated power and a time of 10-30 seconds. The inert gas is argon, the displacement treatment pressure is 5-50 kPa, and the number of treatments is 2-3 times. The final pressure of the second vacuuming is ≤1×10⁻⁶ kPa. -2 Pa, and maintain stable pressure for 10-20 minutes after reaching the endpoint pressure.

[0011] Step S3 specifically includes the following steps: Step S31: Inject the mixed gas into the preformed tube through the gas passage; Step S32: After the mixed gas is filled, pressure compensation is performed on the preformed tube to stabilize the gas pressure inside the preformed tube at the filling pressure. Step S33: After the pressure inside the preformed tube stabilizes, the air passage on the preformed tube is sealed by melting to obtain a sealed tube.

[0012] In step S31, the mixed gas includes an inert gas and a halogen gas component, wherein the inert gas is argon, and the halogen gas component includes hydrogen bromide, the content of hydrogen bromide in the mixed gas is 50-500 ppm; the charging pressure is 80-300 kPa. In step S32, the pressure compensation is to continue connecting the gas source after the mixed gas is filled, and maintain the pressure at the filling pressure for 30-180 seconds. In step S33, the length of the sealing area of ​​the closed fusion seal is 1-8mm.

[0013] The light-emitting heating component in step S4 is obtained according to the following steps: The sealed tube is subjected to at least three power-on shaping processes in sequence, including a first power-on shaping, a second power-on shaping, and a third power-on shaping. After the power-on shaping is completed, the sealed tube is allowed to cool naturally to room temperature to obtain a light-emitting heating component.

[0014] The first power-on test is performed at 40-50% of the rated power for 3-5 minutes; the second power-on test is performed at 60-70% of the rated power for 5-10 minutes; and the third power-on test is performed at 85-100% of the rated power for 20-60 minutes.

[0015] A light-emitting heating component, wherein the light-emitting heating component is obtained by the preparation method described above.

[0016] Compared with the prior art, this disclosure has the following beneficial effects: This disclosure provides a light-emitting heating component and its preparation method. By connecting heating wires and fine filaments to form a composite filament, and then sequentially assembling, degassing and impurity removal, gas filling and voltage stabilization, and electro-forming shaping, the light-emitting heating component is gradually established according to its structural state, internal cleanliness state, working gas state, and stable operating state during the preparation process. Specifically, the degassing and impurity removal process reduces the level of residual impurities inside the assembly, minimizing the possibility of water vapor, oxygen, and other impurities participating in adverse reactions during the high-temperature operation of the light-emitting heating component, and reducing the impact of blackening of the substrate tube on heat output. The gas filling and voltage stabilization process stabilizes the mixed gas pressure within the pre-formed tube before sealing, reducing the inconsistency of filling pressure and halogen gas composition between different light-emitting heating components. The electro-forming shaping process gradually transitions the sealed tube to a stable operating state, reducing the possibility of continuous changes in initial heat output. Therefore, the above solution improves upon the problem of insufficient process control in existing preparation methods, reduces the need to increase input power due to a decrease in heat output during long-term operation, thereby helping to reduce long-term energy consumption and improve the consistency of the operating state of the light-emitting heating component. Attached Figure Description

[0017] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this disclosure and, together with the description, serve to explain the principles of this disclosure. It is obvious that the drawings described below are merely some embodiments of this disclosure, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort.

[0018] The structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed herein, and are not intended to limit the conditions under which this disclosure can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and purposes that this disclosure can produce, should still fall within the scope of the technical content disclosed herein.

[0019] Figure 1 This is a flowchart of the preparation method in the embodiments of this disclosure; Figure 2 This is a schematic diagram of the overall structure of the light-emitting heating component in an embodiment of this disclosure. Figure 3 This is another overall structural schematic diagram of the light-emitting heating component in an embodiment of this disclosure.

[0020] Illustration: 1. Combined wire; 2. Heating wire; 3. Base tube; 4. Fine wire; 5. Capillary tube. Detailed Implementation

[0021] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the examples set forth herein; rather, these embodiments are provided so that this disclosure will be more thorough and complete, and will fully convey the concept of the exemplary embodiments to those skilled in the art.

[0022] Furthermore, the described features, structures, or characteristics can be combined in any suitable manner in one or more embodiments. Numerous specific details are provided in the following description to give a thorough understanding of embodiments of this disclosure. However, those skilled in the art will recognize that the technical solutions of this disclosure can be practiced without one or more of the specific details, or other methods, components, apparatuses, steps, etc., can be employed. In other instances, well-known methods, apparatuses, implementations, or operations are not shown or described in detail to avoid obscuring various aspects of this disclosure.

[0023] The block diagrams shown in the accompanying drawings are merely functional entities and do not necessarily correspond to physically independent entities. That is, these functional entities can be implemented in software, in one or more hardware modules or integrated circuits, or in different network and / or processor devices and / or microcontroller devices.

[0024] The flowcharts shown in the accompanying drawings are merely illustrative and do not necessarily include all content and operations / steps, nor do they necessarily have to be performed in the described order. For example, some operations / steps can be broken down, while others can be combined or partially combined; therefore, the actual execution order may change depending on the specific circumstances.

[0025] Please see Figure 1 A method for preparing a light-emitting heating component, the method comprising the following steps: Step S1: Connect the heating wire and the thin wire to obtain the combined wire, and then put the combined wire and the capillary tube into the base tube to obtain the assembly. Step S2: Partially seal the end of the assembly to fix the assembly wire to the end of the assembly, and retain the air passage communicating with the inner cavity of the base tube; then exhaust and remove impurities from the inside of the assembly through the air passage to obtain the pre-formed tube. Step S3: Inject mixed gas into the preformed tube through the gas channel and perform gas filling and pressure stabilization treatment on the preformed tube; after the gas filling and pressure stabilization treatment is completed, seal the gas channel to obtain a sealed tube; Step S4: The closed tube is energized and shaped to obtain the light-emitting heating component.

[0026] Specifically, in step S1, the heating wire and the thin wire are connected to obtain a combined wire, and then the combined wire and the capillary tube are installed into the base tube to obtain the assembly. Step S1 specifically includes the following steps: Step S11: Clean the base tube and capillary tube, and then preheat them. In step S11, the cleaning process involves ultrasonic cleaning in anhydrous ethanol for 5-15 minutes, rinsing with deionized water, and then drying with nitrogen gas; the preheating process is carried out at a temperature of 250-450℃ for 1-4 hours; both the substrate tube and the capillary tube are quartz glass tubes. Step S12: Wind and shape the heating wire to obtain a shaped wire; In step S12, the heating wire is a tungsten wire; Step S13: Connect the forming filament with the fine filament to obtain the combined filament, and put the combined filament and capillary tube into the base tube to obtain the assembly.

[0027] In step S13, the forming wire and the fine wire are connected by welding, the heating section of the heating wire is spaced apart from the inner wall of the base tube, the fine wire is a tungsten wire, and the base tube and the capillary tube are both quartz glass tubes.

[0028] In step S11, the base tube and capillary tube are ultrasonically cleaned in anhydrous ethanol to separate the oil, particles and other impurities that can be carried away by the cleaning medium from the surface of the tube and capillary tube. After ultrasonic cleaning, deionized water is used for rinsing to reduce the residue of cleaning medium and soluble impurities. Then, nitrogen gas is used to dry the base tube and capillary tube, and the dried base tube and capillary tube are preheated.

[0029] In step S12, tungsten wire is used as the heating wire. The heating wire is wound according to the heating area of ​​the light-emitting heating component and the internal space of the substrate tube. The wound heating wire is then shaped to obtain a shaped wire.

[0030] In step S13, the forming wire and the fine wire are connected by welding to obtain a combined wire. Then, the combined wire and the capillary tube are installed into the base tube, and the position of the combined wire is adjusted so that the heating section of the heating wire is spaced apart from the inner wall of the base tube, thereby obtaining an assembly for subsequent local sealing and exhaust impurity removal.

[0031] Step S1, by cleaning, drying, and preheating the base tube and capillary tube before assembly, reduces the possibility of moisture, oil, particles, and other contaminants entering the assembly, thus reducing the initial impurity load in the enclosed space from the source. This mitigates the risk of residual moisture, oxygen, and other impurities on the inner wall of the base tube and the surface of the heating wire participating in adverse reactions under high-temperature operating conditions, potentially promoting tungsten migration from the heating wire to the inner wall of the base tube, leading to tube wall blackening and decreased infrared transmittance. Furthermore, step S1 reduces the total amount of impurities to be removed subsequently, providing better initial conditions for vacuum baking, electrostatic degassing, and inert gas replacement. Simultaneously, winding and shaping the heating wire, and spacing the heating section from the inner wall of the base tube, helps reduce direct contact between the heating wire and the inner wall of the base tube, and the resulting localized heat concentration, ensuring the heating wire maintains a relatively stable position during subsequent electrostatic degassing and electrostatic shaping processes. Therefore, step S1 mainly controls the initial cleanliness and assembly status to provide prerequisites for reducing the risk of pipe wall blackening, maintaining the stability of subsequent heat output, and reducing additional energy consumption caused by output attenuation.

[0032] In step S11, the ultrasonic cleaning time with anhydrous ethanol is 5-15 minutes. This cleaning time allows the ultrasonic action and anhydrous ethanol to continuously act on the surface of the base tube and capillary, helping to remove oil and particles adhering to the surface before assembly, while avoiding insufficient surface treatment due to a short cleaning time. Rinsing with deionized water reduces the possibility of ionic components remaining on the tube surface from ordinary water, and nitrogen blowing helps reduce liquid water residue after rinsing. The preheating temperature is 250-450℃, and the preheating time is 1-4 hours, allowing the base tube and capillary to dry and pre-treat under a certain thermal intensity and duration. This helps promote the desorption of residual moisture and some volatile deposits from the tube surface, thereby reducing the burden on subsequent degassing and impurity removal processes. Both the heating wire and the fine wire are made of tungsten wire, enabling the combined wire to withstand the high-temperature working conditions during subsequent electrostatic degassing, electrostatic shaping, and normal light-emitting heating. The base tube and capillary are made of quartz glass tubes, allowing them to cooperate with subsequent vacuum baking, local sealing, and high-temperature working processes. The heating section is spaced apart from the inner wall of the base tube, which reduces the possibility of local heat concentration and assembly interference caused by direct contact, and provides a structural basis for obtaining a more stable working state and heat output in the tube.

[0033] It should be noted that step S1 is an assembly preparation step in the fabrication process of the light-emitting heating component. It involves processing the substrate tube, capillary tube, heating wire, and fine wires, resulting in the formation of an assembly. The assembly is an intermediate component where the combined wire and capillary tube have been inserted into the substrate tube and adjusted to their predetermined positions, but the ends of the substrate tube have not yet been partially sealed. In the assembly, the combined wire and capillary tube have established the spatial relationship required for subsequent processing. The heating section is spaced apart from the inner wall of the substrate tube, and the capillary tube serves to receive the gas channels to be formed later. Since the interior of the assembly remains connected to the external environment, this step primarily establishes the structural foundation of the light-emitting heating component without altering the internal gas state. After the assembly is formed, it directly proceeds to subsequent steps for end fixing and exhaust / purification.

[0034] Specifically, in step S2, the end of the assembly is partially sealed to fix the assembly wire to the end of the assembly, while retaining the air passage that communicates with the inner cavity of the base tube; then the interior of the assembly is vented and impurities are removed through the air passage to obtain the pre-formed tube. Step S2 specifically includes the following steps: Step S21: Partially seal the lead-out end of the composite wire to fix the composite wire to the end of the base tube, and keep the inner hole of the capillary connected to the inner cavity of the base tube. The inner hole of the capillary forms an air passage to obtain a semi-finished tube. In step S21, the length of the sealing section at the end of the base tube in the combined wire is 1-5 mm; the equivalent circle diameter corresponding to the minimum flow cross-sectional area of ​​the air passage is 0.4-1.5 mm. Step S22: Connect the air passage to the vacuum exhaust system, perform segmented vacuuming of the semi-finished tube through the air passage, and then vacuum bake the semi-finished tube. In step S22, the segmented vacuuming includes a first vacuuming and a second vacuuming, wherein the final pressure of the first vacuuming is ≤10 Pa, and the final pressure of the second vacuuming is ≤1×10 Pa. -2 Pa; the vacuum baking temperature is 250-350℃ and the time is 60-120min; Step S23: Under vacuum exhaust, the combined wires in the semi-finished tube are degassed by gradation through electric current; then, inert gas is introduced into the semi-finished tube through the gas channel for replacement, and the semi-finished tube is evacuated again to obtain the pre-formed tube.

[0035] In step S23, the graded degassing includes a first degassing stage, a second degassing stage, and a third degassing stage. The first degassing stage has a power of 20-30% of the rated power and a time of 30-60 seconds; the second degassing stage has a power of 40-50% of the rated power and a time of 30-60 seconds; the third degassing stage has a power of 60-70% of the rated power and a time of 10-30 seconds. The inert gas is argon, the displacement treatment pressure is 5-50 kPa, and the number of treatments is 2-3 times. The final pressure of the second vacuuming is ≤1×10⁻⁶ kPa. -2 Pa, and maintain stable pressure for 10-20 minutes after reaching the endpoint pressure.

[0036] It is understandable that the rated power is the rated input electrical power of the light-emitting heating component.

[0037] In step S2, the lead-out end of the composite wire is first partially sealed to fix it to the end of the base tube. Simultaneously, the inner hole of the capillary is kept in communication with the inner cavity of the base tube, forming the air passage for subsequent evacuation and inflation, resulting in a semi-finished tube. Subsequently, the air passage is connected to a vacuum exhaust system, and the semi-finished tube is evacuated in stages through the air passage. Under vacuum, the semi-finished tube is then vacuum-baked to promote the desorption of residual moisture and adsorbed impurities from the inner wall of the base tube, the inner wall of the capillary, and the surface of the composite wire. After vacuum baking, while maintaining vacuum exhaust, the composite wire inside the semi-finished tube is degassed in stages by electrostatic discharge, allowing the composite wire to further release adsorbates from its surface and near-surface areas during gradual heating. Then, inert gas is introduced into the semi-finished tube through the air passage for displacement, and the semi-finished tube is evacuated again. After reaching the set endpoint pressure, the pressure is stabilized, ultimately yielding a pre-formed tube.

[0038] Step S2, based on the aforementioned steps, sequentially performs end fixing and degassing / purification treatment on the assembly. By partially sealing the ends of the assembly, the internal filaments are fixed relative to the base tube, and the inner hole of the capillary tube remains connected to the interior of the assembly. This ensures the assembly maintains its intended assembly state during subsequent vacuuming, vacuum baking, electrostatic degassing, and gas replacement processes. Subsequently, segmented vacuuming and vacuum baking are performed inside the assembly through the gas channels, gradually expelling free gas from the internal cavity and promoting the desorption of moisture, oxygen, and other volatile impurities adsorbed on the surfaces of the assembly. Further staged electrostatic degassing of the internal filaments allows them to release adsorbed substances from their surface and near-surface areas during gradual heating. Inert gas replacement and re-vacuuming are used to dilute and remove residual impurity gases from inside the assembly. Thus, step S2 can reduce the level of residual impurities inside the assembly while maintaining its structural state, transforming the assembly into a preformed tube suitable for subsequent gas filling and voltage stabilization, and reducing the possibility of tungsten migration and blackening of the substrate tube caused by residual impurities participating in adverse reactions when the light-emitting heating component is working.

[0039] In step S2, the length of the formed sealing section is 1-5mm, which allows the end of the assembly to form a sealing area for fixing the assembly wire, while preventing the sealing area from extending too far into the heating section and affecting subsequent energization. The equivalent circle diameter of the air passage is 0.4-1.5mm, allowing the assembly to connect with the vacuum exhaust system and air source through the air passage, and meeting the gas flow requirements during the evacuation and replacement processes. The first evacuation ≤10Pa, the second evacuation ≤1×10 -2 The pressure inside the assembly is gradually reduced by 5-50 kPa, which helps to expel free gases from the internal cavity first, and then further expel the desorbed gases released during the vacuum baking process. The vacuum baking temperature is 250-350℃, and the time is 60-120 min, used to promote the desorption of residual moisture and volatile impurities from the internal surface of the assembly. The staged energizing degassing uses progressively increasing power and corresponding holding times to gradually heat the internal filaments of the assembly, reducing the possibility of excessively rapid local temperature rise caused by a single high-power energizing. Argon purging pressure is 5-50 kPa, and the number of purging cycles is 2-3 times, which can repeatedly dilute and expel residual impurities from inside the assembly; the subsequent vacuuming is ≤1×10⁻⁶ kPa. -2 Maintaining the pressure at 10-20 minutes helps stabilize the exhaust state inside the assembly, providing a cleaner pre-formed pipe environment for subsequent filling with the mixed gas.

[0040] It should be noted that step S2 is a degassing and impurity removal step in the fabrication process of the light-emitting heating component. The object of this process is the assembly formed in the preceding steps, and the result is the formation of a preformed tube. In this step, the assembly is first partially sealed to form a semi-formed tube. The semi-formed tube is an intermediate component where the composite wire has been fixed to the end of the base tube and the gas passage remains open. Subsequently, the semi-formed tube undergoes degassing and impurity removal to form a preformed tube. The preformed tube is an intermediate component that has undergone internal impurity removal but has not yet been filled with the working gas mixture. The degassing and impurity removal process includes vacuuming, vacuum baking, staged electrostatic degassing, inert gas replacement, and re-vacuuming. Its purpose is to improve the internal environment of the preformed tube, not to establish a working gas environment. Since the gas passage of the preformed tube remains connected to the outside, after this step, it can directly proceed to subsequent steps for gas mixture filling and pressure stabilization.

[0041] It should also be noted that the processes in this step are performed sequentially in the following order: segmented vacuuming, vacuum baking, staged electrostatic degassing, inert gas replacement, and re-vacuuming. Segmented vacuuming first reduces the gas pressure inside the semi-finished tube, providing a low-pressure environment for the desorption and discharge of adsorbates during vacuum baking. After vacuum baking, staged electrostatic degassing is performed, allowing the composite filament to gradually heat up in a low-pressure environment, enabling the adsorbates released by the composite filament to be discharged promptly through the gas channels. Subsequently, inert gas replacement is performed to dilute any remaining impurity gases in the gas channels and the inner cavity of the substrate tube. After replacement, vacuuming is performed again to remove the inert gas and the diluted impurity gases. Therefore, the above processing sequence allows the internal conditions created by the previous process to be utilized by the subsequent process; they are not independent processes running in parallel.

[0042] The first and second evacuations constitute a continuous vacuuming process. After the first evacuation, the semi-finished tube is not reconnected to the outside air; instead, the second evacuation continues while the semi-finished tube remains connected to the vacuum exhaust system. The inert gas replacement pressure is the gas pressure reached inside the semi-finished tube after each injection of inert gas. The stabilization after the second vacuuming involves maintaining the vacuum exhaust while ensuring that the detection pressure does not exceed the corresponding endpoint pressure for 10-20 minutes. Once the set endpoint pressure is reached and stabilization is achieved, the exhaust and impurity removal process is considered complete, and the resulting intermediate component is identified as the pre-formed tube.

[0043] Specifically, in step S3, mixed gas is injected into the preformed tube through the gas channel, and the preformed tube is subjected to gas filling and pressure stabilization treatment; after the gas filling and pressure stabilization treatment is completed, the gas channel is sealed and melted to obtain a sealed tube; Step S3 specifically includes the following steps: Step S31: Inject the mixed gas into the preformed tube through the gas passage; In step S31, the mixed gas includes an inert gas and a halogen gas component, wherein the inert gas is argon, and the halogen gas component includes hydrogen bromide, the content of hydrogen bromide in the mixed gas is 50-500 ppm; the charging pressure is 80-300 kPa. Step S32: After the mixed gas is filled, pressure compensation is performed on the preformed tube to stabilize the gas pressure inside the preformed tube at the filling pressure. In step S32, the pressure compensation is to continue connecting the gas source after the mixed gas is filled, and maintain the pressure at the filling pressure for 30-180 seconds. Step S33: After the pressure inside the preformed tube stabilizes, the air passage on the preformed tube is sealed by melting to obtain a sealed tube.

[0044] In step S33, the length of the sealing area of ​​the closed fusion seal is 1-8mm.

[0045] In step S3, the preformed tube obtained in the preceding steps undergoes mixed gas filling, pressure compensation, and sealing treatment. First, the air passage of the preformed tube is connected to the mixed gas source, allowing the mixed gas to enter the inner cavity of the preformed tube through the air passage, and gradually increasing the gas pressure inside the preformed tube to the corresponding filling pressure. After the mixed gas filling is complete, the air passage of the preformed tube remains connected to the mixed gas source, and the preformed tube is pressure-stabilized at the current filling pressure, allowing the mixed gas to continue to be added to the preformed tube to compensate for pressure deviations caused by air passage flow resistance, changes in gas distribution within the tube, and changes in the state of the filling system during the filling process. Once the gas pressure inside the preformed tube stabilizes, the air passage on the preformed tube is sealed, isolating the inner cavity of the preformed tube from the external environment, and sealing the pressure-stabilized mixed gas inside the preformed tube, thus obtaining a sealed tube with a closed inner cavity, providing a processing object for subsequent electro-energization and shaping processes.

[0046] Step S3 involves filling the preformed tube with a mixed gas and performing pressure compensation before sealing, ensuring that the gas composition and pressure within the preformed tube stabilize before sealing. Compared to directly sealing after filling with the mixed gas, stabilizing the pressure while the preformed tube remains connected to the mixed gas source helps reduce deviations in the actual sealing pressure from the set value caused by insufficient gas entry into the preformed tube cavity, pressure differences across the gas passages, or continued pressure changes after filling. This reduces the likelihood of significant differences in gas pressure and halogen gas composition between different sealed tubes. Improved consistency of the gas state within the preformed tube establishes a more stable initial gas environment for subsequent electrification and shaping processes. It also helps reduce instability in the tungsten-halogen cycle and deviations in heat output caused by deviations in filling pressure or halogen gas composition from the predetermined state during the operation of the light-emitting heating component. This contributes to reducing batch variations and minimizing additional energy consumption to maintain consistent heating performance.

[0047] In step S3, the mixed gas introduced into the preformed tube includes argon as an inert gas and halogen gas components. Argon is used to create a relatively stable gas environment within the preformed tube and, together with the halogen gas components, constitutes the working atmosphere of the light-emitting heating component. The halogen gas component content is 50-500 ppm, ensuring the preformed tube contains trace amounts of halogen gas components for participation in the tungsten-halogen cycle, while avoiding the inability to form the necessary cycle conditions using only inert gas. The charging pressure of the mixed gas is 80-300 kPa, enabling the preformed tube to achieve the preset gas pressure state and providing the gas environment for subsequent electro-forming and light-emitting heating processes. After the mixed gas is introduced, the gas source remains connected, and the pressure is maintained at the charging pressure for 30-180 seconds, allowing time for the gas to further enter the preformed tube cavity and complete pressure equilibrium, which helps reduce pressure deviation before and after sealing. The sealing area of ​​the closed-sealing process is 1-8mm in length, which makes the air passage of the pre-formed tube form a continuous closed area. While meeting the air passage sealing requirements, the axial range of the sealing area is controlled, thereby obtaining a closed tube that can maintain the internal mixed gas state.

[0048] It should be noted that step S3 is a gas filling and sealing step in the fabrication process of the light-emitting heating component. The object of this step is the preformed tube formed in the preceding steps, and the result is the formation of a sealed tube. After the preformed tube has undergone degassing and impurity removal, a working gas environment has not yet been formed inside. Therefore, a mixed gas needs to be injected into the preformed tube through the gas channel, and pressure compensation is performed before sealing. The gas filling and pressure stabilization process includes two continuous processes: mixed gas filling and pressure compensation. Mixed gas filling is used to establish the working gas environment for the light-emitting heating component, while pressure compensation is used to stabilize the pressure state inside the preformed tube. The sealed tube is an intermediate component where the mixed gas is sealed and the gas channel is closed. After the sealed tube is formed, its inner cavity is no longer connected to the external environment. Therefore, after this step, no vacuuming or refilling is performed; instead, it directly proceeds to the subsequent step of electrical shaping.

[0049] It should also be noted that pressure compensation does not involve increasing the target pressure inside the preformed tube after the gas mixture reaches the charging pressure. Instead, it maintains the charging pressure while keeping the preformed tube connected to the gas mixture source. When the gas mixture enters the preformed tube from the gas source through the gas passage, the flow cross-section of the gas passage restricts gas flow, and the gas pressure at different locations within the preformed tube may not have fully reached equilibrium at the end of charging. By maintaining a stable pressure at the charging pressure, the gas mixture can continue to be supplied to the preformed tube cavity, gradually bringing the pressure on both sides of the gas passage and in different areas within the preformed tube closer to uniformity. Therefore, pressure compensation addresses preformed tubes that have been charged with gas mixture but not yet sealed, reducing the possibility of deviation between the actual pressure inside the preformed tube and the set charging pressure at the time of sealing.

[0050] Furthermore, the mixed gas consists of argon and hydrogen bromide, and the hydrogen bromide content in the halogen gas component is a volume concentration calculated based on the total volume of the mixed gas. The mixed gas is pre-prepared according to a set ratio before being injected into the preformed tubes to ensure consistency in the composition of the mixed gas injected into different preformed tubes. The injection pressure is the absolute pressure that the preformed tube needs to reach after the mixed gas is injected, with 25°C as the reference temperature. Unless otherwise stated, all pressures involved in this disclosure are absolute pressures; the injection pressure does not represent the rated output pressure of the mixed gas source equipment. During the injection process, the injection pressure is detected by a pressure detection device located between the mixed gas source and the preformed tube gas passage, near the gas passage connection end. When the pressure reaches the set injection pressure, the preformed tube remains connected to the mixed gas source, and pressure stabilization is performed at this injection pressure. During pressure stabilization, the target pressure is not actively increased; instead, the mixed gas continues to compensate for the pressure difference caused by the gas passage flow resistance and the incomplete balance of gas pressure within the preformed tube. When the set pressure stabilization time is reached and the pressure detection value no longer shows continuous changes, the inflation and pressure stabilization process is considered complete; then, the air passage is sealed and melted while maintaining the pressure state inside the pre-formed tube.

[0051] Specifically, in step S4, the closed tube is energized and shaped to obtain a light-emitting heating component.

[0052] The light-emitting heating component in step S4 is obtained according to the following steps: The sealed tube is subjected to at least three power-on shaping processes in sequence, including a first power-on shaping, a second power-on shaping, and a third power-on shaping. After the power-on shaping is completed, the sealed tube is allowed to cool naturally to room temperature to obtain a light-emitting heating component.

[0053] The first power-on test is performed at 40-50% of the rated power for 3-5 minutes; the second power-on test is performed at 60-70% of the rated power for 5-10 minutes; and the third power-on test is performed at 85-100% of the rated power for 20-60 minutes.

[0054] In step S4, the sealed tube undergoes an energizing and shaping process. First, the sealed tube is connected to a power supply device compatible with its rated power for a first energizing and shaping process, causing the internal filaments to gradually heat up under conditions below the rated power. After the first energizing and shaping is completed, the power is increased for a second energizing and shaping process, further stabilizing the internal temperature and the working state of the filaments. Subsequently, the power is increased again for a third energizing and shaping process, allowing the sealed tube to operate continuously under conditions close to its rated operating state. After the third energizing and shaping is completed, the power supply is stopped, allowing the sealed tube to cool naturally to room temperature without additional cooling. By sequentially completing the first, second, and third energizing and shaping processes, followed by natural cooling, the internal filaments and gas mixture undergo a gradual heating and stabilization process, ultimately resulting in a light-emitting heating component.

[0055] Step S4 involves a phased power increase during energization of the sealed tube, gradually transitioning it from its initial state to near its rated operating state. Compared to a one-time energization using the rated power, this phased power increase helps reduce the likelihood of a rapid temperature rise in the composite filament within a short period, and allows the gas mixture, composite filament, and substrate tube inside the sealed tube to gradually adapt to the temperature changes caused by energization. As the energization process continues, the remaining small amount of gas components inside the sealed tube and the resistivity of the composite filament further stabilize, while providing the necessary temperature conditions for the gradual establishment of the tungsten-halogen cycle. This treatment helps reduce the continuous fluctuations in heat output of the light-emitting heating component during the initial use phase, ensuring a relatively stable operating state after fabrication. This reduces the likelihood of needing to increase input power or extend heating time due to insufficient initial output or output fluctuations, and provides a post-processing basis for improving energy consumption performance during long-term operation.

[0056] In step S4, the first power-on conditioning uses 40-50% of the rated power and is maintained for 3-5 minutes. This allows the composite wire inside the sealed tube to begin heating under relatively low power conditions, providing a transitional phase for subsequent power increases and helping to reduce the possibility of excessively rapid local temperature rise during initial power-on. The second power-on conditioning uses 60-70% of the rated power and is maintained for 5-10 minutes. This further increases the internal temperature of the sealed tube based on the first power-on conditioning, and allows the composite wire and gas mixture to operate continuously under medium power conditions, promoting gradual stabilization of the internal state of the sealed tube. The third power-on conditioning uses 85-100% of the rated power and is maintained for 20-60 minutes. This allows the sealed tube to be conditioned for a longer period under conditions close to its rated operating state, which helps to observe and stabilize the energizing state of the composite wire and the heat output of the sealed tube. After power-on conditioning, the sealed tube is allowed to cool naturally to room temperature. This allows the internal temperature of the sealed tube to decrease gradually, reducing the possibility of inconsistent temperature changes between the base tube, sealing area, and composite wire caused by rapid cooling, thus obtaining a light-emitting heating component that has completed power-on conditioning.

[0057] It should be noted that step S4 is a state establishment step in the fabrication process of the light-emitting heating component. Its object is the sealed tube formed in the preceding steps, and its result is the formation of the light-emitting heating component. After the sealed tube completes the gas mixture sealing, its internal gas composition and pressure state remain basically stable. Therefore, this step does not change the internal gas composition of the sealed tube. Instead, it uses an electric current to shape the sealed tube under a predetermined internal environment, gradually transitioning the composite filament from the processing state to the designed working state. This electric current shaping includes multiple processing stages with progressively increasing power, each stage implemented sequentially to jointly establish the working state of the sealed tube. After the electric current shaping is completed, the sealed tube is naturally cooled to form the light-emitting heating component. At this point, the light-emitting heating component completes the entire fabrication process and can be used as the final product in subsequent testing or application stages.

[0058] It should also be noted that the first, second, and third power-on shaping processes are performed sequentially, with the power of each subsequent power-on shaping stage being higher than that of the previous stage. The power output at each stage refers to the actual input power applied to the sealed tube by the power supply device, calculated based on the rated input power of the light-emitting heating component. Between different power-on shaping stages, the output of the power supply device is adjusted to transition the sealed tube from one power state to the next; the sealed tube is not re-evacuated, re-inflated, or resealed between the three stages. The operating state in this step refers to the light-emitting heating component operating under its designed rated voltage and rated power conditions. The power-on shaping process is considered complete when the sealed tube has sequentially completed the first, second, and third power-on shaping processes and has naturally cooled to room temperature after the power supply is stopped. The sealed tube after power-on shaping forms the light-emitting heating component. In actual production, the light-emitting heating component can also undergo electrical performance, airtightness, and appearance testing; if the testing is successful, it is considered a finished product.

[0059] It is understood that the preparation method disclosed herein is implemented sequentially in the order of assembly preparation, degassing and impurity removal, gas filling and sealing, and electro-solidification. The intermediate products formed in each step are, in turn, the assembly, the pre-formed tube, the sealed tube, and the light-emitting heating component. Specifically, step S1 mainly establishes the structural state of the light-emitting heating component, step S2 mainly establishes the internal cleanliness state, step S3 mainly establishes the working gas state, and step S4 mainly establishes the stable working state. The intermediate state formed in the previous step serves as the processing object for the next step, and the next step continues based on the processing of the previous step. Therefore, the steps are implemented consecutively in the order of gradually establishing the internal state, jointly completing the preparation process of the light-emitting heating component.

[0060] This disclosure also provides a light-emitting heating component, such as... Figure 2-3 As shown, the light-emitting heating component is obtained using the above-described preparation method. The light-emitting heating component includes a substrate tube 3, a combined wire 1, a capillary tube 5, and a mixed gas. The combined wire 1 is disposed in the inner cavity of the substrate tube 3. The combined wire 1 includes a heating wire 2 and a thin wire 4. The heating section of the heating wire 2 is spaced apart from the inner wall of the substrate tube 3. The capillary tube 5 is disposed at the end of the substrate tube 3 and communicates with the inner cavity of the substrate tube 3. The mixed gas is encapsulated in the inner cavity of the substrate tube 3.

[0061] For details on the preparation method, please refer to Examples 1, 2 and 3.

[0062] Example 1: This embodiment provides a method for preparing a light-emitting heating component, including the following steps.

[0063] Step S1 involves pre-treating and assembling the base tube, capillary tube, heating wire, and fine wire to obtain the assembly.

[0064] Step S11: Place the quartz glass substrate tube and capillary tube in anhydrous ethanol for ultrasonic cleaning for 10 minutes. After ultrasonic cleaning, rinse with deionized water and then dry with nitrogen. Place the dried substrate tube and capillary tube in a heating device and preheat at 350°C for 2 hours. After preheating, allow the substrate tube and capillary tube to cool in a clean environment to a temperature suitable for assembly.

[0065] Step S12: Using tungsten wire as the heating wire, the heating wire is wound according to the internal space and heating area requirements of the base tube, and then the wound heating wire is shaped to obtain the shaped wire.

[0066] Step S13: Using tungsten wire as the fine wire, the forming wire and the fine wire are connected by welding to obtain a composite wire. The composite wire and capillary tube are installed into the base tube, and the position of the composite wire is adjusted so that the heating section of the heating wire is spaced apart from the inner wall of the base tube, thus completing the assembly of the composite wire, capillary tube and base tube to obtain the assembly.

[0067] Step S2 involves fixing the ends of the assembly and removing air and impurities to obtain a pre-formed pipe.

[0068] Step S21: Partially seal the lead-out end of the assembly wire in the assembly, fixing the assembly wire to the end of the base tube, and keeping the inner hole of the capillary tube in communication with the inner cavity of the base tube, using the inner hole of the capillary tube as the air passage to obtain a semi-finished tube. The length of the sealing section of the assembly wire at the end of the base tube is 3mm, and the equivalent circle diameter corresponding to the minimum flow cross-sectional area of ​​the air passage is 0.8mm.

[0069] Step S22: Connect the air passage to the vacuum exhaust system. First, perform a first evacuation of the semi-finished tube until the pressure inside the semi-finished tube does not exceed 8 Pa. Then, perform a second evacuation until the pressure inside the semi-finished tube does not exceed 8 × 10 Pa. -3 Pa. Maintain vacuum exhaust and vacuum bake the semi-finished tube at 300°C for 90 minutes.

[0070] Step S23: Maintain the connection between the gas duct and the vacuum exhaust system, and perform staged degassing by energizing the composite filaments inside the semi-finished tube. The first degassing stage uses 25% of the rated power of the light-emitting heating component for 45 seconds; the second stage uses 45% of the rated power for 45 seconds; and the third stage uses 65% of the rated power for 20 seconds. After staged degassing, argon gas is introduced into the semi-finished tube through the gas duct for replacement. The argon replacement pressure is 25 kPa, and the replacement is performed three times. After each replacement, the argon gas and diluted impurity gases are extracted. After replacement, the semi-finished tube is evacuated again until the pressure inside the semi-finished tube does not exceed 8 × 10⁻⁶ kPa.-3 Pa, and held stably under this pressure for 15 minutes to obtain a preformed tube.

[0071] Step S3 involves filling the preformed tube with mixed gas, compensating for pressure, and performing a sealing process to obtain a sealed tube.

[0072] Step S31: Connect the gas channel of the preformed tube to the mixed gas source, and fill the preformed tube with a mixed gas including argon and hydrogen bromide through the gas channel. The content of the halogen gas component is 200 ppm, and the filling pressure of the mixed gas is 180 kPa.

[0073] Step S32: After the mixed gas is filled, keep the gas passage of the preformed tube connected to the mixed gas source, and maintain the pressure at a filling pressure of 180 kPa for 90 seconds to make the gas pressure in the preformed tube tend to stabilize.

[0074] Step S33: After the pressure is stabilized, the gas passage on the preformed tube is sealed by fusion. The length of the sealing area formed by the fusion is 4mm, so that the mixed gas is sealed in the preformed tube to obtain a sealed tube.

[0075] Step S4: The sealed tube is energized and shaped to obtain the light-emitting heating component.

[0076] Connect the sealed tube to the power supply device. First, perform a first power-on test using 45% of the rated power of the light-emitting heating component for 4 minutes. After the first power-on test, increase the power to 65% of the rated power for a second power-on test for 8 minutes. After the second power-on test, increase the power to 95% of the rated power for a third power-on test for 40 minutes. After the third power-on test, stop the power supply and allow the sealed tube to cool naturally to room temperature, thus obtaining the light-emitting heating component.

[0077] Example 2: The basic content of this embodiment is the same as that of embodiment 1, except that: In step S11, the ultrasonic cleaning time with anhydrous ethanol is 5 minutes, the preheating temperature is 250°C, and the preheating time is 4 hours.

[0078] In step S21, the length of the sealing section is 1 mm, and the equivalent circle diameter corresponding to the minimum flow cross-sectional area of ​​the airway is 0.4 mm.

[0079] In step S22, the endpoint pressure of the first pumping is 10 Pa, and the endpoint pressure of the second pumping is 1 × 10 Pa. -2 Pa; the vacuum baking temperature is 250℃, and the vacuum baking time is 120min.

[0080] In step S23, the first degassing stage uses 20% of the rated power for 60 seconds, the second degassing stage uses 40% of the rated power for 60 seconds, and the third degassing stage uses 60% of the rated power for 30 seconds; the argon replacement pressure is 5 kPa, and the replacement is performed 3 times; the final pressure of the second vacuuming is 1 × 10⁻⁶ kPa. -2 Pa, and remain stable for 20 minutes.

[0081] In step S31, the content of halogen gas components is 50 ppm, and the charging pressure of the mixed gas is 80 kPa.

[0082] In step S32, the voltage stabilization holding time is 180s.

[0083] In step S33, the length of the sealing area is 1 mm.

[0084] In step S4, the first power-on test uses 40% of the rated power and takes 5 minutes; the second power-on test uses 60% of the rated power and takes 10 minutes; and the third power-on test uses 85% of the rated power and takes 60 minutes.

[0085] Example 3: The basic content of this embodiment is the same as that of embodiment 1, except that: In step S11, the ultrasonic cleaning time with anhydrous ethanol is 15 min, the preheating temperature is 450℃, and the preheating time is 1 h.

[0086] In step S21, the sealing section is 5 mm long and the equivalent circle diameter corresponding to the minimum flow cross-sectional area of ​​the airway is 1.5 mm.

[0087] In step S22, the final pressure of the first pumping is 5 Pa, and the final pressure of the second pumping is 5 × 10⁻⁶ Pa. -3 Pa; the vacuum baking temperature is 350℃, and the vacuum baking time is 60min.

[0088] In step S23, the first degassing stage uses 30% of the rated power for 30 seconds, the second degassing stage uses 50% of the rated power for 30 seconds, and the third degassing stage uses 70% of the rated power for 10 seconds; the argon replacement pressure is 50 kPa, and the replacement is performed twice; the final pressure of the second vacuuming is 5 × 10⁻⁶ kPa. -3 Pa, and maintain it stably for 10 minutes.

[0089] In step S31, the content of halogen gas components is 500 ppm, and the charging pressure of the mixed gas is 300 kPa.

[0090] In step S32, the voltage stabilization holding time is 30s.

[0091] In step S33, the length of the sealing area is 8mm.

[0092] In step S4, the first power-on test uses 50% of the rated power for 3 minutes; the second power-on test uses 70% of the rated power for 5 minutes; and the third power-on test uses 100% of the rated power for 20 minutes.

[0093] Comparative Example 1: The basic content of this embodiment is the same as that of embodiment 1, except that: Step S2 does not include staged degassing by electricity, argon purging, or re-vacuuming after purging.

[0094] Specifically, the air passage is connected to the vacuum exhaust system, and the semi-finished tube is evacuated to 8×10⁻⁶. -3 Pa, and vacuum-baked at 300℃ for 90 minutes. After vacuum baking, the combined wire is not degassed by gradation or replaced by argon gas. Instead, the mixed gas filling and pressure stabilization treatment in step S3 are carried out directly.

[0095] Comparative Example 2: The basic content of this embodiment is the same as that of embodiment 1, except that: Pressure compensation is not performed on the preformed tube in step S3.

[0096] Specifically, a halogen gas mixture with a content of 200 ppm is introduced into the preformed tube through the gas channel. When the pressure of the mixture reaches 180 kPa, the introduction of the mixture is stopped, and the gas channel is immediately sealed. Pressure stabilization is carried out without maintaining the connection between the preformed tube and the mixture source.

[0097] Comparative Example 3: The basic content of this embodiment is the same as that of embodiment 1, except that: Step S4 does not involve the three-stage power-on shaping process with progressively increasing power.

[0098] Specifically, after connecting the sealed tube to the power supply device, a single-stage power-on shaping process was performed using 95% of the rated power. To ensure that the total input electrical energy for power-on shaping in this comparative example is basically equivalent to that in Example 1, the single-stage power-on time was set to 47 minutes. After power-on was completed, the power supply was stopped, and the sealed tube was allowed to cool naturally to room temperature, resulting in the light-emitting heating component.

[0099] The following are the performance data of the light-emitting heating components obtained in Examples 1, 2, 3, Comparative Examples 1, 2, and 3. Please refer to Table 1 for details: Table 1 The pressure recovery rate is tested according to GB / T 32218—2015; the cold pressure variation coefficient is calculated according to GB / T3358.2—2009; the initial output drift rate is tested according to GB / T 7287—2008; the blackening area ratio after 500 hours is tested according to GB / T 7287—2008 under continuous operating conditions and tested using the image area method; the output retention rate after 500 hours is tested according to GB / T 7287—2008; and the power consumption to reach the target temperature is tested according to GB / T 7287—2008.

[0100] As shown in Table 1, Example 1 exhibits a lower pressure recovery rate, a lower blackening area ratio, and a higher output retention rate compared to Comparative Example 1. This demonstrates that the composite exhaust and impurity removal treatment reduces the impact of residual impurities on long-term operation. Example 1 also shows a lower cold-state pressure variation coefficient compared to Comparative Example 2, indicating that post-charge pressure stabilization improves the consistency of sealing pressure for products in the same batch. Furthermore, Example 1 has a lower initial output drift rate compared to Comparative Example 3, demonstrating that the three-stage power-on shaping process enables the light-emitting heating component to quickly enter a stable output state after fabrication. Since Examples 1 to 3 are all superior to the Comparative Example, this also demonstrates that within the parameter range defined in the claims, the complete process can collectively improve tube wall blackening, output retention, and energy consumption performance under the same heating conditions.

[0101] Other embodiments of this disclosure will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This application is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of this disclosure are indicated by the following claims.

[0102] It should be understood that this disclosure is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this disclosure is limited only by the appended claims.

Claims

1. A method for preparing a light-emitting heating component, characterized in that, The preparation method includes the following steps: Step S1: Connect the heating wire and the thin wire to obtain the combined wire, and then put the combined wire and the capillary tube into the base tube to obtain the assembly. Step S2: Partially seal the end of the assembly to fix the assembly wire to the end of the assembly, and retain the air passage communicating with the inner cavity of the base tube; then exhaust and remove impurities from the inside of the assembly through the air passage to obtain the pre-formed tube. Step S3: Inject mixed gas into the preformed tube through the gas channel and perform gas filling and pressure stabilization treatment on the preformed tube; after the gas filling and pressure stabilization treatment is completed, seal the gas channel to obtain a sealed tube; Step S4: The closed tube is energized and shaped to obtain the light-emitting heating component.

2. The method for preparing the light-emitting heating component according to claim 1, characterized in that, Step S1 specifically includes the following steps: Step S11: Clean the base tube and capillary tube, and then preheat them. Step S12: Wind and shape the heating wire to obtain a shaped wire; Step S13: Connect the forming filament with the fine filament to obtain the combined filament, and put the combined filament and capillary tube into the base tube to obtain the assembly.

3. The method for preparing the light-emitting heating component according to claim 2, characterized in that, In step S11, the cleaning process involves ultrasonic cleaning in anhydrous ethanol for 5-15 minutes, rinsing with deionized water, and then drying with nitrogen gas; the preheating process is carried out at a temperature of 250-450℃ for 1-4 hours; both the substrate tube and the capillary tube are quartz glass tubes. In step S12, the heating wire is a tungsten wire; In step S13, the forming wire and the fine wire are connected by welding, the heating section of the heating wire is spaced apart from the inner wall of the base tube, the fine wire is a tungsten wire, and the base tube and the capillary tube are both quartz glass tubes.

4. The method for preparing the light-emitting heating component according to claim 1, characterized in that, Step S2 specifically includes the following steps: Step S21: Partially seal the lead-out end of the composite wire to fix the composite wire to the end of the base tube, and keep the inner hole of the capillary connected to the inner cavity of the base tube. The inner hole of the capillary forms an air passage to obtain a semi-finished tube. Step S22: Connect the air passage to the vacuum exhaust system, perform segmented vacuuming of the semi-finished tube through the air passage, and then vacuum bake the semi-finished tube. Step S23: Under vacuum exhaust, the combined wires in the semi-finished tube are degassed by gradation through electric current; then, inert gas is introduced into the semi-finished tube through the gas channel for replacement, and the semi-finished tube is evacuated again to obtain the pre-formed tube.

5. The method for preparing the light-emitting heating component according to claim 4, characterized in that, In step S21, the length of the sealing section at the end of the base tube in the combined wire is 1-5 mm; the equivalent circle diameter corresponding to the minimum flow cross-sectional area of ​​the air passage is 0.4-1.5 mm. In step S22, the segmented vacuuming includes a first vacuuming and a second vacuuming, wherein the final pressure of the first vacuuming is ≤10 Pa, and the final pressure of the second vacuuming is ≤1×10 Pa. -2 Pa; the vacuum baking temperature is 250-350℃ and the time is 60-120min; In step S23, the graded degassing includes a first degassing stage, a second degassing stage, and a third degassing stage. The first degassing stage has a power of 20-30% of the rated power and a time of 30-60 seconds; the second degassing stage has a power of 40-50% of the rated power and a time of 30-60 seconds; the third degassing stage has a power of 60-70% of the rated power and a time of 10-30 seconds. The inert gas is argon, the displacement treatment pressure is 5-50 kPa, and the number of treatments is 2-3 times. The final pressure of the second vacuuming is ≤1×10⁻⁶ kPa. -2 Pa, and maintain stable pressure for 10-20 minutes after reaching the endpoint pressure.

6. The method for preparing the light-emitting heating component according to claim 1, characterized in that, Step S3 specifically includes the following steps: Step S31: Inject the mixed gas into the preformed tube through the gas passage; Step S32: After the mixed gas is filled, pressure compensation is performed on the preformed tube to stabilize the gas pressure inside the preformed tube at the filling pressure. Step S33: After the pressure inside the preformed tube stabilizes, the air passage on the preformed tube is sealed by melting to obtain a sealed tube.

7. The method for preparing the light-emitting heating component according to claim 6, characterized in that, In step S31, the mixed gas includes an inert gas and a halogen gas component, wherein the inert gas is argon, and the halogen gas component includes hydrogen bromide, the content of hydrogen bromide in the mixed gas is 50-500 ppm; the charging pressure is 80-300 kPa. In step S32, the pressure compensation is to continue connecting the gas source after the mixed gas is filled, and maintain the pressure at the filling pressure for 30-180 seconds. In step S33, the length of the sealing area of ​​the closed fusion seal is 1-8mm.

8. The method for preparing the light-emitting heating component according to claim 1, characterized in that, The light-emitting heating component in step S4 is obtained according to the following steps: The sealed tube is subjected to at least three power-on shaping processes in sequence, including a first power-on shaping, a second power-on shaping, and a third power-on shaping. After the power-on shaping is completed, the sealed tube is allowed to cool naturally to room temperature to obtain a light-emitting heating component.

9. The method for preparing the light-emitting heating component according to claim 8, characterized in that, The first power-on test is performed at 40-50% of the rated power for 3-5 minutes; the second power-on test is performed at 60-70% of the rated power for 5-10 minutes; and the third power-on test is performed at 85-100% of the rated power for 20-60 minutes.

10. A light-emitting heating component, characterized in that, The light-emitting heating component is obtained by the preparation method as described in any one of claims 1-9.

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