An electric heater wire forming apparatus for manufacturing a glass tube heater

Abstract

The application relates to the field of glass tube heaters and preparation technology thereof, in particular to a glass tube heater and an electric heating wire forming device. The glass tube heater comprises a nickel-chromium alloy electric heating wire which is wound into a non-circular cross-section coil, wherein the cross-section of the coil can be a polygon and has smooth round corners, preferably a central symmetrical hexagonal star shape, six corners are arranged along the radial direction and two edges are parallel to each other. In addition, an electric heating wire forming device for manufacturing the above-mentioned glass tube heater is also provided, which comprises an inner clamp and an outer stamping clamp, the cross-section profile of the inner clamp is the same as the cross-section inner profile of the non-circular coil, the outer stamping clamp comprises a plurality of stamping heads and a linear driving component, and a guide sleeve and a retraction cylinder. Through optimization of the electric heating wire shape and the forming process, the application improves the heating efficiency and the service life, and simplifies the production process.

Description

Technical Field

[0001] This application relates to the field of glass tube heaters and their manufacturing techniques, and in particular to an electric heating wire forming apparatus for manufacturing glass tube heaters. Background Technology

[0002] Glass tube heaters are widely used in various industrial and civil fields, playing a crucial role, especially in liquid and gas heating. Currently, most glass tube heaters on the market use iron-chromium-aluminum heating wires, a material with excellent electrical conductivity and high-temperature resistance, hence its widespread application. However, with increasing market demand and technological advancements, the requirements for heater reliability and durability are constantly rising. In existing technologies, various sealing measures are typically employed to prevent the heating wires from rusting due to moisture. Common methods include using rubber sealing rings, potting compound sealing, and glass tube fusion sealing. While these methods can improve the sealing performance to some extent, they still have some problems. For example, rubber seals may fail due to aging; potting compound seals may result in poor sealing due to improper operation; and glass tube fusion sealing is not only inefficient but may also lead to incomplete sealing. Furthermore, there are also iron-free nickel-chromium heating wires on the market, but due to their lower resistivity, they cannot be directly used in heaters operating under 220V voltage conditions, limiting their application range. Despite the various sealing measures mentioned above, it is still difficult to completely prevent corrosion of the heating wire due to moisture intrusion during actual use. These problems not only affect the lifespan of the heater but also increase maintenance costs and reduce user experience. Therefore, how to effectively solve the problem of heating wire rusting due to moisture has become a key technical challenge that urgently needs to be addressed. Utility Model Content

[0003] The purpose of this application is to overcome the above-mentioned technical problems and provide an electric heating wire forming device for manufacturing glass tube heaters.

[0004] A glass tube heater includes a nickel-chromium alloy heating wire wound into a coil with a non-circular cross-section.

[0005] By adopting the above technical solution, nickel-chromium alloy heating wire replaces traditional iron-chromium-aluminum alloy heating wire, exhibiting superior corrosion resistance and aging resistance, effectively preventing the problem of heating wire corrosion and breakage caused by moisture intrusion. Simultaneously, the non-circular coil design increases the effective length of the heating wire, improving the resistance value and enabling the heater to meet specific power requirements. This design not only solves the problem of poor sealing in traditional heaters but also simplifies the manufacturing process and reduces production costs.

[0006] Preferably, the cross-section of the coil is polygonal, and the corners of the polygon are set as smooth rounded corners.

[0007] By adopting the above technical solution, the coil's cross-section is designed as a polygon with smooth rounded corners, which effectively reduces stress concentration points and improves the mechanical strength and service life of the heating wire. At the same time, this design makes the coil easier to manufacture, avoiding the processing difficulties and safety hazards that sharp corners might cause.

[0008] Preferably, the cross-section of the coil is a centrally symmetrical hexagonal star.

[0009] By adopting the above technical solution, designing the coil cross-section as a centrally symmetrical hexagonal star effectively increases the length of the heating wire, thereby improving the resistance value and ensuring the heater operates normally under 220V voltage. Simultaneously, this special coil shape increases the surface area of ​​the heating wire per unit volume, improving heat dissipation efficiency and further enhancing heating performance. Furthermore, the centrally symmetrical design helps ensure the uniformity and stability of the coil after deformation, reducing localized overheating caused by irregular shape and extending the service life of the heating wire.

[0010] Preferably, the six corners of the coil are arranged radially, and the two sides of the corners of the coil are parallel to each other.

[0011] By adopting the above technical solution, the six corners of the coil are arranged radially with the two sides of each corner parallel to each other, which effectively increases the actual length of the heating wire, improves the resistance value, and ensures that the required power is met. At the same time, this design makes the coil more stable during the forming process, avoids the deformation problem that is prone to occur in traditional circular coils, and improves production efficiency and finished product quality.

[0012] An electric heating wire forming apparatus for manufacturing the aforementioned glass tube heater includes an inner clamp for supporting a cylindrical coil and an outer stamping clamp for extruding and deforming the coil, wherein the cross-sectional profile of the inner clamp is the same as the inner cross-sectional profile of the non-circular coil.

[0013] By adopting the above technical solution, the heating wire forming equipment provided by this invention can accurately deform cylindrical coils into the required non-circular cross-sectional shape. Specifically, the combined use of the inner clamp and the outer stamping clamp ensures the coil remains stable during the deformation process, avoiding errors and instabilities that may occur with traditional manual or semi-automatic equipment. This design not only improves production efficiency but also ensures product quality and consistency. Especially for complex polygonal or multi-faceted star-shaped cross-sections, this equipment can achieve high-precision forming, further enhancing the overall performance and reliability of the heater.

[0014] Preferably, the outer stamping fixture includes a stamping head and a linear drive component, with multiple stamping heads arranged around the inner fixture and multiple linear drive components corresponding to the stamping heads.

[0015] By adopting the above technical solution, effective forming of nickel-chromium alloy heating wire coils can be achieved. Multiple stamping heads are arranged around the inner clamps to ensure uniform pressure is applied simultaneously at different positions on the coil, avoiding localized stress concentration and thus guaranteeing the accuracy and consistency of the coil's cross-sectional shape. This design is suitable for forming various non-circular coil cross-sections; different coil shapes can be quickly switched simply by changing the corresponding stamping head, increasing the equipment's flexibility and applicability.

[0016] Preferably, when the cross-section of the coil is a centrally symmetrical hexagonal star, the punching head includes a convex punch corresponding to the convex corner contour of the hexagonal star and a concave punch corresponding to the concave corner contour of the hexagonal star; six convex punches and six concave punches are provided.

[0017] By adopting the above technical solution, the centrally symmetrical hexagonal star-shaped coil can effectively increase the length of the heating wire, thereby increasing the resistance value to meet power requirements. Simultaneously, this special coil shape design allows for a more compact and rational arrangement of the heating wire within a limited space, improving heating efficiency. Furthermore, the design of the convex and concave punches precisely matches the contour of the hexagonal star, ensuring the stability and consistency of the coil during the forming process, avoiding the localized stress concentration problems that may exist in traditional circular coils, and improving the product's durability.

[0018] Preferably, the outer stamping fixture further includes a guide sleeve. The main body of the guide sleeve is a hollow cylinder coaxially sleeved on the inner fixture. Guide grooves are provided on the peripheral sidewall of the guide sleeve corresponding to each stamping head and extending radially through the guide sleeve. The stamping head slides into the corresponding guide groove.

[0019] By adopting the above technical solution, the guide sleeve enables the stamping head to move along a precise path, ensuring that the coil forms the required cross-sectional shape during the extrusion process, thereby improving the forming accuracy and consistency.

[0020] Preferably, one end of the guide sleeve is configured as a clearance hole that slides and engages with the inner clamp; it also includes a retraction cylinder for driving the inner clamp to retract into the guide sleeve.

[0021] By adopting the above technical solution, one end of the guide sleeve is set as a clearance hole for sliding cooperation with the inner clamp, and a retraction cylinder is added to drive the inner clamp to retract inward to the guide sleeve. This effectively achieves precise control and high-efficiency automation of the coil during the forming process. After the coil is formed, it fits tightly with the inner clamp. By driving the inner clamp to retract through the retraction cylinder, the coil and the inner clamp move relative to each other, allowing the operator to easily remove the coil.

[0022] In summary, this application includes at least one of the following beneficial technical effects: 1. By using a nickel-chromium alloy heating wire instead of an iron-chromium-aluminum alloy heating wire, the problem of the heating wire rusting due to moisture is completely solved, improving the reliability and durability of the heater; 2. By changing the winding shape of the traditional circular coil and adopting a non-circular (such as polygonal, hexagonal star, etc.) coil design, the length of the heating wire is increased, thereby achieving the required resistance value and power requirements and adapting to the 220V voltage working environment; 3. The overall structure of the heater is simplified, eliminating the need for complex sealing measures, reducing production costs and maintenance difficulty, and improving the product's economy and practicality. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the coil structure of this application;

[0024] Figure 2 This is a schematic diagram of the structure of the heating wire forming equipment in this application. Figure 1 ;

[0025] Figure 3 This is a schematic diagram of the structure of the heating wire forming equipment in this application. Figure 2 .

[0026] Reference numerals: 1. Nickel-chromium alloy heating wire; 2. Inner clamp; 3. Outer stamping clamp; 4. Stamping head; 41. Convex punch; 42. Concave punch; 5. Linear drive component; 6. Guide sleeve; 61. Guide groove; 62. Clearance hole; 7. Retraction cylinder. Detailed Implementation

[0027] The technical solutions in the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. The described embodiments are only possible technical implementations of this utility model and not all possible implementations. Those skilled in the art can obtain other embodiments in conjunction with the embodiments of this utility model without creative effort, and these embodiments are also within the protection scope of this utility model.

[0028] The inventors of this application discovered that the iron-chromium-aluminum alloy heating wire used in existing glass tube heaters is prone to rusting due to moisture, leading to problems such as wire breakage. Therefore, this application mainly adopts the following solutions: changing the heating wire material from iron-chromium-aluminum to nickel-chromium alloy, and changing the winding shape of the heating wire to something other than the current circular shape, such as an irregular triangle or irregular ellipse, preferably a wavy shape. The heater made using the above materials and methods will not corrode the heating wire even if moisture enters the heater's interior, achieving the effect of improving the heater's reliability and durability.

[0029] The glass tube heater provided in this application includes a glass tube, terminals fixed at both ends of the glass tube, and a nickel-chromium alloy heating wire 1 installed inside the glass tube. The nickel-chromium alloy heating wire 1 is wound into a coil with a non-circular cross-section. Specifically, this non-circular coil can be polygonal, such as a triangle, square, pentagon, etc., or it can be elliptical or other irregular shapes. This design allows the length of the heating wire to be increased, thereby achieving the required resistance value and meeting the power requirements.

[0030] The nickel-chromium alloy heating wire 1 contains a high proportion of nickel, giving it excellent corrosion and oxidation resistance. Therefore, even in humid environments, the heating wire will not rust, fundamentally solving the problem of traditional iron-chromium-aluminum alloy heating wires being prone to rusting due to moisture. Furthermore, because nickel-chromium alloy has low resistivity, a longer heating wire is needed to achieve the same resistance value. This can be achieved by changing the coil shape without significantly altering other structural components.

[0031] refer to Figure 1 In this embodiment, the coil cross-section is selected as a centrally symmetrical hexagonal star. This shape not only increases the length of the heating wire, but also further optimizes the heat distribution and reduces the formation of hot spots.

[0032] Specifically, the hexagonal star-shaped coil cross-section is centrally symmetrical, with each corner featuring a smooth rounded corner to reduce stress concentration points. The six corners are arranged radially, with adjacent sides parallel to each other, forming a stable geometric structure. This design is not only aesthetically pleasing but also effectively disperses heat, extending the lifespan of the heating wire.

[0033] refer to Figure 2 and Figure 3 In the manufacturing process, a heating wire forming device for manufacturing glass tube heaters is used. The cross-sectional profile of the inner clamp 2 matches the inner profile of the hexagonal star-shaped coil, while the outer stamping clamp 3 includes multiple stamping heads 4 and a linear drive component 5. Each stamping head 4 is equipped with a convex punch 41 and a concave punch 42, corresponding to the protruding and concave portions of the hexagonal star, respectively. Six of each type of punch are provided to ensure uniform pressure on all parts during coil deformation.

[0034] In addition, the outer stamping fixture 3 also includes a guide sleeve 6, the main body of which is a hollow cylinder coaxially fitted on the inner fixture 2. A guide groove 61 is radially opened on the peripheral side wall, and the stamping head 4 slides in engagement with the corresponding guide groove 61. One end of the guide sleeve 6 is provided with a clearance hole 62 that slides in engagement with the inner fixture 2, and is equipped with a retraction cylinder 7, which is used to drive the inner fixture 2 to retract inward to the guide sleeve 6, so as to facilitate the smooth demolding of the coil.

[0035] The implementation principle of this embodiment is as follows: by selecting nickel-chromium alloy as the heating wire material, the problem of the heating wire rusting due to moisture is completely solved. Combined with a specific coil shape design, the length of the heating wire is increased while ensuring good conductivity and heat dissipation. The entire manufacturing process is simple and efficient, greatly improving the reliability and durability of the product. The use of a complex yet efficient hexagonal star coil design further enhances the durability and heat dissipation performance of the heating wire. Dedicated molding equipment ensures precise coil molding, simplifies the production process, reduces production costs, and significantly improves the overall performance of the product.

[0036] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A heating wire forming device for manufacturing glass tube heaters, characterized in that, The glass tube heater includes a nickel-chromium alloy heating wire (1) wound into a coil with a non-circular cross-section; the heating wire forming equipment includes an inner clamp (2) for supporting the cylindrical coil and an outer stamping clamp (3) for extruding and deforming the coil, wherein the cross-sectional profile of the inner clamp (2) is the same as the inner cross-sectional profile of the non-circular coil.

2. The electric heating wire forming equipment for manufacturing glass tube heaters according to claim 1, characterized in that, The outer stamping fixture (3) includes a stamping head (4) and a linear drive component (5). Multiple stamping heads (4) are arranged around the inner fixture (2), and multiple linear drive components (5) are arranged corresponding to the stamping heads (4).

3. The electric heating wire forming equipment for manufacturing glass tube heaters according to claim 2, characterized in that, The cross-section of the coil is a centrally symmetrical hexagonal star. The punching head (4) includes a convex punch (41) corresponding to the convex corner profile of the hexagonal star and a concave punch (42) corresponding to the concave corner profile of the hexagonal star. There are 6 convex punches (41) and 6 concave punches (42).

4. The electric heating wire forming equipment for manufacturing glass tube heaters according to claim 2, characterized in that, The outer stamping fixture (3) also includes a guide sleeve (6). The main body of the guide sleeve (6) is a hollow cylinder coaxially sleeved on the inner fixture (2). The guide sleeve (6) has a guide groove (61) that is provided on the peripheral side wall corresponding to each stamping head (4) along the radial direction of the guide sleeve (6). The stamping head (4) slides and engages with the corresponding guide groove (61).

5. The heating wire forming equipment for manufacturing glass tube heaters according to claim 4, characterized in that, One end of the guide sleeve (6) is configured with a clearance hole (62) that slides with the inner clamp (2); it also includes a retraction cylinder (7) that drives the inner clamp (2) to retract into the guide sleeve (6).

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