Factors Affecting Special-Shaped Carbon Fiber Heating Tubes

In many heating applications, straight carbon fiber heating tubes cannot meet the heating needs of objects with special shapes, leading to the development of various special-shaped carbon fiber heating tubes. According to their different shapes, heating tubes can be classified into: round heating tubes, W-shaped heating tubes, U-shaped heating tubes, and Ω-shaped heating tubes. Special-shaped heating tubes can meet the needs of different fields. What are the advantages and disadvantages of special-shaped carbon fiber heating tubes compared to straight heating tubes?

Special-shaped heating tubes possess all the advantages of straight heating tubes and can be processed into different shapes according to the shape of the heated object, allowing for more even and reasonable heating.

The processing procedure is complicated, requiring high processing experience and higher costs.

What factors during the production process of these special-shaped heating tubes affect the lifespan of carbon fiber heating tubes?

First, let me introduce the production process of special-shaped heating tubes. The processing procedure for special-shaped carbon fiber heating tubes includes an additional quartz tube bending process compared to straight heating tubes. Other processes, such as electric heating wire insertion, sealing, and vacuuming, are the same as for straight heating tubes. Here, we will only discuss the factors affecting the lifespan of heating tubes during the bending process.

The quartz tube is placed on a bending machine and heated. The heated quartz tube bends and deforms according to the predetermined shape under the action of traction. Different drawings require different processing methods and ranges. For example, a U-shaped heating tube only needs to bend the middle part to the desired size, while a round heating tube requires softening the entire quartz tube and then bending it into a round shape.

After high-temperature treatment, the microcrystalline structure inside the quartz tube changes slightly, resulting in surface stress on the quartz tube material. The magnitude of this stress directly affects whether the quartz tube will crack during later use of the heating tube. Therefore, the heating temperature and heating time of the quartz tube during the bending process are crucial process parameters.

The processing of quartz tube bending requires experienced craftsmen because the process parameters for bending quartz tubes of different specifications vary. Which factors of the quartz tube specifications affect the bending process parameters? Mainly the diameter and wall thickness of the quartz tube. The larger the diameter and thicker the wall, the longer the heating time required.

Other factors influencing the heating time and temperature of the quartz tube are the stepping speed and the traction force. The stepping speed and the traction force need to be well coordinated; otherwise, the quartz tube is prone to breaking or thinning. Why? If the stepping speed is slow, the quartz tube is heated by the flame for a longer time, resulting in higher temperatures and easier deformation. If the speed is fast, the quartz tube may not be fully heated, making it prone to breaking or cracking during traction. Excessive traction force can thin or break the quartz tube, while insufficient traction force can deform it.

If the above control points are not well managed during the quartz tube bending process, carbon fiber heating tubes are prone to bursting when energized and heated, thereby affecting their lifespan.

Next, in the process of inserting the electric heating wire into the special-shaped carbon fiber heating tube, it is crucial to ensure that the heating wire is not broken or damaged. Additionally, care must be taken to control the force used to pull the heating wire, as excessive force can destroy the spiral structure of the heating wire. The heating wire must also be kept clean during insertion to prevent contamination. Contaminants can corrode the quartz tube at high temperatures. Therefore, this process requires employees to wear gloves and clean the placement area for the heating wire.

In summary, the bending process of quartz tubes is a critical factor affecting the lifespan of carbon fiber heating tubes. Proper control of heating temperature, heating time, stepping speed, and traction force during the bending process, along with careful handling of the heating wire during insertion, are essential to ensure the longevity and reliability of special-shaped carbon fiber heating tubes.

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