High-voltage constant-power water-cooling load resistor unit and manufacturing method thereof

Abstract

The invention relates to the technical field of resistors, in particular to a high-voltage constant-power water-cooling load resistor unit and a manufacturing method thereof.The high-voltage constant-power water-cooling load resistor unit comprises an insulated supporting pipe and a plurality of resistor modules, and the two ends of the supporting pipe penetrate through to form a heat dissipation channel; a plurality of limiting grooves are formed in the inner wall of the supporting pipe, and the resistor modules are inserted into the limiting grooves from ports of the supporting pipe in a one-to-one correspondence mode. Each resistor module comprises a plurality of resistor blocks which are arranged at intervals and a conductive strip which is used for positioning the plurality of resistor blocks and is connected in series. Compared with the prior art, the inner pipe formed by high-pressure blow molding is adopted, the pipe wall of the inner pipe is very thin, heat of the resistor can be easily dissipated into water, and the heat dissipation performance is good. The plurality of resistor modules are arranged at the limiting grooves in the inner wall of the supporting tube, so that more resistor modules can be accommodated, different numbers of resistor modules can be electrically connected according to requirements during use, and the use is more flexible; and when a local resistor module has a fault, the corresponding resistor module can be conveniently replaced.

Description

Technical Field

[0001] The present invention relates to the technical field of resistors, and in particular to a high-voltage constant-power water-cooled load resistor unit and a manufacturing method thereof. Background Art

[0002] With the development of data centers, there are more and more liquid-cooled servers, so water-cooled loads are used more and more. Constant-power water-cooled loads can keep the power of the equipment constant when the voltage fluctuates. Therefore, they are used more and more in data centers. The most important component in constant-power water-cooled loads is the constant-power resistor. The performance of the constant-power resistor directly affects the test performance of the constant-power load.

[0003] For example, a Chinese patent document with publication number CN110033908A discloses a ceramic water-cooled resistor, including a water pump, a water tank and a resistor assembly, wherein the resistor assembly includes a metal outer tube, a ceramic resistor tube, a mica tube, a metal water inlet pipe and a metal water outlet pipe, wherein the mica tube is inserted into the metal outer tube, the ceramic resistor tube is inserted into the mica tube, and both ends of the metal outer tube are encapsulated with quartz slurry; the metal water inlet pipe and the metal water outlet pipe also serve as wiring lead-out terminals; the water tank is filled with non-conductive deionized water, the water pump is connected to the metal water inlet pipe and the water tank respectively, and the metal water outlet pipe is connected to the water tank, so that the water pump drives the deionized water in the water tank to circulate through the metal water inlet pipe-ceramic resistor tube-metal water outlet pipe-water tank in sequence, and the deionized water is in direct contact with the inner wall of the ceramic resistor tube. The heat is directly transferred to the deionized water and taken away without passing through the traditional insulating layer, so the cooling effect is better.

[0004] The ceramic resistor tube is located in the metal outer tube, so each metal outer tube can only be equipped with one resistor tube, which is not convenient for adjusting the resistance value of the resistor. It is also not convenient for maintenance when the resistor tube fails. In addition, the existing water cooling uses an insulating tube for indirect heat conduction, or uses deionized water for direct contact heat dissipation. There is a gap between the insulating tube and the resistor, causing the heat to concentrate in the gap and overheat, which directly affects the heat dissipation performance of the resistor. Summary of the invention

[0005] In view of all or part of the above-mentioned technical problems existing in the prior art, the present invention provides a high-voltage constant-power water-cooled load resistor unit and a manufacturing method thereof.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] Provided is a high-voltage constant-power water-cooled load resistor unit, comprising an insulating support tube and a plurality of resistor modules, wherein both ends of the support tube are penetrated to form a heat dissipation channel; a plurality of limit grooves are arranged on the inner wall of the support tube, and a plurality of resistor modules are inserted into the plurality of limit grooves from the ports of the support tube in a one-to-one correspondence; each resistor module comprises a plurality of resistor blocks arranged in a separated manner and a conductive strip for positioning the plurality of resistor blocks and connecting them in series; a semi-solid insulating thin tube is passed through the support tube and blow-molded to form an inner tube for circulating a cooling liquid, and the semi-solid insulating thin tube is cured and pasted on the side of the conductive strip.

[0008] As a further optional solution, the conductive strips of each resistor module include a first copper strip and a second copper strip arranged in parallel, and the first copper strip and the second copper strip jointly clamp the plurality of resistor blocks.

[0009] As a further optional solution, the first copper bar and the second copper bar are both copper tube flattened structures, and their cross-sections are in a U-shaped shape, so that the first copper bar and the second copper bar are hollow.

[0010] As a further optional solution, conductive glue is provided between the resistor block and the conductive strip to achieve bonding and fixing of the two.

[0011] As a further optional solution, the support tube is a polygonal tube, and the inner sides of multiple straight sides of the support tube are respectively provided with the limiting grooves.

[0012] As a further optional solution, the inner wall of the support tube is provided with an L-shaped limiting strip, and two limiting strips arranged opposite to each other and spaced apart together form the limiting groove, and the two side portions of the resistor unit are embedded in the limiting strips.

[0013] As a further optional solution, the conductive strip and the limiting strip are interference fit.

[0014] As a further optional solution, the resistor block is a PTC ceramic resistor.

[0015] As a further optional solution, sealing plates are provided at both ends of the support tube, and the conductive strips of multiple resistance modules pass through the sealing plates and are electrically connected to each other. The sealing plates are provided with a water inlet pipe and a water outlet pipe; the semi-solid insulating thin tube covers the inner walls of the water inlet pipe and the water outlet pipe, and after passing through the water inlet pipe and the water outlet pipe, it is turned outward and wraps the port.

[0016] The present invention also provides a method for manufacturing the above-mentioned high-voltage constant-power water-cooled load resistor unit, which is characterized by comprising the following steps:

[0017] Resistor manufacturing steps: fixing and clamping a plurality of resistor blocks in the first copper bar and the second copper bar with conductive glue to form a resistor module;

[0018] Installation steps: insert multiple resistor modules into the limit slots from the ports of the support tube, and let the ends of the conductive strips pass through the outside of the support tube;

[0019] Blow molding steps: put the semi-solid insulating thin tube into the support tube, and then perform high-pressure blow molding to make the semi-solid insulating thin tube close to the conductive sheet.

[0020] Beneficial effects of the present invention:

[0021] Compared with the prior art, the high-voltage constant-power water-cooled load resistor unit of the present invention and the manufacturing method thereof adopt an inner tube formed by high-pressure blow molding, the inner tube wall is very thin, the heat of the resistor is easy to dissipate into the water, and the heat dissipation performance is good; the entire inner tube waterway is formed in one piece, the sealing performance is good, and it is not easy to leak; the resistor and cooling water adopt a water-electricity separation structure, the water quality requirement is low, tap water can be used for cooling, the application range is wider, and water will not affect the resistor, and the resistor life is longer; the fixings around the resistor are all made of insulating materials, the insulation performance is high, and the resistor can be made into a high-voltage resistor, so that the application range of the resistor is wider, the structure is simple, the process is simple, the cost is low, and it is easy to mass produce.

[0022] Multiple resistance modules are arranged in the limiting grooves on the inner wall of the support tube, which can accommodate more resistance modules. Different numbers of resistance modules can be electrically connected as needed during use, which makes it more flexible to use. Moreover, when a local resistance module fails, the corresponding resistance module can be replaced more conveniently without the entire resistance being scrapped, thus saving application costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 Schematic diagram of the structure of a high-voltage constant-power water-cooled load resistor unit in an embodiment.

[0024] Figure 2 1 is a decomposition diagram of a high-voltage constant-power water-cooled load resistance unit method in an embodiment.

[0025] Figure 3 It is a cross-sectional view and a partially enlarged view of a high-voltage constant-power water-cooled load resistance unit in an embodiment.

[0026] Figure 4 It is a cross-sectional view of another cross section of a high-voltage constant-power water-cooled load resistance unit in the embodiment.

[0027] Reference numerals:

[0028] Support pipe 1, limiting groove 11;

[0029] Resistance module 2, resistance block 21, conductive strip 22, first copper strip 221, second copper strip 222;

[0030] Limiting strip 3, inner tube 4, water inlet pipe 5, water outlet pipe 6, sealing plate 7. DETAILED DESCRIPTION

[0031] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. In the absence of conflict, the following embodiments and features in the embodiments can be combined with each other.

[0032] A high voltage constant power water-cooled load resistor unit of this embodiment, such as Figures 1 to 4 As shown, it includes an insulating support tube 1 and a plurality of resistor modules 2, and the two ends of the support tube 1 penetrate to form a heat dissipation channel. The inner wall of the support tube 1 is arranged with a plurality of limit grooves 11, and the plurality of resistor modules 2 are inserted into the plurality of limit grooves 11 from the ports of the support tube 1 one by one; each resistor module 2 includes a plurality of resistor blocks 21 arranged in a separated manner and a conductive strip 22 for positioning the plurality of resistor blocks 21 and connecting them in series.

[0033] Specifically, the conductive strips 22 of each resistor module 2 include a first copper strip 221 and a second copper strip 222 arranged in parallel, and the first copper strip 221 and the second copper strip 222 jointly clamp the plurality of resistor blocks 21 .

[0034] Specifically, the first copper bar 221 and the second copper bar 222 are both copper tube flattened structures, and their cross-section is in the shape of a square, that is, a hollow structure, which is easy to dissipate heat, and the structure can be squeezed and deformed, providing a certain deformation space for the thermal expansion of the resistor block 21. When using deionized or other insulating coolants, the first copper bar 221 and the second copper bar 222 can be injected, which can greatly increase the cooling efficiency of the resistor and increase the resistor power. The wall thickness of one side of the first copper bar 221 and the second copper bar 222 that fits the resistor block 21 is thinner than the other side, which is easier to deform when the resistor block 21 expands thermally, or the side wall is made into a wavy shape, which has a stronger deformation ability. Or the insulating liquid is poured into the internal hollow space of the first copper bar 221 and the second copper bar 222 to enhance heat transfer, preferably not filled, to provide a certain space for the evaporation and condensation of the liquid therein.

[0035] Specifically, conductive glue is provided between the resistor block 21 and the conductive strip 22 to achieve bonding and fixing of the two, so that the conductive strip 22 and the plurality of resistor blocks 21 are fixed as a whole, which is convenient for loading and unloading.

[0036] Specifically, the support tube 1 is a polygonal tube, and in this example, a quadrilateral is adopted, and the inner sides of the plurality of straight sides thereof are respectively provided with the limiting grooves 11 , so that more resistance modules 2 can be accommodated.

[0037] Specifically, the inner wall of the support tube 1 is provided with an L-shaped limiting strip 3, and the limiting strip 3 is arranged along the length direction of the support tube 1. Two limiting strips 3 arranged in a spaced relationship and facing each other together form the limiting groove 11, and the two sides of the resistor unit are partially embedded in the limiting strips 3. It can be seen from the figure that the limiting strip 3 corresponding to each side is located in the middle of the side wall of the corresponding support tube 1, and a certain distance is left between the adjacent side walls.

[0038] Specifically, the conductive strip 22 and the limiting strip 3 are interference fit.

[0039] Specifically, the resistor block 21 is a PTC ceramic resistor.

[0040] Specifically, an inner tube 4 is passed through the support tube 1 , and an inlet pipe 5 and an outlet pipe 6 connected to the inner tube 4 are provided at both ends of the support tube 1 . External cooling water enters from the inlet pipe 5 , takes away heat through the inner tube 4 , and flows out from the outlet pipe 6 .

[0041] Specifically, sealing plates 7 are provided at both ends of the support tube 1 , and the water inlet pipe 5 and the water outlet pipe 6 are provided at the sealing plates 7 ; the conductive strips 22 of the plurality of resistance modules 2 pass through the sealing plates 7 and are electrically connected to each other.

[0042] The inner tube 4 is formed in this way: a semi-solid insulating thin tube is inserted into the support tube 1 and blown to form the inner tube 4 for circulating the coolant. The semi-solid insulating thin tube is solidified and pasted on the side of the conductive strip 22, and of course, it is also partially pasted on the surface of the limit strip 3. The inner tube 4 is roughly square under the support of the limit strip 3 and the conductive strip 22. It can be seen that a chamber is formed between the adjacent limit strips 3 on different sides, and this chamber can be filled with liquid for heat conduction cooling. The semi-solid insulating thin tube covers the inner wall of the water inlet pipe 5 and the water outlet pipe 6, and after passing through the water inlet pipe 5 and the water outlet pipe 6, it is turned outward to wrap the port.

[0043] In practice, a heat-transmitting hole may be opened in the support tube 1 to partially expose the outer conductive strip 22 .

[0044] In practice, the support tube 1 and the limit strip 3 can be integrally injection-molded using insulating glue.

[0045] In the description of the present invention, it is obvious that the described embodiments are only some embodiments of the present invention, rather than all embodiments. The components of the embodiments of the present invention generally described and shown in the drawings herein can be arranged and designed in various different configurations.

[0046] Therefore, the above detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without making creative efforts are within the scope of protection of the present invention.

[0047] In the description of the present invention, it should be noted that the terms "middle", "upper", "lower", "horizontal", "inner", "outer", etc. indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, or the positions or positional relationships in which the product of the invention is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific position, be constructed and operated in a specific position, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance.

[0048] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "disposed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection. It can be a mechanical connection or an electrical connection. It can be directly connected or indirectly connected through an intermediate medium, and it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

Claims

1. A high voltage constant power water-cooled load resistor unit, characterized in that: It includes an insulating support tube and multiple resistance modules, both ends of the support tube are penetrated to form a heat dissipation channel; the inner wall of the support tube is arranged with multiple limit grooves, and the multiple resistance modules are inserted into the multiple limit grooves from the ports of the support tube one by one; each resistance module includes multiple resistance blocks arranged in a separated manner and a conductive strip that positions the multiple resistance blocks and connects them in series; a semi-solid insulating thin tube is passed through the support tube and blow-molded to form an inner tube for circulating cooling liquid, and the semi-solid insulating thin tube is cured and pasted on the side of the conductive strip.

2. A high voltage constant power water-cooled load resistor unit according to claim 1, characterized in that: The conductive strips of each resistor module include a first copper strip and a second copper strip arranged in parallel, and the first copper strip and the second copper strip jointly clamp a plurality of resistor blocks.

3. A high voltage constant power water-cooled load resistor unit according to claim 2, characterized in that: The first copper bar and the second copper bar are both copper tube flattened structures, and their cross sections are in a square shape, so that the first copper bar and the second copper bar are hollow.

4. The high-voltage constant-power water-cooled load resistor unit according to claim 1 is characterized in that: Conductive glue is provided between the resistor block and the conductive strip, so that the two are bonded and fixed.

5. The high-voltage constant-power water-cooled load resistor unit according to claim 1 is characterized in that: The support tube is a polygonal tube, and the inner sides of its multiple straight sides are respectively provided with the limiting grooves.

6. A high voltage constant power water-cooled load resistor unit according to claim 5, characterized in that: The inner wall of the support tube is provided with an L-shaped limiting strip, and two limiting strips which are arranged facing each other and separated from each other jointly form the limiting groove, and the two side portions of the resistor unit are distributed and embedded in the limiting strips.

7. A high voltage constant power water-cooled load resistor unit according to claim 6, characterized in that: The conductive strip and the limiting strip are interference fit.

8. The high-voltage constant-power water-cooled load resistor unit according to claim 1 is characterized in that: The resistor block is a PTC ceramic resistor.

9. The high-voltage constant-power water-cooled load resistor unit according to claim 1, characterized in that: Sealing plates are provided at both ends of the support tube, and the conductive strips of multiple resistance modules pass through the sealing plates and are electrically connected to each other; the sealing plates are provided with a water inlet pipe and a water outlet pipe; the semi-solid insulating thin tube covers the inner walls of the water inlet pipe and the water outlet pipe, and passes through the water inlet pipe and the water outlet pipe and then turns outward to wrap the port.

10. A method for manufacturing a high voltage constant power water-cooled load resistor unit as claimed in any one of claims 1 to 9, characterized in that: The following steps are involved: Resistor manufacturing steps: fixing and clamping a plurality of resistor blocks in the first copper bar and the second copper bar with conductive glue to form a resistor module; Installation steps: insert multiple resistor modules into the limit slots from the ports of the support tube, and let the ends of the conductive strips pass through the outside of the support tube; Blow molding steps: put the semi-solid insulating thin tube into the support tube, and then perform high-pressure blow molding to make the semi-solid insulating thin tube close to the conductive sheet.

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