High-efficiency heat dissipation insulator based on phase change heat transfer and manufacturing method thereof

Abstract

The invention discloses an efficient heat dissipation insulator based on phase change heat transfer, which comprises an insulator main body, a phase change heat transfer upper fitting, a heat dissipation medium and a lower fitting, and is characterized in that the phase change heat transfer upper fitting comprises an upper fitting accessory I, an upper fitting accessory II, an upper fitting accessory III and an upper fitting accessory IV; the first upper fitting accessory and the third upper fitting accessory form a closed cavity communicated with the upper portion of a body and an extension cavity communicated with the lower portion of the body, the second upper fitting accessory is fixedly attached to the inner surface of the cavity of the first upper fitting accessory and is provided with a liquid absorption core extending downwards into the extension cavity, the liquid absorption core adsorbs a filling working medium, and the filling working medium is filled with the filling working medium. The invention further discloses a manufacturing method. According to the invention, the basic insulation function of the insulator is ensured, the heat dissipation capability of the insulator is greatly improved, the service life of the insulator is effectively prolonged, and the stability and reliability of the insulator in a high-temperature environment are improved.

Description

Technical Field

[0001] The present invention relates to the field of power equipment, and particularly to a highly efficient heat dissipation insulator based on phase change heat transfer and a manufacturing method thereof. Background Art

[0002] Insulators are important components in the power system, used to support and insulate live conductors. With the continuous development of the power system and the progress of high-voltage transmission technology, higher requirements are imposed on the heat transfer performance of insulators. However, traditional insulators face the problem of poor heat dissipation during long-term operation, which not only affects the service life of the insulators but also reduces their stability and reliability under high-current conditions.

[0003] Currently, common insulators on the market are mainly made of insulating materials (such as epoxy resin, ceramics), and their structure usually includes an insulator body, upper and lower fittings, etc. The upper fitting is connected to the live conductor, and the lower fitting is connected to the equipment housing. This structure can meet the basic insulation requirements, but there are still obvious deficiencies in heat dissipation. Especially in high-temperature or high-current environments, heat is likely to accumulate inside the insulator, leading to a decline in insulation performance and even possible safety problems such as insulation breakdown. To improve the heat dissipation performance of insulators, some existing technologies have adopted methods such as adding heat dissipation fins on the surface of the insulator or using materials with better thermal conductivity. However, these methods can only improve the heat dissipation effect to a limited extent and cannot fundamentally solve the problem of heat accumulation caused by high internal thermal resistance of the insulator. In addition, the heat dissipation mechanism of traditional insulators mainly relies on natural convection and radiation heat dissipation, and there are significant limitations in heat dissipation efficiency. Especially in large or high-voltage insulators, due to their large volume, it is difficult to dissipate internal heat in a timely manner, and local overheating is more likely to occur. Summary of the Invention

[0004] The technical problem to be solved by the embodiments of the present invention is to provide a highly efficient heat dissipation insulator based on phase change heat transfer for large or high-voltage insulators, which overcomes the defect that it is difficult to dissipate internal heat in a timely manner due to their large volume.

[0005] A highly efficient heat dissipation insulator based on phase change heat transfer includes an insulator body, a phase change heat transfer upper fitting, a heat dissipation medium, and a lower fitting. The phase change heat transfer upper fitting is fixedly arranged at the upper mouth part of the insulator body, the lower fitting is fixedly arranged at the lower part of the insulator body, and the heat dissipation medium is filled in the inner cavity formed between the phase change heat transfer upper fitting and the lower fitting; The upper fitting for phase change heat transfer includes upper fitting accessory one, upper fitting accessory two, and upper fitting accessory three. Upper fitting accessory one and upper fitting accessory three form a sealed chamber and an extended chamber at the upper and lower parts of the body respectively. Upper fitting accessory two is fixedly attached to the inner surface of the chamber of upper fitting accessory one and has a wick extending downward into the extended chamber. The wick adsorbs the perfusion working fluid.

[0006] Further, an upper fitting accessory four is provided on the outer wall of the extended chamber, and the upper fitting accessory four is a heat sink.

[0007] Further, the upper fitting accessory three is in a T shape, and its top is welded and sealed to the lower part of the upper fitting accessory one.

[0008] Further, the upper fitting accessory two is sintered on the upper fitting accessory one through copper powder.

[0009] Further, the upper fitting accessory one has an annular outer wall, which is threadedly connected to the upper mouth of the insulator body.

[0010] Further, the top of the upper fitting accessory one has a concave position.

[0011] Correspondingly, an embodiment of the present invention also provides a method for manufacturing the above-mentioned high-efficiency heat dissipation insulator based on phase change heat transfer, including the following steps: S1: Prepare the insulator body through an injection molding process or a 3D printing additive manufacturing process; S2: Machine the upper mold and the lower mold corresponding to the shape of the upper fitting accessory two, and place the prepared upper fitting accessory one between the upper mold and the lower mold; S3: Fill copper powder into the gap between the upper fitting accessory one and the lower mold from the opening of the upper mold, and sinter at a high temperature under a protective gas atmosphere to form a capillary wick. After cooling, demold and take out the upper fitting accessory one sintered with the upper fitting accessory two; S4: Clean the end faces of the upper fitting accessory one and the upper fitting accessory three to be welded; S5: Coat the brazing filler metal on the welding surface of the upper fitting accessory three, and use fixture one, fixture two and bolts to fit and clamp the welding surfaces of the upper fitting accessory one and the upper fitting accessory three together; S6: Place the whole device in an atmosphere furnace, and heat it to 30°C - 50°C above the liquidus temperature of the brazing filler metal under a protective gas atmosphere or in a vacuum for brazing; S7: Naturally cool to room temperature and clean the residual flux; S8: Conduct appearance inspection and airtightness detection, pour the phase change liquid working fluid from the perfusion port of the upper fitting accessory three, evacuate, seal, and weld and seal; S9: Install the upper fitting accessory four outside the upper fitting accessory three to obtain a complete upper fitting for phase change heat transfer; S10: Assemble the upper fitting for phase change heat transfer with the insulator body by means of threaded connection; S11: Inject a heat dissipation medium into the central cavity of the insulator body and assemble the lower fitting.

[0012] Furthermore, the temperature range of the high-temperature sintering in S3 is 920°C - 950°C.

[0013] Furthermore, the filler metal in S5 is selected from one of copper-based filler metals and silver-based filler metals.

[0014] Implementing the embodiments of the present invention has the following beneficial effects: Through the innovative design of the phase change heat transfer structure, the present invention can optimize the heat transfer path, reduce the heat transfer resistance between the upper and lower fittings of the insulator, and significantly improve the heat dissipation performance of the insulator, especially under high-current working conditions; the present invention also effectively reduces the internal heat accumulation, extends the service life of the insulator, and improves its stability and reliability in a high-temperature environment at the same time. Description of the Drawings

[0015] Figure 1 It is the front view schematic diagram and sectional schematic diagram of the present invention; Figure 2 It is the top view schematic diagram of the present invention; Figure 3 It is the bottom view schematic diagram of the present invention; Figure 4 It is the front view schematic diagram and sectional schematic diagram of the upper fitting of the present invention; Figure 5 It is the structural schematic diagram used in the present invention; Figure 6 It is the front view schematic diagram and sectional schematic diagram of the mold-pressed sintered upper fitting accessory three of the present invention; Figure 7 It is the detailed structure of the upper fitting accessory one and upper fitting accessory two of the present invention after demolding; Figure 8 It is the detailed structure of the assembly of fixture one, upper fitting accessory one, upper fitting accessory two during the brazing process of the upper fitting of the present invention; Figure 9 It is the detailed structure of the assembly of fixture one, upper fitting accessory one, upper fitting accessory two, upper fitting accessory three (before sealing) during the brazing process of the upper fitting of the present invention; Figure 10 It is the detailed structure of the assembly of fixture one, upper fitting accessory one, upper fitting accessory two, upper fitting accessory three (before sealing), fixture two during the brazing process of the upper fitting of the present invention; Figure 11 It is the detailed structure of the assembly of fixture one, upper fitting accessory one, upper fitting accessory two, upper fitting accessory three (before sealing), fixture two, bolts during the brazing process of the upper fitting of the present invention; Figure 12 This is the detailed structure of the assembly of the first upper fitting accessory, the second upper fitting accessory, and the third upper fitting accessory of the present invention. Figure 13 This is the schematic diagram of heat transfer of the present invention.

[0016] Description of the drawings: 1 - Insulator body, 2 - Phase change heat transfer, 3 - Heat dissipation medium, 4 - Lower fitting, 5 - Upper mold, 6 - Lower mold, 11 - Insulator body, 12 - Shed, 21 - First upper fitting accessory, 22 - Second upper fitting accessory, 23 - Third upper fitting accessory, 24 - Fourth upper fitting accessory, 231 - Pouring port, 51 - Opening of the upper mold, 71 - First fixture, 72 - Second fixture, 73 - Bolt, 81 - Bolt, 82 - Energized conductor, 83 - Equipment housing. Detailed implementation manners

[0017] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the drawings.

[0018] Embodiment 1: The embodiment of the present invention provides an efficient heat dissipation insulator based on phase change heat transfer, including an insulator body 1, a phase change heat transfer upper fitting 2, a heat dissipation medium 3, and a lower fitting 4.

[0019] Combined with Figure 2 、 Figure 3 As shown, the phase change heat transfer upper fitting 2 is fixedly arranged at the upper opening of the insulator body 1, the lower fitting 4 is fixedly arranged at the lower part of the insulator body 1, and the heat dissipation medium 3 is filled in the inner cavity formed between the phase change heat transfer upper fitting 1 and the lower fitting 4.

[0020] The insulator body 1 is composed of an insulator body 11 and a shed 12, and is made by an injection molding process. In the present invention, the insulator body 1 is made of an epoxy resin material, having good insulation performance and mechanical strength.

[0021] The phase change heat transfer upper fitting 2 includes a first upper fitting accessory 21, a second upper fitting accessory 22, a third upper fitting accessory 23, and a fourth upper fitting accessory 24.

[0022] The first upper fitting accessory 21 and the third upper fitting accessory 23 form a closed chamber and an extended chamber at the upper and lower parts of the connected body. The second upper fitting accessory 22 is fixedly attached to the inner surface of the chamber of the first upper fitting accessory 21 and has a liquid absorption core extending downward into the extended chamber. The liquid absorption core adsorbs a perfusion working fluid and diffuses throughout the second upper fitting accessory 22. The volume of the perfusion working fluid is generally 10% to 20% of the total volume of the inner cavity of the upper fitting. The perfusion working fluid is, for example, deionized water, acetone, etc.

[0023] Such as Figure 4, the upper fitting accessory 1 21 is a copper-made heat dissipation structure housing part 1; the upper fitting accessory 2 22 is a copper powder sintered capillary wick; the upper fitting accessory 3 23 is a copper-made heat dissipation structure housing part 2.

[0024] The upper fitting accessory 3 23 is in a T shape, and its top is welded and sealed with the lower part of the upper fitting accessory 1 21.

[0025] The upper fitting accessory 1 21 forms a structure with a chamber, and the chamber is covered by welding at the bottom through the upper fitting accessory 3 23.

[0026] The upper fitting accessory 1 21 and the upper fitting accessory 3 23 form a closed chamber communicating with the upper part of the body and an extended chamber at the lower part. The bottom of the extended chamber is a perfusion port 231, which is sealed after the perfusion of the working medium and the vacuum pumping treatment are completed.

[0027] The upper fitting accessory 4 24 is a heat sink. In this embodiment, the preferred structure is a spiral heat dissipation fin fixedly arranged on the outer wall of the extended chamber to increase the heat dissipation area. The upper fitting accessory 4 24 is used to conduct heat into the heat dissipation medium 3. There is enough space between the inner wall surfaces of the upper fitting accessory 2 22 and the upper fitting accessory 3 23 to facilitate the flow of steam. The heat dissipation medium 3 is transformer oil, dimethyl silicone oil, etc.

[0028] The upper fitting accessory 1 21 has an annular outer wall with an external thread for threaded connection with the upper mouth of the insulator body.

[0029] The top of the upper fitting accessory 1 21 has a concave position with a thread inside for connection with the live conductor 82 through a bolt 81, while the insulator body 1 is fixedly connected to the equipment housing 83.

[0030] The lower fitting 4 is tightly connected to the lower part of the insulator body 1 by thread, and is made of a copper plate structure with good heat conduction performance.

[0031] The embodiment of the present invention also provides a method for manufacturing the above-mentioned high-efficiency heat dissipation insulator based on phase change heat transfer, which is implemented through the following steps.

[0032] S1: Use the injection molding process to prepare the insulator body 1; S2: As Figure 6 shown, prepare the upper fitting accessory 1 21 and the upper fitting accessory 3 23, and machine the upper mold 5 and the lower mold 6 through a machine tool; S3: Precisely assemble the upper mold 5, the fitting accessory 1 21, and the lower mold 6, and use a fixture to fix the upper mold 5 and the lower mold 6; S4: Fill the copper powder into the gap between the first accessory of the fitting 21 and the lower die 6 from the opening 51 of the upper die, and perform high-temperature sintering in an atmosphere of a nitrogen-hydrogen mixed gas composed of 5% hydrogen and 95% nitrogen to form a capillary wick. In this embodiment, the high-temperature sintering temperature is 930 °C. After cooling, demold and take out the first accessory of the upper fitting 21 sintered with the second accessory of the upper fitting 22; S5: Clean the end faces to be welded of the first accessory of the upper fitting 21 and the third accessory of the upper fitting 23; S6: As Figures 8 - 10 shown, apply brazing filler metal to the welding surface of the third accessory of the upper fitting 23, and use the first fixture 71, the second fixture 72 and the bolt 73 to assemble and clamp the welding surfaces of the first accessory of the upper fitting 21 and the third accessory of the upper fitting 23. Among them, the whole upper fitting is inverted, the first fixture 71 is placed at the bottom, the second fixture 72 is provided with a perforation, which is arranged outside the extension cavity of the third accessory of the upper fitting 23, and the first fixture 71 and the second fixture 72 are fixed by the bolt 73.

[0033] In this embodiment, the brazing filler metal is a low-temperature silver-based brazing filler metal, its liquidus temperature is 610 °C, and the main chemical composition components are Ag, Cu, Zn, Cd, Ni; S7: Put the whole device into an atmosphere furnace, heat it to 640 °C in a vacuum environment, and perform brazing welding; S8: Naturally cool to room temperature and clean the residual flux; S9: Perform appearance inspection and airtightness detection, pour the phase change liquid working medium from the filling port of the third accessory of the upper fitting 23, evacuate, seal, and weld and seal; S10: Install the fourth accessory of the upper fitting 24 outside the third accessory of the upper fitting 23 to obtain the complete phase change heat transfer upper fitting 2; S11: Assemble the phase change heat transfer upper fitting 2 with the insulator body 1 by means of threaded connection; S12: Inject the heat dissipation medium 3 into the central cavity of the insulator body 1 and assemble the lower fitting 4.

[0034] As Figure 13As shown in the figure, the main heat transfer path of the present invention can be described as follows: Heat is first input into the upper fitting attachment 1. The liquid perfusion working medium adsorbed by the wick is heated and evaporated into a gas state. When it diffuses to reach the extension cavity, it condenses into a liquid state on the inner wall surface at the bottom end of the upper fitting attachment 3 and releases the latent heat of phase change. The liquid working medium flows back through the wick to maintain the phase change heat transfer cycle, and the heat is conducted through the wall surface to the upper fitting attachment 4 (heat sink). Subsequently, the heat is conducted through the heat dissipation medium outside the upper fitting attachment 4 to the lower fitting and the insulator body, and finally the heat is output from the system. This heat transfer process reflects the unique design of the present invention in thermal management, effectively realizing the export of heat to the lower fitting and the insulator body, thereby improving the heat dissipation efficiency of the overall system, effectively reducing the operating temperature of the insulator, and improving the reliability and service life of the insulator.

[0035] Embodiment 2: The present invention provides a highly efficient heat dissipation insulator based on phase change heat transfer and a manufacturing method thereof. As Figures 1 - 3 shown, the highly efficient heat dissipation insulator of the present invention includes an insulator body 1, a phase change heat transfer upper fitting 2, a heat dissipation medium 3, and a lower fitting 4.

[0036] Preferably, the insulator body 1 is composed of an insulator body 11 and a petticoat 12, and is made by a 3D printing additive manufacturing process. In the present invention, the insulator body 1 is made of an epoxy resin material and has good insulation performance and mechanical strength.

[0037] The phase change heat transfer upper fitting 2 is tightly connected to the upper part of the insulator body 1 by a thread. As Figure 4 shown, the phase change heat transfer upper fitting 2 includes an upper fitting attachment 1 21, an upper fitting attachment 2 22, an upper fitting attachment 3 23, and an upper fitting attachment 4 24. The upper fitting attachment 1 21 is a copper-made heat dissipation structure housing component 1; the upper fitting attachment 2 22 is a copper powder sintered capillary wick; the upper fitting attachment 3 23 is a copper-made heat dissipation structure housing component 2; the upper fitting attachment 4 24 is a spiral heat sink fin.

[0038] In the present invention, the upper fitting attachment 2 22 is formed by filling copper powder into a mold and pressing and sintering it together with the upper fitting attachment 1 21. As Figure 6 shown, the mold includes two parts, an upper mold 5 and a lower mold 6, where the upper mold 5 is the main body of the mold and the lower mold 6 is the mold base.

[0039] Preferably, the upper fitting attachment 3 23 extends along the axial direction of the insulator body 1 and is provided with a filling port 231 at the end. The upper fitting attachment 4 24 is arranged on the outer surface of the upper fitting attachment 3 23 to increase the heat dissipation area. There is enough space between the inner wall surface of the upper fitting attachment 2 22 and the upper fitting attachment 3 23 to facilitate the flow of steam.

[0040] In the present invention, the upper fitting 2 for phase change heat transfer has a vacuum-sealed space inside and contains a phase change liquid working medium, forming an efficient phase change heat transfer structure.

[0041] The heat dissipation medium 3 is filled in the inner cavity of the insulator body 1 between the upper fitting 2 and the lower fitting 4. Preferably, the heat dissipation medium 3 is dimethyl silicone oil, which has good insulation and heat conduction properties.

[0042] The lower fitting 4 is tightly connected to the lower part of the insulator body 1 by threads and is made of a copper plate structure, which has good heat conduction properties.

[0043] The manufacturing method of the high-efficiency heat dissipation insulator of the present invention includes the following steps: a) Using an injection molding process to prepare the insulator body 1; b) Preparing the upper fitting accessory one 21 and the upper fitting accessory three 23, and machining the upper die 5 and the lower die 6 through a machine tool; c) Precisely assembling the upper die 5, the upper fitting accessory one 21, and the lower die 6, and using a fixture to fix the upper die 5 and the lower die 6; d) Filling copper powder into the gap between the upper fitting accessory one 21 and the lower die 6 from the opening 51 of the upper die, and performing high-temperature sintering under a nitrogen-hydrogen mixed gas composed of 10% hydrogen and 90% nitrogen to form a capillary wick. In this embodiment, the high-temperature sintering temperature is 950 °C. After cooling, demold and take out the upper fitting accessory one 21 sintered with the upper fitting accessory two 22; e) Cleaning the end faces of the upper fitting accessory one 21 and the upper fitting accessory three 23 to be welded; f) Coating the soldering material on the welding surface of the upper fitting accessory three 23, and using the fixture one 71, the fixture two 72, and the bolt 73 to assemble and clamp the welding surfaces of the upper fitting accessory one 21 and the upper fitting accessory three 23. In this embodiment, the soldering material is a low-temperature silver-based soldering material, whose liquidus temperature is 610 °C, and the main chemical composition components are Ag, Cu, Zn, Cd, and Ni; g) Placing the whole device into an atmosphere furnace, and heating to 650 °C under a nitrogen-hydrogen mixed gas composed of 5% hydrogen and 95% nitrogen for brazing welding; h) Naturally cooling to room temperature and cleaning the residual flux; i) Performing appearance inspection and airtightness detection, filling the phase change liquid working medium, evacuating, sealing, and welding and sealing from the filling port of the upper fitting accessory three 23; j) Installing the upper fitting accessory four 24 outside the upper fitting accessory three 23 to obtain the complete upper fitting 2 for phase change heat transfer; k) Assembling the upper fitting 2 for phase change heat transfer with the insulator body 1 by a threaded connection method; l) Injecting the heat dissipation medium 3 into the central cavity of the insulator body 1 and assembling the lower fitting 4.

[0044] The above-disclosed is only a preferred embodiment of the present invention, and of course, it cannot be used to limit the scope of the rights of the present invention. Therefore, equivalent changes made according to the claims of the present invention still fall within the scope covered by the present invention.

Claims

1. An efficient heat dissipation insulator based on phase change heat transfer, characterized in that: It includes an insulator body, a phase change heat transfer upper hardware, a heat dissipation medium, and a lower hardware. The phase change heat transfer upper hardware is fixedly arranged at the upper opening of the insulator body, the lower hardware is fixedly arranged at the lower part of the insulator body, and the heat dissipation medium is filled in the inner cavity formed between the phase change heat transfer upper hardware and the lower hardware. The phase change heat transfer upper hardware includes upper hardware accessory 1, upper hardware accessory 2, and upper hardware accessory 3. The upper hardware accessory 1 and the upper hardware accessory 3 form a closed upper chamber and a lower extension chamber connected to the body. The upper hardware accessory 2 is fixedly attached to the inner surface of the chamber of the upper hardware accessory 1, and has a liquid wick extending downward into the extension chamber, and the liquid wick absorbs the perfusion working fluid.

2. The high-efficiency heat dissipation insulator based on phase change heat transfer according to claim 1, characterized in that: The outer wall of the extension cavity is provided with an upper hardware accessory four, and the upper hardware accessory four is a heat sink.

3. The high-efficiency heat dissipation insulator based on phase change heat transfer according to claim 1, characterized in that: The upper hardware accessory three is in a T-shape, and the top is welded and sealed with the lower part of the upper hardware accessory.

4. The high-efficiency heat dissipation insulator based on phase change heat transfer according to claim 1, characterized in that: The upper hardware accessory 2 is sintered on the upper hardware accessory 1 by copper powder.

5. The high-efficiency heat dissipation insulator based on phase change heat transfer according to any one of claims 1 to 4, characterized in that: The upper hardware accessory 1 has an annular outer wall, which is threadedly connected to the upper opening of the insulator body.

6. The high-efficiency heat dissipation insulator based on phase change heat transfer according to claim 5, characterized in that: The top of the upper hardware accessory is provided with a concave position.

7. A method for manufacturing a high-efficiency heat dissipation insulator based on phase change heat transfer as claimed in any one of claims 1 to 6, comprising the following steps: S1: Prepare the insulator body by injection molding or 3D printing additive manufacturing process; S2: machining an upper die and a lower die corresponding to the shape of the upper hardware accessory 2 by machine tools, and placing the prepared upper hardware accessory 1 between the upper die and the lower die; S3: Fill the copper powder into the gap between the upper hardware accessory 1 and the lower mold from the opening of the upper mold, sinter at high temperature under a protective gas atmosphere to form a capillary wick, and after cooling, demould and take out the upper hardware accessory 1 sintered with the upper hardware accessory 2; S4: Clean the end faces of the upper hardware accessory 1 and the upper hardware accessory 3 to be welded; S5: Apply brazing material to the surface to be welded of the upper hardware accessory 3, and use the clamp 1, the clamp 2 and the bolts to clamp the welding surfaces of the upper hardware accessory 1 and the upper hardware accessory 3 together; S6: Place the entire device in an atmosphere furnace, heat it to 30°C-50°C above the liquidus temperature of the solder under a protective gas atmosphere or vacuum, and perform brazing welding; S7: Cool naturally to room temperature and clean the residual flux; S8: Perform appearance inspection and air tightness test, pour phase change liquid working fluid from the pouring port of the upper hardware accessory 3, evacuate, seal, and weld to seal; S9: Install the upper hardware accessory 4 outside the upper hardware accessory 3 to obtain a complete phase change heat transfer upper hardware; S10: Assemble the phase change heat transfer upper fitting with the insulator body by thread connection; S11: Inject heat dissipation medium into the central cavity of the insulator body and assemble the lower hardware.

8. The method according to claim 7, characterized in that The high temperature sintering temperature of S3 is in the range of 920°C to 950°C.

9. The method according to claim 8, characterized in that The solder of S5 is selected from copper-based solder and silver-based solder.

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