Power line for immersed liquid cooling and preparation method thereof

Abstract

The invention relates to a power line for immersed liquid cooling and a preparation method thereof, the power line comprises at least one core wire and a sheath, and the sheath wraps the outside of the core wire; a gap between the outer wall of the core wire and the inner wall of the sheath is filled with a thermosetting adhesive layer. The preparation method comprises the following steps: putting one end of the power line into the low-viscosity liquid thermosetting adhesive in the processing process, sucking the thermosetting adhesive by utilizing a siphonic effect, and then carrying out thermosetting treatment, so that the whole power line has the characteristics of long-time oil resistance, siphoning prevention and capillary prevention, can effectively prevent liquid permeation and diffusion, and has the advantages of long service life and low cost. It is ensured that the power line has high reliability and durability in a liquid cooling environment, the electrical performance is prevented from being affected by liquid permeation, and meanwhile visual monitoring convenient to maintain is provided.

Description

Technical Field

[0001] The present invention relates to the technical field of power cords, and in particular to a power cord for immersion liquid cooling and a preparation method thereof. Background Art

[0002] In recent years, as data centers have shifted towards high power, high density, and ultra-large scale, the use of high-performance chips and integrated circuits has become increasingly widespread. Conventional air cooling technology has become difficult to meet the extremely high heat dissipation needs of data centers. Therefore, in order to ensure the working stability and reliability of data center equipment while reducing the energy consumption of the cooling system, the research and development and optimization of efficient thermal management and heat dissipation technologies have become key links in data center system design.

[0003] In the above development context, liquid cooling technology, especially immersion liquid cooling technology, has attracted much attention in the industry due to its advantages such as high heat dissipation efficiency, uniform temperature, low noise and pollution-free, high integration and high reliability. Among them, the power cord of immersion liquid cooling provides stable and reliable power supply for various components inside servers, storage devices, switches and other equipment.

[0004] Currently, PVC-insulated and PVC-sheathed power cables are commonly used in data centers. However, these cables have numerous drawbacks, primarily manifesting in the following areas: Over extended use, the sheath surface can absorb oil, causing it to swell, deform, harden, and crack; siphoning can occur within the cable; and wicking can lead to difficult-to-solve capillary effects, causing oil to rise along the cable's surface and affect the stability of immersion cooling systems. Therefore, a power cable that can operate stably in coolant-immersion environments is urgently needed. Summary of the Invention

[0005] To this end, the technical problem to be solved by the present invention is to overcome the problem in the prior art that the power cord does not have the long-term compatibility with the coolant, cannot ensure long-term safe operation in the coolant environment, and cannot meet the requirements of stable and reliable data centers.

[0006] To address the above-mentioned technical problems, the present invention provides a power cord for immersion liquid cooling, comprising: at least one core wire and a sheath, the sheath wrapping around the outside of the core wire; wherein the gap between the outer wall of the core wire and the inner wall of the sheath is filled with a layer of thermosetting adhesive. The power cord for immersion liquid cooling of the present invention utilizes highly oil-resistant, low-capillary polyester materials (primarily TPU and TPEE), effectively preventing oil absorption and surface damage. Furthermore, during processing, one end of the power cord is placed in a low-viscosity liquid thermosetting adhesive, which is absorbed by the siphon effect and then subjected to a thermosetting treatment. This ensures that the power cord as a whole possesses long-term oil resistance and anti-siphon properties, effectively preventing liquid penetration and diffusion, and ensuring the long-term stability of the power cord in a liquid cooling environment.

[0007] In one embodiment of the present invention, the core wire includes a conductor and an insulator wrapped around an outer wall of the conductor.

[0008] In one embodiment of the present invention, there are multiple core wires, and the gaps between the multiple core wires are filled with a thermosetting adhesive layer.

[0009] In one embodiment of the present invention, the thermosetting adhesive layer is made of low-viscosity thermosetting adhesive.

[0010] In one embodiment of the present invention, there are multiple conductors.

[0011] In one embodiment of the present invention, the sheath is a transparent sheath.

[0012] The present invention also provides a method for preparing a power cord for immersion liquid cooling, comprising the following steps: placing one end of the power cord into a low-viscosity liquid thermosetting adhesive, while the other end of the power cord is outside the low-viscosity liquid thermosetting adhesive, and utilizing a siphon effect on the end of the power cord immersed in the low-viscosity liquid thermosetting adhesive to absorb the low-viscosity liquid thermosetting adhesive into the gaps between the core wire and the sheath and between the core wires of the power cord, until the low-viscosity liquid thermosetting adhesive drips out from the other end of the power cord, and the gaps between the core wire and the sheath and between the core wires of the power cord are filled with the low-viscosity liquid thermosetting adhesive, and then taking out the power cord that has absorbed the low-viscosity liquid thermosetting adhesive and placing it in an oven for heating and performing a thermosetting treatment, so that the low-viscosity liquid thermosetting adhesive in the power cord is cross-linked and cured.

[0013] In one embodiment of the present invention, the conductors in the power cord are twisted and compressed.

[0014] In one embodiment of the present invention, after the low-viscosity liquid thermosetting adhesive in the power cord is cross-linked and solidified, the adhesive on the surface of the power cord is cleaned after cooling, and the cleaned power cord is subjected to an airtightness test.

[0015] In one embodiment of the present invention, the preparation of the power cord also includes terminal crimping, which specifically includes the following steps: stripping the sheath and insulation of the power cord to expose the conductor of the power cord, and performing high-temperature injection molding of the terminal at the position where the conductor is exposed, so that the tin layer on the conductor dissolves at high temperature and fills the gap between the injection molding material and the conductor and between the conductors.

[0016] The power cord for immersion liquid cooling and the preparation method thereof of the present invention have the following beneficial effects compared with the prior art: 1. The insulation material and sheath material should have long-term oil stability, which is mainly reflected in the service life of at least 5 years; 2. Utilize the siphon effect between the gaps in the power cord to absorb low-viscosity thermosetting adhesive and then perform thermosetting treatment to achieve the siphon blockage of the power cord, so that the power cord will not produce the siphon effect when immersed in liquid cooling oil for a long time; 3. The sheath material uses transparent sheath material with visual effect.

[0017] The power cord for immersion liquid cooling of the present invention can ensure that the power cord has high reliability and durability in a liquid cooling environment, avoid liquid penetration affecting electrical performance, and provide visual monitoring for easy maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to make the content of the present invention more clearly understood, the present invention is further described in detail below based on specific embodiments of the present invention in conjunction with the accompanying drawings, wherein: Figure 1 is a cross-sectional view of a power line for immersion liquid cooling in a preferred embodiment of the present invention; Figure 2 A physical diagram of a terminal in a preferred embodiment of the present invention; Figure 3 This is a cross-sectional view of the terminal interior in a preferred embodiment of the present invention; Figure 4 This is a simulation diagram of the terminal in the preferred embodiment of the present invention; Figure 5 In the preferred embodiment of the present invention Figure 4 A partial enlarged view of point A in the middle; Figure 6 This is a schematic structural diagram of a device for immersion liquid cooling power lines in a preferred embodiment of the present invention.

[0019] Description of the accompanying drawings in the specification: conductor 1, insulator 2, sheath 3, thermosetting adhesive layer 4, load end 10, upper pressure plate 20, box body 30, valve 40, connecting pipe 50, locking cap 60. DETAILED DESCRIPTION

[0020] The present invention will be further described below with reference to the accompanying drawings and specific embodiments so that those skilled in the art can better understand the present invention and implement it. However, the embodiments are not intended to limit the present invention. Example

[0021] Reference Figure 1 As shown, the power cord for immersion liquid cooling of the present invention includes: at least one core wire and a sheath 3, wherein the sheath 3 is wrapped around the outside of the core wire; wherein the gap between the outer wall of the core wire and the inner wall of the sheath 3 is filled with a thermosetting adhesive layer 4.

[0022] Specifically, the core wire includes a conductor 1 and an insulator 2 wrapped around the outer wall of the conductor 1. The conductors 1 are provided in multiple numbers, so the core wire is a multi-core wire.

[0023] When there are multiple core wires in the power cord, the gaps between the core wires are filled with a thermosetting adhesive layer 4 .

[0024] Preferably, the thermosetting adhesive layer 4 is made of low-viscosity thermosetting adhesive.

[0025] Preferably, the insulator 2 is made of highly oil-resistant and aging-resistant polymer materials, which can effectively resist oil corrosion in a liquid cooling environment and prevent reactions after contact with oil.

[0026] In the present invention, the sheath 3 is made of a polymer material with high oil resistance and low capillary permeability (mainly TPU and TPEE), which can effectively prevent oil erosion and prevent the oil from climbing up to the outside of the liquid cooling cabinet through capillary action. Therefore, the sheath 3 has a low capillary property. In addition, the sheath 3 is a transparent sheath, which enables the power cord to have a visual effect during the siphon thermosetting glue processing and subsequent use, facilitating monitoring and management; at the same time, the low capillary property can reduce liquid adsorption. Example

[0027] A method for preparing a power cord for immersion liquid cooling is characterized in that it includes the following steps: placing one end of the power cord into a low-viscosity liquid thermosetting adhesive, while the other end of the power cord is outside the low-viscosity liquid thermosetting adhesive, and using the siphon effect of the end of the power cord immersed in the low-viscosity liquid thermosetting adhesive to absorb the low-viscosity liquid thermosetting adhesive into the gaps between the core wire and the sheath and between the core wires of the power cord until the low-viscosity liquid thermosetting adhesive drips out from the other end of the power cord, and the gaps between the core wire and the sheath and between the core wires of the power cord are filled with the low-viscosity liquid thermosetting adhesive, and then taking out the power cord that has absorbed the low-viscosity liquid thermosetting adhesive and placing it in an oven for heating and performing a thermosetting treatment, so that the low-viscosity liquid thermosetting adhesive in the power cord is cross-linked and cured.

[0028] Reference Figure 2 As shown in the figure, the principle of the siphon effect is that the fluid thermosetting adhesive is injected into the internal gaps of the power cord (such as the gap between the conductor and the insulation layer) through pressure difference, and then the adhesive is cured by baking, ultimately achieving the sealing, fixation or protection of the cable structure.

[0029] The siphon effect is utilized to introduce low-viscosity thermosetting adhesive to fill the gaps in the power cord to achieve the subsequent anti-siphon effect of the power cord. The above-mentioned power cord preparation process ensures the long-term stability of the power cord in an immersion liquid cooling environment. The power cord structure is anti-siphon and the surface is anti-linting. At the same time, the entire cable has visualization capabilities to detect cable abnormalities in a timely manner and perform emergency treatment. Example

[0030] In the above embodiment 2, one of the methods for preparing the power cord for immersion liquid cooling is as follows: Figure 6 As shown, it includes: a load end 10, an upper pressure plate 20, a box body 30, a valve 40, a connecting pipe 50 and a locking cap 60. Low-viscosity liquid thermosetting glue is injected into the box body 30. A plurality of connecting pipes 50 are provided. One end of the connecting pipe 50 is installed on the box body 30, and the connecting pipe 50 is connected to the inside of the box body 30. The connecting pipe 50, the valve 40 and the locking cap 60 are arranged in a one-to-one correspondence. A valve 40 is installed on each connecting pipe 50. The end of the connecting pipe 50 extending out of the box body 30 is inserted into one end of the power cord, and the one end of the power cord is locked on the connecting pipe 50 by the locking cap 60. After the connection is completed, pressure is applied to the upper pressure plate 20 through the load end 10 to open the valve 40 and control the flow of the low-viscosity liquid thermosetting glue through the valve 40, so that the low-viscosity liquid thermosetting glue in the box body 30 gradually enters the gap of the power cord under the siphon effect until the low-viscosity liquid thermosetting glue drips out from the end of the power cord away from the box body 30.

[0031] Remove the glue-injected power cord and heat it in an oven to crosslink and cure the thermosetting adhesive (for example, epoxy resin adhesive requires baking at 80-120°C). After the low-viscosity liquid thermosetting adhesive in the power cord has crosslinked and cured, let it cool. Clean the adhesive from the surface of the power cord and perform an airtightness test on the cleaned power cord. Example

[0032] Reference Figure 3-5 As shown, the conductors in the power cord are in the form of twisted, twisted and compressed, that is, the conductors are twisted together by twisting, and are compressed conductors. Twisting is a common electronic component manufacturing technology, mainly used to manufacture conductor parts in electronic equipment such as wires, cables and printed circuit boards. The basic principle is to twist one or more filaments together to form a whole, and perform plating on the surface of the twisted conductor. Commonly used plating materials include tin, silver, nickel, etc. A compressed conductor is a twisted conductor that is mechanically compressed or stretched, or the shape and configuration of the single wire are appropriately selected to reduce the twisting gap. Compressed conductors are usually round, and the natural gap between the single wires is small, which can improve the conductivity of the cable and reduce material usage.

[0033] The power cord used in the present invention has multiple conductors 1, and the outer wall of each conductor 1 is coated with a tin layer. After the tin-plated conductors 1 are twisted together, a tin layer is coated on the outside of the multiple twisted conductors 1, thereby increasing the thickness of the overall tin layer of the conductor 1.

[0034] The preparation of the power cord also includes terminal crimping, which specifically includes the following steps: stripping the sheath and insulation of the power cord to expose the conductor of the power cord, and performing high-temperature injection molding of the terminal at the position where the conductor is exposed. The tin layer on the conductor is dissolved at high temperature and fills the gaps between the injection molding material and the conductor and between the conductors (such as Figure 5 The position of the conductor in the terminal (such as Figure 4 A in the middle), Figure 4 For the general Figure 3 Actual photo of the integral terminal after being cut open, revealing the internal conductor.

[0035] The technical solution mentioned above utilizes a twisted and compressed tinning design to enhance airtightness during crimping of the cable terminals. Tinning facilitates the process of crimping the cable terminals, allowing workers to fill gaps between conductors with the tinned layer, further blocking the gaps and preventing liquid penetration. Furthermore, during the high-temperature injection molding process, the tin layer dissolves and adheres to other components, further reducing the siphon effect caused by gaps between conductors. This design ensures cable reliability in liquid-cooled environments and reduces the risk of liquid penetration through the terminals due to siphoning.

[0036] Obviously, the above embodiments are merely examples for clarity of explanation and are not intended to limit the implementation methods. Those skilled in the art will appreciate that other variations or modifications can be made based on the above description. It is not necessary and impossible to enumerate all implementation methods here. Obvious variations or modifications arising therefrom remain within the scope of protection of the present invention.

Claims

1. A power cord for immersion liquid cooling, characterized in that: include: At least one core wire and a sheath, wherein the sheath is wrapped around the outside of the core wire; wherein the gap between the outer wall of the core wire and the inner wall of the sheath is filled with a thermosetting adhesive layer.

2. The power cord for immersion liquid cooling according to claim 1, characterized in that: The core wire comprises a conductor and an insulator wrapped around the outer wall of the conductor.

3. The power cord for immersion liquid cooling according to claim 1 or 2, characterized in that: There are multiple core wires, and the gaps between the multiple core wires are filled with a thermosetting adhesive layer.

4. The power cord for immersion liquid cooling according to claim 1, characterized in that: The thermosetting adhesive layer adopts low-viscosity thermosetting adhesive.

5. The power cord for immersion liquid cooling according to claim 2, characterized in that: A plurality of conductors are provided.

6. The power cord for immersion liquid cooling according to claim 1, characterized in that: The sheath is a transparent sheath.

7. A method for preparing a power cord for immersion liquid cooling, characterized in that: The steps include: One end of the power cord is placed in the low-viscosity liquid thermosetting adhesive, while the other end of the power cord is outside the low-viscosity liquid thermosetting adhesive. The end of the power cord immersed in the low-viscosity liquid thermosetting adhesive uses a siphon effect to absorb the low-viscosity liquid thermosetting adhesive into the gaps between the core wire and the sheath of the power cord and between the core wires, until the low-viscosity liquid thermosetting adhesive drips out from the other end of the power cord, and the gaps between the core wire and the sheath and between the core wires of the power cord are filled with the low-viscosity liquid thermosetting adhesive. Then, the power cord that has absorbed the low-viscosity liquid thermosetting adhesive is taken out and placed in an oven for heating to perform a thermosetting treatment, so that the low-viscosity liquid thermosetting adhesive in the power cord is cross-linked and cured.

8. The method for preparing a power cord for immersion liquid cooling according to claim 7, characterized in that: The conductors in the power cord are twisted and compressed.

9. The method for preparing a power cord for immersion liquid cooling according to claim 7, characterized in that: After the low-viscosity liquid thermosetting adhesive in the power cord is cross-linked and solidified, the adhesive on the surface of the power cord is cleaned after cooling, and the cleaned power cord is subjected to an air tightness test.

10. The method for preparing a power cord for immersion liquid cooling according to claim 8, characterized in that: The preparation of the power cord also includes terminal crimping, which specifically includes the following steps: stripping the sheath and insulation of the power cord to expose the conductor of the power cord, and performing high-temperature injection molding of terminals at the position where the conductor is exposed. The tin layer on the conductor dissolves at high temperature and fills the gaps between the injection molding material and the conductor, as well as between the conductors.

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