Coating for bus duct heat dissipation conductor and coating method

Abstract

The invention relates to the technical field of coatings, and discloses a coating for a bus duct heat dissipation conductor and a coating method.The coating method comprises the steps that a composite coating of phase change material microcapsules, cold storage crystals and a thermal expansion material is prepared, the coating with a hydrophobic breathable layer and an umbrella-shaped protection structure is formed, and the synergistic effect of all functional components is achieved through a layered coating method. According to the invention, the temperature self-adaptive adjustment effect is realized, the cold and hot bidirectional adjustment function is realized, the problem of coating performance degradation in a high-humidity environment is effectively solved, the instantaneous high-temperature risk of the bus duct is reduced by 15-20 DEG C, and the operation safety of a power system is improved.

Description

Technical Field

[0001] This invention relates to the field of coating technology, and more specifically, to a coating and coating method for a busbar heat dissipation conductor. Background Technology

[0002] Busbar trunking is a widely used power transmission equipment in industrial and commercial buildings. The heat generated during high-load operation can lead to temperature increases, affecting equipment lifespan and safety. Traditional heat dissipation coatings primarily rely on single heat conduction or radiation mechanisms for heat dissipation, which cannot meet the heat dissipation requirements under complex operating conditions. Especially in industrial environments with large load fluctuations and significant changes in ambient temperature and humidity, traditional heat dissipation coatings face the following technical problems: 1) Insufficient heat dissipation capacity, unable to cope with instantaneous high temperatures; 2) Lack of environmental adaptability, especially with significant performance degradation under high humidity conditions; 3) Heat dissipation efficiency fluctuates greatly with changes in ambient temperature; 4) Fixed coating surface area, unable to adaptively adjust heat dissipation efficiency according to temperature changes; 5) Interference between multifunctional coating components, reducing service life. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention provides a coating and coating method for a busbar heat dissipation conductor.

[0004] A coating for a busbar trunking heat dissipation conductor, the coating comprising a base coating and a surface coating, wherein: the base coating comprises phase change material microcapsules, a cold storage crystal, a buffer isolation material, a thermally conductive filler, and a base material, wherein the phase change material microcapsules and the cold storage crystal form an "umbrella-like" protective structure, and the buffer isolation material covers the cold storage crystal to form an isolation layer; the surface coating comprises a thermal expansion material, a hydrophobic component, and a base material, wherein the initiation temperature of the thermal expansion material is 5-10°C higher than the phase change temperature of the phase change material, and the hydrophobic component forms a hydrophobic and breathable layer with microscopic gaps on the surface.

[0005] Preferably, the phase change material microcapsules comprise a phase change material with a melting point in the range of 45-60℃ and a wall material, wherein the average particle size of the phase change material microcapsules is 5-20μm, and the thickness of the wall material accounts for 10-15% of the total diameter of the microcapsules.

[0006] Preferably, the cold storage crystals are selected from sodium sulfate decahydrate, mannitol or salt hydrates, and their surfaces are modified with silane coupling agents to form a hydrophobic shell. The particle size range of the cold storage crystals is 10-30 μm.

[0007] Preferably, the thermal expansion material is selected from expanded graphite, hollow microspheres or polyacrylate microspheres, and its surface has a polymer elastic protective layer. The expansion ratio of the thermal expansion material is 1.5-3 times its original volume.

[0008] Preferred: The weight ratio of the components of the base coating is as follows: 40-50 parts of base material, 25-35 parts of phase change material microcapsules, 10-15 parts of cold storage crystals, 5-10 parts of thermally conductive filler, 3-5 parts of buffer and isolation material, and 1-2 parts of additives.

[0009] Preferred: The weight ratio of the components of the surface coating is: 50-60 parts of base material, 15-25 parts of thermal expansion material, 8-12 parts of hydrophobic component, 8-12 parts of thermally conductive filler, and 2-3 parts of additives.

[0010] Preferably, the micro-gap size of the hydrophobic and breathable layer is 0.5-2nm, which can block liquid water molecules but allow heat conduction.

[0011] A method for applying a coating to a heat dissipation conductor in a busbar trunking includes the following steps: Step 1: Pre-treat the surface of the busbar trunking; Step 2: Prepare the base coating by mixing phase change material microcapsules and cold storage crystals with a buffer and isolation material; Step 3: Apply the base coating to the surface of the busbar trunking and use a temperature gradient curing process to make the phase change material microcapsules form an "umbrella-shaped" protective structure around the cold storage crystal; Step 4: Prepare a surface coating containing thermally expanding materials and hydrophobic components; Step 5: Apply the topcoat to the surface of the bottomcoat and use a temperature and humidity cycle curing process to form a hydrophobic and breathable layer on the surface of the hydrophobic component.

[0012] Preferably, in step 2, the cold storage crystal is first premixed with the buffer material so that the cold storage crystal particles are wrapped by the buffer material, and then mixed with other components.

[0013] Preferably, in step 3, the temperature gradient curing process involves a bottom temperature that is 5-10°C higher than the top temperature, and the curing temperature is controlled below the glass transition temperature of the bottom coating substrate and does not exceed 80°C.

[0014] Preferably, in step 5, the temperature and humidity cycling curing process includes: first curing at 30-40℃ and 30-40% relative humidity for 2-4 hours, and then curing at 60-70℃ and 10% relative humidity for 1-2 hours.

[0015] Preferably, when preparing the surface coating in step 4, the temperature is controlled not to exceed the starting temperature of the thermal expansion material to prevent the thermal expansion material from expanding prematurely during the preparation process.

[0016] The beneficial effects of this invention are as follows: Dual-directional cooling and heating effect: Under low load and low temperature conditions (ambient temperature below 25℃), the cold storage crystal absorbs and stores cold energy; when the load increases and the temperature rises (busbar surface temperature exceeds 45℃), the cold storage crystal releases cold energy, the phase change material absorbs heat, and the thermal expansion material increases the heat dissipation area. This multi-layered synergistic effect enables the coating to automatically adjust its heat dissipation performance according to temperature changes; when the temperature rises by 10℃, the heat dissipation coefficient increases by 25-40%.

[0017] Stability in high humidity environments: Through the dual protection of an "umbrella-shaped" protective structure and a hydrophobic and breathable layer, the coating maintains over 90% heat dissipation efficiency and extends its service life by more than 50% even in environments with relative humidity reaching 80%. The hydrophobic and breathable structure blocks liquid water while ensuring unobstructed heat conduction channels, allowing the coating to maintain good heat dissipation performance in humid and hot environments.

[0018] Minimizing interference between functional components: The application of buffer and isolation materials reduces mutual interference between different functional materials, especially reducing the mechanical compression of phase change material microcapsules by thermally expanding materials. This ensures that the functional performance of the coating decreases by no more than 10% after 1000 temperature cycles, and improves the service life by more than 3 times compared to traditional composite coatings.

[0019] Reduced risk of sudden high temperature: Compared with traditional heat dissipation coatings, the coating of this embodiment can reduce the temperature peak by 15-20°C and reduce the rate of temperature rise by 40-60% when the temperature rises rapidly due to a sudden increase in busbar load (such as when the load increases from the rated value to 150%), which significantly reduces the risk of equipment overheating.

[0020] Environmental adaptability: Through the stepwise activation of three functional materials at different temperature ranges (25-80℃), the coating is able to adapt to various working environments. Within an ambient temperature range of -10℃ to 50℃, the coating can maintain stable heat dissipation performance, with heat dissipation efficiency fluctuations not exceeding 15%. Attached Figure Description

[0021] Figure 1 This is a comparison chart of the thermal regulation effects of the present invention; Figure 2 This is a humidity stability test chart of the present invention; Figure 3 This is a test diagram of the functional component interference of the present invention; Figure 4 This is a load surge test diagram of the present invention; Figure 5 This is an environmental adaptability test diagram of the present invention. Detailed Implementation

[0022] The subject matter described herein will now be discussed with reference to exemplary embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and implement the subject matter described herein, and changes may be made to the function and arrangement of the elements discussed without departing from the scope of this specification. Various processes or components may be omitted, substituted, or added as needed in the examples. Furthermore, some features described in the examples may be combined in other examples.

[0023] At least one embodiment of the present invention discloses a coating for a busbar heat dissipation conductor. The coating includes a base coating and a surface coating. The base coating includes phase change material microcapsules, a cold storage crystal, a buffer isolation material, a thermally conductive filler, and a base material. The phase change material microcapsules and the cold storage crystal form an "umbrella-like" protective structure. The buffer isolation material covers the cold storage crystal to form an isolation layer. The surface coating includes a thermal expansion material, a hydrophobic component, and a base material. The starting temperature of the thermal expansion material is 10°C higher than the phase change temperature of the phase change material. The hydrophobic component forms a hydrophobic and breathable layer with microscopic gaps on the surface.

[0024] In at least one embodiment of the present invention, the starting temperature of the thermal expansion material is disclosed to be 8°C higher than the phase change temperature of the phase change material.

[0025] In at least one embodiment of the present invention, the starting temperature of the thermal expansion material is disclosed to be 10°C higher than the phase change temperature of the phase change material.

[0026] At least one embodiment of the present invention discloses a phase change material microcapsule comprising a phase change material with a melting point in the range of 45°C and a wall material, wherein the average particle size of the phase change material microcapsule is 5 μm and the wall material thickness accounts for 10% of the total diameter of the microcapsule.

[0027] At least one embodiment of the present invention discloses phase change material microcapsules comprising a phase change material with a melting point in the range of 52°C and a wall material, wherein the average particle size of the phase change material microcapsules is 12 μm, and the wall material thickness accounts for 12% of the total diameter of the microcapsules. At least one embodiment of the present invention discloses a phase change material microcapsule comprising a phase change material with a melting point in the range of 60°C and a wall material, wherein the average particle size of the phase change material microcapsule is 20 μm and the wall material thickness accounts for 15% of the total diameter of the microcapsule.

[0028] In at least one embodiment of the present invention, the cold storage crystals are selected from sodium sulfate decahydrate, mannitol or salt hydrates, and their surfaces are modified by silane coupling agent to form a hydrophobic shell. The particle size range of the cold storage crystals is 30 μm.

[0029] In at least one embodiment of the present invention, the cold storage crystals are selected from sodium sulfate decahydrate, mannitol or salt hydrates, and their surfaces are modified by silane coupling agent to form a hydrophobic shell. The particle size range of the cold storage crystals is 10 μm.

[0030] In at least one embodiment of the present invention, the cold storage crystals are selected from sodium sulfate decahydrate, mannitol or salt hydrates, and their surfaces are modified by silane coupling agent to form a hydrophobic shell. The particle size range of the cold storage crystals is 20 μm.

[0031] In at least one embodiment of the present invention, the thermally expanding material is selected from expanded graphite, hollow microspheres or polyacrylate microspheres, and its surface has a polymer elastic protective layer. The expansion ratio of the thermally expanding material is 3 times its original volume.

[0032] In at least one embodiment of the present invention, the thermally expanding material is selected from expanded graphite, hollow microspheres or polyacrylate microspheres, and its surface has a polymer elastic protective layer. The expansion ratio of the thermally expanding material is 1.5 times its original volume.

[0033] In at least one embodiment of the present invention, the thermally expanding material is selected from expanded graphite, hollow microspheres or polyacrylate microspheres, and its surface has a polymer elastic protective layer. The expansion ratio of the thermally expanding material is twice the original volume.

[0034] In at least one embodiment of the present invention, the weight ratio of the components of the undercoat is disclosed as follows: 50 parts base material, 35 parts phase change material microcapsules, 15 parts cold storage crystals, 5 parts thermally conductive filler, 3 parts buffer and isolation material, and 1 part additive.

[0035] In at least one embodiment of the present invention, the weight ratio of the components of the undercoat is disclosed as follows: 40 parts base material, 25 parts phase change material microcapsules, 10 parts cold storage crystals, 10 parts thermally conductive filler, 5 parts buffer and isolation material, and 2 parts additives.

[0036] In at least one embodiment of the present invention, the weight ratio of the components of the undercoat is disclosed as follows: 45 parts base material, 30 parts phase change material microcapsules, 13 parts cold storage crystals, 8 parts thermally conductive filler, 4 parts buffer and isolation material, and 1.5 parts additives.

[0037] In at least one embodiment of the present invention, the component weight ratio of the surface coating is disclosed as follows: 50 parts of base material, 15 parts of thermal expansion material, 8 parts of hydrophobic component, 12 parts of thermally conductive filler, and 3 parts of additive.

[0038] In at least one embodiment of the present invention, the component weight ratio of the surface coating is disclosed as follows: 60 parts of base material, 25 parts of thermal expansion material, 12 parts of hydrophobic component, 8 parts of thermally conductive filler, and 2 parts of additive.

[0039] In at least one embodiment of the present invention, the component weight ratio of the surface coating is disclosed as follows: 55 parts of base material, 20 parts of thermal expansion material, 10 parts of hydrophobic component, 10 parts of thermally conductive filler, and 2.5 parts of additive.

[0040] At least one embodiment of the present invention discloses that the micro-gap size of the hydrophobic and breathable layer is 0.5 nm, which can block liquid water molecules but allow heat conduction.

[0041] At least one embodiment of the present invention discloses that the micro-gap size of the hydrophobic and breathable layer is 2 nm, which can block liquid water molecules but allow heat conduction.

[0042] At least one embodiment of the present invention discloses that the micro-gap size of the hydrophobic and breathable layer is 1.3 nm, which can block liquid water molecules but allow heat conduction.

[0043] At least one embodiment of the present invention discloses a method for applying a coating to a busbar trunking heat dissipation conductor, comprising the following steps: Step 1: Pre-treat the surface of the busbar trunking; Step 2: Prepare the base coating by mixing phase change material microcapsules and cold storage crystals with a buffer and isolation material; Step 3: Apply the base coating to the surface of the busbar trunking and use a temperature gradient curing process to make the phase change material microcapsules form an "umbrella-shaped" protective structure around the cold storage crystal; Step 4: Prepare a surface coating containing thermally expanding materials and hydrophobic components; Step 5: Apply the topcoat to the surface of the bottomcoat and use a temperature and humidity cycle curing process to form a hydrophobic and breathable layer on the surface of the hydrophobic component.

[0044] In step 2, the cold storage crystal is first premixed with the buffer material so that the cold storage crystal particles are wrapped by the buffer material, and then mixed with other components.

[0045] At least one embodiment of the present invention discloses that, in step 3, the temperature gradient curing process is such that the bottom temperature is 5°C higher than the top temperature, and the curing temperature is controlled below the glass transition temperature of the bottom coating substrate and does not exceed 80°C.

[0046] At least one embodiment of the present invention discloses that, in step 3, the temperature gradient curing process is such that the bottom temperature is 10°C higher than the top temperature, and the curing temperature is controlled below the glass transition temperature of the bottom coating substrate and does not exceed 80°C.

[0047] At least one embodiment of the present invention discloses that, in step 3, the temperature gradient curing process is such that the bottom temperature is 8°C higher than the top temperature, and the curing temperature is controlled below the glass transition temperature of the bottom coating substrate and does not exceed 80°C.

[0048] At least one embodiment of the present invention discloses that, in step 5, the temperature and humidity cycle curing process includes: first curing at 40°C and 40% relative humidity for 4 hours, and then curing at 70°C and less than 10% relative humidity for 2 hours.

[0049] At least one embodiment of the present invention discloses that, in step 5, the temperature and humidity cycle curing process includes: first curing at 30°C and 30% relative humidity for 2 hours, and then curing at 60°C and less than 10% relative humidity for 1 hour.

[0050] At least one embodiment of the present invention discloses that, in step 5, the temperature and humidity cycle curing process includes: first curing at 35°C and 35% relative humidity for 3 hours, and then curing at 65°C and less than 10% relative humidity for 1.5 hours.

[0051] At least one embodiment of the present invention discloses that, in step 4, when preparing the surface coating, the temperature is controlled not to exceed the starting temperature of the thermal expansion material to prevent the thermal expansion material from expanding prematurely during the preparation process.

[0052] Specific implementation examples The coating method for a heat dissipation conductor of a busbar trunking proposed in this embodiment includes the following steps: 1. Raw material preparation and processing 1.1 Preparation of phase change material microcapsules Microcapsules were prepared by interfacial polymerization using phase change materials (paraffin, higher fatty acids or their derivatives) with melting points in the range of 45-60℃.

[0053] The specific steps are as follows: The phase change material is heated to a molten state and mixed with an organic solvent to form an oil phase; An emulsifier is added to the aqueous phase, and the oil phase is dispersed into the aqueous phase under high-speed shearing to form an O / W emulsion; Add wall material precursors (polyurethane, melamine formaldehyde, etc.) to the system, and control the reaction temperature and time to allow the wall material to polymerize on the surface of oil droplets to form microcapsule walls; The process involves solidification, filtration, washing, and drying to obtain phase change material microcapsules.

[0054] The average particle size of the phase change material microcapsules is controlled within the range of 5-20 μm, and the wall thickness accounts for 10-15% of the total diameter of the microcapsules. This size and wall thickness ratio ensures that the phase change material has efficient heat absorption and release properties while maintaining sufficient mechanical strength.

[0055] 1.2 Selection and treatment of cold storage crystals Sodium sulfate decahydrate, mannitol, or other salt hydrates were selected as the cold storage crystals. To improve the stability and moisture resistance of the cold storage crystals, the following treatment methods were adopted: The cold storage crystals are ground to a particle size range of 10-30μm. The surface of the cold storage crystal is modified with silane coupling agents (KH550, KH570, etc.) to form a hydrophobic shell; The cyclone classification technique is used to remove excessively large or small particles to obtain cold storage crystals with uniform particle size distribution.

[0056] This process gives the surface of the cold storage crystal an oleophilic and hydrophobic property while maintaining its internal structure, thus enabling it to retain its cold absorption and release capabilities while also providing moisture protection.

[0057] 1.3 Preparation of thermally expanding materials Expanded graphite, hollow microspheres, or organic expandable materials (polyacrylate microspheres) are selected as the thermal expansion components. The start-up temperature and expansion ratio of the thermal expansion material are adjusted to achieve a reasonable match with the operating temperature of the phase change material and the cold storage crystal. By adjusting the activation temperature of the thermal expansion material, its activation temperature is made 5-10℃ higher than that of the phase change material. Control the thermal expansion ratio within the range of 1.5-3 times the original volume to avoid cracking of the coating structure due to excessive expansion; By employing polymer coating technology, an elastic protective layer is formed on the surface of thermally expanding materials, thereby improving their ability to cyclically expand and contract.

[0058] By controlling the temperature gradient, the thermal expansion material is activated when the heat absorption capacity of the phase change material is close to saturation, forming a stepwise enhancement of heat dissipation capacity and avoiding coating cracking problems.

[0059] 2. Formulation Design and Preparation of Composite Coatings 2.1 Formulation and preparation of the primer coating The base coating mainly consists of phase change material microcapsules and cold storage crystals, with the specific formulation ratio as follows: Base material (epoxy resin or silicone resin): 45 parts by weight; Phase change material microcapsules: 30 parts by weight; Cold storage crystal: 12 parts by weight; Thermally conductive fillers (alumina, boron nitride, etc.): 8 parts by weight; Buffering and insulating material (modified polymers such as polyvinyl alcohol and polyacrylate): 4 parts by weight; Additives (dispersants, defoamers, etc.): 1 part by weight.

[0060] The preparation steps are as follows: Mix the base material and dispersant, and stir at low speed until homogeneous; Gradually add the thermally conductive filler and increase the stirring speed until fully dispersed; Reduce the stirring speed and slowly add the phase change material microcapsules to avoid breakage; The cold storage crystal and the buffer material are premixed separately and then added to the above mixture; Add other additives, adjust the viscosity, and complete the preparation of the base coat.

[0061] By using the premixing technology of buffer isolation materials, the cold storage crystal particles are encapsulated by the buffer material, reducing their direct contact with the phase change material microcapsules, thereby reducing the mutual interference between components.

[0062] 2.2 Formulation and Preparation of Surface Coating The surface coating mainly consists of thermally expanding materials and hydrophobic components, with the specific formulation ratios as follows: Base material (fluorinated resin or modified acrylic resin): 55 parts by weight; Thermal expansion material: 20 parts by weight; Hydrophobic component (fluorosilane or nano-silica): 10 parts by weight; Thermally conductive filler (alumina or boron nitride): 10 parts by weight; Additives (dispersants, defoamers, etc.): 2 parts by weight.

[0063] The preparation steps are as follows: Mix the base material and dispersant, and stir appropriately; Add the thermally conductive filler in batches to ensure thorough dispersion; Under the condition that the temperature does not exceed the start-up temperature of the thermal expansion material, slowly add the thermal expansion material; - Premix the hydrophobic component separately with a portion of the base material, and then combine it with the above mixture; Adjust the viscosity to complete the preparation of the surface coating.

[0064] The hydrophobic components in the surface coating employ a structure with micro- and nano-scale pores. This structure forms a barrier layer against liquid water molecules while maintaining unobstructed heat conduction channels.

[0065] 3. Coating process and structure formation 3.1 Busbar Surface Pretreatment Before applying the coating, the surface of the busbar trunking needs to be properly pretreated: Remove surface oxide layers, oil stains, and other impurities; Sandblasting or chemical etching methods can be used to increase surface roughness and improve adhesion. Apply a primer coating to enhance the adhesion between the coating and the substrate.

[0066] These steps are standard surface treatment techniques and can be performed using industry-standard methods.

[0067] 3.2 Application of base coat and formation of "umbrella" protective structure The underlying coating is applied using the following process: The difference in sedimentation rates between phase change material microcapsules and cold storage crystals in the coating is controlled (by adjusting the stirring speed and application temperature) to create a vertical gradient distribution between the two during the coating process. After coating, a temperature gradient curing process is used (the bottom temperature is 5-10℃ higher than the top temperature) to form an "umbrella-shaped" protective structure around the cold storage crystals using phase change material microcapsules. The curing temperature is controlled below the glass transition temperature of the underlying coating substrate (generally not exceeding 80℃) to prevent thermal deactivation of functional materials.

[0068] The "umbrella-like" protective structure is formed by utilizing the differences in density, particle size, and surface properties between phase change material microcapsules and cold storage crystals. Through controlled coating and curing conditions, the microcapsules, under the combined influence of gravity, capillary force, and surface tension, form a protective envelope around the cold storage crystals. This distribution pattern partially surrounds the cold storage crystals with the phase change material microcapsules, creating a physical barrier and reducing direct contact between the cold storage crystals and ambient moisture.

[0069] 3.3 Surface coating and formation of hydrophobic and breathable layer The surface coating is applied using the following process: After the base coat has fully cured, apply the top coat by spraying or brushing. The coating thickness is controlled within the range of 50-100μm to ensure sufficient hydrophobic properties; A temperature and humidity cycling curing process is adopted (first curing at 30-40℃ and 30-40% relative humidity for 2-4 hours, then curing at 60-70℃ and less than 10% relative humidity for 1-2 hours) to promote the enrichment of hydrophobic components on the coating surface and form a hydrophobic and breathable layer.

[0070] The principle of hydrophobic and breathable layer formation: During the curing process, hydrophobic component molecules migrate to the coating surface due to the principle of minimizing surface energy, forming an ordered hydrophobic structure. At the same time, the temperature and humidity cycling curing process maintains microscopic gaps between hydrophobic molecules. These gaps are approximately 0.5-2 nm in size, which can block liquid water molecules (approximately 0.3 nm in diameter) but allow heat conduction.

[0071] Experiment or test examples To verify the technical effectiveness of the busbar heat dissipation conductor coating and coating method described in this embodiment, the following experiments and tests were conducted: Experiment 1: Test of the effect of bidirectional temperature regulation Experimental Objective Verify the changes in the heat dissipation capacity of the coating at different temperatures, especially demonstrating the effect of increasing the heat dissipation coefficient by 25-40% when the temperature rises.

[0072] Experimental equipment Controllable temperature heat source (power adjustable electric heating plate); Temperature measuring devices (infrared thermometer, thermocouple); Data acquisition system; Standard busbar trunking specimen (specifications: 100mm×50mm×300mm).

[0073] Experimental steps Three different coated samples were prepared: Sample A: Composite coating (base layer + top layer) of this embodiment; Sample B: Traditional heat dissipation coating (commercially available thermal conductive coating); Sample C: Uncoated control group; The three types of samples were fixed on busbar trunking specimens of the same specifications in the same manner; The heat source temperature was increased from 25℃ to 85℃ in increments of 10℃, and the temperature was kept constant at each temperature point for 30 minutes.

[0074] At each temperature point, measure and record: Heat source temperature; Coating outer surface temperature; Thermal conductivity rate (calculated by measuring the rate of temperature change); The heat dissipation coefficient at each temperature is calculated using the formula: h = q / (Ts-Ta), where h is the heat dissipation coefficient, q is the heat flux density per unit area, Ts is the surface temperature of the coating, and Ta is the ambient temperature.

[0075] Experimental results Table 1. Heat dissipation coefficients (W / m²·K) of the three samples at different temperatures Experimental results show that when the temperature increases from 35℃ to 45℃ (an increase of 10℃), the heat dissipation coefficient of the composite coating in this embodiment increases from 15.8 W / m²·K to 19.6 W / m²·K, an increase of 24.1%; when the temperature increases from 45℃ to 55℃, the heat dissipation coefficient increases from 19.6 W / m²·K to 25.3 W / m²·K, an increase of 29.1%; and when the temperature increases from 55℃ to 65℃, the heat dissipation coefficient increases from 25.3 W / m²·K to 31.8 W / m²·K, an increase of 25.7%. This verifies the technical effect claimed in this embodiment: "when the temperature increases by 10℃, the heat dissipation coefficient increases by 25-40%".

[0076] In contrast, the increase in heat dissipation coefficient of traditional coatings with increasing temperature is only about 10-15%, which is far lower than that of the coating in this embodiment.

[0077] Figure 1 Comparison chart of thermal regulation effects.

[0078] Experiment 2: Stability Test under High Humidity Environment Experimental Objective Verify the performance stability of the coating in high humidity environments, especially demonstrating that it can still maintain a heat dissipation efficiency of over 90% in an environment with a relative humidity of 80%.

[0079] Experimental equipment Constant temperature and humidity chamber; Heat source (built-in heating resistor); Temperature sensor; Data recording system; Standard busbar trunking test specimen.

[0080] Experimental steps Two types of coated samples were prepared: Sample A: Composite coating (base layer + top layer) of this embodiment; Sample D: Control group coating without the addition of an "umbrella-shaped" protective structure and a hydrophobic and breathable layer; Two samples were coated on busbar trunking specimens of the same specifications; Set different ambient humidity conditions: Condition 1: Relative humidity 30% (low humidity); Condition 2: Relative humidity 50% (medium humidity); Condition 3: Relative humidity 80% (high humidity); Condition 4: Relative humidity 95% (extremely high humidity).

[0081] Under each humidity condition: Place the sample in a constant temperature and humidity chamber, and keep the temperature at 40℃. The busbar trunking is heated by electricity to reach a temperature of 60°C. Record the heat dissipation efficiency after reaching a steady state; The heat dissipation efficiency was measured every 24 hours after continuous exposure to humidity for 7 days.

[0082] Calculate relative heat dissipation efficiency: Compare the heat dissipation efficiency under each humidity condition with the heat dissipation efficiency under low humidity conditions (30% relative humidity) to obtain a percentage.

[0083] Experimental results Table 2. Relative heat dissipation efficiency (%) of coatings under different humidity conditions Experimental results show that after 7 days of exposure to an environment with a relative humidity of 80%, the composite coating of this embodiment still maintained a heat dissipation efficiency of 94.8%, far exceeding the 63.5% of the control group coating. Even in an environment with extremely high humidity (95%), the heat dissipation efficiency of the composite coating remained at 91.7%, while that of the control group coating dropped to 52.9%. This verifies the effectiveness of the "umbrella-shaped" protective structure and the hydrophobic and breathable layer in this embodiment, proving the technical effect of the coating maintaining a heat dissipation efficiency of over 90% in high humidity environments.

[0084] Figure 2 : Humidity stability test chart.

[0085] Experiment 3: Test to minimize interference between functional components Experimental Objective The effectiveness of the buffer material in reducing interference between functional components was verified, specifically by demonstrating that the functional performance of the coating decreased by no more than 10% after 1000 temperature cycles.

[0086] Experimental equipment Temperature cycling test chamber; Microscopic observation equipment; Thermal performance testing equipment; Data recording system; Standard busbar trunking test specimen.

[0087] Experimental steps Two types of coated samples were prepared: Sample A: Composite coating of this embodiment containing buffering and insulating material; Sample E: Control group coating without cushioning and isolation material; Temperature cycling tests were performed on the samples: Temperature cycling range: 25℃-75℃; Heating rate: 5℃ / minute; Cooling rate: 3℃ / minute; Maintain the temperature at both the high and low points for 15 minutes each; Number of loops completed: 0, 200, 400, 600, 800, 1000; Perform the following test after each specified number of iterations: Microstructural observation: Detection of the breakage rate of phase change material microcapsules; Thermal performance testing: The heat dissipation coefficient is measured under standard conditions; Surface morphology observation: Inspect the surface condition and cracking of the coating; Calculate the relative performance retention rate: Using the performance in the initial state (0 cycles) as a benchmark, calculate the performance retention rate after each number of cycles.

[0088] Experimental results Table 3. Retention rate of functional properties of coatings during temperature cycling tests (%) Experimental results show that after 1000 temperature cycles, the microcapsule integrity rate of the composite coating containing buffer material (sample A) was 94.3%, the heat dissipation coefficient retention rate was 94.9%, and the overall performance retention rate reached 94.6%. In contrast, the overall performance retention rate of the coating without buffer material (sample E) was only 62.5% after 1000 cycles.

[0089] This verifies the effectiveness of the buffer material in this embodiment, proving the technical effect that "the functional performance of the coating decreases by no more than 10% after 1000 temperature cycles." Furthermore, microscopic observation reveals that the phase change material microcapsules in sample A maintained good morphological integrity, while the microcapsules in sample E showed obvious damage and deformation, indicating that the buffer material effectively reduced the mechanical compression of the phase change material microcapsules by the thermally expanding material.

[0090] Figure 3 Interference test diagram of functional components.

[0091] Experiment 4: Test to Reduce the Risk of Instantaneous High Temperatures Experimental Objective The study verified the temperature control capability of the coating under sudden load increases in the busbar trunking, particularly demonstrating its ability to reduce peak temperature by 15-20℃ and reduce the rate of temperature rise by 40-60%.

[0092] Experimental equipment Adjustable power supply; High-precision temperature sensor array; Thermal imager; Data acquisition and analysis system; Standard busbar trunking test specimen; Experimental steps Two types of coated samples were prepared: Sample A: The composite coating of this embodiment; Sample B: Traditional thermally conductive coating; Temperature sensors were placed on both types of samples, at the following locations: Internal conductor surface; Coated surface; Ambient temperature at a distance of 10cm from the coating surface; Configure a load simulation scheme: Initial state: 50% rated load, maintain for 30 minutes to reach stability; Instantaneous load increase: a sudden increase from 50% of rated load to 150% of rated load; Duration: Continue running for 60 minutes after the load surge; Record the following data: Temperature-time curve; Rate of temperature rise; Peak temperature; Stable temperature.

[0093] Experimental results Table 4. Comparison of temperature control effects during load surge tests Experimental results show that, under the same sudden load increase conditions, the composite coating of this embodiment can reduce the peak temperature from 87.2℃ to 68.7℃, a reduction of 18.5℃, which meets the technical effect of "reducing the peak temperature by 15-20℃". Simultaneously, the temperature rise rate is reduced from 4.3℃ / min to 1.8℃ / min, a reduction of 58.1%, which meets the technical effect of "reducing the temperature rise rate by 40-60%". Furthermore, the composite coating also reduces the temperature fluctuation amplitude by 65.3%, indicating that the coating's multiple temperature regulation mechanisms can effectively mitigate temperature fluctuations in the busbar under load fluctuation conditions, significantly improving the system's stability and safety.

[0094] Figure 4 : Load surge test diagram.

[0095] Experiment 5: Environmental Adaptability Test Experimental Objective Verify the stability of the coating's heat dissipation efficiency under different ambient temperatures, especially demonstrating that the heat dissipation efficiency fluctuation does not exceed 15% within an ambient temperature range of -10℃ to 50℃.

[0096] Experimental equipment Adjustable temperature environment chamber; Constant power load simulation device; Temperature measurement system; Data acquisition and analysis system; Standard busbar trunking test specimen.

[0097] Experimental steps The busbar trunking specimen coated with the composite coating of this embodiment was installed in the environmental chamber; The busbar load was set to 75% of the rated load and kept constant throughout the test. The heat dissipation performance of the coating was tested at the following ambient temperatures: -10℃ (low temperature environment); 0℃ (cold environment); 10℃ (cool environment); 20℃ (normal temperature environment, as a baseline); 30℃ (warm environment); 40℃ (high temperature environment); 50℃ (extremely high temperature environment); Measure the following data at each temperature point: Busbar conductor temperature; Coating surface temperature; Temperature difference; Heat dissipation efficiency; Calculate the relative heat dissipation efficiency: Using the heat dissipation efficiency at an ambient temperature of 20℃ as the benchmark (100%), calculate the relative heat dissipation efficiency under other temperature conditions.

[0098] Experimental results Table 5. Relative heat dissipation efficiency of coatings under different ambient temperatures Experimental results show that, within an ambient temperature range of -10℃ to 50℃, the heat dissipation efficiency of the composite coating in this embodiment fluctuates between +8.5% and -10.8%, with a maximum fluctuation of 10.8%, which meets the technical requirement of "heat dissipation efficiency fluctuation not exceeding 15%". It is noteworthy that even with an ambient temperature change of 60℃ (from -10℃ to 50℃), the coating's heat dissipation efficiency remains highly stable, thanks to the tiered activation mechanism of the three functional materials in different temperature ranges.

[0099] In low-temperature environments, the heat-storing crystals play a major role, releasing stored heat to maintain the coating temperature; in normal-temperature environments, phase change materials primarily regulate temperature; and in high-temperature environments, thermal expansion materials enhance heat dissipation by increasing surface area. The synergistic effect of these three functional materials ensures that the coating exhibits excellent heat dissipation performance and environmental adaptability across a wide temperature range.

[0100] Figure 5 : Environmental adaptability test diagram.

[0101] The embodiments of the present invention have been described above. However, the embodiments are not limited to the specific implementation methods described above. The specific implementation methods described above are merely illustrative and not restrictive. Those skilled in the art can make more equivalent embodiments under the guidance of the present embodiments, and all of them are within the protection scope of the present embodiments.

Claims

1. A coating for a busbar trunking heat dissipation conductor, characterized in that, The coating comprises a base coat and a top coat, wherein: the base coat comprises phase change material microcapsules, cold storage crystals, buffering and isolating materials, thermally conductive fillers, and a base material, wherein the buffering and isolating materials encapsulate the cold storage crystals to form an isolation layer; the top coat comprises a thermal expansion material, a hydrophobic component, and a base material, wherein the initiation temperature of the thermal expansion material is 5-10°C higher than the phase change temperature of the phase change material, and the hydrophobic component forms a hydrophobic and breathable layer with microscopic gaps on the surface of the top coat.

2. The coating for a busbar heat dissipation conductor according to claim 1, characterized in that, The phase change material microcapsules comprise a phase change material with a melting point in the range of 45-60℃ and a wall material. The average particle size of the phase change material microcapsules is 5-20μm, and the thickness of the wall material accounts for 10-15% of the total diameter of the microcapsules.

3. The coating for a busbar heat dissipation conductor according to claim 1, characterized in that, The cold storage crystals are selected from sodium sulfate decahydrate, mannitol or salt hydrates, and their surfaces are modified with silane coupling agents to form a hydrophobic shell. The particle size range of the cold storage crystals is 10-30 μm.

4. The coating for a busbar heat dissipation conductor according to claim 1, characterized in that, The thermal expansion material is selected from expanded graphite, hollow microspheres or polyacrylate microspheres, and its surface has a polymer elastic protective layer. The expansion ratio of the thermal expansion material is 1.5-3 times its original volume.

5. The coating for a busbar heat dissipation conductor according to claim 1, characterized in that, The components of the underlying coating are in the following weight ratios: 40-50 parts base material, 25-35 parts phase change material microcapsules, 10-15 parts cold storage crystals, 5-10 parts thermally conductive filler, 3-5 parts buffer and isolation material, and 1-2 parts additives.

6. The coating for a busbar heat dissipation conductor according to claim 1, characterized in that, The surface coating consists of the following components by weight: 50-60 parts base material, 15-25 parts thermal expansion material, 8-12 parts hydrophobic component, 8-12 parts thermally conductive filler, and 2-3 parts additives.

7. The coating for a busbar heat dissipation conductor according to claim 1, characterized in that, The microscopic gap size of the hydrophobic and breathable layer is 0.5-2 nm.

8. A method for applying a coating to a heat dissipation conductor in a busbar trunking, characterized in that, Includes the following steps: Step 1: Pre-treat the surface of the busbar trunking; Step 2: Prepare the base coating by mixing phase change material microcapsules and cold storage crystals with a buffer and isolation material; Step 3: Apply the base coating to the surface of the busbar trunking and use a temperature gradient curing process to make the phase change material microcapsules form an "umbrella-shaped" protective structure around the cold storage crystal; Step 4: Prepare a surface coating containing thermally expanding materials and hydrophobic components; Step 5: Apply the topcoat to the surface of the bottomcoat and use a temperature and humidity cycle curing process to form a hydrophobic and breathable layer on the surface of the hydrophobic component.

9. The coating method according to claim 8, characterized in that, In step 2, the cold storage crystal is first premixed with the buffer material so that the cold storage crystal particles are wrapped by the buffer material, and then mixed with other components.

10. The coating method according to claim 8, characterized in that, In step 3, the temperature gradient curing process involves a bottom temperature that is 5-10°C higher than the top temperature, and the curing temperature is controlled below the glass transition temperature of the bottom coating substrate and does not exceed 80°C.

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