Bus duct with unit modular splicing and labyrinth waterproof structure

Abstract

The application provides a bus duct adopting unit modular splicing and a labyrinth waterproof structure, which comprises an outer shell, the outer shell comprising an upper shell and a lower shell, the upper shell being connected with the lower shell through buckling; a plurality of inclined micro flow channels are arranged on the side wall of the outer shell, the micro flow channels being arranged at intervals along the length direction of the outer shell, and the micro flow channels being arranged in an inclined downward manner; a labyrinth sealing structure is arranged at the joint of the upper shell and the lower shell, the labyrinth sealing structure comprising: an outer flow guide groove, a drain hole being arranged at the bottom of the flow guide groove; a sealing strip embedding groove, an elastic sealing strip being arranged in the sealing strip embedding groove, the elastic sealing strip generating sealing pressure in a compressed state; and a capillary block groove, a hydrophobic layer being arranged on the groove wall of the capillary block groove, so that the technical problems of low heat dissipation efficiency of the outer shell of the bus duct, insufficient protection ability of the joint sealing structure, and mutual contradiction between heat dissipation and sealing performance in the prior art are solved.

Description

Technical Field

[0001] This invention relates to a busbar trunking system employing modular splicing and a labyrinthine waterproof structure. Background Technology

[0002] Busbar trunking is a power distribution device used for power transmission and distribution. It consists of conductive copper busbars, insulating supports, and a metal casing, and is widely used in power supply and distribution systems in industrial plants, data centers, commercial buildings, and other locations. With the continuous increase in electrical load, the current-carrying capacity of busbar trunking is increasing, making it crucial to improve its heat dissipation and protection performance as a key technical challenge in this field.

[0003] In existing busbar trunking heat dissipation solutions, one approach is to install a heat dissipation guide plate inside the outer shell, transferring the heat generated by the copper busbars to the outer shell surface for dissipation. For example, Chinese patent CN112803332A discloses a well-sealed heat-dissipating busbar trunking with a heat dissipation guide plate in the middle of the inner shell cavity and waterproof components at both ends of the shell, achieving waterproofing through a corrugated groove surface and sealing rings. However, in this solution, there is contact thermal resistance between the heat dissipation guide plate and the outer shell, limiting the heat transfer efficiency. Furthermore, the outer shell surface has a flat wall structure, resulting in a limited heat dissipation area, and the temperature rise of the outer shell remains high during high current-load operation.

[0004] In summary, existing busbar trunking enclosures have shortcomings in both heat dissipation efficiency and sealing protection, especially in high-current-carrying applications. How to improve heat dissipation performance while maintaining a high level of protection and preventing heat dissipation vents from damaging the sealing structure remains a technical problem to be solved. Therefore, a new busbar trunking enclosure structural design is needed that can achieve reliable sealing protection performance while ensuring heat dissipation efficiency. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art by providing a busbar trunking system that employs modular splicing and a labyrinthine waterproof structure. This addresses the technical problems of low heat dissipation efficiency of the busbar trunking shell, insufficient protective capacity of the joint sealing structure, and the contradiction between heat dissipation and sealing performance in the prior art. This objective is achieved as follows:

[0006] This invention proposes a busbar trunking system employing modular splicing and a labyrinthine waterproof structure, comprising: an outer shell, the outer shell including an upper shell and a lower shell, the upper shell and the lower shell being fastened together; multiple inclined microchannels are provided on the sidewalls of the outer shell, the microchannels being spaced apart along the length of the outer shell, the microchannels being inclined downwards; a labyrinthine sealing structure is provided at the joint between the upper shell and the lower shell, the labyrinthine sealing structure including: an outer guide groove, the bottom of the guide groove having a drainage hole; a sealing strip embedding groove, provided inside the guide groove, the sealing strip embedding groove having an elastic sealing strip installed inside, the elastic sealing strip generating sealing pressure under compression; and a capillary blocking groove, provided inside the sealing strip embedding groove, the groove wall of the capillary blocking groove having a hydrophobic layer.

[0007] Furthermore, the width of the microchannel is 1-3mm, the depth is 2-5mm, the tilt angle is 10-30°, and the spacing between the microchannels is 3-10mm.

[0008] Furthermore, the microchannels have a width of 2mm, a depth of 3mm, an inclination angle of 15°, a spacing of 5mm between the microchannels, and the microchannel array covers 40% of the surface area of ​​the outer shell sidewall.

[0009] Furthermore, the width of the guide channel is 6-10mm, the depth is 5-8mm, the diameter of the drain hole is 2-5mm, and the spacing between the drain holes is 30-80mm.

[0010] Furthermore, the elastic sealing strip is made of EPDM rubber, silicone rubber, or fluororubber.

[0011] Furthermore, the pre-compression of the elastic sealing strip is 15-25%, generating a sealing pressure of 0.1-0.2 MPa.

[0012] Furthermore, the width of the capillary blocking groove is 0.3-1mm and the depth is 6-10mm.

[0013] Furthermore, the hydrophobic layer is a superhydrophobic coating sprayed onto the wall of the capillary blocking groove, and the contact angle of the superhydrophobic coating is ≥150°.

[0014] Furthermore, the length of a single section of the outer shell is 2000-4000mm, and the cross-sectional dimensions are 150-250mm × 100-200mm.

[0015] Compared with the prior art, the beneficial effects of the present invention are: by setting a microchannel array structure on the side wall of the shell, the microchannels are set downward to accelerate the rise of hot air by natural convection, and the array coverage of 40% increases the heat dissipation surface area by about 60%. Under a current carrying capacity of 630A, the temperature rise of the shell is reduced to 45K, which is 25% lower than that of the traditional flat-wall shell, effectively solving the problem of excessive temperature rise during high current carrying capacity operation.

[0016] By setting a three-layer labyrinth sealing structure at the joint, the first layer, the outer guide groove, intercepts and discharges most of the external moisture. The second layer, the EPDM sealing strip, generates a sealing pressure of 0.15MPa through pre-compression to form the core sealing layer. The third layer, the capillary blocking groove, combined with the superhydrophobic coating, prevents trace amounts of moisture from seeping in through capillary action. The synergistic effect of the three-layer structure improves the sealing reliability by more than 80%, and the protection level reaches IP65, meeting the high protection requirements of industrial power distribution systems.

[0017] The microchannel array is located on the side wall of the outer shell, without damaging the joint sealing structure. The labyrinth sealing structure drains the infiltrated water through the guide channel, without affecting the heat dissipation function of the outer shell. This effectively solves the technical problem of the contradiction between heat dissipation and sealing performance in traditional busbar trunking, and achieves synergistic optimization of efficient heat dissipation and high protection level. Attached Figure Description

[0018] Figure 1 This is a three-dimensional structural diagram of a busbar trunking system that employs modular splicing and a labyrinthine waterproof structure.

[0019] Figure 2 This is a front structural diagram of a busbar trunking system that employs modular splicing and a labyrinthine waterproof structure.

[0020] Figure 3 This is a front structural diagram of the joint of a busbar trunking system that employs modular splicing and a labyrinthine waterproof structure.

[0021] In the diagram: 1. Upper shell, 2. Lower shell, 4. Microchannel, 5. Joint, 6. Guide groove, 7. Sealing strip embedding groove, 8. Inner capillary blocking groove, 9. Elastic sealing strip, 10. Drain hole, 11. Busbar conductor, 12. Insulating support. Detailed Implementation

[0022] To enhance understanding of the present invention, the present invention will be further described in detail below with reference to embodiments and accompanying drawings. These embodiments are only used to explain the present invention and do not constitute a limitation on the scope of protection of the present invention.

[0023] Example 1

[0024] Please refer to Figure 1-3A busbar trunking system employing modular splicing and a labyrinthine waterproof structure includes an upper shell 1 and a lower shell 2, which are connected by a snap-fit ​​mechanism to form a receiving cavity. The outer shell is made of aluminum alloy, with a standard single-section length of 3000mm and a cross-sectional dimension of 200mm × 150mm. The upper shell 1 and lower shell 2 are fastened using a snap-fit ​​structure, with a set of snaps placed every 300mm along the length of the outer shell to ensure the mechanical strength of the connection.

[0025] Multiple inclined microchannels 4 are arranged in an array along the length of the casing. Each microchannel 4 is 2mm wide, 3mm deep, and inclined downwards at a 15° angle. The spacing between adjacent microchannels 4 is 5mm. The microchannel array covers 40% of the surface area of ​​the casing sidewall. The inclined arrangement of the microchannels 4 utilizes the principle of natural convection. When the copper busbar heats up, the temperature of the inner wall of the casing rises. The heat is conducted through the casing to the surface of the microchannels 4. The air inside the microchannels 4 expands due to heat, reducing its density, and flows upwards along the inclined direction, forming natural convection and accelerating heat dissipation. The array distribution of the microchannels 4 increases the heat dissipation surface area by approximately 60% compared to traditional flat-wall casings, significantly improving heat dissipation efficiency.

[0026] A labyrinth sealing structure is provided at the joint 5 between the upper shell 1 and the lower shell 2. The labyrinth sealing structure consists of three layers, from the outside to the inside: an outer guide groove 6, a sealing strip embedding groove 7, and an inner capillary blocking groove 8, forming a tiered protection system.

[0027] The first layer is the outer guide channel 6, which is 8mm wide and 6mm deep. Drainage holes 10, each 3mm in diameter, are opened at the bottom of the guide channel 6, and the spacing between the drainage holes 10 is 50mm. As the first line of defense, the guide channel 6 intercepts most of the moisture when it comes into contact with the joint 5. Under gravity, the moisture settles to the bottom of the guide channel 6 and is discharged through the drainage holes 10, preventing moisture from entering the second layer of sealing strip embedded groove 7.

[0028] The second layer is the sealing strip embedding groove 7, which is located inside the guide groove 6. The groove is 7mm deep and 5mm wide. An elastic sealing strip 9, made of EPDM rubber, is installed inside the sealing strip embedding groove 7. EPDM rubber has excellent weather resistance, ozone resistance, and elastic recovery properties, making it suitable for long-term outdoor use. The pre-compression of the elastic sealing strip 9 is set to 20%. When the upper housing 1 and lower housing 2 are engaged, the elastic sealing strip 9 is compressed, generating a sealing pressure of 0.15MPa. This sealing pressure ensures that the elastic sealing strip 9 fits tightly against the groove wall, forming an effective sealing layer that prevents moisture and dust penetration. The cross-sectional shape of the elastic sealing strip 9 is rectangular. When uncompressed, it is 6mm thick and 5mm wide. After compression, the thickness decreases to 4.8mm, the compression amount is 1.2mm, and the compression rate is 20%.

[0029] The third layer is the inner capillary blocking groove 8, which is located inside the sealing strip embedded groove 7. The width of the capillary blocking groove 8 is 0.5 mm and the depth is 8 mm. The inner wall of the capillary blocking groove 8 is coated with a superhydrophobic coating. The superhydrophobic coating is a nano-silica composite coating, which is uniformly coated on the inner wall surface of the groove through a spraying process. The contact angle of the superhydrophobic coating is greater than 150°, exhibiting extremely strong hydrophobic properties. The working principle of the capillary blocking groove 8 is based on the capillary blocking effect. When a trace amount of water passes through the first two layers of protection and reaches the capillary blocking groove 8, due to the groove width of only 0.5 mm, the water is difficult to pass through the narrow groove under the action of capillary force. At the same time, the hydrophobic effect of the superhydrophobic coating further prevents water adhesion and penetration, thereby achieving ultimate protection.

[0030] The collaborative sealing mechanism of the three-layer labyrinth sealing structure is as follows: the outer guide groove 6 drains most of the external moisture, the elastic sealing strip 9 embedded in the sealing strip groove 7 prevents moisture penetration through sealing pressure, and the inner capillary blocking groove 8 utilizes the capillary blocking effect and the superhydrophobic coating for ultimate protection. The failure probability of the three-layer structure is multiplied, and the overall sealing reliability is significantly improved.

[0031] The busbar system includes the aforementioned housing, busbar conductors 11, and insulating supports 12. The busbar conductors 11 are located inside the housing and consist of multiple conductive copper busbars, which are TMY tin-plated copper busbars. For a 630A current-carrying system, two copper busbars with a cross-sectional area of ​​80mm × 10mm are configured, and the resistivity of the copper busbars is 0.0175Ω·mm². 2 / m. Insulation spacing is maintained between conductive copper busbars, with a phase-to-phase distance ≥20mm and a ground distance ≥15mm, meeting electrical safety creepage distance requirements. The tin plating layer on the copper busbar surface is 8-12μm thick; tin plating improves the copper busbar's oxidation resistance and contact resistance stability.

[0032] Insulating supports 12 are used to support and fix the busbar conductor 11. Insulating supports 12 are spaced apart along the length of the outer casing, with one set every 500 mm. The insulating supports 12 are made of reinforced epoxy resin, with a Comparative Tracking Index (CTI) ≥ 600V, meeting high-voltage insulation requirements. The insulating supports 12 have a slot-type design; the copper busbar is inserted into the slot and fixed by friction. The slot depth is 12 mm and the width is 82 mm, matching the cross-sectional dimensions of an 80 mm × 10 mm copper busbar, with a 2 mm insertion allowance. The insulating supports 12 can withstand electrodynamic impacts under short-circuit conditions, ensuring no displacement or deformation of the copper busbar. The short-circuit current is designed for a peak value of 40 kA, and the mechanical strength of the insulating supports 12 meets the requirements for short-circuit conditions.

[0033] The heat dissipation path of the busbar system is as follows: When the copper busbar is energized, it generates Joule heat. The heat is first conducted to the insulation layer on the surface of the copper busbar, and then conducted to the inner wall of the outer shell through the insulation layer. After the temperature of the inner wall of the outer shell rises, the heat is conducted through the aluminum alloy shell to the surface of the microchannel 4 on the side wall of the outer shell. The surface of the microchannel 4 comes into contact with the ambient air and dissipates heat through natural convection. The 15° tilt angle design allows the hot air to flow upward along the microchannel 4, forming a stable natural convection circulation and accelerating heat dissipation.

[0034] Example 2

[0035] Based on Example 1, this embodiment provides preferred ranges for microchannel parameters, sealing groove parameters, shell dimensions, and spacing of insulating support members, as well as optional solutions for sealing strip materials.

[0036] The parameters of microchannel 4 can be adjusted as follows: width 1-3mm, depth 2-5mm, tilt angle 10-30°, and spacing between adjacent microchannels 4 3-10mm. Those skilled in the art can adjust the microchannel parameters according to heat dissipation requirements and housing dimensions. When the current carrying capacity is high, a larger microchannel width and depth can be selected to increase the heat dissipation area; when housing space is limited, the microchannel spacing can be reduced to improve array coverage. In Example 1, the parameters of 2mm width, 3mm depth, 15° tilt angle, and 5mm spacing are preferred, resulting in the best heat dissipation effect at a current carrying capacity of 630A.

[0037] The parameters of the outer drainage channel 6 can be adjusted as follows: width 6-10mm, depth 5-8mm, drainage hole diameter 2-5mm, and spacing between drainage holes 10 30-80mm. Those skilled in the art can adjust the drainage channel parameters according to the joint width and expected drainage volume. When the joint width is large, a wider drainage channel can be selected to increase drainage capacity; when the rainfall intensity is high, the spacing between drainage holes 10 can be reduced to improve drainage efficiency. In Example 1, the parameters of 8mm width, 6mm depth, 3mm drainage hole diameter, and 50mm spacing are preferred.

[0038] The material for the elastic sealing strip 9 can be EPDM rubber, silicone rubber, or fluororubber. EPDM rubber is the preferred material due to its excellent weather resistance and cost-effectiveness, making it suitable for most outdoor environments. Silicone rubber is suitable for high-temperature environments, with a temperature range of -60℃ to 200℃, while fluororubber is suitable for chemically corrosive environments. The pre-compression of the elastic sealing strip 9 ranges from 15-25%, generating a sealing pressure ranging from 0.1-0.2 MPa. The parameters in Example 1, with a pre-compression of 20% and a sealing pressure of 0.15 MPa, are preferred.

[0039] The parameters of the inner capillary blocking groove 8 can be adjusted to a width of 0.3-1 mm and a depth of 6-10 mm. Those skilled in the art can adjust the groove width according to the effective range of the capillary blocking effect. When the groove width is less than 0.3 mm, water is difficult to enter the groove, but the processing difficulty of the groove increases; when the groove width is greater than 1 mm, the capillary blocking effect weakens. In Example 1, the parameters of 0.5 mm width and 8 mm depth are preferred, ensuring the capillary blocking effect while facilitating manufacturing.

[0040] The dimensions of the outer shell are adjusted to: single section length of 2000-4000mm, and cross-sectional dimensions of 150-250mm × 100-200mm. The spacing of the insulating support members 12 is 400-600mm. Other structures and working principles in this embodiment are the same as in Embodiment 1, and will not be repeated here.

[0041] Example 3

[0042] This embodiment provides performance test data for Embodiment 1, including temperature rise test, IP65 protection level test, sealing pressure test, and superhydrophobic coating contact angle test.

[0043] Temperature rise test: The test conditions were an ambient temperature of 25℃, a current carrying capacity of 630A, and continuous operation for 4 hours. In Example 1, the surface temperature of the microchannel 4 on the side wall of the casing was 70℃, with a temperature rise of 45K. In the comparative test, Comparative Example 1 used a traditional flat-wall casing without a microchannel array. Under the same test conditions, the casing surface temperature was 85℃, with a temperature rise of 60K. Compared with Comparative Example 1, Example 1 showed a temperature rise reduction of 15K, an improvement of 25%, indicating that the microchannel array structure significantly improved heat dissipation efficiency and met the temperature rise limit of 65K required by GB7251.1 standard, leaving a temperature rise margin of 20K.

[0044] Dustproof and waterproof tests were conducted according to GB / T 4208-2017 and IEC 60529 standards. For the dustproof test, the casing was placed in a dust chamber with a vacuum of 2 kPa for 8 hours. No dust was found to have entered the interior after the test, meeting the IP6X dustproof sealing requirement. For the waterproof test, low-pressure water spray at 12.5 L / min was used for 3 minutes. No water seepage was observed at the seams after the test, meeting the IPX5 low-pressure water spray requirement, and the overall protection level reached IP65. In the comparative test, Comparative Example 2 used a single-layer sealing strip structure. Under the same waterproof test conditions, the seam seepage rate was 15%, and the protection level was only IP54. Example 1 showed an over 80% improvement in sealing reliability compared to Comparative Example 2.

[0045] A pressure sensor was used to measure the sealing pressure generated by the elastic sealing strip 9 under different pre-compression amounts. The sealing pressure was 0.10 MPa at a pre-compression of 15%, 0.15 MPa at 20%, and 0.20 MPa at 25%. Insufficient pre-compression resulted in insufficient sealing pressure, while excessive pre-compression could lead to permanent deformation of the sealing strip. A pre-compression of 20% was considered the optimal parameter.

[0046] The contact angle of the superhydrophobic coating on the inner wall of the capillary blocking groove 8 was measured using a contact angle meter. The result was 152°, which is greater than 150° and meets the requirements of the superhydrophobic definition. The high contact angle of the superhydrophobic coating indicates that water droplets are difficult to spread and adhere to the coating surface. It works in synergy with the capillary blocking effect to achieve protection.

[0047] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

[0048] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A busbar trunking system employing modular splicing and a labyrinthine waterproof structure, characterized in that: include: The outer casing includes an upper shell and a lower shell, which are fastened together. Multiple inclined microchannels are provided on the sidewalls of the outer casing, spaced apart along the length of the casing and inclined downwards. A labyrinth sealing structure is provided at the joint between the upper and lower shells. The labyrinth sealing structure includes: an outer guide groove with a drainage hole at its bottom; a sealing strip embedding groove located inside the guide groove, where an elastic sealing strip is installed and generates sealing pressure under compression; and a capillary blocking groove located inside the sealing strip embedding groove, with a hydrophobic layer on its wall.

2. The busbar trunking with modular splicing and labyrinth waterproof structure according to claim 1, characterized in that, The width of the microchannel is 1-3mm, the depth is 2-5mm, the tilt angle is 10-30°, and the spacing between the microchannels is 3-10mm.

3. A busbar trunking system employing modular splicing and a labyrinthine waterproof structure as described in claim 2, characterized in that... The microchannels are 2mm wide, 3mm deep, and tilted at 15°. The spacing between the microchannels is 5mm, and the microchannel array covers 40% of the surface area of ​​the outer shell sidewall.

4. A busbar trunking system employing modular splicing and a labyrinthine waterproof structure as described in claim 1, characterized in that, The width of the guide channel is 6-10mm, the depth is 5-8mm, the diameter of the drain hole is 2-5mm, and the spacing between the drain holes is 30-80mm.

5. A busbar trunking system employing modular splicing and a labyrinthine waterproof structure as described in claim 1, characterized in that, The elastic sealing strip is made of EPDM rubber, silicone rubber or fluororubber.

6. A busbar trunking system employing modular splicing and a labyrinthine waterproof structure as described in claim 5, characterized in that, The pre-compression of the elastic sealing strip is 15-25%, and the resulting sealing pressure is 0.1-0.2 MPa.

7. A busbar trunking system employing modular splicing and a labyrinthine waterproof structure as described in claim 1, characterized in that, The capillary blocking groove has a width of 0.3-1mm and a depth of 6-10mm.

8. A busbar trunking system with modular splicing and labyrinth waterproof structure according to claim 1, characterized in that, The hydrophobic layer is a superhydrophobic coating sprayed onto the wall of the capillary blocking groove, and the contact angle of the superhydrophobic coating is ≥150°.

9. A busbar trunking system employing modular splicing and a labyrinthine waterproof structure according to claim 1, characterized in that, The length of a single section of the outer shell is 2000-4000mm, and the cross-sectional dimensions are 150-250mm × 100-200mm.

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