Isolation type DC power supply lightning protection device

Abstract

The embodiment of the utility model provides an isolation type DC power supply lightning protection device. The device comprises an arc chamber; the insulating plate is arranged in the arc chamber; the high-voltage electrode is positioned at one end in the arc chamber, is connected with an input power supply and is used for introducing and transmitting high voltage; the low-voltage electrode is positioned at the other end in the arc chamber, is connected with a load and is used for outputting low voltage subjected to lightning protection treatment; the heat insulation plate is arranged outside the arc chamber and used for reducing the temperature difference inside and outside the arc chamber; wherein the insulating plate adopts a multi-layer structure, and heat-conducting silicone grease is arranged between every two layers; wherein the first layer of the insulating plate is a ceramic material layer, the second layer of the insulating plate is a polyimide material layer, the third layer of the insulating plate is an epoxy resin material layer, and the thickness of heat-conducting silicone grease between every two layers is 0.1-0.3 mm. According to the scheme of the embodiment of the invention, the problem that the inner wall of the arc chamber is carbonized and the electrical insulation performance of the arc chamber is reduced due to the fact that the insulating layer of the internal arc chamber is easy to ionize due to instantaneous high voltage and high current generated by lightning stroke can be solved.

Description

Technical Field

[0001] This application relates to the field of power protection technology, specifically to an isolated DC power surge protector. Background Technology

[0002] Isolated DC power supply surge protectors are primarily used to protect DC power systems from damage caused by overvoltage events such as lightning strikes. This device provides an isolation barrier between the DC power supply and sensitive equipment, preventing instantaneous high voltage and current surges from being directly conducted to downstream circuits, thus ensuring the safety and reliability of the equipment. However, this type of surge protector also presents certain technical challenges. When a lightning strike occurs, the instantaneous high voltage and high current generated can cause significant stress to the arc chamber inside the surge protector, making the insulation layer inside the arc chamber prone to ionization, leading to carbonization of the inner wall of the arc chamber. As the degree of carbonization deepens, its electrical insulation performance gradually decreases, severely affecting the effectiveness and stability of the surge protector, thereby weakening its protective function for the power system. Summary of the Invention

[0003] In view of this, the present disclosure provides an isolated DC power surge protector, which at least partially solves the problems existing in the prior art.

[0004] This application discloses an isolated DC power supply surge protector, comprising:

[0005] Arc chambers are used to absorb and isolate the instantaneous high voltage and high current generated by lightning strikes;

[0006] Insulating boards are installed inside the arc chamber;

[0007] The high-voltage electrode, located at one end of the arc chamber, is connected to the input power supply and is used to introduce and transmit high voltage.

[0008] The low-voltage electrode, located at the other end of the arc chamber, is connected to the load and is used to output a low voltage that has been protected against lightning strikes.

[0009] Insulation panels are installed on the outside of the arc chamber to reduce the temperature difference between the inside and outside of the arc chamber.

[0010] The insulating board has a multi-layer structure, with thermally conductive silicone grease between each layer;

[0011] The insulating board has a first layer of ceramic material, a second layer of polyimide material, and a third layer of epoxy resin material, with the thickness of the thermal grease between each layer being 1-3 mm.

[0012] According to one embodiment, the arc chamber is further provided with a graphite coating.

[0013] According to one embodiment, the gap between the outer edge of the insulating plate and the arc chamber does not exceed 5 mm.

[0014] According to one embodiment, the high-voltage electrode adopts a conical design with a tip diameter of 2-4 mm.

[0015] According to one embodiment, a support rod is provided between the high-voltage electrode and the low-voltage electrode and the inner wall of the arc chamber.

[0016] According to one embodiment, both the low-voltage electrode and one end of the high-voltage electrode are provided with spring contacts.

[0017] According to one embodiment, an aluminum oxide film layer with a thickness of 5-1 mm is provided between the low-voltage electrode and the high-voltage electrode and the insulating plate.

[0018] According to one embodiment, the outer surface of the heat insulation panel is coated with a nano heat insulation coating layer with a thickness of 2-5 mm.

[0019] This disclosure provides an isolated DC power supply surge protector, comprising: an arc chamber for absorbing and isolating instantaneous high voltage and high current generated by lightning strikes; an insulating plate disposed within the arc chamber; a high-voltage electrode located at one end of the arc chamber and connected to an input power supply for introducing and transmitting high voltage; a low-voltage electrode located at the other end of the arc chamber and connected to a load for outputting a low voltage after lightning protection; and a heat insulation plate disposed outside the arc chamber to reduce the temperature difference between the inside and outside of the arc chamber. The insulating plate has a multi-layer structure, with thermally conductive silicone grease between each layer. The first layer of the insulating plate is a ceramic material layer, the second layer is a polyimide material layer, and the third layer is an epoxy resin material layer, with the thickness of the thermally conductive silicone grease between each layer being 1-3 mm. This disclosure solves the problem that instantaneous high voltage and high current generated by lightning strikes easily ionize the insulating layer of the internal arc chamber, leading to carbonization of the inner wall of the arc chamber and reducing its electrical insulation performance. Attached Figure Description

[0020] In the accompanying drawings, unless otherwise specified, the same reference numerals throughout the various drawings denote the same or similar parts or elements. These drawings are not necessarily drawn to scale. It should be understood that these drawings depict only some embodiments disclosed in this application and should not be construed as limiting the scope of this application.

[0021] Figure 1 This is a schematic diagram of the structure of an isolated DC power supply surge protector according to the present invention;

[0022] Figure 2 This is a schematic diagram of the internal structure of the arc chamber in an isolated DC power surge protector according to this utility model;

[0023] Figure 3This utility model describes an isolated DC power supply surge protector. Figure 2 Enlarged view of point B in the middle;

[0024] Figure 4 This utility model describes an isolated DC power supply surge protector. Figure 1 Enlarged view of point A in the middle.

[0025] In the diagram: 1. Arc chamber; 2. Insulating plate; 3. High-voltage electrode; 4. Low-voltage electrode; 5. Heat insulation plate; 6. Alumina film layer; 7. Nano-insulating coating layer; 8. Support rod; 9. Spring contact; 10. Graphite coating Detailed Implementation

[0026] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of this application. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0027] like Figure 1 and Figure 2 As shown, an isolated DC power surge protector of this application includes several key components to cope with the high voltage and high current caused by lightning strikes. It mainly includes an arc chamber 1, an electrical insulation board 2, a high-voltage electrode 3, a low-voltage electrode 4, and a heat insulation board 5.

[0028] First, the core component of this DC power surge protector is the arc chamber 1, which absorbs and isolates the instantaneous high voltage and high current surges introduced from the outside during a lightning strike, effectively protecting the safety of downstream equipment. Inside the arc chamber 1, there is a specially constructed insulating plate 2 as an important supporting component. Furthermore, the arc chamber 1 is wrapped with a heat insulation plate 5 to reduce the degree to which the high temperature generated by the discharge diffuses to the outside.

[0029] Insulation board 2 is an indispensable component in ensuring the overall reliability and stability of the lightning protection device. Insulation board 2 employs a multi-layered structure. The first layer is composed of ceramic material with excellent heat and wear resistance, providing a barrier against damage or destruction to the material surface under extreme conditions. Next is a layer of polyimide material with outstanding electrical properties and excellent high-temperature resistance, ensuring that a high insulation level is maintained for a long time, preventing short-circuit accidents even in harsh environments. The third layer is made of epoxy resin material with excellent bonding strength and easy curing, facilitating manufacturing processes.

[0030] In addition, the high-voltage electrode 3 is located at one end inside the arc chamber 1 and is connected to the input power supply. It plays the role of introducing and transmitting the powerful electric force generated by the lightning strike. The low-voltage electrode 4 is placed at the other end inside the arc chamber 1 and is directly connected to the target electrical device that needs to be protected to supply the purified output voltage.

[0031] To improve heat dissipation and ensure stable operation, thermally conductive silicone grease of appropriate thickness (ranging from 0.1 to 0.3 mm) is uniformly filled between every two layers of insulating board in this application. This material can fully contact both sides and effectively transfer heat away, keeping the temperature control of the entire system at a suitable level.

[0032] Specifically, the arc chamber 1 can be made of high-strength, corrosion-resistant metal material, with a cylindrical or sealed container-like structure to withstand and release enormous energy. It also requires a special coating to increase wear resistance and oxidation resistance. The installation location should be near areas susceptible to lightning strikes, such as near power grid connections, but without obstructing surrounding ventilation paths to prevent the accumulation of hot spots.

[0033] As for the insulating board 2, it can be manufactured with ideal geometric dimensions and precision through mold casting. Then, using automated spraying technology, different raw materials are laid out according to a predetermined program to form the required three-layer composite structure. For the application of thermal grease, a professional dispensing machine can be used to precisely control the amount and coverage of the grease, thereby achieving a good bonding interface and efficient heat conduction.

[0034] The heat insulation board 5 is usually made of lightweight foamed polymer or other non-conductive magnetic heat insulation materials and is fixed around the outer wall of the arc chamber 1 to ensure good sealing while achieving ideal heat preservation effect and prevent excessive heat leakage from the inside, which could lead to excessive external temperature rise and damage to nearby components.

[0035] When faced with drastic changes in internal environmental parameters caused by lightning strikes, especially sudden spikes in extremely high temperatures, traditional single-material or low-layer designs are prone to localized carbonization, weakening their original protective effectiveness. However, the improvements offered in this solution address these issues. Through a multi-layered combination and the addition of specially added high-efficiency heat-conducting gap filler, the probability of failure due to temperature stress is reduced, while the overall impact load resistance is enhanced. This makes the device less prone to failure during long-term operation, thereby improving user safety and reducing subsequent maintenance costs.

[0036] In one embodiment, see Figure 3In this application, an isolated DC power surge protector further incorporates a graphite coating 10 within its arc chamber 1. This graphite coating 10 adheres tightly to the inner surface of the arc chamber 1 and exhibits excellent conductivity and high-temperature resistance. Graphite materials possess high stability under high-energy conditions, effectively reducing the local temperature of the arc chamber 1 under extreme arc generation conditions and preventing material degradation.

[0037] The introduction of graphite coating 10 further optimizes the structural design of the surge protector, enabling it to maintain stable performance under instantaneous high voltage and high current. By selecting appropriate technology, the coating's robustness and uniformity can be achieved, thereby ensuring the overall heat resistance and conductivity of the arc chamber 1.

[0038] For example, in one embodiment, the inner wall of the arc chamber 1 first needs to be properly pretreated to ensure good adhesion and peel resistance. Next, a liquid graphite material mixed with special additives is uniformly applied to the surface of the arc chamber 1 using a spraying or dip coating process, and after drying or curing, a stable graphite coating 10 is formed. Furthermore, considering the application requirements in actual operation, parameters such as the viscosity, thickness, and solid content of the graphite solution can be adjusted before spraying to achieve the best protective effect.

[0039] This design not only enhances the arc chamber 1's resistance to extreme environmental factors, but also provides a reliable physical guarantee for the isolated DC power surge protector, enabling the equipment to maintain excellent working condition under complex and harsh conditions.

[0040] In one embodiment, the outer edge of the insulating plate 2 of the isolated DC power surge protector of this application maintains a very small gap with the arc chamber 1, which does not exceed 0.5 mm. The insulating plate 2 is a key component installed inside the arc chamber 1, serving a role in separation and protection. To ensure the accuracy of its installation position and electrical performance, the gap between the outer edge of the insulating plate 2 and the arc chamber 1 is strictly controlled. This design not only helps to optimize the utilization efficiency of the space inside the arc chamber 1, but also improves the overall compactness and safety of the equipment.

[0041] Specifically, the insulating plate 2 and the arc chamber 1 are manufactured using precision machining processes to meet tolerance requirements, ensuring that the gap formed after assembly is strictly controlled within a specified range. To ensure stable gap dimensions, a laser rangefinder can be used for online monitoring during production, and defective products can be adjusted or rejected promptly. This manufacturing method ensures that each batch of products meets high-precision requirements. Furthermore, for ease of assembly and subsequent maintenance, the insulating plate 2 can be installed at a designated location inside the arc chamber 1 using elastic sealing gaskets to ensure stability while maintaining a reasonable gap.

[0042] For example, the insulation board 2 is first precisely cut and machined using a CNC machine tool according to the design drawings, ensuring its dimensions are accurate to the micrometer level. Then, the insulation board 2 is fixed using specialized fixtures and molds, and carefully installed into the pre-treated arc chamber 1. The entire assembly process requires professional engineers to strictly follow operating procedures, and high-precision testing tools are used for final quality inspection to ensure that every detail fully meets design requirements. This ensures both installation accuracy and effectively prevents the influence of external environmental factors.

[0043] In one embodiment, such as Figure 4 As shown, the high-voltage electrode 3 of the isolated DC power surge protector of this application adopts a conical design, which helps to more effectively handle instantaneous high voltage. Specifically, the diameter of the tip of the high-voltage electrode 3 is set between 2-4 mm to optimize electrical breakdown characteristics. To adapt to different needs in actual application scenarios, the conical high-voltage electrode 3 can be flexibly adjusted in parameters, ensuring both electrical performance and mechanical strength. Due to the special structure of this conical design, the high-voltage electrode 3 can achieve efficient voltage concentration and guidance within a small space, further enhancing the overall stability and reliability of the surge protector.

[0044] For example, a conical high-voltage electrode 3 can be securely mounted at one end of the arc chamber 1 and connected to the input power supply via a specially designed connector. In practice, it is necessary to ensure that the electrode is machined to the required tip diameter range with high precision, and to select high-strength, highly conductive, and corrosion-resistant materials. Furthermore, considering the special requirements of the conical design, special attention must be paid to the relative positions and gaps between the electrode and the insulating plate 2 and other internal components during installation to avoid short-circuit risks due to insufficient distance, thus ensuring the safe operation of the entire system.

[0045] Return to reference Figure 2 In one embodiment, a support rod 8 is provided between the high-voltage electrode 3 and the low-voltage electrode 4 of the isolated DC power surge protector of this application and the inner wall of the arc chamber 1. The main function of the support rod 8 is to provide structural support between the high-voltage electrode 3 and the low-voltage electrode 4 and the inner wall of the arc chamber 1, ensuring the positioning accuracy and stability of the electrodes and preventing positional displacement under external vibration or extreme environmental conditions. At the same time, the support rod 8 can also effectively reduce the bending deformation of the electrodes due to their own weight.

[0046] One end of the support rod 8 is fixed to the inner wall of the arc chamber 1, while the other end is securely connected to the high-voltage electrode 3 and the low-voltage electrode 4. This design not only improves the installation strength of the electrodes but also ensures the consistency of their position throughout the entire operation, contributing to the improved reliability and durability of the entire system. Furthermore, the material chosen for the support rod 8 must possess excellent insulation properties and mechanical strength; for example, high-performance composite materials can be used to ensure stable physical properties even in harsh environments. The design of the support rod 8 also considers electrical clearance requirements to prevent safety hazards caused by insulation failure.

[0047] Specifically, the support rod 8 can be connected between the inner wall of the arc chamber 1 and the electrode via threads or snap-fit. For example, specific interface holes are pre-drilled in the inner wall of the arc chamber 1, and connectors are installed at corresponding positions on the electrode. The support rod 8 is installed and fixed through these connecting parts, thereby achieving stable support and precise positioning of the electrode. This installation method is simple, reliable, and easy to operate, and also facilitates the adjustment or replacement of the electrode and support rod 8 during subsequent maintenance and repair.

[0048] In one embodiment, continue to refer to Figure 2 In this application, both the low-voltage electrode 4 and the high-voltage electrode 3 of an isolated DC power surge protector are equipped with spring contacts 9. This structural design ensures the connection stability of the various key components during long-term use of the surge protector. As a flexible contact component, the spring contact 9 can effectively compensate for minor displacements or deformations caused by factors such as vibration and thermal expansion and contraction, thereby making the electrical connection between the electrodes more reliable.

[0049] Specifically, the spring contact 9 is installed at one end of the low-voltage electrode 4 and the high-voltage electrode 3. The spring contact 9 is typically made of a metal material with good elasticity and is precision-machined to ensure stable elastic recovery performance. The spring contact 9 is securely installed at a suitable position at the electrode end through welding or other fixing methods, ensuring stable and tight contact with the external circuitry. Furthermore, to ensure smooth current transmission, the materials selected for the electrode end faces and contacts should have good conductivity and high-temperature resistance to avoid premature wear or failure due to heat generation.

[0050] For example, in the actual design, the high-voltage electrode 3 is located at one end inside the arc chamber 1 and is responsible for connecting to the input power supply, while the low-voltage electrode 4 is located at the other end inside the arc chamber 1 and is connected to the load. With this layout, in the event of an emergency, the spring contact 9 can automatically adjust the contact force between the electrodes, ensuring circuit continuity while preventing arcing, thereby further improving the safety and reliability of the entire device. This design ensures that the electrical connection between the internal and external components of the arc chamber 1 is always in optimal condition, ensuring stable operation of the equipment under various environmental conditions.

[0051] In one embodiment, an alumina film layer 6 is provided between the low-voltage electrode 4 and the high-voltage electrode 3 of the isolated DC power surge protector of this application and the insulating plate 2. This alumina film layer 6, as a key insulating protective structure, has a thickness ranging from 5 micrometers to 1 millimeter. In the internal structural design of the surge protector, the presence of the alumina film layer 6 plays a crucial role in ensuring the electrical insulation between various functional components. Specifically, this special film layer not only significantly enhances the insulation strength between the high-voltage and low-voltage electrodes 4 and the insulating plate 2 inside the arc chamber 1, ensuring that short circuits or leakage do not occur between high and low voltages, but also improves the overall safety and reliability of the device.

[0052] In one embodiment, the high-voltage electrode 3 and low-voltage electrode 4 of the aforementioned isolated DC power surge protector are physically isolated and positioned on both sides of an insulating plate 2 composed of multiple layers of material. An aluminum oxide film is applied at the contact points between the two electrodes and the insulating plate 2 to form an effective barrier preventing abnormalities caused by external interference during power transmission. This structure ensures that even in the face of severe environmental changes or lightning strikes, the internal components of the equipment can operate normally, maintaining stable signal transmission.

[0053] For example, a uniform and dense alumina film 6 can be deposited on the contact surfaces of the high-voltage electrode 3 and the low-voltage electrode 4, as well as on the corresponding parts of the insulating plate 2, using physical vapor deposition or other surface coating techniques suitable for industrial production. This coating must be manufactured strictly according to specified thickness standards and ensure good adhesion, allowing the film to function stably under different conditions over a long period. Furthermore, during installation, the integrity and uniformity of the alumina film 6 should be carefully checked to ensure there are no cracks or defects.

[0054] In one embodiment, the outer surface of the heat insulation plate 5 of the isolated DC power surge protector of this application is coated with a nano-thermal insulation coating layer 7 with a thickness of 0.2-0.5 mm. The nano-thermal insulation coating is a material with excellent thermal insulation properties, effectively reducing heat transfer between the arc chamber 1 and the external environment. This design not only improves the thermal insulation efficiency of the heat insulation plate 5 but also extends the overall service life of the surge protector. In some application scenarios, the instantaneous high voltage and high current generated by lightning strikes may cause the equipment temperature to rise rapidly. The nano-coating of the heat insulation plate 5 can effectively reduce the conduction of this high temperature to the casing and surrounding equipment, ensuring the safety of the entire system.

[0055] The heat insulation panel 5 is typically installed on the outside of the arc chamber 1. Its main function is to prevent excessively high temperatures inside the arc chamber 1 while protecting the surrounding environment. The heat insulation panel 5 has a complex structure, requiring not only excellent physical and mechanical properties but also stable heat insulation performance during long-term use. Specifically, the nano-heat insulation coating layer 7 on the outer surface of the heat insulation panel 5 is applied using a uniform spraying process to ensure that the thickness is controlled within a specified range. By optimizing the coating composition and spraying process, the heat insulation performance of the heat insulation panel 5 can be significantly improved without affecting other components.

[0056] For example, in implementing this feature, a precision spraying device can be used to uniformly apply the nano-insulating coating to the outer surface of the insulation board 5, and the spraying amount can be strictly controlled to ensure that the coating reaches a standard thickness of 0.2-0.5 mm. To further ensure the coating quality, multi-angle spraying and real-time thickness monitoring can be used to monitor the coating process and ensure the integrity and uniformity of the final coating.

[0057] In actual operation, when this device is in use, the input power supply can be connected to the high-voltage electrode 3. At this time, the instantaneous high voltage and high current generated by the lightning strike will be introduced into the arc chamber 1. Inside the arc chamber 1, the multi-layer structure of the insulating plate 2 can effectively isolate this high energy. The first layer of ceramic material prevents electrical breakdown, the second layer of polyimide material provides further electrical isolation, and the third layer of epoxy resin material enhances mechanical stability and chemical resistance. At the same time, the thermally conductive silicone grease between each layer can effectively conduct and dissipate heat. After processing, the low-voltage electrode 4 safely outputs the low voltage, which has been protected against lightning strikes, to the load. The heat insulation plate 5 is located outside the arc chamber 1, which can reduce the temperature difference between the inside and outside, maintain the stable operating temperature of the internal components, and thus ensure the reliability and safety of the entire surge protector.

[0058] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various variations or substitutions within the technical scope disclosed in this application, and these should all be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. An isolated DC power supply surge protector, characterized in that, The utility model relates to a lightning protection device for low-voltage electrical equipment, comprising: An arc chamber (1) for absorbing and isolating the instantaneous high voltage and high current generated by lightning strike; An insulating plate (2) arranged in the arc chamber (1); A high-voltage electrode (3) located at one end of the arc chamber and connected to the input power source for introducing and transmitting high voltage; A low-voltage electrode (4) located at the other end of the arc chamber and connected to the load for outputting low voltage after lightning protection treatment; A heat insulation plate (5) arranged outside the arc chamber (1) for reducing the temperature difference between the inside and outside of the arc chamber; Wherein, the insulating plate (2) adopts a multi-layer structure, and heat-conducting silicone grease is arranged between each layer; wherein The first layer of the insulating plate (2) is a ceramic material layer, the second layer is a polyimide material layer, and the third layer is an epoxy resin material layer, and the thickness of the heat-conducting silicone grease between each layer is 0.1-0.3mm.

2. The lightning protection device for an isolated DC power supply according to claim 1, characterized in that: The arc chamber (1) is further provided with a layer of graphite coating (10) inside.

3. The lightning protection device for an isolated DC power supply according to claim 1, characterized in that: The gap between the outer edge of the insulating plate (2) and the arc chamber (1) is not more than 0.5mm.

4. The lightning protection device for an isolated DC power supply according to claim 1, characterized in that: The high-voltage electrode (3) adopts a conical design, and the diameter of the tip part is 2-4mm.

5. The lightning protection device for an isolated DC power supply according to claim 1, characterized in that: Supporting rods (8) are arranged between the high-voltage electrode (3) and the low-voltage electrode (4) and the inner wall of the arc chamber (1).

6. The lightning protection device for an isolated DC power supply according to claim 1, characterized in that: Spring contacts (9) are arranged on one end of the low-voltage electrode (4) and the high-voltage electrode (3).

7. The lightning protection device for an isolated DC power supply according to claim 1, characterized in that: Alumina film layers (6) are arranged between the low-voltage electrode (4) and the high-voltage electrode (3) and the insulating plate (2).

8. The lightning protection device for an isolated DC power supply according to claim 1, characterized in that: The outer surface of the heat insulation plate (5) is coated with a nano heat insulation coating layer (7) with a thickness of 0.2-0.5mm.

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