Phase change heat transfer insulator structure
By introducing phase change heat transfer fittings and heat dissipation medium into the insulator structure, the heat transfer path is optimized, solving the problem of insufficient heat dissipation of traditional insulators under high temperature or high current environments. This achieves more efficient heat dissipation, extends the service life of the insulator, and improves its stability.
Patent Information
- Application Number
- CN202520447601.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-14
- Publication Date
- 2026-03-06
- Estimated Expiration
- 2035-03-14
AI Technical Summary
Traditional insulators have poor heat dissipation performance under high temperature or high current conditions, which leads to internal heat accumulation and affects service life and stability.
The insulator structure with phase change heat transfer capability is adopted. By setting the upper phase change heat transfer fitting, heat dissipation medium and lower fitting on the main body of the insulator, the heat transfer path is optimized by using liquid wick and spiral heat dissipation fins to realize phase change heat transfer cycle.
It significantly improves the heat dissipation performance of insulators, reduces internal heat accumulation, extends service life, and enhances stability and reliability in high-temperature environments.
Smart Images
Figure CN223977748U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of power equipment, and in particular to an insulator structure capable of phase change heat transfer. Background Technology
[0002] Insulators are a crucial component of power systems, used to support and insulate live conductors. With the continuous development of power systems and the advancement of high-voltage transmission technology, the requirements for the heat transfer performance of insulators are becoming increasingly stringent. However, traditional insulators face the problem of poor heat dissipation during long-term operation, which not only affects their service life but also reduces their stability and reliability under high-current conditions.
[0003] Currently, most insulators on the market are made of insulating materials (such as epoxy resin and ceramics). Their structure typically includes the insulator body, upper and lower fittings, with the upper fitting connecting to the live conductor and the lower fitting connecting to the equipment housing. This structure meets basic insulation requirements, but it still has significant shortcomings in heat dissipation. Especially under high temperature or high current conditions, heat easily accumulates inside the insulator, leading to a decrease in insulation performance and potentially causing safety problems such as insulation breakdown. To improve the heat dissipation performance of insulators, some existing technologies employ methods such as adding heat dissipation fins to the insulator surface or using materials with better thermal conductivity. However, these methods often only improve heat dissipation to a limited extent and cannot fundamentally solve the problem of heat accumulation caused by high internal thermal resistance of the insulator. Furthermore, the traditional heat dissipation mechanism of insulators mainly relies on natural convection and radiation, which has significant limitations in terms of heat dissipation efficiency. Especially in large or high-voltage insulators, due to their large size, internal heat is difficult to dissipate in a timely manner, making localized overheating more likely. Utility Model Content
[0004] The technical problem to be solved by this utility model embodiment is to provide an insulator structure with phase change heat transfer capability, which is used in large or high voltage insulators to address the defect that internal heat is difficult to dissipate in a timely manner due to its large size.
[0005] A phase-change heat transfer insulator structure includes an insulator body, an upper phase-change heat transfer fitting, a heat dissipation medium, and a lower fitting. The upper phase-change heat transfer fitting is fixedly disposed at the upper opening of the insulator body, and the lower fitting is fixedly disposed at the lower part of the insulator body. The heat dissipation medium fills the inner cavity formed between the upper phase-change heat transfer fitting and the lower fitting.
[0006] The phase change heat transfer upper fitting includes upper fitting accessory one, upper fitting accessory two, and upper fitting accessory three. Upper fitting accessory one and upper fitting accessory three form a sealed upper chamber and a lower extension chamber connected as a whole. Upper fitting accessory two is fixedly attached to the inner surface of the chamber of upper fitting accessory one and has a liquid-absorbing core extending into the extension chamber. The liquid-absorbing core adsorbs the filling working fluid. Upper fitting accessory four is a spiral heat dissipation fin.
[0007] Furthermore, the upper hardware accessory three is T-shaped, and its top is welded and sealed to the lower part of the upper hardware accessory.
[0008] Furthermore, the second upper fitting accessory is sintered onto the first upper fitting accessory using copper powder.
[0009] Furthermore, the upper hardware accessory has an annular outer wall that is threadedly connected to the upper opening of the insulator body.
[0010] Furthermore, the top of the upper hardware accessory has a recess.
[0011] Furthermore, the bottom of the upper hardware accessory three has a filling port for filling the upper hardware accessory three with working fluid and for vacuuming and sealing.
[0012] Implementing the embodiments of this utility model has the following beneficial effects: Through an innovative phase-change heat transfer structure design, this utility model optimizes the heat transfer path, reduces the thermal resistance between the upper and lower fittings of the insulator, and significantly improves the heat dissipation performance of the insulator, especially under high-current conditions. This utility model also effectively reduces internal heat accumulation, extends the service life of the insulator, and improves its stability and reliability in high-temperature environments. Attached Figure Description
[0013] Figure 1 This is a front view and a cross-sectional view of the present invention;
[0014] Figure 2 This is a top view of the present invention;
[0015] Figure 3 This is a bottom view of the present invention;
[0016] Figure 4 This is a front view and a cross-sectional view of the fittings of this utility model;
[0017] Figure 5 This is a schematic diagram of the structure used in this utility model;
[0018] Figure 6 This is a front view and a cross-sectional view of the mold pressing and sintering fitting accessory 3 of this utility model.
[0019] Figure 7 The detailed structure of the upper fitting accessory one and upper fitting accessory two after demolding is shown below;
[0020] Figure 8 The detailed structure of the assembly of clamp one, upper hardware accessory one, and upper hardware accessory two during the brazing process of the upper hardware of this utility model;
[0021] Figure 9 This utility model provides a detailed structure for the assembly of clamp one, upper hardware accessory one, upper hardware accessory two, and upper hardware accessory three (before sealing) during the brazing process of the upper hardware fittings.
[0022] Figure 10 This utility model provides a detailed structure for the assembly of clamp 1, clamp accessory 1, clamp accessory 2, clamp accessory 3 (before sealing) and clamp 2 during the brazing process of the upper fittings.
[0023] Figure 11 The detailed structure of clamp 1, clamp accessory 1, clamp accessory 2, clamp accessory 3 (before sealing), clamp 2, and bolt assembly during the brazing process of the fittings of this utility model is shown below.
[0024] Figure 12 The detailed structure of the upper hardware accessory one, upper hardware accessory two, and upper hardware accessory three of this utility model;
[0025] Figure 13 This is a schematic diagram of heat transfer in this utility model.
[0026] Figure descriptions: 1-Insulator body, 2-Phase change heat transfer, 3-Heat dissipation medium, 4-Lower fitting, 5-Upper mold, 6-Lower mold, 11-Insulator body, 12-Upper skirt, 21-Upper fitting accessory 1, 22-Upper fitting accessory 2, 23-Upper fitting accessory 3, 24-Upper fitting accessory 4, 231-Injection port, 51-Opening of upper mold, 71-Clamp 1, 72-Clamp 2, 73-Bolt, 81-Bolt, 82-Current conductor, 83-Equipment housing. Detailed Implementation
[0027] To make the objectives, technical solutions and advantages of this utility model clearer, the utility model will be described in further detail below with reference to the accompanying drawings.
[0028] Example 1:
[0029] This utility model embodiment provides an insulator structure with phase change heat transfer capability, comprising an insulator body 1, an upper phase change heat transfer fitting 2, a heat dissipation medium 3, and a lower fitting 4.
[0030] Combination Figure 2 , Figure 3The phase change heat transfer upper fitting 2 is fixedly installed at the upper opening of the insulator body 1, and the lower fitting 4 is fixedly installed at the lower part of the insulator body 1. The heat dissipation medium 3 is filled in the inner cavity formed between the phase change heat transfer upper fitting 1 and the lower fitting 4.
[0031] The insulator body 1 consists of an insulator body 11 and a shed 12, and is manufactured by injection molding. In this invention, the insulator body 1 is made of epoxy resin material, which has good insulation performance and mechanical strength.
[0032] The phase change heat transfer fitting 2 includes fitting accessory 1 21, fitting accessory 22, fitting accessory 3 23, and fitting accessory 4 24.
[0033] Upper fitting accessory 1 21 and upper fitting accessory 3 23 form a sealed, interconnected upper chamber and lower extension chamber of a single body. Upper fitting accessory 2 22 is fixedly attached to the inner surface of the chamber of upper fitting accessory 1 21 and has a liquid-absorbing core extending into the extension chamber. The liquid-absorbing core adsorbs the filling medium and diffuses it throughout upper fitting accessory 2. The volume of the filling medium is generally 10% to 20% of the total volume of the inner cavity of the upper fitting. The filling medium may be, for example, deionized water or acetone.
[0034] like Figure 4 Attachment 1 (21) is a copper heat dissipation structure housing component 1; Attachment 2 (22) is a copper powder sintered capillary wick; Attachment 3 (23) is a copper heat dissipation structure housing component 2.
[0035] The upper hardware accessory 323 is T-shaped, and its top is welded and sealed to the lower part of the upper hardware accessory 121.
[0036] The upper fitting accessory 1 21 forms a cavity structure, which is welded to the bottom by the upper fitting accessory 3 23.
[0037] The upper fitting accessory 1 21 and the upper fitting accessory 3 23 form a sealed, interconnected upper chamber and lower extension chamber. The bottom of the extension chamber is the injection port 231, which is sealed after the injection of the working medium and the vacuum treatment are completed.
[0038] Fitting Attachment 4 24 consists of spiral heat dissipation fins fixedly mounted on the outer wall of the extension cavity to increase the heat dissipation area. Fitting Attachment 4 24 is used to transfer heat into the heat dissipation medium 3. Sufficient space exists between the inner walls of Fitting Attachment 2 22 and Fitting Attachment 3 23 to facilitate steam flow. The heat dissipation medium 3 is transformer oil, dimethyl silicone oil, etc.
[0039] The upper hardware accessory 21 has an annular outer wall with external threads for threaded connection with the upper opening of the insulator body.
[0040] The top of the upper hardware accessory 1 21 has a recess with a threaded groove for connecting to the live conductor 82 via bolt 81, while the insulator body 1 is fixedly connected to the equipment housing 83.
[0041] The lower fitting 4 is tightly connected to the lower part of the insulator body 1 by threads, and adopts a copper plate structure, which has good thermal conductivity.
[0042] This utility model embodiment also provides a method for manufacturing the above-mentioned phase-change heat-transferring insulator structure, which is implemented through the following steps.
[0043] S1: The insulator body 1 is prepared using injection molding process;
[0044] S2: As Figure 6 As shown, prepare upper hardware accessory 1 21 and upper hardware accessory 3 23, and process the upper mold 5 and lower mold 6 by machine tool;
[0045] S3: Precisely assemble the upper mold 5, hardware accessory 1 21, and lower mold 6, and use a clamp to fix the upper mold 5 and lower mold 6;
[0046] S4: Copper powder is filled into the gap between fitting accessory 1 21 and lower mold 6 through the opening 51 of the upper mold. Under a nitrogen-hydrogen mixed atmosphere consisting of 5% hydrogen and 95% nitrogen, it is sintered at high temperature to form a capillary wick. In this embodiment, the high-temperature sintering temperature is 930℃. After cooling, the upper fitting accessory 1 21 with the sintered upper fitting accessory 22 is demolded and removed.
[0047] S5: Clean the end faces of fitting accessory 1 21 and fitting accessory 3 23 to be welded;
[0048] S6: As Figure 8-10 As shown, brazing filler metal is applied to the surface to be welded on the upper fitting accessory 23. The welding surfaces of the upper fitting accessory 21 and the upper fitting accessory 23 are assembled and clamped together using clamp 1 71, clamp 2 72, and bolt 73. The upper fitting is inverted as a whole, with clamp 1 71 placed at the bottom and clamp 2 72 having a through hole that passes through the extension cavity of the upper fitting accessory 23. Clamp 1 71 and clamp 2 72 are fixed together by bolt 73.
[0049] In this embodiment, a low-temperature silver-based solder is selected, with a liquidus temperature of 610°C and a main chemical composition of Ag, Cu, Zn, Cd, and Ni.
[0050] S7: Place the entire device into an atmosphere furnace and heat it to 640°C in a vacuum environment for brazing.
[0051] S8: Allow to cool naturally to room temperature and clean off any residual flux;
[0052] S9: Conduct visual inspection and airtightness test, pour phase change liquid working fluid into the filling port of accessory 3.23 of the upper hardware, evacuate, seal, and weld the seal;
[0053] S10: Install the upper hardware accessory 24 outside the upper hardware accessory 3 23 to obtain the complete phase change heat transfer upper hardware 2;
[0054] S11: Assemble the phase change heat transfer upper hardware 2 with the insulator body 1 by means of threaded connection;
[0055] S12: Inject heat dissipation medium 3 into the central cavity of the insulator body 1 and assemble the lower fitting 4.
[0056] like Figure 13 As shown, the main heat transfer path of this invention can be described as follows: Heat is first input into the upper fitting accessory one. The liquid working fluid adsorbed by the wick evaporates into a gaseous state upon heating. When it diffuses to the extension cavity, it condenses into a liquid state on the inner wall surface at the bottom of the upper fitting accessory three, releasing the latent heat of phase change. The liquid working fluid flows back through the wick to maintain the phase change heat transfer cycle, while the heat is conducted through the wall surface to the upper fitting accessory four (heat sink). Subsequently, the heat is conducted to the lower fitting and the insulator body via the heat dissipation medium outside the upper fitting accessory four, ultimately achieving heat output from the system. This heat transfer process reflects the unique design of this invention in terms of thermal management, effectively realizing the export of heat to the lower fitting and the insulator body, thereby improving the overall system's heat dissipation efficiency, effectively reducing the insulator's operating temperature, and improving the insulator's reliability and service life.
[0057] Example 2:
[0058] This utility model provides an insulator structure capable of phase change heat transfer and its manufacturing method. For example... Figure 1-3 As shown, the high-efficiency heat dissipation insulator of this utility model includes an insulator body 1, an upper phase change heat transfer fitting 2, a heat dissipation medium 3, and a lower fitting 4.
[0059] Preferably, the insulator body 1 is composed of an insulator body 11 and a shed 12, and is manufactured using a 3D printing additive manufacturing process. In this invention, the insulator body 1 is made of epoxy resin material, which has good insulation performance and mechanical strength.
[0060] The phase change heat transfer upper fitting 2 is tightly connected to the upper part of the insulator body 1 via threads. For example... Figure 4 As shown, the phase change heat transfer upper fitting 2 includes upper fitting accessory 1 21, upper fitting accessory 22, upper fitting accessory 3 23, and upper fitting accessory 4 24. Upper fitting accessory 1 21 is a copper heat dissipation structure shell component 1; upper fitting accessory 22 is a copper powder sintered capillary wick; upper fitting accessory 23 is a copper heat dissipation structure shell component 2; and upper fitting accessory 4 24 is a spiral heat dissipation fin.
[0061] In this utility model, the upper hardware accessory 22 is formed by filling copper powder into a mold and pressing and sintering it together with the upper hardware accessory 21. For example... Figure 6 As shown, the mold consists of two parts: an upper mold 5 and a lower mold 6. The upper mold 5 is the main body of the mold, and the lower mold 6 is the base of the mold.
[0062] Preferably, the upper fitting accessory 23 extends axially along the insulator body 1 and has a filling port 231 at its end. The upper fitting accessory 24 is disposed on the outer surface of the upper fitting accessory 23 to increase the heat dissipation area. There is sufficient space between the upper fitting accessory 22 and the inner wall of the upper fitting accessory 23 to facilitate steam flow.
[0063] In this invention, the phase change heat transfer upper fitting 2 has a vacuum sealed space inside and contains a phase change liquid working medium, forming a highly efficient phase change heat transfer structure.
[0064] The heat dissipation medium 3 is filled in the cavity inside the insulator body 1 between the upper fitting 2 and the lower fitting 4. Preferably, the heat dissipation medium 3 is transformer oil, which has good insulation and thermal conductivity.
[0065] The lower fitting 4 is tightly connected to the lower part of the insulator body 1 by threads, and adopts a copper plate structure, which has good thermal conductivity.
[0066] The manufacturing method of the high-efficiency heat dissipation insulator of this utility model includes the following steps:
[0067] a) The insulator body 1 is prepared using injection molding;
[0068] b) Prepare upper hardware accessory 1 21 and upper hardware accessory 3 23, and process the upper mold 5 and lower mold 6 using a machine tool;
[0069] c) Precisely assemble the upper mold 5, upper hardware accessory 1 21, and lower mold 6, and use clamps to fix the upper mold 5 and lower mold 6;
[0070] d) Copper powder is filled into the gap between the upper fitting accessory 21 and the lower mold 6 through the opening 51 of the upper mold. Under a nitrogen-hydrogen mixture consisting of 10% hydrogen and 90% nitrogen, the mixture is sintered at high temperature to form a capillary wick. In this embodiment, the high-temperature sintering temperature is 950°C. After cooling, the upper fitting accessory 21 with the sintered upper fitting accessory 22 is demolded and removed.
[0071] e) Clean the end faces of fitting accessory 1 21 and fitting accessory 3 23 to be welded;
[0072] f) Apply brazing filler metal to the surface to be welded on the upper hardware accessory 23. Use clamp 1 71, clamp 2 72, and bolt 73 to assemble and clamp the welding surfaces of the upper hardware accessory 21 and the upper hardware accessory 23. In this embodiment, a low-temperature silver-based brazing filler metal is selected, with a liquidus temperature of 610°C and a main chemical composition of Ag, Cu, Zn, Cd, and Ni.
[0073] g) Place the entire apparatus in an atmosphere furnace and heat it to 650°C under a nitrogen-hydrogen mixture consisting of 5% hydrogen and 95% nitrogen for brazing.
[0074] h) Allow to cool naturally to room temperature and clean off any residual flux;
[0075] i) Conduct visual inspection and airtightness test, pour phase change liquid working fluid into the filling port of the upper hardware accessory 3 23, evacuate, seal and weld the seal;
[0076] j) Install the upper hardware accessory 24 on the outside of the upper hardware accessory 3 23 to obtain the complete phase change heat transfer upper hardware 2;
[0077] k) Assemble the phase change heat transfer upper hardware 2 with the insulator body 1 by means of threaded connection;
[0078] l) Inject heat dissipation medium 3 into the central cavity of the insulator body 1 and assemble the lower fitting 4.
[0079] The above-disclosed embodiment is merely a preferred embodiment of the present utility model and should not be construed as limiting the scope of the present utility model. Therefore, any equivalent variations made in accordance with the claims of the present utility model shall still fall within the scope of the present utility model.
Claims
1. A phase change heat transferable insulator structure, characterized by, The insulator body, the phase change heat transfer upper fitting, the heat dissipation medium, and the lower fitting are fixedly arranged at the upper opening of the insulator body, the lower part of the insulator body, and the inner cavity formed between the phase change heat transfer upper fitting and the lower fitting, respectively. The phase change heat transfer upper fitting comprises upper fitting accessories one, two, and three.
2. The phase change heat transferable insulator structure according to claim 1, wherein The upper fitting accessory two is fixedly attached to the inner surface of the cavity of the upper fitting accessory one and has a liquid absorbing core extending into the extension cavity.
3. The phase change heat transferable insulator structure according to claim 2, wherein The upper fitting accessory three is T-shaped and is welded to the lower part of the upper fitting accessory two.
4. The phase change heat transferable insulator structure according to claim 3, wherein The upper fitting accessory two is sintered on the upper fitting accessory one by copper powder.
5. The phase change heat transferable insulator structure according to claim 4, wherein The upper fitting accessory one has an annular outer wall and is screwed to the upper opening of the insulator body.
6. The phase change heat transferable insulator structure according to claim 5, wherein The upper fitting accessory one has a recess at the top. The upper fitting accessory three has a filling port at the bottom for filling working medium, vacuumizing, and sealing.