The hollow structure design of the charging pile copper substrate is the key to achieving efficient heat dissipation and lightweight. I will analyze how the hollow structure can find a balance between heat dissipation and weight from the aspects of heat dissipation principle and structural design points.
During the operation of the charging pile, the charging pile copper substrate carries a large current transmission. If the large amount of heat generated cannot be dissipated in time, it will affect the charging efficiency and equipment life. At the same time, the overweight charging pile copper substrate is not conducive to the installation and transportation of the charging pile. The hollow structure design has become an important means to balance heat dissipation and weight by optimizing the space of the charging pile copper substrate.
The hollow structure can significantly improve the heat dissipation path of the charging pile copper substrate. The principle is that the hollow area reduces the solid material of the charging pile copper substrate and increases the air circulation space. When the charging pile is working, the heat generated by the charging pile copper substrate can be transferred to the surface through heat conduction. The hollow design allows the air to flow more freely between the plates and take away the heat by convection. Compared with the solid charging pile copper substrate, the hollowed structure increases the heat dissipation surface area, the contact area between the air and the charging pile copper substrate is larger, and the heat exchange is more sufficient. For example, with a honeycomb hollow design, air can enter the hollow area from multiple directions, forming a three-dimensional heat dissipation channel, accelerating the heat transfer speed, and effectively reducing the temperature of the charging pile copper substrate.
The hollow structure of the charging pile copper substrate directly reduces the amount of material used, thereby reducing weight. The weight reduction effect varies depending on the hollow ratio and design form. For example, a regular grid-shaped hollow can remove a large amount of redundant materials while ensuring the structural strength. Taking a solid charging pile copper substrate with an original area of 1 square meter and a thickness of 2 mm as an example, if a 30% hollowing rate design is adopted, its weight can be reduced by about 23 kg (the density of copper is 8.96g/cm³). This lightweight design not only reduces the overall weight of the charging pile, facilitates installation and transportation, but also reduces material costs and improves economic benefits.
To achieve a balance between heat dissipation path optimization and weight, it is necessary to comprehensively consider factors such as the shape, size, and distribution of the hollow structure. In terms of hollow shape, symmetrical shapes such as circles and hexagons are more uniform in stress distribution, which can reduce the decrease in structural strength caused by hollowing; the size of the hollow needs to be determined according to the actual current and heat load of the charging pile copper substrate. Too large hollowing may weaken the heat conduction capacity, and too small hollowing will not achieve the effect of weight reduction and heat dissipation. In addition, the distribution of the hollow area is also critical. The hollowing should be concentrated in the parts with low heat load and less impact on the structural strength, and the hollowing should be appropriately reduced in the areas where the current is concentrated and the strength needs to be guaranteed. Through finite element analysis and other technologies, the heat flow distribution and structural stress of the charging pile copper substrate under different hollow designs can be simulated to find the best design solution.
To further optimize the heat dissipation effect, the charging pile copper substrate with a hollow structure is often used in combination with other heat dissipation measures. For example, with the heat dissipation fins, the hollowed charging pile copper substrate is closely fitted with the fins, and the fins can increase the heat dissipation area and strengthen air convection; a micro fan is installed in the hollow area to force air flow and improve the heat dissipation efficiency. At the same time, a high thermal conductivity interface material is used to fill the gap between the charging pile copper substrate and the heat dissipation component to reduce thermal resistance. These auxiliary measures further enhance the heat dissipation capacity of the charging pile copper substrate without adding too much weight, so that the heat dissipation and weight balance can reach a better state.
The processing technology of the hollow structure directly affects the design implementation effect. At present, common processing methods include etching, laser cutting, CNC milling, etc. Etching process can realize complex hollow patterns, but the depth is limited; laser cutting has high precision and fast speed, and is suitable for processing hollow structures of various shapes; CNC milling can process thicker charging pile copper substrates and realize large-size hollowing. When selecting the process, it is necessary to consider the complexity, precision requirements and cost factors of the hollow structure to ensure that the designed hollow structure can meet the needs of heat dissipation and weight balance, and ensure processing quality and production efficiency.
The hollow structure design of the charging pile copper substrate finds a balance between heat dissipation efficiency and weight by optimizing the heat dissipation path and reasonably removing materials. By scientifically designing the shape, size and distribution of the hollow structure, combining auxiliary heat dissipation measures, and selecting appropriate manufacturing processes, the comprehensive performance of the charging pile copper substrate can be effectively improved, providing a guarantee for the stable and efficient operation of the charging pile, while also promoting the charging pile industry to develop in the direction of lightweight and energy-saving.
