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Why is the thermal insulation performance of the shell of the color steel plate box type substation

source：www.taicredit.cn  |  Release time：2025年06月30日
       The excellent thermal insulation performance of the shell of the color steel plate box type substation is mainly due to its material combination design and structural optimization. It blocks heat transfer through multi-layer composite structure and reduces heat conduction efficiency by combining air layer, reflection layer and other designs. The following analysis will be conducted from three aspects: technical principles, material characteristics, and structural advantages:
1、 Core insulation principle: thermal blocking mechanism of multi-layer composite structure
1. Thermal conduction suppression of insulation layer
       Material selection: The interlayer of color steel plate is usually filled with insulation materials such as rock wool, polyurethane (PU) or extruded polystyrene board (XPS). Its thermal conductivity coefficient λ is extremely low (such as rock wool λ ≤ 0.04W/(m · K), PU λ ≤ 0.025W/(m · K)), far lower than traditional steel plate (λ=54W/(m · K)), which can significantly reduce thermal conductivity efficiency.
       Case comparison: The composite structure of 0.5mm color steel plate and 50mm rock wool has a thermal resistance of R=1.25 (m 2 · K)/W, while the thermal resistance of 2mm steel plate is only 0.0037 (m 2 · K)/W. The thermal insulation capacity of the former is 338 times that of the latter.
       Thickness design: The thickness of the insulation layer is adjusted according to the usage environment (usually 50-100mm). For example, in high temperature areas (such as southern summer), using a 100mm PU insulation layer can make the temperature difference between the inside and outside of the shell reach more than 20 ℃, avoiding overheating of equipment inside the box due to high environmental temperature (such as controlling transformer oil temperature below 95 ℃).
2. The synergistic effect of the air layer and the reflection layer
       Air layer insulation: Some color steel plate structures are equipped with a 5-10mm air layer between the steel plate and the insulation layer. The thermal conductivity of the air is λ=0.026W/(m · K), and the static air layer can suppress convective heat transfer, further reducing heat transfer (the thermal resistance of the air layer is about 0.15 (m 2 · K)/W).
       Energy saving reflective layer: An aluminum foil reflective layer (reflectivity ≥ 90%) can be added to the inner side of the outer panel of the shell to reduce heat absorption by reflecting solar radiation heat (infrared band). For example, during direct sunlight in summer, the aluminum foil reflective layer can lower the surface temperature of the outer panel by 10-15 ℃, thereby reducing heat conduction into the box.
2、 Material characteristics: Block the heat transfer path from the source
1. Thermal insulation auxiliary effect of color steel plate substrate and coating
       Optimization of substrate thermal resistance value: The color steel plate adopts a galvanized steel plate+organic coating structure. Although the steel plate itself has strong thermal conductivity, by adjusting the coating thickness (20-30 μ m) and material (such as polyester coating with added insulation filler), the thermal resistance can be slightly increased (about 0.001 (m 2 · K)/W). More importantly, the coating color can be customized to light colors (such as white, light gray), reducing the solar radiation absorption rate (α ≤ 0.3, black coating α ≈ 0.9), and reducing the heat absorption of the shell.
       Data comparison: The surface temperature of the white coated shell at noon in summer (about 45 ℃) is 20 ℃ lower than that of the black coated shell (about 65 ℃), and the temperature inside the box is correspondingly reduced by 5-8 ℃.
2. Advantages of physical properties of insulation materials
       The porous structure of rock wool: Rock wool is made of molten basalt fibers, with an internal porosity of ≥ 90% and a pore diameter of 1-3mm. Air is enclosed in the pores and cannot circulate, thereby suppressing thermal convection losses. At the same time, the fiber structure has a scattering effect on thermal radiation, reducing the efficiency of thermal radiation transfer.
       Closed cell structure of polyurethane: PU insulation layer is closed cell foam (closed cell ratio ≥ 95%), and the diameter of a single bubble is 0.1~0.5mm. At the same time of isolating air flow, the material itself has high chemical stability, and is not easy to age and shrink after long-term use, to ensure that the thermal insulation performance is durable (10 year thermal resistance attenuation ≤ 5%).
3、 Structural design: Enhance insulation effect through geometric and installation optimization
1. Modular splicing insulation sealing design
       Joint treatment: The color steel plate panels are spliced with tongue and groove joints and sealed with sealing strips (such as EPDM rubber strips) to avoid heat leakage in the gaps. For example, the joint between the top plate and the side plate is designed as an "L-shaped groove+double channel seal", which can reduce the thermal bridge effect (heat loss at the joint) by more than 80%. Compared with traditional bolt connections (which are prone to forming thermal bridges), the temperature fluctuation inside the box is reduced by 12 ℃.
       Application of insulation pads: Install insulation pads (such as nylon or PVC material) at the connection between steel plates and brackets to block the thermal bridge formed by direct metal contact. For example, when connecting the bracket to the bottom plate, using a 20mm thick nylon pad can reduce the thermal conductivity efficiency of that area by 70% and avoid the bottom of the box becoming a weak point for heat dissipation.
2. Active insulation coordination of ventilation and heat dissipation
       Passive ventilation structure: The top of the shell is equipped with louvers and dust-proof nets (such as rainproof louvers, with a ventilation area of ≥ 0.1m 2/㎡ of the shell), which use the thermal pressure effect (internal hot air rising) to form natural convection and take away the heat inside the box. When used in conjunction with the insulation layer, the temperature inside the box can be raised by 10-15 ℃ compared to the ambient temperature (the temperature difference can reach 30-40 ℃ without insulation).
       Active cooling system: In some high-temperature environments, the enclosure of the transformer box integrates a temperature controlled fan and heat sink. When the temperature inside the box exceeds 40 ℃, the fan automatically starts, combined with an insulation layer to reduce external heat intrusion, forming a dual guarantee of "passive insulation+active cooling", ensuring that the equipment can still operate normally at extreme high temperatures (ambient temperature of 45 ℃).