A high-strength composite insulator suitable for high-altitude areas

Abstract

This invention belongs to the technical field of composite insulators for high-voltage transmission lines in high-altitude areas. It provides a high-strength composite insulator suitable for high-altitude regions, comprising a core rod, top connecting hardware, bottom connecting hardware, shed assembly, and a sealing structure. The shed assembly consists of large and small sheds. The core rod and shed assembly are made of high-strength fiber-reinforced resin-based composite material and high-altitude aging-resistant polymer insulating material, respectively. The large and small sheds are arranged alternately along the core rod axis. A sealing structure is provided at the connection end between the hardware and the core rod, and the interface between the shed assembly and the core rod is reinforced. This insulator is suitable for extreme high-altitude environments, improves overall mechanical and insulation performance, and ensures the safe and stable operation of high-voltage transmission lines in high-altitude areas.

Description

Technical Field

[0001] This invention relates to the field of composite insulators for high-voltage transmission lines in high-altitude areas, and specifically to a high-strength composite insulator suitable for high-altitude areas. Background Technology

[0002] High-altitude areas are generally characterized by extreme environments such as low air pressure, strong ultraviolet radiation, large diurnal temperature variations, susceptibility to icing, strong winds, and high humidity corrosion. These environments place extremely high demands on the mechanical strength, insulation performance, weather resistance, and structural stability of composite insulators. Existing composite insulators, when applied to high-altitude environments, often exhibit problems such as core rod breakage due to insufficient strength, sheds aging and cracking due to strong ultraviolet radiation, debonding at the core rod-shed interface due to temperature differences and moisture intrusion, corrosion failure of fittings, flashover caused by icing and contamination of sheds, and wind-induced fatigue damage to sheds in strong winds. These issues prevent them from consistently meeting the safe operation requirements of high-voltage transmission lines in high-altitude areas, and in severe cases, can even affect the normal power supply of transmission lines. Therefore, there is an urgent need for a high-strength composite insulator that can adapt to various extreme scenarios at high altitudes and possesses excellent comprehensive performance. Summary of the Invention

[0003] The present invention aims to solve the problems mentioned in the background art by providing a high-strength composite insulator suitable for high-altitude areas.

[0004] The specific technical solution is as follows: A high-strength composite insulator suitable for high-altitude areas includes a core rod, with a top connecting hardware fixedly connected to the top end of the core rod and a bottom connecting hardware fixedly connected to the bottom end of the core rod. The core rod is covered with a skirt assembly, which consists of several large skirts and several small skirts. The large and small skirts are arranged alternately along the axial direction of the core rod. Both the large and small skirts are made of high-molecular insulating material resistant to high-altitude aging. The core rod is made of high-strength fiber-reinforced resin-based composite material. The connection ends of the top connecting hardware and the core rod, as well as the connection ends of the bottom connecting hardware and the core rod, are equipped with sealing structures. The interface between the skirt assembly and the core rod is treated with interface reinforcement.

[0005] In this design, the main structure of the insulator is formed by a core rod paired with top and bottom connecting fittings. The alternating arrangement of large and small skirts along the core rod axis expands the creepage path within a limited space while reducing dirt accumulation between the skirts. The skirts are made of high-altitude aging-resistant polymer insulation material, which can resist the erosion of insulation components by strong ultraviolet radiation and large temperature differences at high altitudes. The core rod is made of high-strength fiber-reinforced resin-based composite material, capable of withstanding various mechanical loads of high-altitude transmission lines. The sealed structure at the connection points of the top and bottom connecting fittings with the core rod prevents external moisture from intruding into the internal structure. The reinforced interface between the skirt assembly and the core rod improves the bonding strength and prevents interface separation. Overall, the insulator possesses stable insulation and mechanical properties simultaneously in complex high-altitude environments.

[0006] The aforementioned high-strength composite insulator suitable for high-altitude areas has a large umbrella skirt whose umbrella extension length is 1.5 to 2.5 times that of the small umbrella skirt, and the umbrella spacing between adjacent large umbrella skirts is 0.8 to 1.2 times that of the large umbrella skirt's umbrella extension length.

[0007] This scheme limits the ratio of the extended length of the large and small umbrella skirts and the ratio of the distance between adjacent large umbrella skirts. By optimizing the spatial arrangement of the umbrella skirts, the effective creepage distance of the insulator is further increased. At the same time, the space between the umbrella skirts is more conducive to the natural shedding of dirt, reducing the amount of dirt adhering to the surface of the umbrella skirts, reducing the probability of flashover caused by dirt in high-altitude and low-pressure environments, and improving the stability of the insulation performance of the insulator.

[0008] The aforementioned high-strength composite insulator suitable for high-altitude areas comprises a polymer insulating material based on methyl vinyl silicone rubber, with the addition of nano-zinc oxide UV stabilizer, methyl phenyl siloxane weather resistant agent, and bis(2,5-dimethyl)sulfide agent. The nano-zinc oxide has a particle size of 5 to 20 nanometers and is added in 2 to 5 parts by weight; the methyl phenyl siloxane weather resistant agent is added in 3 to 8 parts by weight; and the bis(2,5-dimethyl)sulfide agent is added in 1 to 2 parts by weight. This polymer insulating material is vulcanized at 160 to 180°C for 10 to 20 minutes. After molding, the tensile strength retention rate of the skirt material after UV aging is not less than 90%, and the elongation at break retention rate after high and low temperature cycling is not less than 85%.

[0009] This solution uses a specific formula and vulcanization process to prepare the polymer insulation material for the umbrella skirt. Methyl vinyl silicone rubber is used as the matrix, combined with anti-UV and weather-resistant additives, and then high-temperature vulcanization molding is carried out. This can significantly improve the umbrella skirt material's resistance to UV aging, avoid the umbrella skirt cracking and performance degradation caused by strong UV radiation at high altitudes, and enhance the mechanical property stability of the material in alternating high and low temperature environments. This allows the umbrella skirt to maintain good insulation and structural properties for a long time and extend the service life of the umbrella skirt in high-altitude environments.

[0010] The aforementioned high-strength composite insulator suitable for high-altitude areas comprises a fiber-reinforced resin-based composite material, wherein the fiber-reinforced resin-based composite material is an alkali-free E-glass fiber-reinforced bisphenol A type epoxy resin composite material, with the glass fibers arranged unidirectionally along the core rod axis and the fiber volume content being 60% to 70%; the epoxy resin is cured using an anhydride curing agent, and the core rod is prepared by a pultrusion molding process at a pultrusion speed of 0.5 to 2 meters per minute and a curing temperature of 120 to 150°C; when the core rod diameter is 20 to 40 mm, the axial tensile strength is 1200 to 1500 MPa, and the flexural strength is not less than 1800 MPa.

[0011] This solution uses alkali-free E-glass fiber reinforced bisphenol A epoxy resin to make the core rod. The glass fiber is arranged unidirectionally along the core rod axis and formed by pultrusion process, which can greatly improve the axial force performance and overall structural strength of the core rod. It can effectively withstand the tensile and bending mechanical loads of high-altitude transmission lines, avoid the core rod from breaking or deforming, and ensure the stability of the overall mechanical structure of the insulator.

[0012] The aforementioned high-strength composite insulator suitable for high-altitude areas uses a combination of crimping and adhesive bonding for the top connecting hardware and the core rod, as well as the bottom connecting hardware and the core rod. The crimping ratio of the crimping section is 1.2 to 1.5, and the adhesive section is filled with epoxy adhesive. The adhesive curing temperature is 80 to 100°C, and the curing time is 30 to 60 minutes.

[0013] This solution uses a combination of crimping and adhesive bonding to connect the top and bottom connecting hardware to the core rod. Combining the advantages of crimping and adhesive bonding, it can significantly improve the connection strength between the hardware and the core rod, avoid loosening of the connection due to wind vibration and conductor vibration in high-altitude areas, and ensure that the hardware and the core rod form a stable whole, thus guaranteeing the reliability of the overall mechanical connection of the insulator.

[0014] The aforementioned high-strength composite insulator suitable for high-altitude areas includes a sealing structure consisting of an annular fluororubber sealing ring installed at the connection end between the fitting and the core rod. The sealing ring has a Shore hardness of 60 to 70 degrees, a compression of 20% to 30%, and a contact gap between the sealing ring and the fitting / core rod of no more than 0.1 mm.

[0015] This solution uses an annular fluororubber sealing ring as the sealing structure. Through reasonable hardness and compression design, the sealing ring is tightly fitted with the fittings and mandrel, which can effectively prevent moisture and water vapor in high-altitude areas from penetrating the interface between the mandrel and the skirt, avoid the problem of debonding due to hydrolysis, improve the sealing reliability of the internal structure of the insulator, and extend the overall service life of the insulator.

[0016] The aforementioned high-strength composite insulator suitable for high-altitude areas includes an interface reinforcement treatment specifically comprising: impregnating the surface of the core rod with an aminosilane coupling agent to a thickness of 1 to 3 micrometers, followed by drying at 80 to 100°C for 10 to 15 minutes; then molding the dried core rod and the shed assembly together by compression molding at a temperature of 150 to 170°C, a molding pressure of 10 to 15 MPa, and a holding time of 15 to 25 minutes; the interface shear strength between the core rod and the shed after the interface reinforcement treatment is not less than 8 MPa.

[0017] In this solution, a strong bonding interface is formed between the core rod and the skirt assembly by coating the core rod with a silane coupling agent and then molding it together. This enhances the interfacial bonding force between the two and avoids the separation and cracking of the interface caused by the large temperature difference between day and night in high-altitude areas. This ensures that the core rod and the skirt maintain a stable bonding state and guarantees the continuous stability of the insulation and mechanical properties of the insulator.

[0018] The aforementioned high-strength composite insulator suitable for high-altitude areas has an arc-shaped mounting groove at the top of the top connecting hardware, the curvature of which is adapted to the outer diameter of the transmission conductor. The bottom of the bottom connecting hardware has a square mounting base at the bottom, and the side wall of the mounting base has a through circular mounting hole with a diameter of 12 to 16 mm.

[0019] The solution features an arc-shaped mounting groove on the top connecting hardware, which allows for a compatible mounting connection with the transmission conductor, ensuring the stability of the connection between the conductor and the insulator. The square mounting base and through mounting hole on the bottom connecting hardware facilitate bolt fixing to high-altitude transmission towers, improving the ease of insulator installation and making the connection more stable after installation, thus meeting the installation and usage requirements of high-altitude transmission lines.

[0020] The aforementioned high-strength composite insulator suitable for high-altitude areas features a canopy with micro-protruding hydrophobic textures on both the large and small canopy skirts. The hydrophobic textures are arranged in a dot matrix pattern, with a texture height of 0.1 to 0.3 mm and a texture spacing of 0.5 to 1 mm. The static contact angle of the canopy is not less than 110 degrees.

[0021] In this design, micro-protrusion hydrophobic textures are set on the canopy of both the large and small umbrella skirts. This improves the hydrophobicity of the umbrella surface, making it difficult for rainwater and water vapor to adhere to the surface. It also enhances the hydrophobic migration of the umbrella surface, reduces the accumulation of dirt on the surface, lowers the risk of dirt flashover in polluted environments at high altitudes, and allows the insulator to maintain good insulation performance even in polluted environments.

[0022] The aforementioned high-strength composite insulators suitable for high-altitude areas have a core rod diameter of 20 to 40 mm, a total creepage distance of not less than 35 mm per kilovolt of rated voltage, and a hydrophobic migration rating of HC1 for the shed assembly.

[0023] This scheme allows the insulation performance of the insulator to match the insulation coordination requirements of high-altitude areas by reasonably setting the diameter of the core rod and the total creepage distance of the skirt assembly. It can still ensure sufficient insulation safety margin in low-pressure environments, avoid insufficient insulation performance due to reduced air pressure, and improve the insulation reliability of the insulator when used in high-altitude areas.

[0024] The aforementioned high-strength composite insulator suitable for high-altitude areas features a thickened, rounded edge on the outer edge of both the large and small umbrella skirts. The thickness of the thickened, rounded edge is 1.2 to 1.5 times the thickness of the main body of the umbrella skirt. The surface of the thickened, rounded edge is provided with serrated grooves for anti-slip icicles. The depth of the serrated grooves is 1 to 2 millimeters, and the spacing between adjacent grooves is 3 to 5 millimeters.

[0025] In this design, a thickened, rounded edge is provided on the outer edge of the large and small umbrella skirts to enhance the structural strength of the skirt edges and prevent damage caused by external forces or icing. The serrated grooves on the edges can disrupt the formation of ice ridges, reduce the impact of ice ridges on insulation performance, improve the insulator's anti-icing ability in high-altitude, low-temperature icing environments, and reduce the probability of flashover caused by icing.

[0026] The aforementioned high-strength composite insulator suitable for high-altitude areas has an anti-corrosion layer on the outer surface of both the top and bottom connecting fittings. The anti-corrosion layer is composed of a hot-dip galvanized layer and an epoxy sealing layer. The thickness of the hot-dip galvanized layer is 80 to 120 micrometers, and the thickness of the epoxy sealing layer is 20 to 40 micrometers. The salt spray test corrosion resistance of the anti-corrosion layer is not less than 1000 hours.

[0027] In this solution, a composite anti-corrosion layer is set on the outer surface of the top and bottom connecting fittings. Through the combination of hot-dip galvanized layer and epoxy sealing layer, it can effectively resist the corrosion of the fittings by the high humidity and strong ultraviolet environment in high-altitude areas, avoid the problems of rust and failure of the fittings, extend the service life of the fittings, and ensure the long-term stability of the fitting connection performance.

[0028] The aforementioned high-strength composite insulator suitable for high-altitude areas has inclined guide grooves on the canopy of both the large and small umbrella skirts. The inclined guide grooves are arranged radially along the umbrella surface, with an inclination angle of 15° to 30°. The width of the guide grooves is 2 to 4 mm, and the depth is 1 to 3 mm. The ends of the guide grooves extend to the outer edge of the umbrella skirt. The inclination angle of the guide grooves is set to 15° to 30°.

[0029] The design incorporates inclined drainage channels on the canopy of both the large and small umbrella skirts. This allows rainwater and de-icing water to drain quickly from the umbrella surface, reducing water retention and the probability of water accumulation and icing. This ensures that the insulators maintain good insulation performance even in rain, snow, and de-icing weather at high altitudes, reducing insulation failures caused by water accumulation and icing.

[0030] The present invention has the following beneficial effects: 1. The core rod is made of alkali-free E glass fiber reinforced bisphenol A epoxy resin composite material. The glass fiber is unidirectionally arranged along the core rod axis and processed by pultrusion molding. The design of this material and molding process greatly improves the axial force performance and overall structural strength of the core rod, which can effectively withstand various mechanical loads of high-altitude transmission lines, avoid problems such as core rod breakage and deformation, and ensure the stability of the overall mechanical structure of the insulator.

[0031] 2. The top and bottom connecting fittings and the core rod adopt a composite fixing method of crimping and adhesive bonding. This method combines the mechanical fastening of crimping with the adhesive sealing, which greatly improves the connection strength between the fittings and the core rod. It avoids loosening of the connection due to wind vibration and conductor vibration in high-altitude areas, and allows the fittings and the core rod to form a stable whole, ensuring the reliability of the overall mechanical connection of the insulator.

[0032] 3. The sealing structure adopts an annular fluororubber sealing ring design. Through reasonable hardness and compression design, the sealing ring is tightly fitted with the hardware and core rod, which can effectively prevent moisture and water vapor in high-altitude areas from penetrating the interface between the core rod and the skirt assembly, avoid the interface from debonding due to hydrolysis, improve the sealing reliability of the internal structure of the insulator, and extend the overall service life of the insulator.

[0033] 4. The interface between the skirt assembly and the core rod is specially reinforced. Through the process of impregnation with aminosilane coupling agent and molding composite molding, a strong interface is formed between the core rod and the skirt assembly, which improves the bonding force between the two. It can adapt to the interface stress generated by the large temperature difference between day and night at high altitudes, and avoid the interface from separating or cracking. This ensures that the core rod and the skirt assembly always maintain a stable bonding state, and guarantees the continuous stability of the insulation and mechanical properties of the insulator.

[0034] 5. The large and small umbrella skirts are arranged alternately along the axis of the core rod in a specific ratio. By optimizing the spatial arrangement of the umbrella skirts, the effective creepage distance of the insulator is further increased. At the same time, the space between the umbrella skirts is more conducive to the natural shedding of dirt, reducing the amount of dirt adhering to the surface of the umbrella skirts, reducing the probability of flashover caused by dirt in high-altitude and low-pressure environments, and improving the stability of the insulation performance of the insulator.

[0035] 6. The large and small umbrella skirts are made of a high-molecular insulating material with methyl vinyl silicone rubber as the base and the addition of nano zinc oxide UV stabilizer and methyl phenyl siloxane weather resistant agent. It is processed by high-temperature vulcanization molding process. The design of this material formula and molding process significantly improves the umbrella skirt material's resistance to ultraviolet aging and its adaptability to high and low temperature cycles. It avoids cracking and performance degradation of the umbrella skirt caused by strong ultraviolet radiation at high altitudes and large temperature differences between day and night. It allows the umbrella skirt to maintain good insulation and structural performance for a long time and extends the service life of the umbrella skirt in high-altitude environments.

[0036] 7. The canopy of both the large and small umbrella skirts 4 features a slightly raised hydrophobic texture and sloping drainage channels. The hydrophobic texture enhances the water-repellent properties of the umbrella surface, making it difficult for rainwater and water vapor to adhere to the surface. The sloping drainage channels allow rainwater and meltwater to drain quickly from the umbrella surface, reducing water retention. Together, these features reduce the accumulation of dirt and the probability of water accumulation and icing on the umbrella, thus lowering the risk of flashover in high-altitude, polluted, rainy, snowy, and melting ice environments.

[0037] 8. The outer edges of the large and small umbrella skirts are reinforced with rounded edges and have serrated grooves on the surface. The rounded edges enhance the structural strength of the umbrella skirt edges, preventing damage caused by external impacts, ice compression, etc. The serrated grooves can disrupt the formation of ice ridges, reduce the impact of ice ridges on insulation performance, improve the insulator's anti-icing ability in high-altitude, low-temperature icing environments, and reduce the probability of flashover caused by icing.

[0038] 9. The outer surfaces of the top and bottom connecting fittings are covered with an anti-corrosion layer composed of a hot-dip galvanized layer and an epoxy sealing layer. Through the combination of the two protective structures, the fittings can effectively resist the erosion of high humidity, strong ultraviolet rays and corrosive media in high-altitude areas, avoid the problems of rust and failure, extend the service life of the fittings, and ensure the long-term stability of the connection performance of the fittings.

[0039] 10. The structure, materials, and processes of each component of the insulator are designed in a coordinated manner, giving it excellent mechanical strength, insulation performance, weather resistance, corrosion resistance, anti-icing performance, and strong wind resistance. It can adapt to different extreme scenarios at high altitudes, effectively solve various defects of existing insulators in high-altitude environments, extend the overall service life of the insulator, ensure the safe and stable operation of high-voltage transmission lines in high-altitude areas, and reduce the maintenance cost and failure rate of transmission lines. Attached Figure Description

[0040] Figure 1 This is a schematic diagram of the structure of a high-strength composite insulator suitable for high-altitude areas provided in an embodiment of the present invention; Figure 2 This is a partial structural schematic diagram of a high-strength composite insulator suitable for high-altitude areas provided in an embodiment of the present invention; Figure 3 The graph shows the change in the axial tensile strength of the mandrel over time. Figure 4 This is a graph showing the change of shear strength of this interface over time. Figure 5 This is a graph showing the retention rate of tensile strength after UV aging. Figure 6 This is a graph showing the elongation at break retention rate after high and low temperature cycling.

[0041] In the attached image: 1. Top connecting hardware; 2. Core rod; 3. Large umbrella skirt; 4. Small umbrella skirt; 5. Bottom connecting hardware; 6. Sealing structure; 7. Guide channel. Detailed Implementation

[0042] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0043] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual images. They should not be construed as limiting the scope of this application. To better illustrate the embodiments of the present invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0044] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "inner," and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present application. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0045] In the description of this invention, unless otherwise explicitly specified and limited, the term "connection" or similar designation indicating a connection between components should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0046] Reference Figures 1-6 ,in Figure 3This reflects the long-term durability of the mandrel material (alkali-free E glass fiber reinforced epoxy resin). Example 3 (diameter 40mm, fiber content 70%) had an initial strength of 1500MPa and retained 1420MPa after 400 hours, which is 21.4% higher than Example 1 (1170MPa). This proves that high fiber content and optimized molding process can significantly enhance creep resistance. High altitudes with large diurnal temperature differences and strong ultraviolet radiation make materials prone to aging. This curve verifies the strength retention rate of Example 3 in extreme environments, supporting the technical positioning of adapting to strong extreme scenarios. Figure 4 The interface bonding quality between the core rod and the umbrella skirt assembly was characterized. The interface shear strength of Example 3 was 10.0 MPa, which decreased by only 0.4 MPa (9.6 MPa) after 400 hours, which was much higher than 8.1 MPa of Example 1. This proves that the synergistic effect of the bis(2,5-dimethyl)sulfide and nano zinc oxide UV stabilizer effectively inhibits interface debonding. Interface failure is one of the main causes of insulator failure. This curve confirms that the interface design of Example 3 can withstand stress fatigue caused by high-altitude strong wind load and temperature difference cycle. Figure 5 The UV aging resistance of the umbrella skirt material (methyl vinyl silicone rubber matrix) was quantified. Example 3 showed a 92% retention rate after 200 hours of UV aging, an 8 percentage point improvement over Example 1 (84%). This was attributed to the shielding effect of the 5-nanometer zinc oxide UV stabilizer (5 parts by weight). High altitudes result in high UV intensity and easy material degradation. This curve validates the stability of the umbrella skirt formulation under extreme UV conditions, supporting the technical effect of "excellent weather resistance." Figure 6 The toughness retention of the material was evaluated under cycling conditions from -40°C to 120°C. After 200 cycles, Example 3 had a retention rate of 88%, which is 8 percentage points higher than Example 1 (80%). This is attributed to the toughening effect of the methylphenylsiloxane weathering agent (8 parts by mass). High altitudes have large temperature differences, which can easily cause the material to become brittle. This curve confirms that the formulation design of Example 3 can resist the toughness decay caused by extreme temperature differences and ensure the long-term safe operation of the insulator.

[0047] This specific implementation provides the following three examples: Example 1: Adapted to high-altitude common extreme scenarios I. Technical Solution The high-strength composite insulator of this embodiment includes a core rod 2, which is made of alkali-free E glass fiber reinforced bisphenol A type epoxy resin composite material. The glass fibers are unidirectionally arranged along the axial direction of the core rod 2, and the fiber volume content is 60%. The epoxy resin is cured with an anhydride curing agent. The core rod 2 is prepared by pultrusion molding process with a pultrusion speed of 1.8 meters per minute and a curing temperature of 125°C. The diameter of the core rod 2 is 25 mm.

[0048] The top end of mandrel 2 is fixedly connected to top connecting hardware 1, and the bottom end of mandrel 2 is fixedly connected to bottom connecting hardware 5. Both the top connecting hardware 1 and mandrel 2, and the bottom connecting hardware 5 and mandrel 2, are fixedly connected using a combination of compression and adhesive bonding. The compression ratio of the compression section is 1.2, and the adhesive section is filled with epoxy adhesive. The adhesive curing temperature is 85℃, and the curing time is 35 minutes. A sealing structure 6 is provided at the connection ends of the top connecting hardware 1 and mandrel 2, and at the connection ends of the bottom connecting hardware 5 and mandrel 2. The sealing structure 6 is an annular fluororubber sealing ring with a Shore hardness of 62, a compression ratio of 22%, and a contact gap of 0.08 mm between the sealing ring and the hardware / mandrel 2.

[0049] The top connecting hardware 1 has an arc-shaped mounting groove at its top, the curvature of which matches the outer diameter of the transmission line. The bottom connecting hardware 5 has a square mounting base at its bottom, with a through circular mounting hole of 13 mm in diameter on its side wall. Both the top connecting hardware 1 and the bottom connecting hardware 5 have an anti-corrosion layer on their outer surfaces. The anti-corrosion layer is composed of a hot-dip galvanized layer and an epoxy sealing layer, with the hot-dip galvanized layer being 85 micrometers thick and the epoxy sealing layer being 25 micrometers thick.

[0050] The core rod 2 is externally covered with a skirt assembly, which consists of several large skirts 3 and several small skirts 4. The large skirts 3 and small skirts 4 are arranged alternately along the axial direction of the core rod 2. The umbrella extension length of the large skirt 3 is 1.8 times the umbrella extension length of the small skirt 4, and the umbrella spacing between adjacent large skirts 3 is 0.9 times the umbrella extension length of the large skirt 3. Both the large skirts 3 and small skirts 4 are made of a high-molecular insulating material resistant to high-altitude aging. This material is prepared by adding 3 parts by weight of nano zinc oxide UV stabilizer with a particle size of 15 nanometers, 4 parts by weight of methylphenylsiloxane weathering agent, and 1.2 parts by weight of bis(2,5-dimethyl)sulfide agent as a base. This high-molecular insulating material is vulcanized at 165℃ for 12 minutes.

[0051] Both the large umbrella skirt 3 and the small umbrella skirt 4 have a slightly raised hydrophobic texture on their canopy surface. The hydrophobic texture is arranged in a dot matrix pattern, with a texture height of 0.15 mm and a texture spacing of 0.6 mm. Each umbrella surface has an inclined guide groove 7, which is arranged radially along the umbrella surface at an angle of 18 degrees, a width of 2.5 mm, and a depth of 1.5 mm. The ends of the inclined guide grooves 7 extend to the outer edge of the umbrella skirt. The outer edges of both the large umbrella skirt 3 and the small umbrella skirt 4 have a rounded, thickened edge. The thickness of the rounded, thickened edge is 1.2 times the thickness of the main body of the umbrella skirt. The surface of the rounded, thickened edge has serrated grooves for anti-slip icicles, with a depth of 1.2 mm and a spacing of 4.5 mm between adjacent grooves.

[0052] The interface between the skirt assembly and the core rod 2 is enhanced by an interface reinforcement treatment: an aminosilane coupling agent is impregnated onto the surface of the core rod 2 to a thickness of 1.5 micrometers, and then dried at 85°C for 11 minutes. The dried core rod 2 and the skirt assembly are then molded together at a molding temperature of 155°C, a molding pressure of 11 MPa, and a holding time of 18 minutes. In this embodiment, the total creepage distance of the skirt assembly is 36 mm per kilovolt rated voltage, and the hydrophobic migration level reaches HC1.

[0053] II. Working Principle The core rod 2 is made of alkali-free E-glass fiber reinforced bisphenol A epoxy resin composite material. The glass fibers are unidirectionally arranged axially and pultruded to provide basic mechanical support for the insulator, which can withstand the tensile, bending and other mechanical loads of transmission lines under normal extreme conditions at high altitudes. The top connecting hardware 1 and the bottom connecting hardware 5 are connected to the core rod 2 by a combination of compression and adhesive bonding. The combination of the mechanical fastening of compression and the adhesive sealing allows the hardware and the core rod 2 to form a stable connection, avoiding loosening of the connection due to normal wind vibration and conductor vibration.

[0054] The fluororubber sealing ring of the sealing structure 6 fits tightly with the fittings and core rod 2, preventing external moisture and water vapor from penetrating the interface between the core rod 2 and the umbrella skirt assembly, thus preventing interface dehydration and adhesion. The arc-shaped mounting groove of the top connecting fitting 1 is adapted to be mounted on the transmission line, and the square mounting base of the bottom connecting fitting 5, along with the mounting holes, enables bolt fixing to the transmission tower, balancing ease of installation and connection stability, and is suitable for conventional installation conditions at high altitudes.

[0055] The large umbrella skirt 3 and the small umbrella skirt 4 are arranged alternately in proportion to expand the insulation creepage path in a limited space, while optimizing the umbrella spacing to make dirt fall off naturally; the hydrophobic texture of the umbrella surface improves the water-repellent performance and reduces the adhesion of rainwater and water vapor, and the inclined drainage groove 7 accelerates the drainage of water and reduces the probability of water accumulation and dirt buildup on the umbrella surface; the rounded thickened edge enhances the edge structural strength of the umbrella skirt, and the serrated groove breaks the formation of icicles, making it suitable for high-altitude environments with regular icing and dirt.

[0056] The polymer insulation material of the insulator skirt is based on methyl vinyl silicone rubber, combined with UV-resistant and weather-resistant additives, and vulcanized at high temperature to improve the skirt's resistance to UV aging and high and low temperature cycling, resisting the corrosion of strong UV radiation at high altitudes and normal temperature differences. The interface reinforcement treatment between the core rod 2 and the skirt assembly is achieved through silane coupling agent coating and molding composite, improving the bonding force between the two and preventing interface separation caused by diurnal temperature differences, thus ensuring stable insulation performance. The composite anti-corrosion layer on the outer surface of the top connecting hardware 1 and the bottom connecting hardware 5 resists the corrosion of the hardware in high-altitude, high-humidity, and weakly corrosive environments, extending the service life of the hardware. The synergistic effect of all components ensures the stability of the insulator's mechanical and insulation performance under normal extreme conditions at high altitudes.

[0057] III. Experimental Data The insulator of this embodiment was placed in a simulated high-altitude extreme environment for performance testing. The test results are as follows: 1. Mechanical properties: The axial tensile strength of the mandrel 2 is 1250 MPa, and the bending strength is 1850 MPa; the interfacial shear strength between the mandrel 2 and the umbrella skirt assembly is 8.5 MPa; there is no loosening or detachment at the connection points between the top connecting hardware 1, the bottom connecting hardware 5 and the mandrel 2.

[0058] 2. Insulation performance: The static contact angle of the umbrella surface is 112 degrees; the pollution flashover voltage meets the requirements for use in normal extreme scenarios at high altitudes; there is no insulation breakdown in the umbrella skirt assembly, and the hydrophobic migration level remains at HC1.

[0059] 3. Weather resistance: The tensile strength retention rate of the umbrella skirt material after UV aging is 92%, and the elongation at break retention rate after high and low temperature cycling is 87%; the umbrella skirt is free from cracking and powdering, and there is no separation at the interface between the core rod 2 and the umbrella skirt assembly.

[0060] 4. Corrosion resistance: After 1000 hours of salt spray testing, the anti-corrosion layers of the top connecting hardware 1 and the bottom connecting hardware 5 showed no rust or bulging on the surface, and the anti-corrosion layers did not peel off.

[0061] 5. Anti-icing performance: After simulating a normal icing environment, the edge of the umbrella skirt is undamaged, the ice ridges fall off easily, and the icing flashover voltage meets the usage requirements.

[0062] IV. Technical Effects The selection of materials and the design of molding process parameters for core rod 2 enable it to have mechanical strength suitable for high-altitude extreme scenarios, stably withstand various mechanical loads of transmission lines in such scenarios, avoid core rod 2 from breaking or deforming, and ensure the stability of the overall mechanical structure of the insulator.

[0063] The composite connection method of top connecting hardware 1, bottom connecting hardware 5 and core rod 2 improves the connection strength between the hardware and core rod 2, allowing the connection part to resist the influence of conventional wind vibration and conductor vibration, and ensuring the reliability of the mechanical connection of the insulator; the parameter design of the sealing structure 6 achieves a good sealing effect, effectively blocking the intrusion of external moisture, avoiding the debonding of the interface between core rod 2 and shed assembly, and improving the sealing reliability of the internal structure of the insulator.

[0064] The optimized arrangement ratio of the large umbrella skirt 3 and the small umbrella skirt 4 effectively increases the effective creepage distance of the insulator, while reducing the amount of dirt adhering to the umbrella skirt surface and lowering the probability of flashover caused by dirt. The structural design of the hydrophobic texture of the umbrella surface and the inclined flow guide groove 7 improves the water-repellent and drainage capacity of the umbrella surface, reducing water and dirt accumulation. The rounded thickened edge and serrated groove give the umbrella skirt basic anti-icing and anti-damage capabilities, ensuring the stable insulation performance of the insulator.

[0065] The polymer insulation material formulation and vulcanization process of the umbrella skirt significantly improve its resistance to ultraviolet aging and high and low temperature cycle mechanical properties, preventing cracking and performance degradation caused by strong ultraviolet radiation and normal temperature differences, and ensuring that the umbrella skirt maintains good insulation and structural performance over a long period of time. The process parameter design of the interface enhancement treatment forms a strong bonding interface between the core rod 2 and the umbrella skirt assembly, improving the bonding force between the two and avoiding interface separation caused by day and night temperature differences, thus ensuring the continuous stability of the insulator's insulation performance.

[0066] The composite anti-corrosion layer of the top connecting hardware 1 and the bottom connecting hardware 5 can effectively resist the erosion of the high humidity and weak corrosion environment in typical high-altitude extreme scenarios, preventing the hardware from rusting and failing, and extending the service life of the hardware. The structural design of the top connecting hardware 1 and the bottom connecting hardware 5 enables the insulator to be compatible with transmission lines and towers, taking into account both ease of installation and connection stability, and adapting to typical high-altitude installation and use conditions. The coordinated design of each component ensures that the insulator has stable mechanical properties, insulation properties, weather resistance, and corrosion resistance in typical high-altitude extreme scenarios, meeting the usage requirements of high-voltage transmission lines in such scenarios.

[0067] Example 2 is adapted to high-altitude and moderately extreme scenarios. I. Technical Solution The high-strength composite insulator of this embodiment includes a core rod 2, which is made of alkali-free E glass fiber reinforced bisphenol A type epoxy resin composite material. The glass fibers are arranged unidirectionally along the axial direction of the core rod 2, and the fiber volume content is 65%. The epoxy resin is cured with an acid anhydride curing agent. The core rod 2 is prepared by pultrusion molding process with a pultrusion speed of 1.0 m / min and a curing temperature of 135℃. The diameter of the core rod 2 is 30 mm.

[0068] The top end of mandrel 2 is fixedly connected to top connecting hardware 1, and the bottom end of mandrel 2 is fixedly connected to bottom connecting hardware 5. Both the top connecting hardware 1 and mandrel 2, and the bottom connecting hardware 5 and mandrel 2, are fixedly connected using a combination of compression and adhesive bonding. The compression ratio of the compression section is 1.35, and the adhesive section is filled with epoxy adhesive. The adhesive curing temperature is 90℃, and the curing time is 45 minutes. A sealing structure 6 is provided at the connection ends of the top connecting hardware 1 and mandrel 2, and at the connection ends of the bottom connecting hardware 5 and mandrel 2. The sealing structure 6 is an annular fluororubber sealing ring with a Shore hardness of 65, a compression allowance of 25%, and a contact gap of 0.05 mm between the sealing ring and the hardware / mandrel 2.

[0069] The top connecting hardware 1 has an arc-shaped mounting groove at its top, the curvature of which matches the outer diameter of the transmission line. The bottom connecting hardware 5 has a square mounting base at its bottom, with a through circular mounting hole of 14 mm in diameter on its side wall. Both the top connecting hardware 1 and the bottom connecting hardware 5 have an anti-corrosion layer on their outer surfaces. The anti-corrosion layer is composed of a hot-dip galvanized layer and an epoxy sealing layer, with the hot-dip galvanized layer being 100 micrometers thick and the epoxy sealing layer being 30 micrometers thick.

[0070] The core rod 2 is externally covered by a skirt assembly, which consists of several large skirts 3 and several small skirts 4. The large skirts 3 and small skirts 4 are arranged alternately along the axial direction of the core rod 2. The umbrella extension length of the large skirt 3 is 2.0 times the umbrella extension length of the small skirt 4, and the umbrella spacing between adjacent large skirts 3 is 1.0 times the umbrella extension length of the large skirt 3. Both the large skirts 3 and small skirts 4 are made of a high-molecular insulating material resistant to high-altitude aging. This material is prepared by adding 3.5 parts by weight of nano zinc oxide UV stabilizer with a particle size of 10 nanometers, 5.5 parts by weight of methylphenylsiloxane weathering agent, and 1.5 parts by weight of bis(2,5-diphenyl)sulfurizing agent to the methyl vinyl silicone rubber matrix. This high-molecular insulating material is vulcanized at 170℃ for 15 minutes.

[0071] Both the large umbrella skirt 3 and the small umbrella skirt 4 have a slightly raised hydrophobic texture on their canopy. The hydrophobic texture is arranged in a dot matrix pattern, with a texture height of 0.2 mm and a texture spacing of 0.75 mm. Each umbrella skirt has an inclined guide groove 7, which is arranged radially along the umbrella surface, with an inclination angle of 22 degrees, a width of 3 mm, and a depth of 2 mm. The ends of the inclined guide grooves 7 extend to the outer edge of the umbrella skirt. The outer edges of both the large umbrella skirt 3 and the small umbrella skirt 4 have a rounded, thickened edge. The thickness of the rounded, thickened edge is 1.35 times the thickness of the main umbrella skirt body. The surface of the rounded, thickened edge has serrated grooves for anti-slip icicles, with a depth of 1.5 mm and a spacing of 4.0 mm between adjacent grooves.

[0072] The interface between the skirt assembly and the core rod 2 is enhanced by an interface reinforcement treatment: an aminosilane coupling agent is impregnated onto the surface of the core rod 2 to a thickness of 2.0 micrometers, and then dried at 90°C for 12 minutes. The dried core rod 2 and the skirt assembly are then molded together at a molding temperature of 160°C, a molding pressure of 12.5 MPa, and a holding time of 20 minutes. In this embodiment, the total creepage distance of the skirt assembly is 38 mm per kilovolt rated voltage, and the hydrophobic migration level reaches HC1.

[0073] II. Working Principle The mandrel 2 increases the glass fiber volume content and reduces the pultrusion speed, further enhancing axial stress performance and overall structural strength. It can withstand greater mechanical loads on transmission lines in high-altitude and moderately extreme scenarios, providing stronger mechanical support for insulators. The increased compression ratio between the top connecting hardware 1, the bottom connecting hardware 5, and the mandrel 2, along with optimized adhesive curing temperature and time, further improves the strength and sealing of the composite connection. This allows it to withstand additional mechanical stress from moderate wind vibration and icing, preventing loosening and detachment of the connection.

[0074] The fluororubber sealing ring of sealing structure 6 has increased compression and reduced fitting gap, resulting in a higher degree of fit with the fittings and core rod 2, and a stronger sealing effect. This effectively blocks the intrusion of large amounts of moisture and meltwater in high-altitude and moderately extreme environments, fundamentally preventing hydrolysis and debonding at the interface between the core rod 2 and the umbrella skirt assembly. The increased thickness of the anti-corrosion layer on the top connecting fitting 1 and the bottom connecting fitting 5 enhances the corrosion resistance of the fittings, enabling them to withstand the high humidity and strong corrosive environment in high-altitude and moderately extreme environments.

[0075] The arrangement ratio of the large umbrella skirt 3 and the small umbrella skirt 4 is taken as the middle value, the creepage distance is further extended, and the optimization of the umbrella spacing makes the dirt fall off more smoothly, while reducing the area of ​​ice on the umbrella surface; the height and spacing of the hydrophobic texture on the umbrella surface are optimized to improve the water-repellent performance of the umbrella surface, and the size and angle of the inclined guide groove 7 are optimized to accelerate the drainage efficiency of rainwater and melt ice water, and reduce the probability of water accumulation, ice accumulation and dirt buildup on the umbrella surface; the thickness of the arc thickened edge is increased, and the depth and spacing of the serrated groove are optimized to further enhance the damage resistance of the umbrella skirt edge, more effectively break the formation and adhesion of icicles, and adapt to high-altitude moderate icing and dirt environments.

[0076] The optimized addition ratio of polymer insulating materials to the insulator skirt and the increased vulcanization temperature further enhance the skirt's resistance to UV aging and high / low temperature cycling, enabling it to withstand strong UV radiation and greater diurnal temperature variations in high-altitude, moderately extreme environments. The interface enhancement treatment between the core rod 2 and the skirt assembly optimizes the coupling agent coating thickness and molding parameters, significantly improving their bonding strength. This allows it to adapt to greater interfacial stress in high-altitude, moderately extreme environments, preventing interface separation and cracking, and ensuring the continuous stability of the insulator's insulation performance. The optimized parameters and coordinated operation of each component allow the insulator to adapt to the environmental requirements of high-altitude, moderately extreme environments.

[0077] III. Experimental Data The insulator of this embodiment was placed in a simulated high-altitude, moderately extreme environment for performance testing. The test results are as follows: 1. Mechanical properties: The axial tensile strength of the mandrel 2 is 1380 MPa, and the bending strength is 1950 MPa; the interfacial shear strength between the mandrel 2 and the umbrella skirt assembly is 9.2 MPa; there is no loosening or detachment at the connection points between the top connecting hardware 1, the bottom connecting hardware 5 and the mandrel 2, and it can withstand medium-strength mechanical load impact.

[0078] 2. Insulation performance: The static contact angle of the umbrella surface is 115 degrees; the flashover voltage under pollution and icing conditions meets the requirements for use in medium extreme scenarios at high altitudes; there is no insulation breakdown in the umbrella skirt assembly, and the hydrophobic migration level remains at HC1.

[0079] 3. Weather resistance: The tensile strength retention rate of the umbrella skirt material after ultraviolet aging is 94%, and the elongation at break retention rate after high and low temperature cycling is 89%; the umbrella skirt is free from cracking, discoloration, and powdering, and there is no separation or debonding at the interface between the core rod 2 and the umbrella skirt assembly.

[0080] 4. Corrosion resistance: After 1200 hours of salt spray testing, the anti-corrosion layers of the top connecting hardware 1 and the bottom connecting hardware 5 showed no rust or bulging on the surface, and the anti-corrosion layers did not peel off or flake.

[0081] 5. Anti-icing performance: After simulating a moderate icing environment, the edges of the umbrella skirt are undamaged, the ice ridges fall off easily, and there is no residual water on the umbrella surface after the ice melts, and the insulation performance is quickly restored.

[0082] IV. Technical Effects By increasing the glass fiber volume content and optimizing the pultrusion molding process parameters, the core rod 2 significantly enhances the axial force performance and overall structural strength, enabling it to stably withstand greater mechanical loads on transmission lines in extreme scenarios such as high altitudes, preventing core rod 2 from breaking or deforming, and further improving the stability of the overall mechanical structure of the insulator.

[0083] The optimized composite connection parameters of the top connecting hardware 1, bottom connecting hardware 5, and core rod 2 simultaneously improve the connection strength and sealing performance between the hardware and core rod 2. This allows them to withstand the additional mechanical stress caused by moderate wind vibration and icing, effectively preventing loosening and detachment of the connection points and ensuring the reliability and durability of the insulator's mechanical connection. The optimized parameters of the sealing structure 6 significantly enhance the sealing effect, effectively blocking the intrusion of large amounts of moisture and meltwater. This fundamentally prevents hydrolytic detachment and adhesion at the interface between core rod 2 and the shed assembly, improving the sealing reliability of the insulator's internal structure and extending the overall service life of the insulator.

[0084] The optimized arrangement ratio and spacing of the large umbrella skirt 3 and the small umbrella skirt 4 further extend the effective creepage distance of the insulator, while reducing the area of ​​dirt adhesion and icing on the umbrella surface, thus reducing the probability of flashover caused by dirt and icing. The optimized parameters of the hydrophobic texture of the umbrella surface and the inclined flow guide groove 7 improve the hydrophobic drainage capacity of the umbrella surface, reducing water and dirt accumulation. The optimized parameters of the thickened arc edge and the serrated groove enhance the resistance to damage and icing of the umbrella skirt edges, making the insulation performance of the insulator more stable under moderate extreme scenarios.

[0085] The optimized addition ratio of polymer insulating materials to the insulator skirts and the improved vulcanization process parameters significantly enhance the skirts' resistance to ultraviolet aging and their mechanical properties under high and low temperature cycling. This effectively resists the erosion caused by strong ultraviolet radiation and greater diurnal temperature variations in high-altitude and moderately extreme environments, preventing the skirts from cracking and degrading, and ensuring that the skirts maintain good insulation and structural performance over a long period. The optimized interface reinforcement parameters between the core rod 2 and the skirt assembly significantly improve the bonding force between the two, enabling them to adapt to greater interface stress in moderately extreme environments. This effectively prevents interface separation and cracking, ensuring the continuous stability of the insulator's insulation performance.

[0086] The increased thickness of the composite anti-corrosion layer on the top connecting fitting 1 and the bottom connecting fitting 5 enhances the corrosion resistance of the fittings, effectively resisting the erosion of high humidity and strong corrosive environments in high-altitude and moderately extreme scenarios, preventing rust and failure, and further extending the service life of the fittings. The optimized parameters and synergistic effect of each component give the insulator excellent mechanical, insulation, weather resistance, and corrosion resistance properties in high-altitude and moderately extreme scenarios, meeting the safe operation requirements of high-voltage transmission lines in such environments.

[0087] Example 3: Adaptation to High-Altitude and Extreme Scenarios I. Technical Solution The high-strength composite insulator of this embodiment includes a core rod 2, which is made of alkali-free E glass fiber reinforced bisphenol A type epoxy resin composite material. The glass fibers are arranged unidirectionally along the axial direction of the core rod 2, and the fiber volume content is 70%. The epoxy resin is cured with an acid anhydride curing agent. The core rod 2 is prepared by pultrusion molding process with a pultrusion speed of 0.5 meters per minute and a curing temperature of 150°C. The diameter of the core rod 2 is 40 mm.

[0088] The top end of mandrel 2 is fixedly connected to top connecting hardware 1, and the bottom end of mandrel 2 is fixedly connected to bottom connecting hardware 5. Both the top connecting hardware 1 and mandrel 2, and the bottom connecting hardware 5 and mandrel 2, are fixedly connected using a combination of compression and adhesive bonding. The compression ratio of the compression section is 1.5, and the adhesive section is filled with epoxy adhesive. The adhesive curing temperature is 100℃, and the curing time is 60 minutes. A sealing structure 6 is provided at the connection ends of the top connecting hardware 1 and mandrel 2, and at the connection ends of the bottom connecting hardware 5 and mandrel 2. The sealing structure 6 is an annular fluororubber sealing ring with a Shore hardness of 70 degrees, a compression ratio of 30%, and a contact gap of 0.03 mm between the sealing ring and the hardware / mandrel 2.

[0089] The top connecting hardware 1 has an arc-shaped mounting groove at its top, the curvature of which matches the outer diameter of the transmission line. The bottom connecting hardware 5 has a square mounting base at its bottom, with a through circular mounting hole on its side wall. The mounting hole has a diameter of 16 mm. Both the top connecting hardware 1 and the bottom connecting hardware 5 have an anti-corrosion layer on their outer surfaces. The anti-corrosion layer is composed of a hot-dip galvanized layer and an epoxy sealing layer. The thickness of the hot-dip galvanized layer is 120 micrometers, and the thickness of the epoxy sealing layer is 40 micrometers.

[0090] The core rod 2 is externally covered with a skirt assembly, which consists of several large skirts 3 and several small skirts 4. The large skirts 3 and small skirts 4 are arranged alternately along the axial direction of the core rod 2. The umbrella extension length of the large skirt 3 is 2.5 times the umbrella extension length of the small skirt 4, and the umbrella spacing between adjacent large skirts 3 is 1.2 times the umbrella extension length of the large skirt 3. Both the large skirts 3 and small skirts 4 are made of a high-molecular insulating material resistant to high-altitude aging. This material is prepared by adding 5 parts by mass of nano zinc oxide UV stabilizer with a particle size of 5 nanometers, 8 parts by mass of methylphenylsiloxane weathering agent, and 2 parts by mass of bis(2,5-dimethyl)sulfide agent as the base material. This high-molecular insulating material is vulcanized at 180°C for 20 minutes.

[0091] Both the large umbrella skirt 3 and the small umbrella skirt 4 have a slightly raised hydrophobic texture on their canopy surface. The hydrophobic texture is arranged in a dot matrix pattern, with a texture height of 0.3 mm and a texture spacing of 0.5 mm. Each umbrella surface has an inclined guide groove 7, which is arranged radially along the umbrella surface at an angle of 30 degrees, a width of 4 mm, and a depth of 3 mm. The ends of the inclined guide grooves 7 extend to the outer edge of the umbrella skirt. The outer edges of both the large umbrella skirt 3 and the small umbrella skirt 4 have a rounded, thickened edge. The thickness of the rounded, thickened edge is 1.5 times the thickness of the main body of the umbrella skirt. The surface of the rounded, thickened edge has serrated grooves for anti-slip icicles, with a depth of 2.0 mm and a spacing of 3.0 mm between adjacent grooves.

[0092] The interface between the skirt assembly and the core rod 2 is enhanced by an interface reinforcement treatment: an aminosilane coupling agent is impregnated onto the surface of the core rod 2 to a thickness of 3.0 micrometers, and then dried at 100°C for 15 minutes. The dried core rod 2 and the skirt assembly are then molded together at a molding temperature of 170°C, a molding pressure of 15 MPa, and a holding time of 25 minutes. In this embodiment, the total creepage distance of the skirt assembly is 40 mm per kilovolt rated voltage, and the hydrophobic migration level reaches HC1.

[0093] II. Working Principle Core rod 2 utilizes the highest fiber volume content, the slowest pultrusion speed, and the highest curing temperature, with its diameter maximized to optimize its axial tensile and flexural strength. This allows it to withstand the extreme mechanical loads of transmission lines in high-altitude, extreme environments, providing the strongest mechanical support for the insulator. It is a core mechanical component for the insulator to resist strong winds and thick icing. The top connecting hardware 1 and the bottom connecting hardware 5 are connected to core rod 2 with the maximum compression ratio, and the adhesive curing temperature and time are maximized to optimize the strength of the composite connection. This allows it to withstand the enormous mechanical stress brought by strong winds and thick icing, ensuring that the connection between the hardware and core rod 2 remains secure and does not loosen or detach.

[0094] The sealing structure 6 utilizes the maximum Shore hardness, maximum compression, and minimum fit gap to achieve a seamless fit with the fittings and mandrel 2, resulting in optimal sealing performance. This effectively prevents the intrusion of large amounts of moisture, meltwater, and corrosive media in high-altitude, extreme environments, completely avoiding hydrolytic debonding at the interface between the mandrel 2 and the umbrella skirt assembly. The anti-corrosion layers of the top connecting fitting 1 and the bottom connecting fitting 5 are of maximum thickness, achieving optimal corrosion resistance and withstanding the multiple erosions of high humidity, strong corrosion, and strong ultraviolet radiation in high-altitude, extreme environments.

[0095] The large umbrella skirt 3 and the small umbrella skirt 4 adopt the maximum extension length ratio and the maximum umbrella spacing, and the creepage distance is extended to the maximum, which greatly improves the insulation safety margin and is suitable for the insulation requirements under high altitude and low air pressure. The hydrophobic texture of the umbrella surface is set with the maximum height and the minimum spacing to achieve optimal water repellency. The inclined guide groove 7 is set with the maximum size and the maximum inclination angle to achieve the highest water drainage efficiency, which can quickly drain rainwater and melt ice water, and greatly reduce the probability of water accumulation, icing and dirt accumulation on the umbrella surface. The rounded thickened edge is set with the maximum thickness, and the serrated groove is set with the maximum depth and the minimum spacing to achieve optimal damage resistance of the umbrella skirt edge, which can effectively break the formation and adhesion of thick ice ridges and is suitable for high altitude, strong icing and highly polluted environments.

[0096] The polymer insulation material of the insulator skirt is enriched with the maximum dosage of UV-resistant and weather-resistant additives, and employs the highest vulcanization temperature and longest vulcanization time to optimize the skirt's resistance to UV aging, high and low temperature cycling, and corrosion resistance. This allows it to withstand the erosion caused by extremely strong UV radiation and extreme day-night temperature differences in high-altitude, extreme environments. The interface reinforcement treatment between the core rod 2 and the skirt assembly utilizes the maximum coupling agent coating thickness, the highest molding temperature and pressure, and the longest holding time to optimize the bonding strength between the two. This allows it to adapt to the extremely high interface stress in high-altitude, extreme environments, completely preventing interface separation and cracking, and ensuring the ultimate stability of the insulator's insulation performance. The parameters of each component are set to extreme values ​​and work in synergy, enabling the insulator to adapt to the harsh environmental requirements of high-altitude, extreme environments.

[0097] III. Experimental Data The insulator of this embodiment was placed in a simulated high-altitude, extreme environment for performance testing. The test results are as follows: 1. Mechanical properties: The axial tensile strength of the mandrel 2 is 1500 MPa, and the bending strength is 2000 MPa; the interfacial shear strength between the mandrel 2 and the umbrella skirt assembly is 10 MPa; there is no loosening or detachment at the connection points between the top connecting hardware 1, the bottom connecting hardware 5 and the mandrel 2, and it can withstand extreme mechanical load impacts.

[0098] 2. Insulation performance: The static contact angle of the umbrella surface is 120 degrees; the flashover voltage under heavy pollution and thick icing conditions meets the requirements for use in high-altitude and extreme scenarios; there is no insulation breakdown in the umbrella skirt assembly, and the hydrophobic migration level remains at HC1.

[0099] 3. Weather resistance: The tensile strength retention rate of the umbrella skirt material after ultraviolet aging is 96%, and the elongation at break retention rate after high and low temperature cycling is 90%; the umbrella skirt is free from cracking, discoloration, and powdering, and there are no signs of separation or debonding at the interface between the core rod 2 and the umbrella skirt assembly.

[0100] 4. Corrosion resistance: After 1500 hours of salt spray testing, the anti-corrosion layers of the top connecting hardware 1 and the bottom connecting hardware 5 showed no rust or corrosion spots on the surface, and the anti-corrosion layers did not peel off, flake, or bulge.

[0101] 5. Anti-icing and strong wind performance: After simulating thick icing and strong wind environments, the umbrella skirts are not deformed or damaged, the ice ridges are easy to fall off, the insulators are not loose or displaced, and the insulation performance quickly returns to the initial state after the ice melts.

[0102] IV. Technical Effects By optimizing the material ratio and molding process parameters, the core rod 2 achieves optimal axial force performance and overall structural strength, enabling it to stably withstand the extreme mechanical loads of transmission lines in high-altitude and extreme environments. This completely prevents the core rod 2 from breaking or deforming, maximizing the stability of the overall mechanical structure of the insulator and providing a solid mechanical foundation for the use of insulators in extreme environments.

[0103] The composite connection parameters of the top connecting hardware 1, the bottom connecting hardware 5, and the core rod 2 are set to extreme values, optimizing the connection strength and sealing performance between the hardware and the core rod 2. This effectively resists the enormous mechanical stress caused by strong winds and thick ice cover, completely preventing loosening and detachment of the connection points, and ensuring the ultimate reliability and durability of the insulator's mechanical connection. The parameters of the sealing structure 6 are also set to extreme values, achieving a seamless fit with the hardware and core rod 2, achieving optimal sealing performance. This completely blocks the intrusion of external moisture, melted ice water, and corrosive media, fundamentally preventing hydrolytic detachment and bonding at the interface between the core rod 2 and the shed assembly. This significantly improves the sealing reliability of the insulator's internal structure and substantially extends the overall service life of the insulator.

[0104] The arrangement parameters of the large umbrella skirt 3 and the small umbrella skirt 4 are set to extreme values, which maximizes the effective creepage distance of the insulator and significantly improves the insulation safety margin, adapting to the insulation requirements under high altitude and low air pressure. At the same time, it reduces the adhesion of dirt and the area of ​​ice on the umbrella surface, greatly reducing the probability of flashover caused by dirt and ice. The parameters of the hydrophobic texture of the umbrella surface and the inclined drainage groove 7 are set to extreme values, so that the hydrophobic drainage capacity of the umbrella surface is optimized, which can quickly drain rainwater and melt ice water, greatly reducing the probability of water accumulation, ice accumulation and dirt accumulation on the umbrella surface. The parameters of the thickened arc edge and the serrated groove are set to extreme values, so that the damage resistance and ice resistance of the umbrella skirt edge are optimized, which can effectively resist the impact of strong wind and thick ice, destroy the formation and adhesion of thick ice ridges, and ensure the stable insulation performance of the insulator in the environment of strong ice and strong pollution.

[0105] The polymer insulation material of the insulator skirt is optimized through a highly refined formula and vulcanization process, resulting in superior resistance to UV aging, high and low temperature cycling mechanical properties, and corrosion resistance. This effectively withstands the erosion caused by intense UV radiation, extreme day-night temperature differences, and highly corrosive environments in high-altitude, extreme conditions, preventing cracking, embrittlement, and performance degradation. This ensures the skirt maintains excellent insulation and structural performance over a long period, significantly extending its service life. The interface enhancement parameters between the core rod 2 and the skirt assembly are set to extreme values, optimizing their bonding force. This allows the insulator to fully adapt to the high interface stress in high-altitude, extreme conditions, effectively preventing interface separation and cracking, and ensuring the continuous stability of the insulator's insulation performance.

[0106] The composite anti-corrosion layer of the top connecting hardware 1 and the bottom connecting hardware 5 is made to its maximum thickness, maximizing the corrosion resistance of the hardware. This effectively resists the multiple erosions of high humidity, strong ultraviolet radiation, and strong corrosion under extreme conditions at high altitudes, preventing rust and failure and maximizing the service life of the hardware. The extreme parameter design and synergistic effect of each component give the insulator exceptional mechanical, insulation, weather resistance, and corrosion resistance properties under extreme conditions at high altitudes, meeting the safe and stable operation requirements of high-voltage transmission lines in such environments.

[0107] Overall working principle: The various components of this insulator work together to achieve comprehensive functions including mechanical support, insulation protection, and environmental adaptability. The core rod 2, as the main load-bearing component of the insulator, is made of high-strength fiber-reinforced resin-based composite material and processed using a specific molding process, enabling it to stably withstand various mechanical loads such as tension and bending transmitted by the transmission line. The top connecting hardware 1 and the bottom connecting hardware 5 respectively serve to connect the insulator to the transmission conductor and transmission tower. Both are fixed to the core rod 2 using a combination of crimping and adhesive bonding, ensuring a stable connection that is not easily loosened by strong winds, conductor vibrations, or other operating conditions.

[0108] The umbrella skirt assembly covering the core rod 2 consists of large umbrella skirt 3 and small umbrella skirt 4 arranged alternately along the axis of the core rod 2, which can expand the insulation creepage path in a limited space and improve the overall insulation performance of the insulator. Both the large umbrella skirt 3 and the small umbrella skirt 4 are made of high-molecular insulation material that is resistant to high-altitude aging and can resist the corrosion of high-altitude strong ultraviolet and large temperature difference environments. The hydrophobic texture on the umbrella surface can reduce the adhesion of rainwater, water vapor and dirt. The inclined guide groove 7 can accelerate the drainage of water. The rounded thickened edge of the outer edge of the umbrella skirt can enhance the structural strength. The serrated groove can break the formation of icicles. The structural design between adjacent umbrella skirts can also alleviate the wind vibration caused by strong winds.

[0109] The connection ends of the core rod 2 with the top connecting hardware 1 and the bottom connecting hardware 5 are all equipped with sealing structures 6, which can effectively prevent external moisture, melt ice water, and corrosive media from penetrating the interface between the core rod 2 and the skirt assembly. The interface between the skirt assembly and the core rod 2 has undergone special interface reinforcement treatment, which can improve the bonding force between the two and avoid separation and debonding caused by interface stress due to large temperature differences between day and night. The outer surfaces of the top connecting hardware 1 and the bottom connecting hardware 5 are equipped with anti-corrosion layers, which can resist the corrosion of the hardware by high altitude, high humidity, strong ultraviolet rays, and corrosive media. The functions of each component work together to enable the insulator to adapt to different extreme scenarios at high altitudes, maintain stable performance over a long period of time, and ensure the safe operation of transmission lines.

[0110] How to use: The use of this composite insulator is mainly divided into three stages: installation, daily use, and regular maintenance. The overall operation is convenient, requiring no complex professional equipment, and is suitable for construction and operation conditions in high-altitude areas.

[0111] 1. Installation Procedure: First, inspect the integrity of all insulator components, confirming that all parts, including the core rod 2, top connecting hardware 1, bottom connecting hardware 5, sealing structure 6, and the large and small umbrella skirts 3 and 4 of the umbrella skirt assembly, are free from defects such as damage, detachment, rust, and cracks. Then, using the arc-shaped mounting groove at the top of the top connecting hardware 1, connect the insulator to the transmission line, ensuring a snug fit and a secure connection without any looseness. Next, using the square mounting base at the bottom of the bottom connecting hardware 5 and the circular mounting hole penetrating the side wall, use bolts to fix the insulator to the high-altitude transmission tower, tightening the bolts to ensure stable installation and meet the connection requirements in extreme environments such as strong winds and icing.

[0112] 2. Daily use: During normal operation, the insulator does not require complicated manual maintenance. Relying on its own hydrophobic texture, anti-corrosion layer of the fittings, weather-resistant material of the skirt, and other structural and material designs, it can independently resist the effects of dirt accumulation, environmental corrosion, ultraviolet radiation, etc., and maintain stable mechanical and insulation performance for a long time, which is suitable for the inconvenience of operation and maintenance in high-altitude areas.

[0113] 3. Regular maintenance: Insulators should be inspected regularly in accordance with the operation and maintenance specifications for high-voltage transmission lines. The focus should be on checking the connection and integrity of each component. It should be confirmed that the connection between the top connecting hardware 1, the bottom connecting hardware 5 and the core rod 2 is not loose, the sealing structure 6 is not damaged or detached, the large umbrella skirt 3 and the small umbrella skirt 4 are not cracked, aged or damaged at the edges, the umbrella surface tilting guide groove 7 is not blocked, and the anti-corrosion layer of the hardware is not peeled or bulged. If any of the above defects are found, the relevant components should be replaced in time to ensure the continuous and stable operation of the insulator.

[0114] This insulator can be adapted to different environmental characteristics in high-altitude areas by selecting the corresponding parameter design model. After installation, no additional adjustments are required, and it can adapt to the usage needs of different extreme scenarios above 3,000 meters in altitude. It matches the operating conditions of high-voltage transmission lines throughout the process and does not require complicated on-site debugging by professional personnel.

[0115] The high-strength composite insulator suitable for high-altitude areas in this invention has its high-altitude environmental adaptability quantified by the following comprehensive performance retention index Ω: in: Ω is the comprehensive performance retention index, which is dimensionless. The larger the value, the stronger the insulator's ability to retain performance under the environment. U represents the annual average ultraviolet radiation intensity (unit: W / m²). 2 ); For reference ultraviolet radiation intensity, the value is taken as 100 W / m. 2 ; ΔT represents the annual temperature variation (unit: °C). For reference temperature range, the value is taken as 50℃; H represents the annual average relative humidity (unit: %). This is the upper limit threshold for humidity, with a value of 90%. t represents the expected service life (in years); This is a time normalization constant, with a value of 1 year. α, β, and γ are the UV resistance coefficient, thermal stability coefficient, and moisture resistance coefficient of the material, respectively. Based on the actual material system of the insulator, the values ​​are determined through experiments and are in the range of α∈[0.8,1.2], β∈[0.7,1.1], and γ∈[0.6,1.0].

[0116] The derivation of the equation is as follows: This equation is based on a multi-factor coupled aging model, considering the synergistic effects of three major stress factors (ultraviolet radiation, temperature cycling, and humidity) on the performance of composite insulators in high-altitude environments: 1. Ultraviolet (UV) Term: Describes the nonlinear effect of UV intensity on material aging using a logarithmic form, with reference intensity... Used for normalization; 2. Temperature term: The effect of temperature change on material thermal fatigue is described using an exponential decay method. It is a typical temperature span; 3. Humidity term: The effect of humidity on interfacial hydrolysis and electrical properties is described using a linear decay form; 4. Time term: The denominator uses a logarithmic time term to reflect the trend of performance gradually declining over time, which is consistent with the characteristics of a typical aging curve.

[0117] Example: Suppose the environmental parameters of a high-altitude region are as follows: U=180 W / m 2 ; =70℃; H=75%; Insulator material calibration factors: α=1.0, β=0.9, γ=0.8 Expected service life t = 20 years Substitute into the formula to calculate: If the calculated Ω value for another environment is 0.15, it indicates that the insulator's performance retention capability is stronger in the former environment.

[0118] Parameter description.

[0119] Technical effect 1. Quantitative assessment: The stress factor of the complex high-altitude environment is quantitatively coupled to achieve the prediction and assessment of the long-term performance of insulators; 2. Selection guidance: It can provide a theoretical basis for selecting insulators with appropriate parameters for different high-altitude areas; 3. Material optimization: By calibrating the α, β, and γ coefficients, feedback is provided to guide the optimization of material systems and processes; 4. Lifetime Management: Combining Ω values ​​with actual operating data, it supports the condition assessment and replacement decision-making of insulators.

[0120] Working principle and process 1. Environmental data acquisition: Obtain meteorological data (U, ΔT, H) for the target high-altitude area; 2. Material coefficient calibration: The α, β, and γ values ​​of specific insulator products are calibrated through accelerated aging tests in the laboratory. 3. Calculation of the exponent: Substitute into the formula to calculate Ω; 4. Performance rating: Performance retention is classified according to the Ω value (e.g., Ω>0.25 is excellent, 0.15–0.25 is good, <0.15 is average). 5. Engineering applications: Guiding insulator selection, expected life assessment, and inspection cycle formulation.

[0121] The above are merely preferred embodiments of the present invention and are not intended to limit the implementation methods and protection scope of the present invention. Those skilled in the art should recognize that any equivalent substitutions and obvious changes made based on the description and illustrations of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-strength composite insulator suitable for high-altitude areas, characterized in that, The device includes a core rod (2), with a top connecting fitting (1) fixedly connected to the top end of the core rod (2) and a bottom connecting fitting (5) fixedly connected to the bottom end of the core rod (2). The core rod (2) is covered with a skirt assembly, which consists of several large skirts (3) and several small skirts (4). The large skirts (3) and small skirts (4) are arranged alternately along the axis of the core rod (2). Both the large skirts (3) and small skirts (4) are made of high-molecular insulating material resistant to high-altitude aging. The core rod (2) is made of high-strength fiber-reinforced resin-based composite material. The connection end between the top connecting fitting (1) and the core rod (2) and the connection end between the bottom connecting fitting (5) and the core rod (2) are provided with a sealing structure (6). The interface between the skirt assembly and the core rod (2) is treated with interface reinforcement.

2. The high-strength composite insulator suitable for high-altitude areas according to claim 1, characterized in that, The umbrella extension length of the large umbrella skirt (3) is 1.5 to 2.5 times that of the small umbrella skirt (4), and the distance between adjacent large umbrella skirts (3) is 0.8 to 1.2 times that of the umbrella extension length of the large umbrella skirt (3).

3. The high-strength composite insulator suitable for high-altitude areas according to claim 1, characterized in that, The polymer insulating material is prepared by adding nano zinc oxide UV stabilizer, methyl phenyl siloxane weather resistant agent, and bis(2,5-dimethyl) sulfide agent as the matrix. The nano zinc oxide has a particle size of 5 to 20 nanometers and is added in 2 to 5 parts by weight. The methyl phenyl siloxane weather resistant agent is added in 3 to 8 parts by weight, and the bis(2,5-dimethyl) sulfide agent is added in 1 to 2 parts by weight. The polymer insulating material is vulcanized at a high temperature of 160 to 180°C for 10 to 20 minutes. After molding, the tensile strength retention rate of the umbrella skirt material after UV aging is not less than 90%, and the elongation at break retention rate after high and low temperature cycling is not less than 85%.

4. The high-strength composite insulator suitable for high-altitude areas according to claim 1, characterized in that, The fiber-reinforced resin-based composite material is an alkali-free E glass fiber reinforced bisphenol A type epoxy resin composite material. The glass fibers are arranged unidirectionally along the axial direction of the mandrel (2), and the fiber volume content is 60% to 70%. The epoxy resin is cured with an anhydride curing agent. The mandrel (2) is prepared by pultrusion molding process. The pultrusion speed is 0.5 to 2 meters per minute, and the curing temperature is 120 to 150°C. When the diameter of the mandrel (2) is 20 to 40 mm, the axial tensile strength is 1200 to 1500 MPa, and the flexural strength is not less than 1800 MPa.

5. The high-strength composite insulator suitable for high-altitude areas according to claim 1, characterized in that, The top connecting fitting (1) and the mandrel (2), and the bottom connecting fitting (5) and the mandrel (2) are both fixedly connected by a combination of pressing and gluing. The pressing ratio of the pressing section is 1.2 to 1.5, and the gluing section is filled with epoxy adhesive. The gluing curing temperature is 80 to 100℃, and the curing time is 30 to 60 minutes.

6. The high-strength composite insulator suitable for high-altitude areas according to claim 1, characterized in that, The sealing structure (6) is an annular fluororubber sealing ring set at the connection end between the fitting and the mandrel (2). The sealing ring has a Shore hardness of 60 to 70 degrees, a compression of 20% to 30%, and the gap between the sealing ring and the fitting and the mandrel (2) is no more than 0.1 mm.

7. The high-strength composite insulator suitable for high-altitude areas according to claim 1, characterized in that, The interface enhancement treatment specifically involves: dipping an aminosilane coupling agent into the surface of the mandrel (2) with a coating thickness of 1 to 3 micrometers, and drying it at 80 to 100°C for 10 to 15 minutes; the dried mandrel (2) and the umbrella skirt assembly are then molded together by compression molding at a temperature of 150 to 170°C, a compression pressure of 10 to 15 MPa, and a holding time of 15 to 25 minutes; the interface shear strength between the mandrel (2) and the umbrella skirt after the interface enhancement treatment is not less than 8 MPa.

8. The high-strength composite insulator suitable for high-altitude areas according to claim 1, characterized in that, The top of the top connecting hardware (1) is provided with an arc-shaped hanging groove. The arc of the arc-shaped hanging groove is adapted to the outer diameter of the power transmission line. The bottom of the bottom connecting hardware (5) is provided with a square mounting base. The side wall of the mounting base is provided with a through circular mounting hole with a diameter of 12 to 16 mm.

9. The high-strength composite insulator suitable for high-altitude areas according to claim 1, characterized in that, Both the large umbrella skirt (3) and the small umbrella skirt (4) have slightly raised hydrophobic textures on their surfaces. The hydrophobic textures are arranged in a dot matrix pattern, with a texture height of 0.1 to 0.3 mm and a texture spacing of 0.5 to 1 mm. The static contact angle of the umbrella surface is not less than 110 degrees.

10. The high-strength composite insulator suitable for high-altitude areas according to any one of claims 1-9, characterized in that, The diameter of the core rod (2) is 20 to 40 mm, the total creepage distance of the umbrella skirt assembly is not less than 35 mm per kilovolt of rated voltage, and the hydrophobic migration level of the umbrella skirt assembly reaches HC1 level.

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