Composite insulator

Abstract

The invention discloses a composite insulator which comprises an insulating tube, umbrella skirts located on the periphery of the insulating tube and two flanges arranged at the two ends of the insulating tube respectively, the insulating tube is a hollow circular tube, supporting pieces are arranged in the two ends of the insulating tube, and each supporting piece is of a solid cylinder structure. The supporting piece and the insulating tube are coaxially arranged, the supporting piece extends inwards from the end of the insulating tube, the outer diameter of the supporting piece is matched with the inner diameter of the insulating tube, the flange is connected to the outer side of the end of the insulating tube in a pressing mode, and the insulating tube, the supporting piece and the flange are tightly connected. According to the composite insulator, compression joint of the hollow insulation tube and the flange is achieved through the supporting piece, the connection strength and the sealing performance between the hollow insulation tube and the flange are guaranteed, the composite insulator is effectively prevented from losing efficacy at the joint of the flange and the insulation tube, the structural strength of the composite insulator can be brought into full play, and compared with a traditional glue joint technology, the composite insulator is more stable. A long-time glue solution curing procedure is omitted, and the production efficiency is improved.

Description

Technical Field

[0001] The present application relates to the field of power transmission and transformation insulation equipment, and in particular to a composite insulator. Background Art

[0002] Currently, most hollow composite insulator structures fail at the connection between the flange and the insulating tube. The connection between the two is one of the most difficult aspects of insulator processing. Insulating tubes are generally made of composite materials, and the most common methods for connecting composite materials are gluing and crimping. Gluing technology involves using high-strength glue, such as epoxy resin, to form a glue interface between the inner surface of the flange and the outer surface of the insulating tube to complete assembly. While this method can simultaneously meet the requirements for connection strength and sealing, the glue takes a long time to cure, making it inconvenient for on-site operations. Furthermore, most glue-fitted structures cannot fully utilize the optimal performance of the insulating tube or flange. This means that the composite insulator may experience structural failure under conditions where the mechanical strength, such as bending, tensile, or compressive strength, is lower than the insulating tube's own. Existing crimping technology is only suitable for solid composite rods, which exert a large force. Directly applying it to the insulating tube can cause the tube to rupture, affecting the product's strength and sealing requirements. Summary of the Invention

[0003] In view of the shortcomings of the existing technology, the main purpose of this application is to provide a composite insulator that uses a support to achieve crimping of the hollow insulating tube and the flange, while ensuring the stable connection and sealing requirements between the two, and also enabling rapid assembly of the composite insulator, thereby improving production efficiency.

[0004] In order to solve the above technical problems, the technical solution adopted in this application is as follows: a composite insulator, comprising an insulating tube, an umbrella skirt located on the outer periphery of the insulating tube, and two flanges respectively arranged at both ends of the insulating tube, wherein the insulating tube is a hollow circular tube, and a support member is provided inside both ends of the insulating tube, and the support member is a solid cylindrical structure. The support member is coaxially arranged with the insulating tube and extends inward from the end of the insulating tube, and the outer diameter of the support member matches the inner diameter of the insulating tube. The flange is crimped onto the outer side of the end of the insulating tube, so that the insulating tube, the support member, and the flange are tightly connected. The use of the support member to crimp the hollow insulating tube and the flange ensures the connection strength and sealing between the two, effectively avoids failure of the composite insulator at the connection between the flange and the insulating tube, can give full play to the structural strength of the composite insulator, and compared with traditional gluing technology, it saves the long glue curing process and improves production efficiency.

[0005] The flange includes a flange cylinder and a flange plate. The flange cylinder is a hollow cylindrical structure, and the inner diameter of the flange cylinder matches the outer diameter of the insulating tube; the flange plate covers one end of the flange cylinder.

[0006] Wherein, the other end of the flange tube away from the flange plate is provided with an inner fillet.

[0007] Wherein, both ends of the support member are provided with chamfers.

[0008] The length of the support member is 10 to 20 mm longer than that of the flange tube.

[0009] The outer diameter of the support member is 0.1 to 0.5 mm smaller than the inner diameter of the insulating tube.

[0010] The outer diameter of the insulating tube is 0.1 to 0.5 mm smaller than the inner diameter of the flange tube.

[0011] Among them, the insulating tube and the supporting parts are both made of fiber-reinforced composite materials.

[0012] Among them, a sealing structure is provided at the connection between the end of the flange tube away from the flange disk and the insulating tube. The sealing structure includes a sealing ring and a sealant. The sealing ring abuts against the outer periphery of the insulating tube and the inner periphery of the flange tube at the same time. The sealant fills the gap between the flange tube and the insulating tube, and covers the connection between the end face of the flange tube away from the flange disk and the insulating tube, so that the sealing ring, the flange tube and the insulating tube are sealed.

[0013] Among them, the flange tube, insulating tube and support are connected by crimping technology. The distance between the end of the target crimping area on the flange tube close to the flange plate and the flange plate is 15 to 25 mm, and the distance between the other end of the target crimping area away from the flange plate and the end face of the flange tube away from the flange plate is 5 to 10 mm.

[0014] The target crimping area includes a plurality of sub-crimping areas, and any two adjacent sub-crimping areas overlap by 0 to 20 mm along the axial direction of the insulating tube.

[0015] The beneficial effects of the present application are: the composite insulator of the present application utilizes a support member to realize the crimping of the hollow insulating tube and the flange, thereby ensuring the connection strength and sealing between the two, effectively avoiding failure of the composite insulator at the connection between the flange and the insulating tube, and can give full play to the structural strength of the composite insulator. Compared with traditional gluing technology, it eliminates the long glue curing process and improves production efficiency.

[0016] At the same time, the composite insulator of the present application is also provided with a sealing structure at the connection between the end of the flange tube away from the flange disc and the insulating tube, which can prevent external dust, water vapor and other impurities from entering the insulating tube, ensuring the normal operation of the composite insulator. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For those skilled in the art, other drawings can be obtained based on these drawings without inventive efforts. Among them:

[0018] Figure 1 is a partial cross-sectional view of a composite insulator 100 according to an embodiment of the present application;

[0019] Figure 2 is a cross-sectional view of a flange 120 in one embodiment of the present application;

[0020] Figure 3 is a top view of the flange 120 in one embodiment of the present application;

[0021] Figure 4 This is a cross-sectional view of a composite insulator 100 before crimping in one embodiment of the present application;

[0022] Figure 5 1 is a cross-sectional view of the composite insulator 100 after crimping in one embodiment of the present application. DETAILED DESCRIPTION

[0023] The following will be combined with the accompanying drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of them. Based on the embodiments of this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0024] See Figure 1 A composite insulator 100 includes an insulating tube 110, an shed (not shown) located on the outer periphery of the insulating tube 110, and two flanges 120 respectively provided at both ends of the insulating tube 110. The insulating tube 110 is a hollow circular tube. Support members 130 are provided inside both ends of the insulating tube 110. The support members 130 are solid cylindrical structures. The support members 130 are coaxially arranged with the insulating tube 110 and extend inward from the ends of the insulating tube 110. The outer diameter of the support member 130 matches the inner diameter of the insulating tube 110. The flanges 120 are crimped onto the outer sides of the ends of the insulating tube 110, so that the insulating tube 110, the support members 130, and the flanges 120 are tightly connected. The composite insulator 100 of the present application utilizes a support member 130 to achieve crimping of the hollow insulating tube 110 and the flange 120, thereby ensuring the connection strength and sealing between the two, effectively preventing failure of the composite insulator 100 at the connection between the flange 120 and the insulating tube 110, and fully utilizing the structural strength of the composite insulator 100. Compared with traditional gluing technology, it eliminates the long glue curing process and improves production efficiency.

[0025] Combine Figure 2 and Figure 3As shown, the flange 120 includes a flange tube 121 and a flange disc 122. The flange tube 121 is a hollow cylindrical structure that is sleeved onto the end of the insulating tube 110. The inner diameter of the flange tube 121 matches the outer diameter of the insulating tube 110. In this embodiment, the flange disc 122 is disc-shaped, with a diameter greater than the outer diameter of the flange tube 121, and the flange disc 122 completely covers one end of the flange tube 121. In other embodiments, the flange disc can also be annular, with an inner diameter smaller than the inner diameter of the flange tube and an outer diameter greater than the outer diameter of the flange tube, that is, the flange disc can partially cover one end of the flange tube. The flange disc 122 is provided to cover one end of the flange tube 121, mainly for connecting with other flanges with fasteners such as bolts, thereby facilitating the installation of the composite insulator 100. The other end of the flange barrel 121 away from the flange disc 122 is provided with an inner fillet with an arc radius of 2 to 3 mm. When the flange barrel 121 and the insulating tube 110 are assembled, the inner fillet can serve as a guide for expanding the diameter, allowing the flange barrel 121 to be more smoothly fitted onto the insulating tube 110, significantly improving assembly efficiency. Furthermore, the inner fillet can prevent structural wear caused by sharp edges, thereby extending the service life of the composite insulator 100. Preferably, the flange 120 further includes a plurality of reinforcing ribs 123. The reinforcing ribs 123 are plate members, arranged along the radial direction of the flange 120 and simultaneously connecting the flange barrel 121 and the flange disc 122. The plurality of reinforcing ribs 123 are evenly distributed along the circumference of the flange 120. The provision of the reinforcing ribs 123 can indirectly increase the contact area between the flange barrel 121 and the flange disc 122, thereby improving the strength of the flange 120. In this embodiment, six reinforcing ribs 123 are provided. These six reinforcing ribs 123 are arranged on the outer circumference of the flange cylinder 121 along the radial direction of the flange cylinder 121. The provision of six reinforcing ribs 123 can improve the strength of the flange 122 and reduce the thickness requirement of the flange 122, thereby saving material and reducing the weight of the composite insulator 100. In other embodiments, the number of reinforcing ribs may be four, five, seven, or more, or the number of reinforcing ribs may be eliminated, as long as the flange strength requirements are met. This is not a limitation herein.

[0026] In one embodiment, the flange sleeve 121, flange plate 122, and reinforcing ribs 123 can be separately formed and then connected by welding or other processes. Alternatively, the flange sleeve 121, flange plate 122, and reinforcing ribs 123 can be integrally cast to further enhance the overall stability and mechanical strength of the flange 120. In other embodiments, the flange sleeve, flange plate, and reinforcing ribs can also be formed by other methods as long as the flange strength is guaranteed, and this is not limited here.

[0027] Insulation tube 110 is a hollow circular tube formed by winding or pultrusion of a fiber-reinforced composite material. This provides excellent mechanical strength and dielectric properties. The inner diameter of flange 121 matches the outer diameter of insulation tube 110 for ease of assembly. Specifically, the outer diameter of insulation tube 110 is slightly smaller than the inner diameter of flange 121, allowing flange 121 to be smoothly fitted around the outer ends of insulation tube 110, facilitating subsequent crimping of flange 120 onto the outer ends of insulation tube 110. In one embodiment, the outer diameter of the insulating tube 110 is 0.1 to 0.5 mm smaller than the inner diameter of the flange tube 121, for example, 0.1 mm, 0.2 mm or 0.5 mm, so that the flange tube 121 and the insulating tube 110 can move relative to each other to adjust the position of the flange tube 121 on the insulating tube 110, thereby ensuring that the flange 120 can be put in place; at the same time, by pre-setting the gap, even if there is a radial processing error between the flange 120 and the insulating tube 110, it is not easy to cause product assembly failure, thereby reducing processing difficulty and improving fault tolerance.

[0028] Combine Figure 4 and Figure 5 As shown, the support member 130 is a solid cylindrical structure. The support member 130 is made of a fiber-reinforced composite material, the same material as the insulating tube 110. The same material has highly consistent hardness, ductility, and deformation characteristics. This ensures that the deformation behavior of the support member 130 and the insulating tube 110 remains synchronized during the crimping process, avoiding local stress concentration or cracking caused by asynchronous deformation of different materials, thereby ensuring the quality of the composite insulator 100. In addition, when designing the crimping process parameters, there is no need to consider the difference in thermal expansion coefficients of different materials, which greatly reduces the design complexity. Of course, in other embodiments, the support member can also be made of other insulating materials with a radial elastic modulus of 10 to 20 GPa, as long as it can support the crimping of the hollow insulating tube and the flange. This is not limited here.

[0029] In this embodiment, both ends of the support member 130 are provided with a 3mm×45° chamfer. When the support member 130 and the insulating tube 110 are assembled, the chamfer can serve as a guide for reducing the diameter, allowing the support member 130 to be more smoothly placed into the inner cavity of the insulating tube 110, significantly improving assembly efficiency. In addition, the chamfer can also prevent structural wear caused by sharp edges, thereby extending the service life of the composite insulator 100. In other embodiments, the chamfers at both ends of the support member can also be set to other sizes and angles, such as 1mm×45°, 2mm×45°, 1mm×60°, 2mm×60°, 3mm×60°, 1mm×30°, 2mm×30°, 3mm×30°, etc., as long as it facilitates the assembly of the support member and the insulating tube, and is not limited here.

[0030] The support member 130 is located within the inner cavity of the insulating tube 110, with one end of the support member 130 flush with the end of the insulating tube 110. The outer diameter of the support member 130 matches the inner diameter of the insulating tube 110, allowing the support member 130 to be smoothly positioned within the insulating tube 110. Specifically, the outer diameter of the support member 130 is 0.1 to 0.5 mm smaller than the inner diameter of the insulating tube 110, for example, 0.1 mm, 0.2 mm, or 0.5 mm. This allows the support member 130 and the insulating tube 110 to move relative to each other to adjust their relative positions, thereby ensuring that the support member 130 can be installed in place. Furthermore, the preset gap can prevent friction between the support member 130 and the insulating tube 110 during assembly, reducing assembly difficulty.

[0031] When the insulating tube 110, flange 120, and support member 130 are assembled, the support member 130 is coaxially arranged in the inner cavity of the insulating tube 110, and the ends of the two are flush; the flange tube 121 is coaxially sleeved on the outer periphery of the end of the insulating tube 110, and the flange plate 122 abuts the end faces of the insulating tube 110 and the support member 130 at the same time. Due to the existence of the assembly gap, the axes of the insulating tube 110, flange 120, and support member 130 may be slightly offset, but the compression between the components during crimping will correct the coaxiality. The length of the support member 130 along its axial direction is defined as L1, the length of the flange tube 121 along its axial direction is defined as L2, and the difference in length between the support member 130 and the flange tube 121 is defined as L3, that is, L3 = L1-L2, and the value range of L3 is 10 to 20 mm. For example, L3 can be 10 mm, 15 mm, or 20 mm. Specifically, when L3 is less than 10 mm, the insulating tube 110 and flange 120 experience significant stress during crimping, risking excessive plastic deformation and potentially causing structural damage. When L3 is greater than 20 mm, the length of the support member 130 becomes excessive, increasing costs. Therefore, setting the length of the support member 130 to be 10 to 20 mm longer than the length of the flange tube 121 can reduce stress on the insulating tube 110 and flange 120 during crimping while controlling costs, preventing damage to both during the crimping process and ensuring product quality.

[0032] A sealing structure (not shown in the figure) is provided at the connection between the other end of the flange tube 121 away from the flange 122 and the insulating tube 110. The sealing structure includes a sealing ring and a sealant. In this embodiment, the cross-section of the sealing ring is circular and is sleeved on the outer periphery of the insulating tube 110. When the flange tube 121 is sleeved on the outer periphery of the insulating tube 110, the sealing ring can simultaneously abut the outer periphery of the insulating tube 110 and the inner periphery of the flange tube 121, and the sealing ring is close to the other end of the flange tube 121 away from the flange 122. At this time, the sealing ring is in a compressed state, thereby isolating the interior of the insulating tube 110 from the outside air, preventing external dust, water vapor and other impurities from entering the interior of the insulating tube 110 through the connection between the insulating tube 110 and the flange tube 121, and ensuring the electrical stability of the composite insulator 100. In other embodiments, the cross-section of the sealing ring can also be rectangular or other shapes, as long as it can isolate the interior of the insulating tube from the outside air, and there is no limitation here. Furthermore, to further enhance the sealing performance of the composite insulator 100, a sealant is provided at the connection between the other end of the flange tube 121 away from the flange plate 122 and the insulating tube 110. The sealant fills the gap between the flange tube 121 and the insulating tube 110 and covers the connection between the end face of the flange tube 121 away from the flange plate 122 and the insulating tube 110, thereby providing a sealed connection between the sealing ring, the flange tube 121, and the insulating tube 110. This further prevents external dust, moisture, and other impurities from entering the insulating tube 110, thereby preventing the internal insulating environment of the composite insulator 100 from exchanging with the external environment, thereby ensuring the electrical stability of the composite insulator 100. The sealing structure of the present application, which simultaneously provides a sealing ring and sealant, achieves a better sealing effect and increases the reliability of the composite insulator 100.

[0033] In this embodiment, the sealing ring is made of EPDM rubber, which has good aging resistance, particularly slow stress relaxation, long service life, and can maintain good sealing performance during its long-term operation. The sealant uses a resin-based adhesive, which has excellent bonding ability and ensures a stable bonding effect; at the same time, the resin-based adhesive has extremely high mechanical strength after curing, ensuring the long-term reliability of the sealant. In other embodiments, the sealing ring can also be made of fluorosilicone rubber, nitrile rubber, hydrogenated nitrile rubber, etc., and the sealant can also be made of polyurethane, polytetrafluoroethylene, etc.; alternatively, the sealing structure can also include only the sealing ring or only the sealant or other structures, as long as the sealing can be achieved, there is no limitation here.

[0034] The flange 120, the insulating tube 110 and the support member 130 are connected by crimping technology, which can be specifically achieved by a crimping device. The crimping device includes a driving mechanism, an annular crimping mechanism, and a plurality of pressing blocks. The plurality of pressing blocks are arranged on the inner circumference of the annular crimping mechanism along the radial direction, and the plurality of pressing blocks are evenly distributed along the circumference of the annular crimping mechanism. The pressure surface of the pressing block matches the outer contour of the flange tube 121. During the crimping operation, the assembled flange 120, the insulating tube 110 and the support member 130 are placed in the annular crimping mechanism, and the pressing block is aligned with the target crimping area on the flange tube 121. The driving mechanism drives the plurality of pressing blocks to move synchronously toward each other along the radial direction of the annular crimping mechanism to form a centripetal extrusion force, and continuously squeeze the flange tube 121 until the flange 120, the insulating tube 110 and the support member 130 are crimped together. Preferably, eight pressing blocks are provided, and the radial angle θ between adjacent pressing blocks is 45°, so that the extrusion force generated by the annular crimping mechanism can be evenly loaded along the circumference of the flange tube 121, avoiding eccentric deformation caused by unilateral pressure and ensuring the quality of crimping; the shape of the crimping surface of the pressing block matches the outer peripheral contour of the flange tube 121, and can convert point loads into surface loads, so that the stress distribution at the interface between the flange tube 121, the insulating tube 110 and the support member 130 is uniform. Compared with traditional gluing technology, the crimping technology applies a uniform extrusion force to form a close contact between the flange 120, the insulating tube 110 and the support member 130, generating a large friction force, which significantly improves the tensile strength and shear strength of the connection parts of the three; moreover, the crimping process can be completed using only a dedicated crimping tool, which is easy to operate, eliminates the long glue curing process, greatly shortens the assembly time, and improves production efficiency.

[0035] The flange tube 121 is provided with a target crimping area that cooperates with the insulating tube 110 and is used to achieve an effective connection between the flange tube 121 and the insulating tube 110. The target crimping area is annular, located on the outer periphery of the flange tube 121 and coaxially arranged with the flange tube 121, that is, the target crimping area is the outer surface area of the flange tube 121 along a portion of its axial structure. The distance between the end of the target crimping area close to the flange 122 and the flange 122 is 15 to 25 mm. Specifically, when the distance between the end of the target crimping area close to the flange 122 and the flange 122 is less than 15 mm, the stress on the flange 120 during crimping is large, and there is a risk of excessive plastic deformation, which can easily cause structural damage; when the distance between the end of the target crimping area close to the flange 122 and the flange 122 is greater than 25 mm, the area of the target crimping area is small, affecting the crimping effect. Therefore, the distance between the end of the target crimping area close to the flange 122 and the flange 122 is set to 15 to 25 mm, which can ensure the crimping effect while reducing the crimping stress on the flange 120, avoiding damage to the flange 120 during the crimping process, and ensuring product quality. The distance between the other end of the target crimping area away from the flange 122 and the end face of the flange tube 121 away from the flange 122 is 5 to 10 mm. Specifically, when the distance between the other end of the target crimping area away from the flange 122 and the end face of the flange tube 121 away from the flange 122 is less than 5 mm, the stress on the insulating tube 110 during crimping is large, and there is a risk of excessive plastic deformation, which can easily cause structural damage. When the distance between the other end of the target crimping area away from the flange 122 and the end face of the flange tube 121 away from the flange 122 is greater than 10 mm, the area of the target crimping area is small, affecting the crimping effect. Therefore, setting the distance between the other end of the target crimping zone, away from flange 122, and the end face of flange tube 121, away from flange 122, to 5-10 mm ensures effective crimping while minimizing the crimping stress on insulating tube 110. This prevents damage to insulating tube 110 during the crimping process and ensures product quality. Within this target crimping zone, several evenly distributed pressure blocks apply circumferential compressive force, ensuring uniform force throughout the crimping process on flange tube 121, insulating tube 110, and support member 130, ensuring a reliable connection among the three.

[0036] The length of the flange tube 121 is positively correlated with the area of its target crimping zone, so as to ensure the crimping effect. When the length of the flange tube 121 exceeds a certain limit, its target crimping zone is too large, which will cause the crimping device to be unable to complete the fixed connection of the flange 120, the insulating tube 110 and the support member 130 through one crimping. In order to ensure the crimping effect, a stepwise crimping method is adopted, that is, only a part of the target crimping zone is crimped each time. Specifically, the target crimping zone includes a number of sub-crimping zones, and any two adjacent sub-crimping zones overlap 0 to 20 mm along the axial direction of the insulating tube 110, so that the target crimping zone on each flange tube 121 is continuous and has no gaps. If the axial overlap area of any two adjacent sub-crimping zones along the insulating tube 110 is less than 0, that is, the target crimping zone is not continuous, the crimping effect will be weakened, and the reliability of the connection will be greatly reduced; if the axial overlap of any two adjacent sub-crimping zones along the insulating tube 110 is greater than 20 mm, it will lead to too many crimping times, extending the crimping time and reducing production efficiency. Therefore, any two adjacent sub-crimping areas overlap by 0 to 20 mm along the axial direction of the insulating tube 110, which can ensure a reliable connection between the flange tube 121, the insulating tube 110 and the support member 130, and the crimping efficiency is higher than when any two adjacent sub-crimping areas do not overlap.

[0037] The solid support member 130 prevents the hollow insulating tube 110 from excessive deformation during the crimping process, thereby ensuring product quality. After crimping, the insulating tube 110 deforms and contracts until it fits tightly against the support member 130. Simultaneously, the flange tube 121 deforms and contracts until it fits tightly against the insulating tube 110, forming contact surfaces with a certain pressure between the flange 120 and the insulating tube 110, and between the insulating tube 110 and the support member 130. This contact surface provides sufficient interfacial pressure and friction, thereby ensuring the strength of the connection between the three, preventing failure at the connection between the flange 120 and the insulating tube 110 during operation of the composite insulator 100 and fully utilizing the structural strength of the composite insulator 100.

[0038] The present application also provides a method for preparing a composite insulator 100, which specifically includes:

[0039] S1: Provide an insulating tube 110, two support members 130, and two flanges 120. The flange 120 includes a flange cylinder 121 and a flange plate 122. The flange cylinder 121 is a hollow cylindrical structure. The flange plate 122 covers one end of the flange cylinder 121. The inner diameter of the flange cylinder 121 matches the outer diameter of the insulating tube 110. The outer diameter of the support member 130 matches the inner diameter of the insulating tube 110.

[0040] Specifically, an insulating tube 110, two support members 130, and two flanges 120 are prepared according to the size of the composite insulator 100 to be prepared. The outer diameter of the insulating tube 110 is 0.1 to 0.5 mm smaller than the inner diameter of the flange tube 121, so that the flange tube 121 and the insulating tube 110 can move relative to each other to adjust the position of the flange tube 121 on the insulating tube 110, thereby ensuring that the flange 120 can be installed in place. The outer diameter of the support member 130 is 0.1 to 0.5 mm smaller than the inner diameter of the insulating tube 110, so that the support member 130 and the insulating tube 110 can move relative to each other to adjust their relative positions, thereby ensuring that the support member 130 can be installed in place.

[0041] The support member 130 is a solid cylindrical structure. The length of the support member 130 is 10 to 20 mm longer than the length of the flange tube 121. Chamfers are prepared at both ends of the support member 130. The chamfers can serve as a guide for reducing the diameter, so that the support member 130 can be placed more smoothly into the inner cavity of the insulating tube 110, significantly improving the assembly efficiency; and the chamfers can also avoid structural wear caused by sharp edges, thereby extending the service life of the composite insulator 100.

[0042] Furthermore, an shed is prepared on the outer circumference of the insulating tube 110 .

[0043] S2: Place the two support members 130 into the inner cavities at both ends of the insulating tube 110 respectively, so that one end of the two support members 130 is flush with the two end portions of the insulating tube 110 respectively.

[0044] When the insulating tube 110 and the support member 130 are assembled in place, the support member 130 is approximately coaxially disposed in the inner cavity of the insulating tube 110 , and the ends of the two are flush.

[0045] S3: Sleeve the two sealing rings on the outer circumference of the insulating tube 110 so that they are located in the target crimping areas of the two flanges 120 respectively.

[0046] The sealing ring has a circular cross section and is sleeved on the outer circumference of the insulating tube 110. The sealing ring is made of EPDM rubber or other rubber.

[0047] The flange barrel 121 is provided with a target crimping area that mates with the insulating tube 110 and is used to effectively connect the flange barrel 121 and the insulating tube 110. The target crimping area is annular and located on the outer periphery of the flange barrel 121 and is coaxial with the flange barrel 121. In other words, the target crimping area is the outer surface area of the flange barrel 121 along its axial direction.

[0048] The distance between the end of the target crimping zone closest to flange 122 and flange 122 is 15-25 mm. This ensures a good crimping effect while minimizing the crimping stress on flange 120, preventing damage to flange 120 during the crimping process and ensuring product quality. The distance between the other end of the target crimping zone, away from flange 122, and the end face of flange tube 121, away from flange 122, is 5-10 mm. This ensures a good crimping effect while minimizing the crimping stress on insulating tube 110, preventing damage to insulating tube 110 during the crimping process and ensuring product quality.

[0049] S4: The flange cylinders 121 of the two flanges 120 are sleeved on the outer peripheries of both ends of the insulating tube 110 , and the end surfaces of the insulating tube 110 and the supporting member 130 that are flush with each other are in contact with the flange plates 122 .

[0050] When the flange tube 121 is sleeved on the outer periphery of the insulating tube 110, the sealing ring abuts against the outer periphery of the insulating tube 110 and the inner periphery of the flange tube 121 at the same time, and the sealing ring is close to the other end of the flange tube 121 away from the flange plate 122. At this time, the sealing ring is in a compressed state.

[0051] S5: Perform crimping operation in the target crimping area to firmly connect the insulating tube 110, the support member 130, and the flange 120.

[0052] The crimping operation is achieved through a crimping device, which applies radial extrusion force in the target crimping area, ensuring that the flange tube 121, the insulating tube 110 and the support member 130 are evenly stressed during the entire crimping process, thereby ensuring the connection reliability of the three.

[0053] In one embodiment, when the length of the flange tube 121 exceeds a certain limit, staged crimping is performed. The target crimping area consists of several sub-crimping areas, with any two adjacent sub-crimping areas overlapping by 0-20 mm along the axial direction of the insulating tube 110, ensuring a continuous, gap-free target crimping area across the entire flange tube 121. Staged crimping is performed, with crimping performed on only one sub-crimping area at a time, until all sub-crimping areas are crimped.

[0054] Furthermore, after step S5 or before step S1 , step S6 may be included: welding a plurality of reinforcing ribs 123 on the flange 122 , the reinforcing ribs 123 simultaneously connecting the flange tube 121 and the flange 122 , and the plurality of reinforcing ribs 123 are evenly distributed along the circumference of the flange 120 .

[0055] The provision of the reinforcing ribs 123 can indirectly increase the contact area between the flange cylinder 121 and the flange plate 122, thereby improving the strength of the flange 120. Six reinforcing ribs 123 or any other number can be provided as long as the overall stability of the flange 120 can be enhanced.

[0056] After step S5, step S7 may be further included: using sealant to fill the gap between the flange tube 121 and the insulating tube 110, and covering the connection between the end surface of the flange tube 121 away from the flange plate 122 and the insulating tube 110, so that the two are further sealed and connected.

[0057] S8: Conduct load destruction test and record relevant test data.

[0058] Specifically, three test pieces were prepared using the above steps. A load was applied to each test piece to perform a load failure test. The failure load, failure strength of the insulating tube 110 , and failure mode were recorded, as shown in Table 1.

[0059] Table 1 Load failure test data record

[0060]

[0061] In the prior art, when the insulating tube and flange are glued together, the insulating tube is subjected to a concentrated load of 24kN, and failure is determined by glue failure. However, the above test results show that after the present application's crimping connection of the insulating tube 110 and flange 120, the external force that the insulating tube 110 can withstand is improved compared to the glued connection. The finished crimped connection mainly results in failure of the insulating tube 110, indicating that the crimping connection fully utilizes the strength of the insulating tube 110, further demonstrating the quality stability of the composite insulator 100 of the present application.

[0062] The beneficial effects of the present application are: the composite insulator of the present application utilizes a support member to realize the crimping of the hollow insulating tube and the flange, thereby ensuring the connection strength and sealing between the two, effectively avoiding failure of the composite insulator at the connection between the flange and the insulating tube, and can give full play to the structural strength of the composite insulator. Compared with traditional gluing technology, it eliminates the long glue curing process and improves production efficiency.

[0063] At the same time, the composite insulator of the present application is also provided with a sealing structure at the connection between the end of the flange tube away from the flange disc and the insulating tube, which can prevent external dust, water vapor and other impurities from entering the insulating tube, ensuring the normal operation of the composite insulator.

[0064] The above description is only an implementation method of the present application and does not limit the patent scope of the present application. Any equivalent structure or equivalent process transformation made using the contents of the description and drawings of this application, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present application.

Claims

1. A composite insulator comprising an insulating tube, an shed located on the outer periphery of the insulating tube, and two flanges respectively provided at both ends of the insulating tube, characterized in that: The insulating tube is a hollow circular tube, and support members are provided inside both ends of the insulating tube. The support members are solid cylindrical structures. The support members are coaxially arranged with the insulating tube and extend inward from the ends of the insulating tube. The outer diameter of the support member matches the inner diameter of the insulating tube. The flange is crimped onto the outside of the ends of the insulating tube, so that the insulating tube, the support member and the flange are tightly connected.

2. The composite insulator according to claim 1, wherein: The flange includes a flange cylinder and a flange plate. The flange cylinder is a hollow cylindrical structure. The inner diameter of the flange cylinder matches the outer diameter of the insulating tube. The flange plate covers one end of the flange cylinder.

3. The composite insulator according to claim 2, wherein: The other end of the flange cylinder away from the flange plate is provided with an inner fillet.

4. The composite insulator according to claim 1, wherein: Both ends of the support member are provided with chamfers.

5. The composite insulator according to claim 2, wherein: The length of the support member is 10 to 20 mm longer than that of the flange tube.

6. The composite insulator according to claim 1, wherein: The outer diameter of the support member is 0.1 to 0.5 mm smaller than the inner diameter of the insulating tube.

7. The composite insulator according to claim 2, wherein: The outer diameter of the insulating tube is 0.1 to 0.5 mm smaller than the inner diameter of the flange tube.

8. The composite insulator according to claim 1, wherein: The insulating tube and the supporting member are both made of fiber-reinforced composite material.

9. The composite insulator according to claim 2, wherein: A sealing structure is provided at the connection between the end of the flange tube away from the flange plate and the insulating tube. The sealing structure includes a sealing ring and a sealant. The sealing ring abuts against the outer periphery of the insulating tube and the inner periphery of the flange tube at the same time. The sealant fills the gap between the flange tube and the insulating tube and covers the connection between the end face of the flange tube away from the flange plate and the insulating tube, so that the sealing ring, the flange tube and the insulating tube are sealed and connected.

10. The composite insulator according to claim 2, wherein: The flange tube, the insulating tube and the support are connected by crimping technology. The distance between the end of the target crimping area on the flange tube close to the flange plate and the flange plate is 15 to 25 mm, and the distance between the other end of the target crimping area away from the flange plate and the end face of the flange tube away from the flange plate is 5 to 10 mm.

11. The composite insulator according to claim 10, wherein: The target crimping area includes a plurality of sub-crimping areas, and any two adjacent sub-crimping areas overlap by 0 to 20 mm along the axial direction of the insulating tube.

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