Porcelain insulator and production process thereof

Abstract

The invention relates to the field of power application equipment, and discloses a porcelain insulator and a production process thereof.The porcelain insulator comprises a porcelain piece, a steel foot is fixedly arranged on the inner wall of the porcelain piece, a felt pad is arranged in a connecting interlayer of the steel foot and the porcelain piece, and a steel cap is fixedly connected to the outer wall of the porcelain piece through a cement adhesive; an external connection assembly is arranged on the inner wall of the steel cap and comprises a containing block, the containing block is installed on the top of the steel cap, the inner wall of the containing block is movably connected with a wire connecting rod and a fixing rod, the outer wall of the fixing rod is sleeved with the wire connecting piece, and the top end of the wire connecting piece extends out of the containing block. The two ends of the fixing rod extend to the outer portion of the containing block. The felt pad is arranged between the steel foot and the porcelain piece, so that water and dust can be effectively prevented, certain elasticity can be provided, the influence of the external environment on a connecting part is relieved, the service life of the insulator is remarkably prolonged, and the durability and reliability of the insulator are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of electric power application equipment, in particular to a porcelain insulator and a production process thereof. Background Art

[0002] Porcelain insulators are critical components in power systems, primarily providing electrical insulation and mechanical support. They are commonly used in power transmission and distribution equipment to prevent current leakage and ensure electrical isolation between conductive parts and other components. Combining these insulating and supporting functions, porcelain insulators are able to withstand the high voltages and mechanical stresses of power systems, ensuring safe operation.

[0003] Currently, many porcelain insulators utilize traditional structural designs, with the connection between the porcelain and steel legs mostly relying on a single mechanical fastener. However, this method is often susceptible to environmental fluctuations, especially in extreme climates, where the connection can become loose or age. Traditional sealing materials, mostly rubber or conventional gaskets, can easily lose their elasticity and sealing properties after high temperatures or prolonged use, leading to degraded insulator performance. Without effective improvement measures, porcelain insulators suffer from poor reliability and high maintenance costs.

[0004] Furthermore, in traditional designs, the connection between the steel cap and the ceramic component is often achieved through simple mechanical scarfing or welding. This method often loosens when subjected to external forces or vibration, especially during long-term use. Common connection methods lose their holding force under vibration or high pressure, affecting the overall structural stability. Because the design does not consider adaptability to high-vibration environments, this connection method has poor durability.

[0005] Furthermore, the installation of wire connectors and fixing rods in existing technologies often fails to consider the strength of the connection, typically adopting a relatively simple structural design. This fails to account for the impact of wire connection strength on overall system stability in high-voltage power systems. This can lead to loose connections, especially when high voltage and high current flow, resulting in current surges and mechanical vibrations. This can make the connections of porcelain insulators extremely susceptible to damage or electrical failure. Summary of the Invention

[0006] In view of the deficiencies in the prior art, the present invention provides a porcelain insulator and a production process thereof, which solve the deficiencies in connection strength, sealing and seismic resistance of the prior art porcelain insulator.

[0007] To achieve the above object, the present invention is implemented through the following technical solution: a porcelain insulator, comprising a porcelain part, wherein a steel leg is fixedly provided on the inner wall of the porcelain part, a felt pad is provided in the interlayer connecting the steel leg and the porcelain part, a steel cap is fixedly connected to the outer wall of the porcelain part by cement adhesive, and an external component is provided on the inner wall of the steel cap; The external connection component includes a receiving block, which is installed on the top of the steel cap. The inner wall of the receiving block is movably connected with a wire connecting rod and a fixing rod, and the wire connector is sleeved on the outer wall of the fixing rod.

[0008] Preferably, the top end of the wire connector extends to the outside of the accommodating block, and both ends of the fixing rod extend to the outside of the accommodating block.

[0009] Preferably, the inner wall of the steel cap is provided with a locking pin, which passes through the locking pin and the porcelain part in sequence and is connected to the steel foot for fixing other components. The top of the steel cap is provided with a port for connecting in series with other porcelain insulators.

[0010] Preferably, the outer wall of the steel foot is provided with cement adhesive for stabilizing the connection position of the steel foot in the middle of the porcelain piece.

[0011] Preferably, the porcelain piece includes but is not limited to being circular or disc-shaped.

[0012] A production process for porcelain insulators comprises the following steps: S1: Preparation of the porcelain body; S2: Install linoleum pads between the porcelain body and the steel feet; S3: Apply cement adhesive between the steel cap and the porcelain body and between the steel foot and the porcelain body for bonding; S4: Install the wire connector and fixing rod, and complete the overall structural connection by setting the locking pin.

[0013] Preferably, the detailed preparation process of step S1 includes: S11. Using a wet porcelain making process and an isostatic pressing process, the particle diameter of the wet porcelain making raw material is 10 μm to 50 μm, and the amount of binder added is 5% to 10%; S12, after the raw materials are uniformly mixed at high temperature, they are molded using a molding pressure of 5 MPa to 10 MPa; S13, then sintering the formed porcelain piece at a temperature ranging from 1200° C. to 1300° C. for 6 hours to 10 hours.

[0014] Preferably, the size of the accommodating block in step S4 is Φ20mm to Φ30mm, and a fixing rod is installed in the accommodating block, with a length of 50mm to 80mm and a diameter of 6mm to 8mm; The wire connector is sleeved on the surface of the fixing rod, the outer diameter of the wire connector is 10mm to 15mm, and both ends of the fixing rod extend to the outside of the accommodating block to enhance the connection strength.

[0015] Preferably, the cement adhesive in step S3 is electrical insulating cement, the bonding strength of which is required to be no less than 4 MPa, and the usage is 50 g to 100 g per square meter.

[0016] The present invention provides a porcelain insulator and a production process thereof, which has the following beneficial effects: 1. The present invention forms a new sandwich design by arranging a felt pad between the steel foot and the porcelain part. The felt pad is not only effectively waterproof and dustproof, but also provides a certain degree of elasticity to mitigate the impact of the external environment on the connection part. This structural optimization improves the overall stability of the porcelain insulator, significantly extends its service life, and increases the durability and reliability of the insulator.

[0017] 2. The present invention provides a locking pin on the inner wall of the steel cap, and the locking pin passes through the porcelain part and the steel leg, thereby achieving firm fixation of each component. This structure not only enhances the connection strength, but also effectively prevents the steel cap and the porcelain part or the steel leg from loosening or shifting under the action of external force, thereby avoiding the common failures caused by loose connections in traditional porcelain insulators.

[0018] 3. The present invention provides ports so that multiple porcelain insulators can be flexibly combined and connected in series according to needs to form a complete system, which effectively improves the maintainability and installation convenience of the porcelain insulator series system. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a structural cross-sectional view of the present invention; Figure 2 It is a step diagram of the preparation method of the present invention.

[0020] Among them, 1. Steel cap; 2. Locking pin; 3. Felt pad; 4. Cement adhesive; 5. Porcelain parts; 6. Steel feet. DETAILED DESCRIPTION

[0021] The following will clearly and completely describe the technical solution of the present invention in conjunction with the accompanying drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0022] Please see the attached Figure 1An embodiment of the present invention provides a porcelain insulator comprising a porcelain component 5, including but not limited to a circular or disc-shaped component. A steel foot 6 is fixedly mounted on the inner wall of the porcelain component 5, and a felt pad 3 is disposed in the interlayer connecting the steel foot 6 and the porcelain component 5. A steel cap 1 is fixedly connected to the outer wall of the porcelain component 5 via cement adhesive 4, and an external component is disposed on the inner wall of the steel cap 1. A locking pin 2 is disposed on the inner wall of the steel cap 1, which sequentially passes through the locking pin 2 and the porcelain component 5 and connects to the steel foot 6, thereby securing other components. A port is disposed on the top of the steel cap 1 for connection in series with other porcelain insulators.

[0023] The outer wall of the steel foot 6 is provided with cement adhesive 4 for stabilizing the connection position of the steel foot 6 in the middle of the porcelain piece 5.

[0024] Specifically, the porcelain insulator includes a porcelain element 5, which can be round or disc-shaped to accommodate various installation requirements. As the core component of the porcelain insulator, porcelain element 5 possesses excellent electrical insulation properties and high mechanical strength, effectively resisting environmental influences and ensuring long-term, stable insulation. Steel legs 6 are fixed to the inner wall of porcelain element 5, providing support and fixation within the porcelain insulator, ensuring the stability of the entire porcelain insulator system.

[0025] To enhance the connection stability between the porcelain component 5 and the steel leg 6, a felt pad 3 is placed between them. This pad not only provides a tight seal but also possesses a certain degree of elasticity, effectively mitigating the effects of environmental fluctuations on the connection. This design significantly improves the stability of the porcelain insulator, especially during long-term use, by reducing the risk of failure due to aging or loosening of the connection.

[0026] Furthermore, the outer wall of the porcelain component 5 is fixedly connected to the steel cap 1 via a cement adhesive 4, which plays a key role in the present invention. This design enables the steel cap 1 to maintain a stable connection with the porcelain component 5 over a long period of time, avoiding the structural instability caused by loose connections in traditional porcelain insulators.

[0027] The inner wall of the steel cap 1 is equipped with external components that can be connected to other porcelain insulators or other components in the power system according to specific application needs, providing flexible adaptability. The inner wall of the steel cap 1 is also equipped with a locking pin 2. The locking pin 2 passes through the porcelain part 5 and the steel leg 6, effectively securing the components and preventing loosening or displacement under external forces. This design enhances the seismic resistance and stability of the porcelain insulator, especially in complex power systems, ensuring its reliability and safety in high-vibration environments.

[0028] To facilitate series connection with other porcelain insulators, a port is provided on the top of steel cap 1. This port design allows multiple porcelain insulators to be connected in series through simple connections, forming a complete system. This enhances the modularity of the porcelain insulator and simplifies installation. This modular design allows for flexible expansion of the porcelain insulator system based on actual needs, adapting to the scale requirements of different power systems.

[0029] Finally, cement adhesive 4 is applied to the outer wall of steel leg 6 to securely attach it to the central portion of porcelain component 5. This cement adhesive 4 ensures a secure connection between steel leg 6 and porcelain component 5, increasing its ability to withstand external forces during use. This improves the porcelain insulator's compressive strength and mechanical stability, ensuring reliable operation in complex electrical environments.

[0030] The external component includes a accommodating block, which is installed on the top of the steel cap 1. The inner wall of the accommodating block is movably connected with a wire connecting rod and a fixed rod. The wire connector is sleeved on the outer wall of the fixed rod. The top of the wire connector extends to the outside of the accommodating block, and both ends of the fixed rod extend to the outside of the accommodating block.

[0031] Specifically, the receiving block is installed at the top of the steel cap 1 and provides a reliable installation position for the wire connection and the fixing rod. The inner wall of the receiving block is movably connected with the wire connection rod and the fixing rod, ensuring that these components can be stably and flexibly connected and adjusted.

[0032] The wire connector is sleeved onto the outer wall of the fixing rod and, through cooperation with the fixing rod, effectively connects the wires to other components. The top of the wire connector extends outside the receiving block, ensuring smooth electrical connection between the wires and the external power system. Furthermore, both ends of the fixing rod extend outside the receiving block, enhancing the firmness and stability of the wire connector, steel cap 1, and porcelain component 5. This structural design not only improves the mechanical strength of the connection but also facilitates subsequent maintenance and repair.

[0033] Please see the attached Figure 2 , a porcelain insulator production process, comprising the following steps: S1: preparing the ceramic body 5; including: S11. Using a wet porcelain making process and an isostatic pressing process, the particle diameter of the wet porcelain making raw material is 10 μm to 50 μm, and the amount of binder added is 5% to 10%; S12, after the raw materials are uniformly mixed at high temperature, they are molded using a molding pressure of 5 MPa to 10 MPa; S13, then sintering the formed ceramic piece 5 at a temperature ranging from 1200° C. to 1300° C. for 6 hours to 10 hours.

[0034] Specifically, S11, using a wet porcelain making process and an isostatic pressing process, the particle diameter of the wet porcelain making raw material is 10 μm to 50 μm, and the amount of the binder added is 5% to 10%; the particle size of the wet porcelain making raw material directly affects the density and electrical insulation performance of the porcelain part, and the particle diameter within this range can ensure sufficient mixing and easy molding; S12. After the raw materials are uniformly mixed at high temperature, they are molded using a molding pressure of 5MPa to 10MPa. This pressure range ensures that the raw materials can be evenly compacted during the molding process, ensuring the structural density and mechanical strength of the porcelain piece. S13. The formed porcelain piece 5 is then sintered at a temperature in the range of 1200° C. to 1300° C. for 6 to 10 hours. The sintering process in this temperature range can ensure that the porcelain piece retains its excellent electrical insulation properties while having sufficient mechanical strength, and the sintering time should be appropriately adjusted according to the thickness and complexity of the porcelain piece.

[0035] By implementing the above steps, a high-performance porcelain body 5 that meets technical requirements can be prepared, has good electrical insulation performance, high mechanical strength and long-term stability, and is suitable for porcelain insulators in high-voltage power systems.

[0036] S2: Install the linoleum pad 3 between the porcelain body 5 and the steel foot 6; Specifically, in this step, first ensure that the contact surface between the porcelain body 5 and the steel legs 6 is clean and free of impurities. Next, a high-temperature, corrosion-resistant, and elastic felt pad 3 is selected as the interlayer material, with a thickness between 2mm and 3mm. This felt pad 3 not only provides a good seal, preventing moisture and other impurities from penetrating the contact area, but also effectively increases the elasticity of the connection, absorbing stress caused by mechanical shock and thermal expansion, thereby improving the stability of the connection.

[0037] During installation, ensure that the felt pad 3 is evenly distributed between the ceramic body 5 and the steel legs 6 to avoid gaps or uneven compaction. The elasticity and sealing properties of the felt pad 3 effectively reduce component loosening caused by thermal expansion and contraction during long-term use, ensuring a long-term, stable connection between the ceramic body 5 and the steel legs 6, and enhancing stable performance in harsh environments.

[0038] S3: Apply cement adhesive 4 between the steel cap 1 and the porcelain body 5 and between the steel foot 6 and the porcelain body 5 for bonding; the cement adhesive 4 is power insulating cement, and its bonding strength is required to be no less than 4MPa, and the usage is 50g to 100g per square meter.

[0039] Specifically, in this step, cement adhesive 4 is used as an adhesive to firmly connect the steel cap 1 to the porcelain body 5, and the steel foot 6 to the porcelain body 5. Cement adhesive 4 is an electrical insulating cement with a bonding strength requirement of no less than 4 MPa. This provides high-strength bonding at the connection points, ensuring reliability and long-term stability in high-voltage power environments.

[0040] Coating process: evenly apply cement adhesive 4 on the connection parts between the steel cap 1 and the porcelain body 5 and the connection parts between the steel foot 6 and the porcelain body 5.

[0041] The usage of cement adhesive 4 is controlled between 50g and 100g per square meter to ensure that the proper usage of adhesive can form a good bonding layer on the connection surface and the bonding effect will not be affected by too much or too little adhesive.

[0042] When applying, ensure that the cement adhesive 4 completely covers the connection surface and avoid bubbles or uncovered gaps to ensure uniformity and stability of the bonding.

[0043] Because the cement adhesive 4 uses electrical insulating cement, it has excellent high temperature resistance, electric field resistance and strong adhesion. During use, it can withstand high voltage and environmental changes in the power system, ensuring long-term and stable connection between the steel cap 1 and the porcelain body 5, and the steel foot 6 and the porcelain body 5.

[0044] Through the coating and bonding steps, the steel cap 1 and the steel foot 6 will be firmly connected to the porcelain body 5, forming a stable structure with high resistance to mechanical impact and electric field strength.

[0045] S4: Install the wire connector and the fixing rod, and complete the overall structural connection by setting the locking pin 2. The size of the accommodating block is Φ20mm to Φ30mm. The fixing rod is installed in the accommodating block. The length of the fixing rod is 50mm to 80mm and the diameter is 6mm to 8mm. The wire connector is sleeved on the surface of the fixing rod, the outer diameter of the wire connector is 10mm to 15mm, and both ends of the fixing rod extend to the outside of the accommodating block to enhance the connection strength.

[0046] Specifically, in this step, first ensure that the receiving block on the steel cap 1 is accurately installed. The size of the receiving block is Φ20mm to Φ30mm, which can accommodate and fix the subsequent fixing rod and wire connector. A fixing rod is installed in the receiving block, and the length of the fixing rod is 50mm to 80mm, and the diameter is 6mm to 8mm. This size design ensures that the fixing rod has sufficient strength to withstand the force of the wire connection and the external power system. The wire connector is sleeved on the surface of the fixing rod, and the outer diameter of the wire connector is 10mm to 15mm. The design ensures that the wire connector can be tightly sleeved on the fixing rod. Both ends of the fixing rod extend to the outside of the receiving block. This design enhances the connection strength between the wire connector and the fixing rod, and effectively disperses the transmission of external forces, reducing the risk of loose connection due to vibration or external force.

[0047] A locking pin 2 connects the fixing rod and the receiving block. This pin, which passes through the fixing rod, porcelain component 5, and connects to the steel leg 6, ensures the overall structural integrity. This pin plays a crucial role in preventing the wire connector, fixing rod, and steel cap 1 from loosening or shifting due to external forces, thus ensuring the stability and safety of the porcelain insulator in practical applications. This installation step secures the wire connector and fixing rod. The use of the locking pin 2 also effectively prevents loosening and malfunction between components, ensuring the overall structural strength and stability.

[0048] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A porcelain insulator, comprising a porcelain part (5), characterized in that: The inner wall of the porcelain part (5) is fixedly provided with a steel foot (6), a felt pad (3) is provided in the interlayer connecting the steel foot (6) and the porcelain part (5), the outer wall of the porcelain part (5) is fixedly connected to a steel cap (1) via a cement adhesive (4), and the inner wall of the steel cap (1) is provided with an external component; The external connection component comprises a receiving block, the receiving block is mounted on the top of the steel cap (1), the inner wall of the receiving block is movably connected with a wire connecting rod and a fixing rod, and the wire connecting piece is sleeved on the outer wall of the fixing rod.

2. A porcelain insulator according to claim 1, characterized in that: The top end of the wire connector extends to the outside of the accommodating block, and both ends of the fixing rod extend to the outside of the accommodating block.

3. The porcelain insulator according to claim 1, characterized in that: The inner wall of the steel cap (1) is provided with a locking pin (2), which passes through the locking pin (2), the porcelain part (5) and is connected to the steel foot (6) in sequence, and is used to fix other components. The top of the steel cap (1) is provided with a port, which is used to be connected in series with other porcelain insulators.

4. The porcelain insulator according to claim 1, characterized in that: The outer wall of the steel foot (6) is provided with a cement adhesive (4) for stabilizing the connection position of the steel foot (6) in the middle of the porcelain piece (5).

5. The porcelain insulator according to claim 1, characterized in that: The porcelain piece (5) includes but is not limited to being circular or disc-shaped.

6. A porcelain insulator production process, according to any one of claims 1 to 5, wherein: The following steps are involved: S1: Preparation of the ceramic body (5); S2: Install the felt pad (3) between the porcelain body (5) and the steel foot (6); S3: applying cement adhesive (4) between the steel cap (1) and the porcelain body (5) and between the steel foot (6) and the porcelain body (5) for bonding; S4: Install the wire connector and the fixing rod, and complete the overall structural connection by setting the locking pin (2).

7. A porcelain insulator production process according to claim 6, characterized in that: The detailed preparation process of step S1 includes: S11. Using a wet porcelain making process and an isostatic pressing process, the particle diameter of the wet porcelain making raw material is 10 μm to 50 μm, and the amount of binder added is 5% to 10%; S12, after the raw materials are uniformly mixed at high temperature, they are molded using a molding pressure of 5 MPa to 10 MPa; S13, then sintering the formed ceramic piece (5) at a temperature ranging from 1200°C to 1300°C for 6 hours to 10 hours.

8. A porcelain insulator production process according to claim 6, characterized in that: In step S4, the size of the accommodating block is Φ20mm to Φ30mm, and a fixing rod is installed in the accommodating block. The length of the fixing rod is 50mm to 80mm and the diameter is 6mm to 8mm; The wire connector is sleeved on the surface of the fixing rod, the outer diameter of the wire connector is 10mm to 15mm, and both ends of the fixing rod extend to the outside of the accommodating block to enhance the connection strength.

9. The porcelain insulator production process according to claim 6, characterized in that: The cement adhesive (4) in step S3 is electrical insulating cement, the bonding strength of which is required to be no less than 4 MPa, and the usage amount is 50 g to 100 g per square meter.

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