High-performance glass insulator and preparation method thereof

Abstract

The invention belongs to the technical field of electrical equipment insulating materials, and particularly discloses a high-performance glass insulator and a preparation method thereof, and the high-performance glass insulator comprises the following components in percentage by mass: 65.0 to 75.0 weight percent of silicon oxide, 6.0 to 8.0 weight percent of calcium oxide, 2.0 to 4.0 weight percent of potassium oxide, 10.0 to 12.0 weight percent of sodium oxide, 3.0 to 5.0 weight percent of magnesium oxide, 2.0 to 4.0 weight percent of aluminum oxide, 0.5 to 1.5 weight percent of zirconium oxide and 0.5 to 1.5 weight percent of barium oxide. According to the high-performance glass insulator and the preparation method thereof, the method is based on a composition-structure-performance correlation model, five core design principles are strictly followed, and the electrical performance, the mechanical performance, the thermal performance and the stability of the glass insulator are synergistically improved by accurately regulating and controlling the glass formula composition and the preparation process.

Description

Technical Field

[0001] This invention belongs to the technical field of electrical equipment insulation materials, specifically relating to a high-performance glass insulator and its preparation method. Background Technology

[0002] As a core insulating and mechanical support component in power transmission lines, the performance of glass insulators directly determines the safety, stability, service life, and maintenance costs of the transmission system. With the rapid development of my country's power grid towards high voltage, direct current, and long-distance transmission, higher demands are placed on the performance of glass insulators. They must not only possess excellent electrical insulation properties (such as low dielectric loss, high dielectric strength, and stable volume resistivity) and mechanical properties (such as high bending strength and high hardness), but also adapt to complex outdoor environments (such as salt spray, ultraviolet radiation, and drastic temperature changes), while simultaneously considering production feasibility, cost control, and the requirements of green and sustainable development.

[0003] Currently, the formulation design of glass insulators in existing technologies is mostly based on empirical adjustments, lacking the support of a systematic composition-structure-performance correlation model. This leads to a high degree of blindness in formulation optimization, making it difficult to achieve synergistic improvement of various performance indicators, and often resulting in the problem of "focusing on one aspect while neglecting another". Specifically, this is reflected in the following aspects: (1) Poor performance synergy: In the existing technology, it is difficult to achieve a balance between the electrical performance, mechanical performance, thermal performance and stability of glass insulators; (2) Insufficient production adaptability: The melting temperature of some existing high-performance glass insulator formulations is too high, which is not compatible with the horseshoe flame furnace equipment of most domestic manufacturers with electric flux. If production is to be realized, the existing equipment needs to be modified on a large scale, which increases production costs and production risks; (3) Imbalance between green environmental protection and cost control: In order to pursue high performance, some existing formulations use rare metal oxides (such as rare earth oxides and precious metal oxides), which not only leads to a significant increase in raw material costs, but also makes it difficult to achieve large-scale industrial production due to the scarcity of rare metal resources; on the other hand, the existing preparation process mostly uses virgin raw materials and does not make full use of recycled resources (such as recycled broken glass), resulting in high energy consumption and large emissions of pollutants such as CO2, which does not meet the requirements of the national "dual carbon" strategy and green industrial development. (4) Poor crystallization control: Most existing glass insulator formulations are not designed with systematic reference to glass formation zone diagrams and phase diagrams. They do not prioritize the selection of composition points near the eutectic point or phase boundary, but simply add a single oxide to suppress crystallization. This results in a high crystallization rate during the melting, cooling, and long-term use of the glass. Crystallization will destroy the uniformity of the glass, leading to a decrease in mechanical strength, an increase in dielectric loss, and a shortening of the insulator's service life. (5) Poor DC electric field adaptability: With the widespread application of DC transmission technology, the performance defects of existing glass insulators under DC electric fields are becoming increasingly prominent. Because existing formulations do not specifically adjust ion mobility, alkali metal ions (Na+) are more susceptible to crystallization. + K +The rapid migration speed of the dielectric leads to increased dielectric loss, and long-term use can easily cause problems such as insulation aging and leakage, making it unable to meet the requirements for long-term stable use under DC electric fields.

[0004] Therefore, there is a need in this field to develop a high-performance glass insulator and its preparation method that can effectively solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide a high-performance glass insulator and its preparation method. This method is based on a composition-structure-performance correlation model and strictly follows five core design principles (performance-oriented, low crystallization optimization, production adaptability, cost control, and green sustainability). By precisely controlling the glass formulation and preparation process, the electrical, mechanical, thermal, and stability properties of the glass insulator are synergistically improved. At the same time, it takes into account the requirements of production adaptability, cost control, and green sustainability. It is compatible with existing production equipment, reduces production costs and pollutant emissions, and can be used stably for a long time under a DC electric field, thereby solving many shortcomings of the existing technology.

[0006] To achieve the above objectives, the present invention provides a high-performance glass insulator comprising the following components by weight percentage: silicon oxide (SiO2) 65.0~75.0 wt%, calcium oxide (CaO) 6.0~8.0 wt%, potassium oxide (K2O) 2.0~4.0 wt%, sodium oxide (Na2O) 10.0~12.0 wt%, magnesium oxide (MgO) 3.0~5.0 wt%, aluminum oxide (Al2O3) 2.0~4.0 wt%, zirconium oxide (ZrO2) 0.5~1.5 wt%, and barium oxide (BaO) 0.5~1.5 wt%.

[0007] Preferably, the composition comprises the following components by mass percentage: 70wt% silicon dioxide (SiO2), 7wt% calcium oxide (CaO), 3wt% potassium oxide (K2O), 11wt% sodium oxide (Na2O), 4wt% magnesium oxide (MgO), 3wt% aluminum oxide (Al2O3), 1wt% zirconium oxide (ZrO2), and 1wt% barium oxide (BaO).

[0008] Al2O3, as a network intermediate, partially replaces Si in the network structure, reduces the amount of non-bridging oxygen, significantly improves the mechanical strength, chemical stability and volume resistivity of glass, and inhibits the migration of alkali metal ions. Its content is controlled at 2.0~4.0wt% to avoid excessive addition leading to an increased tendency for glass crystallization. K2O and Na2O form a mixed alkali effect. By precisely controlling the mass ratio, the activation energy of alkali metal ion migration is synergistically regulated, which greatly reduces the ion migration rate and dielectric loss under DC electric field. This solves the insulation degradation problem caused by DC migration of single alkali metal ions. Na2O is the dominant alkali metal oxide, which ensures the fluidity of glass melting, while K2O assists in regulating ion migration performance. ZrO2, as a high field strength and high stability oxide, significantly improves the glass densification degree, reduces dielectric loss under a fixed electric field, and enhances the long-term stability of DC operation. At the same time, it enhances the resistance to salt spray and acid and alkali corrosion. Its content is controlled at 0.5~1.5wt%, balancing performance improvement and cost control. BaO, as an alkaline earth metal modifier, adjusts the viscosity-temperature characteristics of glass, improves the refractive index and mechanical strength, reduces high-temperature viscosity, improves forming performance, and inhibits the precipitation of crystalline phases. Its content is controlled at 0.5~1.5wt% to avoid excessive glass density and increased production costs. MgO and CaO work synergistically as network modifiers to regulate the compactness of the glass structure, improve chemical stability and mechanical properties, and participate in the construction of low crystallization systems to inhibit crystal growth.

[0009] This invention also provides a method for preparing a high-performance glass insulator, comprising the following steps: Step S1: Weigh the raw materials according to the mass percentage of each component: quartz sand, soda ash, potassium carbonate, calcium carbonate, magnesium oxide, aluminum oxide, zirconium oxide, barium carbonate, and recycled crushed glass; crush each raw material to a particle size ≤1mm and sieve it through a 100-mesh sieve. Step S2: Place each raw material into a drying oven for drying; Step S3: Put all raw materials and composite clarifying and homogenizing agent into a V-type mixer for mixing, and then sieve through a 20-40 mesh screen to obtain a mixture; The mixture is stored in sealed bags for ≤24 hours and is used as needed. Step S4: The mixture is uniformly added to the furnace at a feeding rate of 2.5~3t / h through a feeder for melting to obtain molten glass; Step S5: The molten glass is sequentially molded and tempered. After completion, an impact test is performed to eliminate unqualified products with internal defects or prone to cracking, thus obtaining high-performance glass insulators.

[0010] Preferably, in step S1, the quartz sand contains ≥99.5% SiO2 and ≤0.02% Fe2O3. Quartz sand boasts high purity and low impurity content, preventing impurities from affecting the transparency and electrical properties of glass. Furthermore, quartz sand is readily available and inexpensive, adhering to the principle of cost control. Soda ash provides excellent fluxing properties, has a low decomposition temperature, effectively provides Na₂O, and is inexpensive and readily available, avoiding the use of high-cost sodium sources (such as sodium nitrate), thus adhering to the principle of cost control. Potassium carbonate provides stable fluxing properties, accurately provides K₂O, and has low impurity content, avoiding impact on the performance stability of the glass. Calcium carbonate decomposes to provide CaO, is inexpensive and readily available, and its decomposition product is CO₂, causing no environmental pollution, thus adhering to the principle of green sustainability. Magnesium oxide has high purity, accurately provides MgO, and is not easily volatile, reducing raw material loss and pollutant emissions during the melting process, thus adhering to the principle of green sustainability. Alumina has high purity and uniform particle size, allowing for uniform dispersion in the glass system to fully exert its reinforcing effect, and its moderate cost avoids excessive use of high-cost aluminum sources. Zirconia effectively fills vacancies in the silicon-oxygen network, improving dielectric loss, and requires only a small amount, keeping costs under control. Barium carbonate can stably provide BaO, and its decomposition temperature is moderate, which does not affect the glass melting process, and its cost is moderate.

[0011] The recycled rubble contains ≥70% SiO2 and ≤1.0% impurities. The amount of recycled rubble added is 20-30% of the total amount of raw materials.

[0012] Recycled glass fragments are derived from waste glass insulators, construction waste glass, etc. After being crushed, screened, and cleaned, they are used to replace some of the virgin quartz sand raw materials, reducing the consumption of virgin resources and CO2 emissions, thus conforming to green and sustainable principles. This amount of recycled glass ensures glass performance while achieving the goal of reducing CO2 emissions.

[0013] Preferably, in step S2, the drying temperature is 105~110℃ and the drying time is 2~3h.

[0014] Preferably, in step S3, the rotation speed of the V-type mixer is 20~30 r / min, and the mixture is mixed until the uniformity is ≥95%.

[0015] Preferably, the composite clarifying and homogenizing agent is composed of cerium dioxide (CeO2), antimony trioxide (Sb2O3), and borate, with the mass ratio of cerium dioxide, antimony trioxide, and borate being 0.8~1:0.5~0.6:0.3~0.4; The amount of compound clarifying and homogenizing agent added is 0.1~0.3% of the total amount of raw materials.

[0016] Preferably, in step S4, the temperature is increased from 23~25℃ to 1500~1550℃ at a rate of 5℃ / min for melting.

[0017] Preferably, step S5 specifically includes: Step S51: The molten glass enters the pressing and molding equipment. The pressing and molding temperature is 750~850℃, the pressing and molding pressure is 8~12MPa, and the holding time is 3~4s to prepare an integrated blank of glass insulator skirt and core rod. Step S52: Place the preform into a uniform temperature furnace and transfer it. The preheating and holding temperature in the uniform temperature furnace is 650~700℃ and the holding time is 2~3 minutes. Then, it enters the physical tempering furnace for tempering and strengthening, and heats the glass preform to the tempering temperature. Step S53: Rapidly cool the glass blank using symmetrical cold air from the top and bottom; the temperature of the cold air is 20~30℃, dry and free of oil and water, the pressure of the cold air is 0.4~0.6MPa, the upper and lower air pressure deviation is ≤±0.02MPa, the distance between the air outlet and the surface of the glass blank is 15~30mm, and the rapid cooling time is 30~60s, so that a uniform compressive stress layer is formed on the glass surface and a tensile stress layer is formed inside, which significantly improves the bending strength and impact resistance; thus obtaining a tempered glass insulator. Air-cooled tempering avoids surface defects caused by water cooling, resulting in better tempering uniformity and a more significant improvement in mechanical strength. At the same time, the air-cooling process consumes less energy and produces no wastewater, which aligns with green and sustainable principles.

[0018] Step S54: After tempering, the glass insulator undergoes an impact test and is cleaned to remove surface defects and stress concentration points, thus obtaining a high-performance glass insulator.

[0019] Preferably, in step S52, the tempering temperature is Tg+50-80℃, where Tg is the glass transition temperature.

[0020] The present invention employs the above-mentioned high-performance glass insulator and its preparation method, and the beneficial effects are as follows: The composition design of the high-performance glass insulator in this invention strictly follows five core principles. These five principles work synergistically and are subject to closed-loop management to ensure the scientific, rational, and practical nature of the formulation. Specifically: (1) Performance-oriented principle: Taking the service performance of UHVDC as the core objective, a multi-component synergistic system of SiO2-CaO-Na2O-K2O-MgO-Al2O3-ZrO2-BaO is constructed, in which each component has complementary functions and synergistic effects. As a glass network forging body, SiO2 provides a three-dimensional network framework to ensure the stability of the glass basic structure, chemical stability and insulation performance. The content is controlled at 65.0~75.0wt% to maintain the network connectivity to ensure insulation performance, while avoiding excessive content that would lead to increased melting temperature and increased melting difficulty.

[0021] (2) Low crystallization optimization principle: Refer to the glass formation zone diagram and phase diagram, prioritize the selection of composition points near the eutectic point or phase boundary, introduce calcium oxide, magnesium oxide and other components to form a multi-component system, reduce the nucleation probability, and accurately control the composition ratio so that the crystallization rate is ≤0.5%. This can avoid defects such as devitrification, crystal spots and stones during melting, forming and tempering, thereby ensuring the uniformity of glass and the consistency of optical and electromechanical properties.

[0022] (3) Production adaptation principle: The melting temperature range of this invention is 750~1550℃, which is fully compatible with existing industrial electric-assisted horseshoe flame kilns. There is no need to modify the kiln structure or add special melting equipment; the high temperature viscosity is moderate, which reduces the erosion of refractory materials.

[0023] (4) Cost control principle: The main raw materials are low-toxicity and readily available materials such as quartz sand, soda ash, potassium carbonate, calcium carbonate, magnesium oxide and aluminum oxide. The raw materials are readily available and the procurement cost is low. Only trace amounts of ZrO2 and BaO are added to achieve functional modification, avoiding excessive addition of rare earth oxides and rare metal oxides. The unit raw material cost is lower than that of the existing high-performance formula. The use of recycled glass powder can further reduce raw material consumption and crushing and processing costs, while reducing waste glass treatment costs. The overall economic benefits are significant.

[0024] (5) Green and sustainable principle: Introduce recycled crushed glass, accounting for 20-30% of the raw material addition, to replace part of the original mineral raw materials, reduce the mining and consumption of quartz sand, soda ash, calcium carbonate, etc., and reduce CO2 emissions by more than 15%; the composite clarifying and homogenizing agent is low in volatility, fluorine-free, arsenic-free, and cadmium-free, and the waste gas in the production process can meet the emission standards after simple treatment, and the waste residue can be recycled as a recycled raw material, thereby realizing green manufacturing of glass insulators throughout the entire life cycle, which is in line with the national "dual carbon" strategy and the requirements of green industrial development.

[0025] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0026] Figure 1 This is a comparison diagram of the bending strength of various glass insulators in experimental examples of a high-performance glass insulator and its preparation method according to the present invention; Figure 2 This is a comparison chart of the Vickers hardness of various glass insulators in the experimental examples of the high-performance glass insulator and its preparation method of the present invention. Detailed Implementation

[0027] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0028] Unless otherwise defined, the technical or scientific terms used in this invention shall have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains.

[0029] Example 1 A method for preparing a high-performance glass insulator includes the following steps: Step S1: Weigh the raw materials according to the following mass percentages: silicon dioxide 70wt%, calcium oxide 7wt%, potassium oxide 3wt%, sodium oxide 11wt%, magnesium oxide 4wt%, aluminum oxide 3wt%, zirconium oxide 1wt%, and barium oxide 1wt%. Weigh the raw materials: quartz sand, soda ash, potassium carbonate, calcium carbonate, magnesium oxide, aluminum oxide, zirconium oxide, barium carbonate, and recycled broken glass.

[0030] Recycled glass shards are derived from waste glass insulators, construction waste glass, etc. After crushing, screening, and cleaning, their SiO2 content is ≥70% and impurity content is ≤1.0%. The amount of recycled glass shards added is 25% of the total raw material addition.

[0031] All raw materials are crushed to a particle size of ≤1mm and then sieved through a 100-mesh sieve.

[0032] Step S2: Place each raw material in a drying oven at 110℃ and dry for 2.5 hours.

[0033] Step S3: Place all raw materials and the composite clarifying and homogenizing agent into a V-type mixer and mix them at a speed of 25 r / min until the homogeneity is ≥95%. Then, sieve the mixture through a 30-mesh screen to obtain the final mixture. Store the mixture in a sealed bag for ≤24 hours, and prepare and use as needed.

[0034] The composite clarifying and homogenizing agent is composed of cerium dioxide, antimony trioxide, and borate, with a mass ratio of 0.9:0.5:0.3. The amount of the composite clarifying and homogenizing agent added is 0.2% of the total amount of raw materials.

[0035] Step S4: The mixture is fed into the furnace at a rate of 3t / h using a feeder, and the temperature is increased from 25℃ to 1550℃ at a rate of 5℃ / min to obtain molten glass.

[0036] During the melting process, the temperature and pressure inside the kiln are monitored in real time, with temperature fluctuations controlled within ±10℃ and pressure controlled within 0.02MPa.

[0037] Step S5: The molten glass is sequentially molded and tempered. After completion, an impact test is performed to eliminate unqualified products with internal defects or prone to cracking, thus obtaining high-performance glass insulators.

[0038] Step S51: The molten glass enters the pressing and molding equipment. The pressing and molding temperature is 800℃, the pressing and molding pressure is 10MPa, and the holding time is 3s to prepare an integrated blank of glass insulator skirt and core rod.

[0039] Step S52: The glass preform is placed into a homogenizing furnace by a robotic arm. The preheating temperature in the homogenizing furnace is 700℃, and the heating and holding time is 2.5 minutes. Then, the preform is placed from the outlet into a physical tempering furnace by the robotic arm for tempering and strengthening. The glass preform is heated to a tempering temperature of 625℃ (tempering temperature is Tg + 50 - 80℃, where Tg is the glass transition temperature; in this embodiment, Tg = 560℃).

[0040] Step S53: Rapidly cool the glass blank using symmetrical cold air from the top and bottom. The temperature of the cold air is 25℃, and it is dry, oil-free, and water-free. The pressure of the cold air is 0.5MPa, and the pressure deviation between the top and bottom air is ≤±0.02MPa. The distance between the air outlet and the surface of the glass blank is 20mm, and the rapid cooling time is 45s, resulting in a tempered glass insulator.

[0041] Step S54: After tempering, the glass insulator undergoes impact testing and cleaning to obtain a high-performance glass insulator.

[0042] The impact test is conducted as follows: Impact testing equipment conforming to insulator industry standards is used. An impact hammer matching the product specifications is selected (impact energy is set according to the glass insulator model, typically 10-20J). Under normal temperature and pressure, the tempered glass insulator is fixed onto a dedicated test fixture, ensuring the fixture does not damage the insulator surface and is securely fixed. The impact hammer is dropped freely from a set height (corresponding to the standard impact energy), impacting the designated test area of ​​the insulator (usually the middle of the insulator skirt or the junction of the porcelain core and skirt). At least three samples are randomly selected from each batch for testing. During the test, the insulator is observed for cracks, chipping, or bursting. If all tested samples show no obvious defects or bursting, the batch is deemed to have passed the impact test. If any sample shows bursting or penetrating cracks, the sampling range needs to be expanded for retesting. Unqualified batches must be reworked and retested until the impact test standard is met, ensuring the elimination of hidden internal defects and preventing potential explosion hazards during subsequent use.

[0043] Example 2 A method for preparing a high-performance glass insulator includes the following steps: Step S1: Weigh the raw materials quartz sand, soda ash, potassium carbonate, calcium carbonate, magnesium oxide, aluminum oxide, zirconium oxide, barium carbonate, and recycled broken glass according to the following mass percentages: silicon oxide 65.0 wt%, calcium oxide 8 wt%, potassium oxide 4 wt%, sodium oxide 12 wt%, magnesium oxide 5 wt%, aluminum oxide 4 wt%, zirconium oxide 0.5 wt%, and barium oxide 1.5 wt%.

[0044] Recycled glass shards are derived from waste glass insulators, construction waste glass, etc. After crushing, screening, and cleaning, their SiO2 content is ≥70% and impurity content is ≤1.0%. The amount of recycled glass shards added is 25% of the total raw material addition.

[0045] All raw materials are crushed to a particle size of ≤1mm and then sieved through a 100-mesh sieve.

[0046] Step S2: Place each raw material in a drying oven at 110℃ and dry for 2.5 hours.

[0047] Step S3: Place all raw materials and the composite clarifying and homogenizing agent into a V-type mixer and mix them at a speed of 25 r / min until the homogeneity is ≥95%. Then, sieve the mixture through a 30-mesh screen to obtain the final mixture. Store the mixture in a sealed bag for ≤24 hours, and prepare and use as needed.

[0048] The composite clarifying and homogenizing agent is composed of cerium dioxide, antimony trioxide, and borate, with a mass ratio of 0.9:0.5:0.3. The amount of the composite clarifying and homogenizing agent added is 0.2% of the total amount of raw materials.

[0049] Step S4: The mixture is fed into the furnace at a rate of 3t / h using a feeder, and the temperature is increased from 25℃ to 1550℃ at a rate of 5℃ / min to obtain molten glass.

[0050] During the melting process, the temperature and pressure inside the kiln are monitored in real time, with temperature fluctuations controlled within ±10℃ and pressure controlled within 0.02MPa.

[0051] Step S5: The molten glass is sequentially molded and tempered. After completion, an impact test is performed to eliminate unqualified products with internal defects or prone to cracking, thus obtaining high-performance glass insulators.

[0052] Step S51: The molten glass enters the pressing and molding equipment. The pressing and molding temperature is 800℃, the pressing and molding pressure is 10MPa, and the holding time is 3s to prepare an integrated blank of glass insulator skirt and core rod.

[0053] Step S52: The glass preform is placed into a homogenizing furnace by a robotic arm. The preheating temperature in the homogenizing furnace is 700℃, and the heating and holding time is 2.5 minutes. Then, the preform is placed from the outlet into a physical tempering furnace by the robotic arm for tempering and strengthening. The glass preform is heated to a tempering temperature of 625℃ (tempering temperature is Tg + 50 - 80℃, where Tg is the glass transition temperature; in this embodiment, Tg = 560℃).

[0054] Step S53: Rapidly cool the glass blank using symmetrical cold air from the top and bottom. The temperature of the cold air is 25℃, and it is dry, oil-free, and water-free. The pressure of the cold air is 0.5MPa, and the pressure deviation between the top and bottom air is ≤±0.02MPa. The distance between the air outlet and the surface of the glass blank is 20mm, and the rapid cooling time is 45s, resulting in a tempered glass insulator.

[0055] Step S54: After tempering, the glass insulator undergoes impact testing and cleaning to obtain a high-performance glass insulator.

[0056] The specific details of the impact test are the same as in Example 1.

[0057] Example 3 A method for preparing a high-performance glass insulator includes the following steps: Step S1: Weigh the raw materials quartz sand, soda ash, potassium carbonate, calcium carbonate, magnesium oxide, aluminum oxide, zirconium oxide, barium carbonate, and recycled broken glass according to the following mass percentages: silicon oxide 75.0 wt%, calcium oxide 6 wt%, potassium oxide 2 wt%, sodium oxide 10 wt%, magnesium oxide 3 wt%, aluminum oxide 2 wt%, zirconium oxide 1.5 wt%, and barium oxide 0.5 wt%.

[0058] Recycled glass shards are derived from waste glass insulators, construction waste glass, etc. After crushing, screening, and cleaning, their SiO2 content is ≥70% and impurity content is ≤1.0%. The amount of recycled glass shards added is 25% of the total raw material addition.

[0059] All raw materials are crushed to a particle size of ≤1mm and then sieved through a 100-mesh sieve.

[0060] Step S2: Place each raw material in a drying oven at 110℃ and dry for 2.5 hours.

[0061] Step S3: Place all raw materials and the composite clarifying and homogenizing agent into a V-type mixer and mix them at a speed of 25 r / min until the homogeneity is ≥95%. Then, sieve the mixture through a 30-mesh screen to obtain the final mixture. Store the mixture in a sealed bag for ≤24 hours, and prepare and use as needed.

[0062] The composite clarifying and homogenizing agent is composed of cerium dioxide, antimony trioxide, and borate, with a mass ratio of 0.9:0.5:0.3. The amount of the composite clarifying and homogenizing agent added is 0.2% of the total amount of raw materials.

[0063] Step S4: The mixture is fed into the furnace at a rate of 3t / h using a feeder, and the temperature is increased from 25℃ to 1550℃ at a rate of 5℃ / min to obtain molten glass.

[0064] During the melting process, the temperature and pressure inside the kiln are monitored in real time, with temperature fluctuations controlled within ±10℃ and pressure controlled within 0.02MPa.

[0065] Step S5: The molten glass is sequentially molded and tempered. After completion, an impact test is performed to eliminate unqualified products with internal defects or prone to cracking, thus obtaining high-performance glass insulators.

[0066] Step S51: The molten glass enters the pressing and molding equipment. The pressing and molding temperature is 800℃, the pressing and molding pressure is 10MPa, and the holding time is 3s to prepare an integrated blank of glass insulator skirt and core rod.

[0067] Step S52: The glass preform is placed into a homogenizing furnace by a robotic arm. The preheating temperature in the homogenizing furnace is 700℃, and the heating and holding time is 2.5 minutes. Then, the preform is placed from the outlet into a physical tempering furnace by the robotic arm for tempering and strengthening. The glass preform is heated to a tempering temperature of 625℃ (tempering temperature is Tg + 50 - 80℃, where Tg is the glass transition temperature; in this embodiment, Tg = 560℃).

[0068] Step S53: Rapidly cool the glass blank using symmetrical cold air from the top and bottom. The temperature of the cold air is 25℃, and it is dry, oil-free, and water-free. The pressure of the cold air is 0.5MPa, and the pressure deviation between the top and bottom air is ≤±0.02MPa. The distance between the air outlet and the surface of the glass blank is 20mm, and the rapid cooling time is 45s, resulting in a tempered glass insulator.

[0069] Step S54: After tempering, the glass insulator undergoes impact testing and cleaning to obtain a high-performance glass insulator.

[0070] The specific details of the impact test are the same as in Example 1.

[0071] Comparative Example 1 A method for preparing a glass insulator includes the following steps: Step S1: Weigh the raw materials quartz sand, soda ash, potassium carbonate, calcium carbonate, magnesium oxide, aluminum oxide, and barium carbonate according to the following mass percentages: silicon oxide 70wt%, calcium oxide 7wt%, potassium oxide 3wt%, sodium oxide 11wt%, magnesium oxide 4wt%, aluminum oxide 3wt%, and barium oxide 2wt%.

[0072] All raw materials are crushed to a particle size of ≤1mm and then sieved through a 100-mesh sieve.

[0073] Step S2: Place each raw material in a drying oven at 110℃ and dry for 2.5 hours.

[0074] Step S3: Place all raw materials and the composite clarifying and homogenizing agent into a V-type mixer and mix them at a speed of 25 r / min until the homogeneity is ≥95%. Then, sieve the mixture through a 30-mesh screen to obtain the final mixture. Store the mixture in a sealed bag for ≤24 hours, and prepare and use as needed.

[0075] The composite clarifying and homogenizing agent is composed of cerium dioxide, antimony trioxide, and borate, with a mass ratio of 0.9:0.5:0.3. The amount of the composite clarifying and homogenizing agent added is 0.2% of the total amount of raw materials.

[0076] Step S4: The mixture is fed into the furnace at a rate of 3t / h using a feeder, and the temperature is increased from 25℃ to 1550℃ at a rate of 5℃ / min to obtain molten glass.

[0077] During the melting process, the temperature and pressure inside the kiln are monitored in real time, with temperature fluctuations controlled within ±10℃ and pressure controlled within 0.02MPa.

[0078] Step S5: The molten glass is sequentially molded and tempered. After completion, an impact test is performed to eliminate unqualified products with internal defects or prone to cracking, thus obtaining high-performance glass insulators.

[0079] Step S51: The molten glass enters the pressing and molding equipment. The pressing and molding temperature is 800℃, the pressing and molding pressure is 10MPa, and the holding time is 3s to prepare an integrated blank of glass insulator skirt and core rod.

[0080] Step S52: The glass preform is transferred into a homogenizing furnace via a robotic arm. The preheating temperature in the homogenizing furnace is 700℃, and the holding time is 2.5 minutes. Then, the preform is transferred from the outlet to a physical tempering furnace via the robotic arm for tempering and strengthening. The glass preform is heated to a tempering temperature of 625℃ (tempering temperature is Tg + 50 - 80℃, where Tg is the glass transition temperature; in this comparative example, Tg = 560℃).

[0081] Step S53: Rapidly cool the glass blank using symmetrical cold air from the top and bottom. The temperature of the cold air is 25℃, and it is dry, oil-free, and water-free. The pressure of the cold air is 0.5MPa, and the pressure deviation between the top and bottom air is ≤±0.02MPa. The distance between the air outlet and the surface of the glass blank is 20mm, and the rapid cooling time is 45s, resulting in a tempered glass insulator.

[0082] Step S54: After tempering, the glass insulator undergoes an impact test and is cleaned to obtain the glass insulator.

[0083] The specific details of the impact test are the same as in Example 1.

[0084] Comparative Example 2 The difference between Comparative Example 2 and Example 1 is that: Step S5: The molten glass is molded and tempered sequentially. After completion, an impact test is performed to eliminate unqualified products with internal defects or prone to cracking, thus obtaining the glass insulator.

[0085] Step S51: The molten glass enters the pressing and molding equipment. The pressing and molding temperature is 800℃, the pressing and molding pressure is 10MPa, and the holding time is 3s to prepare an integrated blank of glass insulator skirt and core rod.

[0086] Step S52: The glass preform is transferred into a homogenizing furnace via a robotic arm. The preheating temperature in the homogenizing furnace is 700℃, and the holding time is 2.5 minutes. Then, the preform is transferred from the outlet to a physical tempering furnace via the robotic arm for tempering and strengthening. The glass preform is heated to a tempering temperature of 625℃ (tempering temperature is Tg + 50 - 80℃, where Tg is the glass transition temperature; in this comparative example, Tg = 560℃).

[0087] Step S53: The glass blank is water-cooled and tempered at 25°C to obtain a tempered glass insulator.

[0088] Step S54: After tempering, the glass insulator undergoes an impact test and is cleaned to obtain the glass insulator. The specific details of the impact test are the same as in Example 1.

[0089] The remaining steps are the same as in Example 1.

[0090] Experimental Example The glass insulators prepared in Examples 1-3 and Comparative Examples 1-2 were subjected to performance testing, and the results are shown in Table 1. Figures 1-2 As shown.

[0091] (1) Thermal performance testing: The melting temperature was measured using a differential thermal analyzer (DTA) at a heating rate of 10℃ / min in air. The coefficient of thermal expansion was measured using a thermal expansion meter at a temperature range of 25~300℃ and a heating rate of 5℃ / min.

[0092] (2) Mechanical performance testing: Bending strength was tested using a universal testing machine with a span of 30 mm and a loading rate of 2 mm / min. Vickers hardness was tested using a Vickers hardness tester with a load of 500 g and a holding time of 10 s.

[0093] (3) Optical performance testing: Visible light transmittance was tested using a transmittance meter with a test wavelength range of 400~760nm and a sample thickness of 3mm. Refractive index was tested using an Abbe refractometer at a test temperature of 25℃.

[0094] (4) Stability test: The crystallization rate was observed using a polarizing microscope, and the proportion of crystallized area to the total area was counted. Salt spray test was conducted in accordance with GB / T10125-2021 "Artificial Atmosphere Corrosion Test - Salt Spray Test", using neutral salt spray, with a test time of 1000h, and the surface of the sample was observed for corrosion.

[0095] (5) Electrical performance testing: Dielectric strength was tested using a breakdown voltage tester with an electrode spacing of 2 mm and a voltage rise rate of 1 kV / s. Volume resistivity was tested using a high-resistivity meter at a test temperature of 25℃ and a humidity of 60%RH.

[0096] Table 1 Performance Test Results

[0097] As shown in Table 1, the melting temperature of the glass insulator prepared in the embodiments of the present invention is 1350~1500℃; the coefficient of thermal expansion is ≤8×10⁻⁶. -6 / ℃ (25~300℃), flexural strength ≥80MPa; Vickers hardness ≥550HV, visible light transmittance ≥90% (3mm), refractive index 1.52~1.60, crystallization rate ≤0.5%; no obvious corrosion after 1000h salt spray test, dielectric strength ≥15kV / mm, volume resistivity ≥1×10 12 The CO2 emission reduction is ≥15% (Ω·cm), which is superior to the comparative example.

[0098] Therefore, this invention employs the aforementioned high-performance glass insulator and its preparation method. This method is based on a composition-structure-performance correlation model and strictly follows five core design principles (performance-oriented, low crystallization optimization, production adaptability, cost control, and green sustainability). By precisely controlling the glass formulation composition and preparation process, it achieves a synergistic improvement in the electrical, mechanical, thermal, and stability properties of the glass insulator. At the same time, it takes into account production adaptability, cost control, and green sustainability requirements, adapts to existing production equipment, reduces production costs and pollutant emissions, and can adapt to long-term stable use under DC electric fields, thereby solving many shortcomings of existing technologies.

[0099] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

Claims

1. A high-performance glass insulator, characterized in that, The composition comprises, by weight percentage, the following: silicon dioxide 65.0-75.0 wt%, calcium oxide 6.0-8.0 wt%, potassium oxide 2.0-4.0 wt%, sodium oxide 10.0-12.0 wt%, magnesium oxide 3.0-5.0 wt%, aluminum oxide 2.0-4.0 wt%, zirconium oxide 0.5-1.5 wt%, and barium oxide 0.5-1.5 wt%.

2. The high-performance glass insulator according to claim 1, characterized in that, The composition comprises the following components by weight percentage: 70 wt% silicon oxide, 7 wt% calcium oxide, 3 wt% potassium oxide, 11 wt% sodium oxide, 4 wt% magnesium oxide, 3 wt% aluminum oxide, 1 wt% zirconium oxide, and 1 wt% barium oxide.

3. A method for preparing a high-performance glass insulator as described in any one of claims 1-2, characterized in that, Includes the following steps: Step S1: Weigh the raw materials according to the mass percentage of each component: quartz sand, soda ash, potassium carbonate, calcium carbonate, magnesium oxide, aluminum oxide, zirconium oxide, barium carbonate, and recycled glass; crush each raw material to a particle size ≤1mm and sieve it through a 100-mesh sieve. Step S2: Place each raw material into a drying oven for drying; Step S3: Put all raw materials and composite clarifying and homogenizing agent into a V-type mixer for mixing, and then sieve through a 20-40 mesh screen to obtain a mixture; The mixture is stored in sealed bags for ≤24 hours and is used as needed. Step S4: The mixture is uniformly added to the furnace at a feeding rate of 2.5~3t / h through a feeder for melting to obtain molten glass; Step S5: The molten glass is sequentially molded and tempered. After completion, an impact test is performed to eliminate unqualified products with internal defects or prone to cracking, thus obtaining high-performance glass insulators.

4. The method for preparing a high-performance glass insulator according to claim 3, characterized in that: In step S1, the SiO2 content in the quartz sand is ≥99.5%; The recycled rubble contains ≥70% SiO2 and ≤1.0% impurities. The amount of recycled rubble added is 20-30% of the total amount of raw materials.

5. The method for preparing a high-performance glass insulator according to claim 3, characterized in that: In step S2, the drying temperature is 105~110℃ and the drying time is 2~3 hours.

6. The method for preparing a high-performance glass insulator according to claim 3, characterized in that: In step S3, the V-type mixer rotates at a speed of 20~30 r / min until the uniformity is ≥95%.

7. The method for preparing a high-performance glass insulator according to claim 3, characterized in that: The composite clarifying and homogenizing agent is composed of cerium dioxide, antimony trioxide, and borate, with a mass ratio of cerium dioxide, antimony trioxide, and borate of 0.8~1:0.5~0.6:0.3~0.

4. The amount of compound clarifying and homogenizing agent added is 0.1~0.3% of the total amount of raw materials.

8. The method for preparing a high-performance glass insulator according to claim 3, characterized in that, In step S4, the melting process specifically involves heating from 23~25℃ to 1500~1550℃ at a rate of 5℃ / min.

9. The method for preparing a high-performance glass insulator according to claim 3, characterized in that, Step S5 is as follows: Step S51: The molten glass enters the pressing and molding equipment. The pressing and molding temperature is 750~850℃, the pressing and molding pressure is 8~12MPa, and the holding time is 3~4s to prepare an integrated blank of glass insulator skirt and core rod. Step S52: Place the preform into a uniform temperature furnace and transfer it. The preheating and holding temperature in the uniform temperature furnace is 650~700℃ and the holding time is 2~3 minutes. Then, it enters the physical tempering furnace for tempering and strengthening, and heats the glass preform to the tempering temperature. Step S53: Rapidly cool the glass blank by symmetrical cold air from the top and bottom; the temperature of the cold air is 20~30℃, dry and free of oil and water, the pressure of the cold air is 0.4~0.6MPa, the upper and lower air pressure deviation is ≤±0.02MPa, the distance between the air outlet and the surface of the glass blank is 15~30mm, and the rapid cooling time is 30~60s, to obtain the tempered glass insulator. Step S54: After tempering, the glass insulator is subjected to impact testing and cleaning to obtain a high-performance glass insulator.

10. A method for preparing a high-performance glass insulator according to claim 9, characterized in that: In step S52, the tempering temperature is Tg+50-80℃, where Tg is the glass transition temperature.

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