Composite insulator and method for manufacturing the same

Abstract

This invention belongs to the field of power equipment manufacturing technology, and relates to a composite insulator and its preparation method. More specifically, it provides an intelligent high-performance composite insulator, comprising metal end caps, an inner core, a middle layer, and an outer layer, as well as an integrated micro-sensor located in the middle layer or the inner core. The inner core is made of glass fiber reinforced epoxy resin; the middle layer is made of silicone rubber containing nano-TiO2; the outer layer is a fluoropolymer coating; the integrated micro-sensor includes a micro-temperature sensor, an electric field sensor, and a stress sensor; the metal end caps are located at both ends of the inner core. The composite insulator of this invention has a three-layer structure design of inner core, middle layer, and outer layer, which comprehensively improves the mechanical, electrical, and anti-pollution flashover performance of the insulator, enhances the insulator's resistance to ultraviolet corrosion, extends its service life, and reduces the economic and labor costs associated with frequent insulator replacements.

Description

Technical Field

[0001] This invention belongs to the field of power equipment manufacturing technology, and more specifically relates to a composite insulator and its preparation method. Background Technology

[0002] In power transmission systems, insulators play a crucial role in both support and insulation. Traditional composite insulators, during long-term operation, face various challenges such as ultraviolet radiation, surface contamination, and mechanical stress, leading to decreased insulation performance and shortened service life. With the continuous development of power systems, the performance requirements for insulators are increasing, creating an urgent need for a composite insulator with higher performance and greater intelligence, along with its manufacturing process. Summary of the Invention

[0003] The purpose of this invention is to provide a composite insulator and its preparation method to solve the problem that traditional composite insulators suffer from decreased insulation performance and shortened lifespan due to factors such as ultraviolet erosion, surface contamination accumulation, and mechanical stress during long-term operation.

[0004] To achieve the above objectives, the present invention provides the following solution: One of the technical solutions of the present invention is to provide an intelligent high-performance composite insulator, comprising a metal end cap, an inner core, a middle layer and an outer layer, and an integrated micro sensor located in the middle layer or the inner core; The inner core is made of glass fiber reinforced epoxy resin; The middle layer is silicone rubber containing nano-TiO2; The outer layer is a fluoropolymer coating; The integrated micro-sensor includes a micro-temperature sensor, an electric field sensor, and a stress sensor; The metal end caps are located at both ends of the inner core.

[0005] The core of the composite insulator of this invention is glass fiber reinforced epoxy resin. The glass fiber and epoxy resin are tightly bonded together, and the high tensile strength of the glass fiber and the excellent mechanical properties of the epoxy resin provide strong support for the insulator.

[0006] The middle layer of the composite insulator of this invention is uniformly dispersed in silicone rubber with nano-TiO2, which enhances the electrical insulation performance and greatly improves the UV resistance and aging resistance.

[0007] The composite insulator of this invention possesses excellent hydrophobicity due to the special molecular structure of fluoropolymer in its outer layer, which significantly reduces surface contaminant adsorption and effectively prevents flashover accidents.

[0008] Integrated micro-sensors located in the middle layer or inner core are used to monitor parameters such as temperature, electric field, and stress in real time via wireless transmission technologies (Bluetooth Low Energy (BLE) and Narrowband Internet of Things (NB-IoT)) and transmit the monitoring data to a remote monitoring center in real time.

[0009] The second technical solution of the present invention provides a method for preparing the above-mentioned intelligent high-performance composite insulator, the steps of which include: After surface treatment of the glass fiber reinforced epoxy resin core, metal end caps are fixed to both ends of the core. Then, the glass fiber reinforced epoxy resin core is covered with a middle layer material through injection molding. Subsequently, a middle layer is formed on the surface of the glass fiber reinforced epoxy resin core through vulcanization. Then, a fluoropolymer is uniformly coated on the surface of the middle layer. After secondary molding and thermosetting, an outer layer is formed. Finally, an integrated micro-sensor is embedded to obtain the intelligent high-performance composite insulator.

[0010] Through secondary molding and thermal curing, the coating and the middle layer are tightly bonded to form a hydrophobic outer layer, while ensuring a stable bond between the outer layer, the middle layer, and the inner core.

[0011] Furthermore, the fluoropolymer includes polytetrafluoroethylene.

[0012] Furthermore, the metal end cap is made of a copper alloy material whose surface has been chemically nickel-plated.

[0013] Furthermore, the preparation steps of the glass fiber reinforced epoxy resin core include: Epoxy resin is mixed with curing agent and accelerator, stirred evenly, and then E-type glass fiber is added. The glass fiber reinforced epoxy resin core is prepared by pultrusion molding process.

[0014] Optionally, the mass ratio of the epoxy resin, curing agent, and accelerator is 100:35-40:2-3.

[0015] Optionally, the epoxy resin includes bisphenol A type epoxy resin, phenolic epoxy resin, alicyclic epoxy resin, or glycidylamine type epoxy resin.

[0016] Optionally, the curing agent includes ethylenediamine, diethylenetriamine, triethylenetetramine, or phthalic anhydride.

[0017] Optionally, the accelerator includes benzyldimethylamine, dimethylimidazole, triethanolamine, or stannous octoate.

[0018] The epoxy resin used in this invention is a high-performance epoxy resin, which has excellent mechanical strength and superior electrical insulation properties. It can maintain stable physicochemical properties under high voltage conditions, ensuring reliable operation of the insulator.

[0019] The E-type glass fiber selected in this invention has a tensile strength as high as 3000-3500MPa, good chemical stability, and can effectively enhance the mechanical properties of composite materials.

[0020] Optionally, the stirring speed for achieving uniform mixing is 500-800 rpm.

[0021] Optionally, the amount of the E-type glass fiber is 30-50% of the sum of the mass of the epoxy resin, curing agent and accelerator.

[0022] Optionally, the parameters of the pultrusion process are: temperature 120-150℃, traction speed 0.5-1.5m / min.

[0023] Furthermore, the surface treatment involves grinding the glass fiber reinforced epoxy resin core to a surface roughness of Ra3.2-6.3μm and then cleaning it.

[0024] The purpose of surface treatment is to improve the adhesion strength with the intermediate layer.

[0025] Furthermore, the parameters of the injection molding process are: temperature 150-180℃, injection pressure 10-15MPa.

[0026] By defining the parameters of the injection molding process, it is ensured that the middle layer material is uniformly coated on the surface of the inner core, thus achieving good adhesion between the inner core and the middle layer.

[0027] Furthermore, the preparation steps of the middle layer material include: Nano-TiO2 is added to vinyl silicone rubber, and after stirring and ultrasonic dispersion, vulcanizing agent and additives are added and mixed evenly to obtain the middle layer material.

[0028] The nano-TiO2 particles used in this invention have a particle size of 20-50nm and a specific surface area greater than 50m² / g, which can significantly improve the UV resistance, aging resistance and self-cleaning performance of insulators.

[0029] This invention uses vinyl silicone rubber, which has excellent high and low temperature resistance, stable performance in the temperature range of -50℃ to 200℃, and good elasticity and flexibility after vulcanization, making it suitable as a weather-resistant middle layer material.

[0030] Optionally, the stirring speed is 100-1500 rpm and the stirring time is 30-60 min.

[0031] Optionally, the power of the ultrasound is 200-300W and the duration is 20-30min.

[0032] The nano-TiO2 particles are initially dispersed by high-speed stirring, and then ultrasonic dispersion is used to ensure that the nano-TiO2 particles are uniformly dispersed in the rubber.

[0033] Optionally, the mass ratio of the nano-TiO2 to the vinyl silicone rubber is 1:20-30.

[0034] Optionally, the mass ratio of the vinyl silicone rubber, vulcanizing agent, and additives is 120-150:2-3:0.5-1.

[0035] Optionally, the vulcanizing agent includes dicumyl peroxide, benzoyl peroxide, or di-tert-butyl peroxide.

[0036] Such as 2,5-dimethyl-2,5-bis(tert-butylperoxy)hexane or other common peroxide sulfiding agents.

[0037] Optionally, the additives include dibutyltin dilaurate, stannous octoate, or titanate coupling agents.

[0038] Furthermore, the parameters for the vulcanization treatment are: temperature 180-200℃, pressure 1-2MPa, and time 30-60min.

[0039] The sulfidation process ensures a tight bond between the middle and outer layers and the metal end caps in the insulator. These metal end caps are made of copper alloy and have a nickel-plated surface.

[0040] Furthermore, the temperature of the secondary molding is 130-150℃, and the pressure is 5-8MPa.

[0041] Secondary molding is carried out in the mold of the insulator to ensure that the shape and size of the insulator fully meet the design requirements and enhance the density and durability of the middle layer material.

[0042] Furthermore, the thermosetting temperature is 150-180℃, and the time is 2-4 hours.

[0043] Thermosetting treatment ensures that the middle layer material is fully cured, thereby improving the aging resistance and electrical insulation performance of the middle layer of the insulator.

[0044] Miniature temperature sensors, electric field sensors, and stress sensors are embedded into the core or middle layer of composite insulators through a process of embedding integrated micro-sensors. After encapsulation, the sensors are ensured to be tightly bonded to the insulator material without affecting the overall performance of the insulator. The embedded integrated micro-sensors transmit monitoring data to a centralized monitoring platform via a wireless transmission module (based on Bluetooth Low Energy (BLE) or Narrowband Internet of Things (NB-IoT) technology). The monitoring platform uses big data analytics and artificial intelligence algorithms to analyze the data in real time and promptly issues early warning information when parameters exceed normal ranges.

[0045] The third technical solution of the present invention provides an application of the above-mentioned intelligent high-performance composite insulator in a power system.

[0046] The present invention discloses the following technical effects: The three-layer structure of the composite insulator forms a synergistic system through complementary material properties and functions: the inner layer of glass fiber reinforced epoxy resin, with its high-strength glass fiber (tensile strength 3000-3500MPa) combined with epoxy resin, provides core mechanical support, bearing the equipment's own weight and external loads; the middle layer of silicone rubber containing nano-TiO2 buffers dynamic stress (such as wind and vibration) through elastic deformation, and its nanoparticles absorb ultraviolet rays, slowing down material aging, while also serving as an intermediate insulating layer to improve overall electrical resistance; the outer layer of fluoropolymer coating, with its low surface energy characteristics (contact angle ≥110°), reduces surface contaminant adhesion and inhibits water film formation, synergistically enhancing anti-flashover capability with the insulation of the middle layer of silicone rubber. Between the materials, the surface treatment of the inner layer (roughness Ra3.2-6.3μm) and the vulcanization process of the middle layer enhance interfacial adhesion, ensuring effective load transfer; the elasticity of the middle layer of silicone rubber alleviates thermal stress caused by the difference in linear expansion coefficients between the inner and outer layers, improving structural stability. The outer coating reduces the direct exposure of the middle layer to harsh environments. The middle layer of nano-TiO2 and the outer layer of fluorocarbon material work together to resist ultraviolet corrosion, significantly improving aging resistance. The sensor integrated into the middle layer is protected by both inner and outer layers and can stably monitor the operating status in environments ranging from -50℃ to 200℃, forming a synergistic system of "mechanical support - insulation protection - condition monitoring". This gives the insulator high strength, weather resistance, and intelligent monitoring capabilities, meeting the long-term reliable operation requirements of high-voltage transmission equipment.

[0047] The composite insulator of this invention, after incorporating nano-TiO2, exhibits significantly improved UV resistance, self-cleaning properties, and aging resistance. The nano-TiO2 particles have a diameter of 20-50 nm and a specific surface area greater than 50 m² / g. 2 / g, uniformly dispersed in the middle layer of silicone rubber, effectively enhances the insulator's resistance to ultraviolet corrosion, extends its service life, and reduces the economic and labor costs associated with frequent insulator replacements. Nano-TiO2 possesses unique light absorption properties and photocatalytic self-cleaning function; the UV-resistant function is located in the middle layer, while the outer layer needs to remain smooth and hydrophobic (unsuitable for adding particles). The middle layer of silicone rubber, acting as an elastic carrier, can uniformly disperse TiO2, absorbing ultraviolet rays that penetrate the outer layer and directly protecting the inner epoxy resin, forming a synergistic protection of "external barrier + internal absorption".

[0048] The composite insulator of this invention features a three-layer structure consisting of an inner core, a middle layer, and an outer layer. This design comprehensively enhances the insulator's mechanical, electrical, and anti-flashover performance. The inner core is made of high-strength glass fiber reinforced epoxy resin, with glass fiber tensile strength reaching 3000-3500 MPa. The glass fiber is tightly bonded to the epoxy resin, providing strong mechanical support and enabling the insulator to withstand greater mechanical stress. The middle layer, composed of nano-TiO2-containing silicone rubber, enhances electrical insulation performance, effectively reducing the probability of electrical faults such as leakage. The outer fluoropolymer coating, with its unique molecular structure, endows the insulator with excellent hydrophobicity, significantly reducing surface contaminant adsorption, effectively preventing flashover accidents, and improving the stability and safety of power transmission.

[0049] The integration of intelligent monitoring technology enables real-time monitoring and intelligent management of insulator operating status. Miniature temperature sensors, electric field sensors, and stress sensors integrated into the middle layer or inner core transmit monitoring data to a remote monitoring center in real time via wireless transmission technologies (such as Bluetooth Low Energy (BLE) and Narrowband Internet of Things (NB-IoT)). The monitoring platform utilizes big data analytics and artificial intelligence algorithms to analyze the data in real time, issuing timely warnings when parameters exceed normal ranges. This allows maintenance personnel to take proactive measures to prevent faults, significantly improving the reliability of the power system, reducing power outages caused by insulator failures, ensuring the stability of power supply, and bringing significant social and economic benefits. Attached Figure Description

[0050] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 A schematic diagram of a high-performance intelligent composite insulator with integrated micro-sensors located in the middle layer. Detailed Implementation

[0051] Various exemplary embodiments of the present invention will now be described in detail. This detailed description should not be considered as a limitation of the present invention, but rather as a more detailed description of certain aspects, features, and embodiments of the present invention.

[0052] It should be understood that the terminology used in this invention is merely for describing particular embodiments and is not intended to limit the invention. Furthermore, with respect to numerical ranges in this invention, it should be understood that each intermediate value between the upper and lower limits of the range is also specifically disclosed. Any stated value or intermediate value within a stated range, as well as each smaller range between any other stated value or intermediate value within said range, is also included in this invention. The upper and lower limits of these smaller ranges may be independently included or excluded from the range.

[0053] Unless otherwise stated, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. While only preferred methods and materials have been described herein, any methods and materials similar or equivalent to those described herein may be used in the implementation or testing of this invention. All references to this specification are incorporated by way of citation to disclose and describe methods and / or materials associated with those references. In the event of any conflict with any incorporated reference, the content of this specification shall prevail.

[0054] Various modifications and variations can be made to the specific embodiments described in this specification without departing from the scope or spirit of the invention, as will be apparent to those skilled in the art. Other embodiments derived from this specification will also be readily apparent to those skilled in the art. This specification and embodiments are merely exemplary.

[0055] The terms “include,” “including,” “have,” “contain,” etc., used in this article are all open-ended terms, meaning that they include but are not limited to.

[0056] The raw materials and reagents involved in the specific embodiments of this invention are all commercially available products.

[0057] The vinyl silicone rubber used in the specific embodiments of this invention possesses excellent high and low temperature resistance, exhibiting stable performance within a temperature range of -50℃ to 200℃. After vulcanization, it exhibits good elasticity and flexibility, making it suitable as a weather-resistant intermediate layer material. The nano-TiO2 particles used have a particle size between 20-50nm and a specific surface area between 50-65m² / g, significantly improving the insulator's UV resistance, aging resistance, and self-cleaning properties. The selected E-type glass fiber has a tensile strength as high as 3000-3500MPa, good chemical stability, and effectively enhances the mechanical properties of the composite material. The epoxy resin used is a high-performance epoxy resin, including bisphenol A type epoxy resin, phenolic epoxy resin, alicyclic epoxy resin, or glycidylamine type epoxy resin (such as E51, NPEL-150, DER-431), possessing excellent mechanical strength and superior electrical insulation properties. It maintains stable physicochemical properties under high-voltage environments, ensuring reliable operation of the insulator.

[0058] The packaging process steps involved in the specific embodiments of the present invention are as follows: Sensor fixing: Embed the miniature sensor into the inner core or middle layer of the pre-set groove, and fix it with high temperature resistant insulating adhesive (such as silicone rubber adhesive) to ensure that the sensor is in close contact with the material; Interface sealing: Waterproof sealant is applied to the gap between the sensor and the insulator material to prevent moisture and dust from seeping in and to ensure long-term stable operation of the sensor; Surface treatment: The area where the sensor is embedded is smoothed to avoid protrusions affecting the uniformity of the outer coating and to ensure overall insulation performance.

[0059] It should be noted that any aspects not described in detail in this invention are conventional practices in the field and are not the focus of this invention.

[0060] Example 1 The fabrication steps of intelligent, high-performance composite insulators include: S1. Mix 5 kg of nano TiO2 with 150 kg of vinyl silicone rubber. First, stir the mixture in a high-speed stirrer at 1200 rpm for 45 min to initially disperse the nanoparticles. Then, use an ultrasonic dispersion device to ultrasonically treat the mixture at 250 W for 25 min to ensure that the nanoparticles are uniformly dispersed in the rubber. Subsequently, add 3 kg of vulcanizing agent (dicumyl peroxide) and 1 kg of additive (dibutyltin dilaurate), and mix evenly to obtain the middle layer material. S2. Mix 100kg of epoxy resin (E51), 40kg of curing agent (ethylenediamine), and 3kg of accelerator (benzyldimethylamine), and stir (650rpm) until uniform. Then add 45% of the total mass of epoxy resin, curing agent, and accelerator, and high-strength E-type glass fiber. Mix until uniform and prepare the glass fiber reinforced epoxy resin core using a pultrusion molding process (temperature 135℃, traction speed 1m / min). S3. The glass fiber reinforced epoxy resin core prepared in step S2 is first sanded with sandpaper until the roughness reaches Ra3.2-6.3μm, then cleaned with ethanol to remove surface impurities and oil stains. The metal end caps are fixed to both ends of the core, and the core is placed in a mold. Using injection molding, the injection temperature is controlled at 165℃ and the injection pressure at 12.5MPa. The middle layer material prepared in step S1 is injected into the mold, and then placed in a vulcanizing tank. High-temperature vulcanization is carried out at 190℃ and 1.5MPa for 45 minutes. (After the glass fiber reinforced epoxy resin core is prepared, the metal end caps are fixed to both ends of the core. When the middle layer material is injected and vulcanized using injection molding, the middle layer material will be tightly bonded to the metal end caps and the core, ensuring the overall structure is stable.) This ensures that the middle layer material is tightly bonded to the metal end caps and the glass fiber reinforced epoxy resin core. S4. After vulcanization, a fluoropolymer (polytetrafluoroethylene, solid content between 30% and 50%) is uniformly coated onto the middle layer surface by spraying (spraying pressure maintained between 0.3 and 0.5 MPa). Then, it is placed in a mold for secondary molding. The molding temperature is 145℃ and the pressure is 6.5 MPa to ensure that the shape and size of the insulator fully meet the design requirements and to enhance the density and durability of the middle layer material. S5. After the secondary molding process, perform heat curing treatment at 175℃ for 3 hours to ensure that the middle layer material is fully cured and improve the aging resistance and electrical insulation performance of the middle layer of the insulator. S6. After thermosetting, the integrated micro-sensors (micro-temperature sensor, electric field sensor and stress sensor) are embedded into the core. After encapsulation, it is ensured that the sensor is tightly bonded to the insulator material without affecting the overall performance of the insulator, resulting in an intelligent and high-performance composite insulator.

[0061] The intelligent high-performance composite insulator prepared in this embodiment transmits monitoring data to a centralized monitoring platform via a wireless transmission module (a module based on Bluetooth Low Energy (BLE) or Narrowband Internet of Things (NB-IoT) technology). The monitoring platform uses big data analysis and artificial intelligence algorithms to perform real-time analysis of the data and issues timely warning information when parameters exceed the normal range, thereby realizing the intelligent operation of the insulator in the power system.

[0062] Example 2 The fabrication steps of intelligent, high-performance composite insulators include: S1. Mix 5 kg of nano TiO2 with 150 kg of vinyl silicone rubber. First, stir the mixture in a high-speed stirrer at 1000 rpm for 60 min to initially disperse the nanoparticles. Then, use an ultrasonic dispersion device to ultrasonically treat the mixture at 200 W for 30 min to ensure that the nanoparticles are uniformly dispersed in the rubber. Subsequently, add 3 kg of vulcanizing agent (dicumyl peroxide) and 1 kg of additive (dibutyltin dilaurate), and mix evenly to obtain the middle layer material. S2. Mix 100kg of epoxy resin (NPEL-150), 35kg of curing agent (diethylenetriamine), and 2kg of accelerator (dimethylimidazole), and stir (800rpm) until uniform. Then add 30% of the total mass of epoxy resin, curing agent, and accelerator, and high-strength E-type glass fiber. Mix until uniform and prepare the glass fiber reinforced epoxy resin core using a pultrusion molding process (temperature 130℃, traction speed 1m / min). S3. The glass fiber reinforced epoxy resin core prepared in step S2 is first sanded with sandpaper until the roughness reaches Ra3.2-6.3μm. Then, it is cleaned with ethanol to remove impurities and oil stains from the surface. The metal end caps are fixed to both ends of the core and placed in the mold. The injection molding process is adopted, and the injection temperature is controlled at 160℃ and the injection pressure is 12MPa. The middle layer material prepared in step S1 is injected into the mold and then placed in the vulcanizing tank. The high-temperature vulcanization treatment is carried out at 190℃ and 1.5MPa for 45 minutes to make the middle layer material tightly bonded to the metal end caps and the glass fiber reinforced epoxy resin core. S4. After vulcanization, the fluoropolymer (polytetrafluoroethylene, solid content between 30% and 50%) is evenly coated onto the surface of the middle layer by spraying (spraying pressure maintained between 0.3 and 0.5 MPa). Then, it is placed in a mold for secondary molding. The molding temperature is 140℃ and the pressure is 6 MPa to ensure that the shape and size of the insulator fully meet the design requirements and enhance the density and durability of the middle layer material. S5. After the secondary molding process, perform heat curing treatment at 160℃ for 3 hours to ensure that the middle layer material is fully cured and improve the aging resistance and electrical insulation performance of the middle layer of the insulator. S6. After thermosetting, the integrated micro-sensors (micro-temperature sensor, electric field sensor and stress sensor) are embedded into the middle layer. After encapsulation, it is ensured that the sensor is tightly bonded to the insulator material without affecting the overall performance of the insulator, resulting in an intelligent and high-performance composite insulator.

[0063] Comparative Example 1 Compared with Example 1, the difference is that no outer layer is provided, and the insulator consists only of an inner core and a middle layer.

[0064] Comparative Example 2 Compared with Example 1, the difference is that no middle layer is provided, and the insulator consists only of an inner core and an outer layer.

[0065] Comparative Example 3 The difference compared to Example 1 is that the amount of nano-TiO2 added in the middle layer is reduced.

[0066] Comparative Example 4 The difference compared to Example 1 is that the amount of E-type glass fiber added to the inner core is reduced.

[0067] Comparative Example 5 The difference from Example 1 is that the integrated micro-sensor is not packaged.

[0068] Comparative Example 6 The difference from Example 1 is that the injection temperature in step S3 is 220°C.

[0069] Test case The composite insulators obtained in Example 1 and Comparative Examples 1-6 were subjected to performance tests, and the results are shown in Tables 1-6.

[0070] Power frequency breakdown voltage (kV) test method: According to IEC 60243 standard, apply a 50Hz AC voltage to the surface of the insulator, gradually increase the voltage until breakdown occurs, and record the voltage value at the moment of breakdown.

[0071] Partial discharge quantity (pC) test method: According to IEC 60270, the partial discharge charge inside the insulator is measured using a partial discharge detector at the rated voltage.

[0072] Pollution flashover voltage (kV) test method: Refer to IEC 60507 salt spray test method, and test the flashover voltage under artificial pollution conditions (salt + diatomaceous earth mixture).

[0073] UV aging strength retention rate (%) test method: ASTM G154 UV aging test, using UVA-340 lamp tube to simulate sunlight, after periodic irradiation for 1000-2000 hours, the mechanical strength retention rate is tested.

[0074] Surface contact angle (°) test method: ASTM D7334 contact angle measurement method, which uses a contact angle meter to test the wettability of water droplets on the material surface.

[0075] Corona aging mass loss rate (%) test method: IEC 61284 corona aging test, exposed in a high voltage corona field for 1000 hours, and the percentage change in mass is measured.

[0076] Volume resistivity (Ω·cm) test method: ASTM D257 standard, using a high resistance meter in a three-electrode system, voltage 500V DC, test time 60 seconds.

[0077] Impulse voltage withstand value (kV) test method: IEC 60060-1 Lightning impulse test, apply a standard 1.2 / 50μs impulse waveform, and record the highest withstand voltage without breakdown.

[0078] Bending fatigue life (ten thousand cycles) test method: ASTM D790 three-point bending fatigue test, cyclically loaded under rated load until fracture.

[0079] Test method for interfacial peel strength (N / mm) after temperature cycling: ASTM D3164 wedge peel test, after 100 cycles of temperature cycling from -40℃ to +85℃, the interfacial bond strength is tested.

[0080] Color difference ΔE test method after aging: ASTM D2244 color difference measurement, using a spectrophotometer in CIELab color space to calculate the color difference before and after aging.

[0081] Surface roughness Ra (μm) test method: ISO 4287 stylus profilometer measurement, sampling length 0.8 mm, evaluation length 4 mm.

[0082] The method for testing the residual soiling rate (%) is as follows: After the artificial soiling test according to IEC 60507, rinse with deionized water, collect the residue, dry it, weigh it, and calculate the residual rate.

[0083] Nanoparticle aggregation rate (%) test method: ASTM E2859 scanning electron microscopy (SEM) statistical method, the proportion of aggregated particles is calculated by image analysis software.

[0084] Tensile strength (MPa) test method: ASTM D638 standard, universal testing machine, tensile rate 5 mm / min, average value of 5 specimens.

[0085] Interlaminar shear strength (MPa) test method: ASTM D2344 short beam shear test, span-to-thickness ratio 4:1, loading rate 1 mm / min.

[0086] Deformation (mm) test method: ASTM D695 compression test, deformation measured with a laser displacement sensor at 80% rated load.

[0087] Intelligent function testing method: IEC 61850 communication protocol verification, checking the data acquisition and transmission functions of the built-in sensors.

[0088] Signal transmission packet loss rate test method: IEEE 802.3 Ethernet test standard, sending 10 packets via a network analyzer. 6 Each data packet was analyzed to determine the percentage of lost packets.

[0089] Nano TiO2 crystal form transformation rate (%): The crystal form ratio was calculated by comparing the characteristic diffraction peak intensities of the anatase phase (101 crystal plane) and the rutile phase (110 crystal plane) using X-ray diffraction (XRD) analysis (according to GB / T 23413).

[0090] Crystal transformation green = Rutile phase peak area / (Anatase phase peak area + Rutile phase peak area).

[0091] Silicone rubber weight loss (%): Perform a heat aging test according to GB / T 3512 or ASTM D3850 standards. Place the silicone rubber sample in a high-temperature oven (e.g., 200℃±5℃) for 168 hours. After removing it and cooling it to room temperature, weigh the mass before and after aging using a precision balance (accuracy 0.1mg).

[0092] Weight loss rate = (initial mass - mass after aging) / initial mass.

[0093] Impact toughness (kJ / m) 2 According to GB / T 1043.1, the pendulum impact test is carried out. The insulator is subjected to a pendulum impact tester at 23℃±2℃ and 50%RH. The energy absorbed when the specimen breaks is measured. The impact toughness per unit area is calculated.

[0094] Impact toughness = Impact absorbed energy / Cross-sectional area.

[0095] Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0096] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An intelligent, high-performance composite insulator, characterized in that, It includes a metal end cap, an inner core, a middle layer and an outer layer, and an integrated micro-sensor located in the middle layer or the inner core; The inner core is made of glass fiber reinforced epoxy resin; The middle layer is a silicone rubber containing nano-TiO2; The outer layer is a fluoropolymer coating; The integrated micro-sensor includes a micro-temperature sensor, an electric field sensor, and a stress sensor; The metal end caps are located at both ends of the inner core.

2. A method for preparing an intelligent high-performance composite insulator as described in claim 1, characterized in that the steps include... include: After surface treatment of the glass fiber reinforced epoxy resin core, metal end caps are fixed to both ends of the core. Then, the glass fiber reinforced epoxy resin core is covered with a middle layer material through injection molding. Subsequently, a vulcanization treatment is performed to form a middle layer on the surface of the glass fiber reinforced epoxy resin core. Then, a fluoropolymer is uniformly coated on the surface of the middle layer. After secondary molding and thermosetting, an outer layer is formed. Finally, an integrated micro-sensor is embedded to obtain the intelligent high-performance composite insulator.

3. The preparation method according to claim 2, characterized in that, The preparation steps of the glass fiber reinforced epoxy resin core include: Epoxy resin is mixed with curing agent and accelerator, stirred evenly, and then E-type glass fiber is added. The glass fiber reinforced epoxy resin core is prepared by pultrusion molding process.

4. The preparation method according to claim 3, characterized in that, The mass ratio of the epoxy resin, curing agent, and accelerator is 100:35-40:2-3; and / or, the epoxy resin includes bisphenol A type epoxy resin, phenolic epoxy resin, alicyclic epoxy resin, or glycidylamine type epoxy resin; and / or, the curing agent includes ethylenediamine, diethylenetriamine, triethylenetetramine, or phthalic anhydride; and / or, the accelerator includes benzyldimethylamine, dimethylimidazole, triethanolamine, or stannous octoate; and / or, the stirring speed for uniform mixing is 500-800 rpm; and / or, the amount of E-type glass fiber is 30-50% of the sum of the mass of the epoxy resin, curing agent, and accelerator; and / or, the parameters of the pultrusion molding process are: temperature 120-150℃, traction speed 0.5-1.5 m / min.

5. The preparation method according to claim 2, characterized in that, The surface treatment involves grinding the glass fiber reinforced epoxy resin core to a surface roughness of Ra3.2-6.3μm and then cleaning it; and / or, the parameters of the injection molding process are: temperature 150-180℃, injection pressure 10-15MPa.

6. The preparation method according to claim 2, characterized in that, The preparation steps of the middle layer material include: Nano-TiO2 is added to vinyl silicone rubber, and after stirring and ultrasonic dispersion, vulcanizing agent and additives are added and mixed evenly to obtain the middle layer material.

7. The preparation method according to claim 6, characterized in that, The stirring speed is 100-1500 rpm for 30-60 min; and / or, the ultrasonic power is 200-300 W for 20-30 min; and / or, the mass ratio of nano-TiO2 to vinyl silicone rubber is 1:20-30; and / or, the mass ratio of vinyl silicone rubber, vulcanizing agent, and additives is 120-150:2-3:0.5-1; and / or, the vulcanizing agent includes dicumyl peroxide, benzoyl peroxide, or di-tert-butyl peroxide; and / or, the additives include dibutyltin dilaurate, stannous octoate, or titanate coupling agents.

8. The preparation method according to claim 2, characterized in that, The fluoropolymer includes polytetrafluoroethylene; and / or, the metal end cap is a copper alloy material with a surface treated by electroless nickel plating.

9. The preparation method according to claim 2, characterized in that, The parameters for the vulcanization treatment are: temperature 180-200℃, pressure 1-2MPa, time 30-60min; and / or, the temperature for the secondary molding is 130-150℃, the pressure is 5-8MPa; and / or, the temperature for the thermosetting is 150-180℃, the time is 2-4h.

10. The application of the intelligent high-performance composite insulator as described in claim 1 in a power system.

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