Tension insulator with composite structure

Abstract

The utility model belongs to the technical field of tension insulators, and particularly relates to a tension insulator with a composite structure, which comprises an insulator core rod, a plurality of umbrella skirts are fixedly mounted on the outer side of the insulator core rod, U-shaped iron rings are fixedly mounted at the top and the bottom of the insulator core rod, an insulating sheath is arranged on the outer side of the insulator core rod, and the insulator core rod is sleeved on the insulating sheath. Through the composite structure design of the core rod, the insulating sheath and the U-shaped iron ring, the advantages of different materials are fully exerted. The core rod provides high-strength mechanical support, the insulating sheath ensures good insulating property and weather resistance, and the U-shaped iron ring realizes reliable connection, so that the mechanical strength, the insulating property, the weather resistance and the like of the insulator are remarkably improved; the umbrella skirt structure on the insulating sheath is elaborately designed, so that the creepage distance is increased, the anti-pollution flashover capability of the insulator is improved, and the insulator effectively adapts to complex electric power environments and severe weather conditions.

Description

Technical Field

[0001] This utility model relates to the field of tension insulator technology, and in particular to a tension insulator with a composite structure. Background Technology

[0002] In power systems, tension insulators are crucial components ensuring the normal operation of power lines. Traditional tension insulators are mostly made of a single material, such as porcelain or glass. While porcelain insulators have good insulation properties, they are brittle and easily break under external impact, leading to line faults. Although glass insulators have high mechanical strength, they are susceptible to environmental pollution and electrical aging over long-term use, resulting in surface corrosion and decreased insulation performance.

[0003] Furthermore, with the continuous increase in power line voltage levels and the increasing complexity of environmental conditions, the performance requirements for tension insulators are also becoming more stringent. Traditional single-structure insulators cannot simultaneously meet the requirements of high strength, high insulation, and good weather resistance. Therefore, developing a new type of composite structure tension insulator is of significant practical importance; thus, we propose a composite structure tension insulator. Utility Model Content

[0004] The purpose of this invention is to provide a tension insulator with a composite structure, which solves the existing problems.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A composite tension insulator includes an insulator core rod, with multiple sheds fixedly installed on the outer side of the insulator core rod, U-shaped iron rings fixedly installed on the top and bottom of the insulator core rod, and an insulating sheath provided on the outer side of the insulator core rod, the insulating sheath including an insulating protective layer, a flexible reinforcing layer and an anti-oxidation layer.

[0007] As a further improvement to the above solution, the insulating protective layer includes an ethylene propylene rubber layer and a low-density polyethylene layer, wherein the low-density polyethylene layer is connected to one side of the ethylene propylene rubber layer.

[0008] As a further improvement to the above solution, the flexible reinforcement layer includes an ethylene-vinyl acetate copolymer layer and a polytetrafluoroethylene layer, wherein the ethylene-vinyl acetate copolymer layer is connected to one side of the low-density polyethylene layer, and the polytetrafluoroethylene layer is connected to one side of the ethylene-vinyl acetate copolymer layer.

[0009] As a further improvement to the above solution, the flexible reinforcement layer includes a chloroprene rubber layer and a composite layer of EPDM rubber and silica, wherein the chloroprene rubber layer is connected to one side of the polytetrafluoroethylene layer, and the composite layer of EPDM rubber and silica is connected to one side of the chloroprene rubber layer.

[0010] As a further improvement to the above solution, the material of the ethylene propylene rubber layer is ethylene propylene rubber, and the material of the low-density polyethylene layer is low-density polyethylene.

[0011] As a further improvement to the above scheme, the material of the ethylene-vinyl acetate copolymer layer is ethylene-vinyl acetate copolymer, and the material of the polytetrafluoroethylene layer is polytetrafluoroethylene.

[0012] As a further improvement to the above solution, the material of the chloroprene rubber layer is chloroprene rubber, and the material of the EPDM rubber and silica composite layer is EPDM rubber and silica.

[0013] As a further improvement to the above solution, the insulator core rod is made of glass fiber reinforced epoxy resin composite material, and the umbrella skirt is made of a conical shape.

[0014] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0015] (1) The present invention provides a composite tension insulator that fully utilizes the advantages of different materials through a composite structure design of a core rod, an insulating sheath, and a U-shaped iron ring. The core rod provides high-strength mechanical support, the insulating sheath ensures good insulation performance and weather resistance, and the U-shaped iron ring achieves reliable connection, thereby significantly improving the insulator in terms of mechanical strength, insulation performance, and weather resistance.

[0016] (2) The composite tension insulator of this utility model has a carefully designed umbrella skirt structure on the insulating sheath, which increases the creepage distance and improves the insulator's anti-pollution flashover capability, effectively adapting to complex power environments and harsh climatic conditions. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of this utility model, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a three-dimensional structural diagram of a composite tension insulator proposed in this utility model;

[0019] Figure 2This is a partial three-dimensional structural diagram of the insulating protective layer, flexible reinforcing layer and anti-oxidation layer proposed in this utility model;

[0020] Figure 3 This is a partial three-dimensional structural diagram of a composite tension insulator proposed in this utility model;

[0021] Figure 4 This is a partial three-dimensional structural diagram of the EPDM rubber and silica composite layer proposed in this utility model.

[0022] In the diagram: 1. Insulator core rod; 2. Sheath; 3. U-shaped iron ring; 4. Insulating sleeve; 5. Insulating protective layer; 6. Flexible reinforcing layer; 7. Anti-oxidation layer; 8. Ethylene propylene rubber layer; 9. Low-density polyethylene layer; 10. Ethylene-vinyl acetate copolymer layer; 11. Polytetrafluoroethylene layer; 12. Chloroprene rubber layer; 13. EPDM rubber and silica composite layer. Detailed Implementation

[0023] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present utility model.

[0024] refer to Figure 1-4 A composite tension insulator includes an insulator core rod 1, multiple sheds 2 fixedly installed on the outside of the insulator core rod 1, U-shaped iron rings 3 fixedly installed on the top and bottom of the insulator core rod 1, and an insulating sleeve 4 provided on the outside of the insulator core rod 1. The insulating sleeve 4 includes an insulating protective layer 5, a flexible reinforcing layer 6, and an anti-oxidation layer 7.

[0025] In this embodiment, the insulating protective layer 5 includes an ethylene propylene rubber layer 8 and a low-density polyethylene layer 9, with the low-density polyethylene layer 9 connected to one side of the ethylene propylene rubber layer 8.

[0026] In this embodiment, the flexible reinforcing layer 6 includes an ethylene-vinyl acetate copolymer layer 10 and a polytetrafluoroethylene layer 11. The ethylene-vinyl acetate copolymer layer 10 is connected to one side of the low-density polyethylene layer 9, and the polytetrafluoroethylene layer 11 is connected to one side of the ethylene-vinyl acetate copolymer layer 10.

[0027] In this embodiment, the flexible reinforcing layer 6 includes a chloroprene rubber layer 12 and a composite layer of EPDM rubber and silica 13. The chloroprene rubber layer 12 is connected to one side of the polytetrafluoroethylene layer 11, and the composite layer of EPDM rubber and silica 13 is connected to one side of the chloroprene rubber layer 12.

[0028] In this embodiment, the EPDM rubber layer 8 is made of EPDM rubber, and the low-density polyethylene layer 9 is made of low-density polyethylene. The innermost layer of the EPDM rubber layer 8, which is closest to the mandrel 1, is made of EPDM rubber. EPDM rubber has good electrical insulation properties, which can effectively isolate the electric field and prevent current leakage from the surface of the mandrel 1. Its molecular structure is stable and has strong resistance to various chemical substances, which can prevent the insulation performance from being reduced due to chemical corrosion. In addition, EPDM rubber is soft and elastic, which can closely adhere to the surface of the mandrel 1, playing a buffering role and reducing the damage to the mandrel 1 caused by external impact.

[0029] The second layer of the outermost layer of the low-density polyethylene layer 9 is made of low-density polyethylene (LDPE). LDPE has high dielectric strength, which further enhances the insulation performance. Its smooth surface can effectively reduce the adhesion of dust, impurities and other contaminants, reducing the risk of insulation performance degradation due to contaminant accumulation. At the same time, LDPE material is relatively lightweight, which will not add too much burden to the insulator, and has good processing performance, making it easy to tightly bond with the ethylene propylene rubber layer 8.

[0030] In this embodiment, the ethylene-vinyl acetate copolymer layer 10 is made of ethylene-vinyl acetate copolymer, and the polytetrafluoroethylene layer 11 is made of polytetrafluoroethylene. The ethylene-vinyl acetate copolymer layer 10 has excellent flexibility and UV resistance. In outdoor environments, it can effectively resist long-term UV radiation, prevent material aging and embrittlement, and thus ensure the long-term reliability of the insulating sheath 4. Its flexibility also allows the insulating sheath 4 to maintain a good shape under different temperature conditions, adapting to the expansion and contraction of power lines caused by temperature changes.

[0031] The second layer of the outermost layer 11 of the polytetrafluoroethylene layer is polytetrafluoroethylene (PTFE). PTFE has an extremely low coefficient of friction, which makes it difficult for pollutants such as rainwater and dust to adhere to the surface of the insulator. Even if pollutants adhere, they are easily washed away under natural conditions. At the same time, PTFE has excellent chemical stability and hardly reacts with any chemical substances. It can effectively resist the erosion of harsh environments such as acid rain and salt spray, further improving the weather resistance of the insulating sheath 4.

[0032] In this embodiment, the chloroprene rubber layer 12 is made of chloroprene rubber, and the composite layer 13 of EPDM rubber and silica is made of EPDM rubber and silica. The inner layer of the chloroprene rubber layer 12 is made of chloroprene rubber. Chloroprene rubber has good ozone resistance and can effectively prevent the material from being oxidized and decomposed in environments with high ozone concentrations, thus extending the service life of the insulating sheath 4. It also has certain flame retardant properties, which can reduce the risk of fire spread and ensure the safety of power lines in special situations such as fires.

[0033] The second layer of the outer layer 3 of the EPDM rubber and silica composite layer 13 is a composite material of EPDM rubber and silica. EPDM rubber provides good elasticity and flexibility, while silica enhances the hardness and wear resistance of the material. This composite material can adapt to changes in mechanical stress under different environments and effectively resist the wear of particles such as wind and sand, ensuring the structural integrity and insulation performance of the insulating sheath 4 in complex environments.

[0034] In this embodiment, the insulator core rod 1 is made of glass fiber reinforced epoxy resin composite material, and the skirt 2 is made of a conical material. The core rod 1 is made of high-strength glass fiber reinforced epoxy resin composite material. This material has excellent mechanical properties, high tensile strength, and can withstand large tensile forces, ensuring the insulator plays a reliable tensioning role in the power line. Simultaneously, the glass fiber reinforced epoxy resin composite material also has good insulation properties, effectively preventing current flow and ensuring the safety of power transmission.

[0035] The core rod 1 is cylindrical with a smooth surface and undergoes a special process to ensure a tight bond with the outer layer material. The diameter and length of the core rod 1 are customized according to different application scenarios and power line requirements to meet varying mechanical strength and insulation needs.

[0036] The shape and size of the umbrella skirts 2 are optimized to increase the creepage distance and improve the insulator's anti-pollution flashover capability. The reasonable spacing between the umbrella skirts 2 effectively prevents rainwater, dust, and other contaminants from forming continuous conductive paths on the insulator surface, while also ensuring good ventilation and reducing contamination accumulation on the insulator surface. The implementation principle of a composite tension insulator in this embodiment is as follows: glass fiber is impregnated in epoxy resin and then pultruded to form a core rod 1. During the manufacturing process, the content and distribution of glass fiber are strictly controlled to ensure that the mechanical and insulating properties of the core rod 1 meet the design requirements.

[0037] A multi-layer composite injection molding process is employed. First, ethylene propylene rubber and low-density polyethylene are injection molded together to form the outer layer one. Next, ethylene-vinyl acetate copolymer and polytetrafluoroethylene are injection molded together to form the outer layer two. Finally, a composite material of chloroprene rubber, EPDM rubber, and silica is injection molded together to form the outer layer three. During each injection molding step, strong adhesion between the layers is ensured, and the shape and dimensions of the skirt 2 conform to design standards.

[0038] The U-shaped iron rings 3 are installed at both ends of the mandrel 1 by welding or bolting to ensure a firm and reliable connection. During installation, strict quality inspection is carried out on the connection points to prevent problems such as loosening or poor connection.

[0039] Before installing insulators, conduct a comprehensive inspection, including visual inspection, insulation performance testing, and mechanical strength testing. Ensure that the insulators are free from damage and cracks, and that all performance indicators meet the requirements. At the same time, prepare the necessary tools and equipment for installation, such as wrenches and cranes.

[0040] According to the design requirements of the power line, the insulator is lifted by a crane and suspended at the designated position on the tower using U-shaped iron rings 3. Then, connecting bolts or clamps are used to connect the insulator to the conductor or other tensioning devices, ensuring a tight connection and even stress distribution. During installation, care is taken to protect the insulating sleeve 4 of the insulator from damage.

[0041] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0042] The foregoing has provided a detailed description of a composite tension insulator provided by this utility model. Specific embodiments have been used to illustrate the principles and implementation methods of this utility model. The descriptions of these embodiments are merely for the purpose of helping to understand the method and core ideas of this utility model. It should be noted that those skilled in the art can make various improvements and modifications to this utility model without departing from its principles, and these improvements and modifications also fall within the protection scope of the claims of this utility model.

Claims

1. A composite tension insulator, characterized by, Include: The insulator core rod (1) is fixedly installed with a plurality of umbrella skirts (2) on the outer side, the top and bottom of the insulator core rod (1) is fixedly installed with a U-shaped iron ring (3), the outer side of the insulator core rod (1) is provided with an insulating sheath (4), the insulating sheath (4) includes an insulating protective layer (5), a flexible reinforcing layer (6) and an oxidation resistant layer (7).

2. A composite tension insulator according to claim 1, wherein The insulating protective layer (5) includes an ethylene-propylene rubber layer (8) and a low-density polyethylene layer (9), and the low-density polyethylene layer (9) is connected to one side of the ethylene-propylene rubber layer (8).

3. A composite tension insulator according to claim 1, wherein The flexible reinforcing layer (6) includes an ethylene-vinyl acetate copolymer layer (10) and a polytetrafluoroethylene layer (11), the ethylene-vinyl acetate copolymer layer (10) is connected to one side of the low-density polyethylene layer (9), and the polytetrafluoroethylene layer (11) is connected to one side of the ethylene-vinyl acetate copolymer layer (10).

4. A composite tension insulator according to claim 1, wherein The flexible reinforcing layer (6) includes a neoprene layer (12) and a ternary ethylene-propylene rubber and silica composite layer (13), the neoprene layer (12) is connected to one side of the polytetrafluoroethylene layer (11), and the ternary ethylene-propylene rubber and silica composite layer (13) is connected to one side of the neoprene layer (12).

5. A composite tension insulator according to claim 2, wherein The material of the ethylene-propylene rubber layer (8) is ethylene-propylene rubber, and the material of the low-density polyethylene layer (9) is low-density polyethylene.

6. A composite tension insulator according to claim 3, wherein The material of the ethylene-vinyl acetate copolymer layer (10) is ethylene-vinyl acetate copolymer, and the material of the polytetrafluoroethylene layer (11) is polytetrafluoroethylene.

7. A composite tension insulator according to claim 4, wherein The material of the neoprene layer (12) is neoprene, and the material of the ternary ethylene-propylene rubber and silica composite layer (13) is ternary ethylene-propylene rubber and silica.

8. A composite tension insulator according to claim 1, wherein The material of the insulator core rod (1) is glass fiber reinforced epoxy resin composite material, and the material of the umbrella skirt (2) is umbrella skirt (2). The shape of the umbrella skirt (2) is conical.

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