Composite insulator

Abstract

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

Description

Technical Field

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

[0002] Currently, most failures in hollow composite insulator structures occur at the connection between the flange and the insulating tube, and this connection is one of the most challenging aspects of insulator manufacturing. Insulating tubes are generally made of composite materials, and common connection methods for composite materials are adhesive bonding and compression bonding. Adhesive bonding involves using high-strength adhesives such as epoxy resin to form a rubber interface between the inner surface of the flange and the outer surface of the insulating tube to complete the assembly. While this method can simultaneously meet the requirements for connection strength and sealing, the adhesive curing time is long, making on-site work inconvenient. Furthermore, most adhesive-bonded structures cannot fully utilize the optimal performance of the insulating tube or flange; that is, the composite insulator may fail under conditions where the mechanical strength of the insulating tube is lower than its own bending, tensile, or compressive strength. Existing compression bonding technology is only suitable for solid composite rods, and the applied force is relatively large. Directly applying it to insulating tubes can cause the tubes to crack, affecting the product's strength and sealing requirements. Utility Model Content

[0003] To address the shortcomings of existing technologies, the main objective of this application is to provide a composite insulator that utilizes a support member to crimp the hollow insulating tube and the flange, ensuring a stable connection and sealing while also enabling rapid assembly of the composite insulator and improving production efficiency.

[0004] To solve the aforementioned technical problems, the technical solution adopted in this application is: a composite insulator, comprising an insulating tube, sheds located on the outer periphery of the insulating tube, and two flanges respectively disposed at both ends of the insulating tube. The insulating tube is a hollow circular tube, and each end of the insulating tube has an internal support member, which is a solid cylindrical structure. The support member is coaxially arranged with the insulating tube and extends inward from the end of the insulating tube. The outer diameter of the support member matches the inner diameter of the insulating tube. The flange is pressed onto the outer side of the end of the insulating tube, so that the insulating tube, support member, and flange are tightly connected. Using the support member to press-fit the hollow insulating tube and the flange ensures the connection strength and sealing between the two, effectively preventing the composite insulator from failing at the connection between the flange and the insulating tube. This fully utilizes the structural strength of the composite insulator, and compared with traditional adhesive bonding technology, it eliminates the long adhesive curing process, improving production efficiency.

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

[0006] The flange cylinder has an inner rounded corner at the end furthest from the flange.

[0007] The support member has chamfers at both ends.

[0008] The length of the support component is 10-20 mm longer than the length of the flange cylinder.

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

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

[0011] The insulating tube and the support components are both made of fiber-reinforced composite materials.

[0012] The flange sleeve has a sealing structure at the connection between the end away from the flange and the insulating tube. The sealing structure includes a sealing ring and a sealant. The sealing ring abuts against the outer circumference of the insulating tube and the inner circumference of the flange sleeve. The sealant fills the gap between the flange sleeve and the insulating tube and covers the connection between the end face of the flange sleeve away from the flange and the insulating tube, so that the sealing ring, flange sleeve and insulating tube are sealed together.

[0013] The flange cylinder, insulating pipe and support are connected by crimping technology. The distance between the end of the target crimping area on the flange cylinder near the flange and the flange is 15-25mm, and the distance between the other end of the target crimping area away from the flange and the end face of the flange cylinder away from the flange is 5-10mm.

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

[0015] The beneficial effects of this application are: the composite insulator of this application uses a support member to realize the crimping of the hollow insulating tube and the flange, which ensures the connection strength and sealing between the two, effectively avoids the failure of the composite insulator at the connection between the flange and the insulating tube, can give full play to the structural strength of the composite insulator, and compared with the traditional adhesive bonding technology, it saves the long time of adhesive curing process and improves production efficiency.

[0016] Meanwhile, the composite insulator of this application also has a sealing structure at the connection between the flange cylinder and the insulating tube at the end away from the flange, which can prevent external dust, moisture and other impurities from entering the interior of the insulating tube and ensure the normal operation of the composite insulator. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application, 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 application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Wherein:

[0018] Figure 1 This is a partial cross-sectional view of a composite insulator 100 in one embodiment of this application;

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

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

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

[0022] Figure 5 This is a cross-sectional view of the composite insulator 100 after crimping in one embodiment of this application. Detailed Implementation

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

[0024] See Figure 1 A composite insulator 100 includes an insulating tube 110, a shed (not shown in the figure) located on the outer periphery of the insulating tube 110, and two flanges 120 respectively disposed at both ends of the insulating tube 110. The insulating tube 110 is a hollow circular tube, and a support member 130 is provided inside both ends of the insulating tube 110. The support member 130 is a solid cylindrical structure, and is coaxially disposed with the insulating tube 110 and extends inward from the end of the insulating tube 110. The outer diameter of the support member 130 matches the inner diameter of the insulating tube 110. The flanges 120 are pressed onto the outer side of the end of the insulating tube 110, so that the insulating tube 110, the support member 130, and the flanges 120 are tightly connected. The composite insulator 100 of this application utilizes the support member 130 to crimp the hollow insulating tube 110 and the flange 120, ensuring the connection strength and sealing between the two, effectively preventing the composite insulator 100 from failing at the connection between the flange 120 and the insulating tube 110, fully utilizing the structural strength of the composite insulator 100, and compared with traditional adhesive bonding technology, eliminating the long adhesive curing process and improving production efficiency.

[0025] Combination Figure 2 and Figure 3As shown, flange 120 includes flange cylinder 121 and flange plate 122. Flange cylinder 121 is a hollow cylindrical structure, fitted onto the end of insulating tube 110, and the inner diameter of flange cylinder 121 matches the outer diameter of insulating tube 110. In this embodiment, flange plate 122 is disc-shaped, and the diameter of flange plate 122 is larger than the outer diameter of flange cylinder 121, completely covering one end of flange cylinder 121. In other embodiments, flange plate can also be annular, with an inner diameter smaller than the inner diameter of flange cylinder and an outer diameter larger than the outer diameter of flange cylinder, meaning flange plate can partially cover one end of flange cylinder. The flange plate 122 covering one end of flange cylinder 121 is mainly used for connecting with bolts and other fasteners to other flanges, facilitating the installation of composite insulator 100. The flange cylinder 121, at the end furthest from the flange plate 122, has an inner rounded corner with a radius of 2-3 mm. During assembly of the flange cylinder 121 and the insulating tube 110, the inner rounded corner acts as a guide to expand the diameter, allowing the flange cylinder 121 to be smoothly fitted onto the insulating tube 110, significantly improving assembly efficiency. Furthermore, the inner rounded corner also prevents structural wear caused by sharp edges, extending the service life of the composite insulator 100. Preferably, the flange 120 also includes several reinforcing ribs 123. The reinforcing ribs 123 are plates, arranged radially along the flange 120 and simultaneously connecting the flange cylinder 121 and the flange plate 122. The reinforcing ribs 123 are evenly distributed circumferentially along the flange 120. The arrangement of the reinforcing ribs 123 indirectly increases the contact area between the flange cylinder 121 and the flange plate 122, thereby improving the strength of the flange 120. In this embodiment, six reinforcing ribs 123 are provided. These six reinforcing ribs 123 are arranged radially along the outer circumferential surface of the flange cylinder 121. Providing six reinforcing ribs 123 improves the strength performance of the flange 122, reducing the required thickness of the flange 122, thereby saving material and reducing the weight of the composite insulator 100. In other embodiments, four, five, seven, or more reinforcing ribs may be provided, or the reinforcing ribs may be omitted, as long as the strength requirements of the flange are met; no limitation is imposed here.

[0026] In one embodiment, the flange cylinder 121, flange 122, and reinforcing rib 123 can be formed separately and then connected by welding or other processes. Alternatively, the flange cylinder 121, flange 122, and reinforcing rib 123 can be integrally cast to further enhance the overall stability of the flange 120 and improve its mechanical strength. In other embodiments, the flange cylinder, flange, and reinforcing rib can also be formed in other ways, as long as the flange strength can be guaranteed, and no limitation is imposed here.

[0027] The insulating tube 110 is a hollow round tube, formed by winding or pultruding fiber-reinforced composite material, which not only has excellent mechanical strength but also good dielectric properties. The inner diameter of the flange 121 matches the outer diameter of the insulating tube 110 for easy assembly. Specifically, the outer diameter of the insulating tube 110 is slightly smaller than the inner diameter of the flange 121, so that the flange 121 can be smoothly fitted onto the outer circumference of both ends of the insulating tube 110, so that the flange 120 can be subsequently pressed onto the outer side of the end of the insulating tube 110. In one embodiment, the outer diameter of the insulating tube 110 is 0.1 to 0.5 mm smaller than the inner diameter of the flange tube 121, for example, 0.1 mm, 0.2 mm or 0.5 mm, so that the flange tube 121 and the insulating tube 110 can move relative to each other to adjust the position of the flange tube 121 on the insulating tube 110, thereby ensuring that the flange 120 can be fitted in place; at the same time, the preset gap makes it less likely for the flange 120 and the insulating tube 110 to fail to assemble even if there are radial machining errors, reducing the processing difficulty and increasing the fault tolerance rate.

[0028] Combination Figure 4 and Figure 5 As shown, the support member 130 is a solid cylindrical structure made of fiber-reinforced composite material, the same material as the insulating tube 110. The identical material ensures high consistency in hardness, ductility, and deformation characteristics, guaranteeing that the deformation behavior of the support member 130 and the insulating tube 110 remains synchronized during the crimping process. This avoids localized stress concentration or cracking caused by asynchronous deformation of different materials, thus ensuring the quality of the composite insulator 100. Furthermore, the design of the crimping process parameters does not require consideration of the differences in the thermal expansion coefficients of different materials, significantly reducing design complexity. Of course, in other embodiments, the support member can also be made of other insulating materials with a radial elastic modulus of 10–20 GPa, as long as it can support the crimping of the hollow insulating tube and the flange; no restrictions are imposed here.

[0029] In this embodiment, both ends of the support member 130 are provided with a 3mm×45° chamfer. When the support member 130 and the insulating tube 110 are assembled, the chamfer can play a guiding role in reducing the diameter, allowing the support member 130 to be inserted more smoothly into the inner cavity of the insulating tube 110, which significantly improves the assembly efficiency. In addition, the chamfer can also avoid structural wear caused by sharp edges, extending the service life of the composite insulator 100. In other embodiments, the chamfers at both ends of the support member can also be set to other sizes and angles, such as 1mm×45°, 2mm×45°, 1mm×60°, 2mm×60°, 3mm×60°, 1mm×30°, 2mm×30°, 3mm×30°, etc., as long as it facilitates the assembly of the support member and the insulating tube, and there is no limitation here.

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

[0031] After the insulating tube 110, flange 120, and support 130 are assembled, the support 130 is coaxially positioned within the inner cavity of the insulating tube 110, with both ends flush. The flange 121 is coaxially fitted around the outer periphery of the end of the insulating tube 110, and the flange 122 simultaneously abuts against the end faces of both the insulating tube 110 and the support 130. Due to the assembly gap, the axes of the insulating tube 110, flange 120, and support 130 may be slightly offset, but the compression between the components during crimping will correct the degree of coaxiality. The axial length of the support 130 is defined as L1, the axial length of the flange 121 as L2, and the length difference between the support 130 and the flange 121 is L3, i.e., L3 = L1 - L2. The value of L3 ranges from 10 to 20 mm; for example, L3 can be 10 mm, 15 mm, or 20 mm. Specifically, when L3 is less than 10mm, the stress on the insulating tube 110 and flange 120 during crimping is relatively large, posing a risk of excessive plastic deformation and potentially causing structural damage. When L3 is greater than 20mm, the length of the support 130 is relatively large, resulting in higher costs. Therefore, setting the length of the support 130 to be 10-20mm longer than the length of the flange 121 can control costs while minimizing the stress on the insulating tube 110 and flange 120 during crimping, preventing damage to both during the crimping process and ensuring product quality.

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

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

[0034] The flange 120, insulating tube 110, and support member 130 are connected by crimping technology, specifically through a crimping device. The crimping device includes a drive mechanism, an annular crimping mechanism, and several pressure blocks. The pressure blocks are arranged radially along the inner circumference of the annular crimping mechanism and are evenly distributed circumferentially along the annular crimping mechanism. The pressure surface of the pressure blocks matches the outer contour of the flange cylinder 121. During the crimping operation, the assembled flange 120, insulating tube 110, and support member 130 are placed in the annular crimping mechanism, and the pressure blocks are aligned with the target crimping area on the flange cylinder 121. The drive mechanism drives the pressure blocks to move synchronously towards each other radially along the annular crimping mechanism, forming a centripetal extrusion force, continuously extruding the flange cylinder 121 until the flange 120, insulating tube 110, and support member 130 are crimped together. Preferably, eight pressure blocks are used, with a radial angle θ between adjacent pressure blocks of 45°. This ensures that the extrusion force generated by the annular pressing mechanism is uniformly applied along the circumference of the flange cylinder 121, avoiding eccentric deformation caused by unilateral pressure and guaranteeing pressing quality. The pressing surface shape of the pressure blocks matches the outer circumferential contour of the flange cylinder 121, converting point loads into surface loads and ensuring uniform stress distribution at the interface between the flange cylinder 121, insulating tube 110, and support member 130. Compared to traditional adhesive bonding technology, pressing technology applies uniform extrusion force to create a tight contact between the flange 120, insulating tube 110, and support member 130, generating greater friction and significantly improving the tensile and shear strength of the connection. Furthermore, the pressing process can be completed using only specialized pressing tools, simplifying operation, eliminating the lengthy adhesive curing process, greatly shortening assembly time, and improving production efficiency.

[0035] The flange 121 has a target crimping area that mates with the insulating tube 110, used to achieve an effective connection between the flange 121 and the insulating tube 110. The target crimping area is annular, located on the outer periphery of the flange 121 and coaxially arranged with it; that is, the target crimping area is the outer surface area of ​​a portion of the flange 121 along its axial direction. The distance between the end of the target crimping area near the flange 122 and the flange 122 is 15-25 mm. Specifically, when the distance between the end of the target crimping area near the flange 122 and the flange 122 is less than 15 mm, the stress on the flange 120 during crimping is relatively large, posing a risk of excessive plastic deformation and easily leading to structural damage; when the distance between the end of the target crimping area near the flange 122 and the flange 122 is greater than 25 mm, the area of ​​the target crimping area is small, affecting the crimping effect. Therefore, setting the distance between the end of the target crimping area closest to flange 122 and flange 122 to 15-25mm ensures a good crimping effect while minimizing the crimping stress on flange 120, preventing damage to flange 120 during crimping and guaranteeing product quality. The distance between the other end of the target crimping area furthest from flange 122 and the end face of flange cylinder 121 furthest from flange 122 is 5-10mm. Specifically, when the distance between the other end of the target crimping area furthest from flange 122 and the end face of flange cylinder 121 furthest from flange 122 is less than 5mm, the stress on insulating tube 110 during crimping is greater, posing a risk of excessive plastic deformation and potentially causing structural damage. When the distance between the other end of the target crimping area furthest from flange 122 and the end face of flange cylinder 121 furthest from flange 122 is greater than 10mm, the target crimping area is smaller, affecting the crimping effect. Therefore, setting the distance between the end of the target crimping zone furthest from the flange 122 and the end face of the flange cylinder 121 furthest from the flange 122 to be 5-10 mm ensures a good crimping effect while minimizing the crimping stress on the insulating tube 110, thus preventing damage to the insulating tube 110 during the crimping process and ensuring product quality. Within this target crimping zone, circumferential compressive force is applied by several evenly distributed pressure blocks, ensuring that the flange cylinder 121, insulating tube 110, and support member 130 are subjected to uniform stress throughout the crimping process, guaranteeing the reliability of their connection.

[0036] The length of the flange cylinder 121 is positively correlated with the area of ​​its target crimping zone to ensure the crimping effect. When the length of the flange cylinder 121 exceeds a certain limit, the target crimping zone becomes too large, preventing the crimping device from completing the fixed connection of the flange 120, insulating tube 110, and support 130 in a single crimp. To ensure the crimping effect, a multi-stage crimping method is adopted, that is, only a portion of the target crimping zone is crimped each time. Specifically, the target crimping zone includes several sub-crimping zones. Any two adjacent sub-crimping zones overlap 0-20mm along the axial direction of the insulating tube 110, ensuring a continuous and gapless target crimping zone on each flange cylinder 121. If the overlap area of ​​any two adjacent sub-crimping zones along the axial direction of the insulating tube 110 is less than 0, meaning the target crimping zone is not continuous, the crimping effect will be weakened, greatly reducing the reliability of the connection. If the overlap area of ​​any two adjacent sub-crimping zones along the axial direction of the insulating tube 110 is greater than 20mm, it will result in too many crimping operations, prolonging the crimping time and reducing production efficiency. Therefore, the overlap of any two adjacent sub-crimping areas along the axial direction of the insulating tube 110 by 0 to 20 mm can ensure a reliable connection between the flange cylinder 121, the insulating tube 110 and the support member 130, and the crimping efficiency is higher than that of any two adjacent sub-crimping areas that do not overlap.

[0037] The solid support member 130 prevents excessive deformation of the hollow insulating tube 110 during crimping, thus ensuring product quality. After crimping, the insulating tube 110 deforms and shrinks until it fits tightly against the support member 130. Simultaneously, the flange 121 deforms and shrinks until it fits tightly against the insulating tube 110. This allows for the formation of contact surfaces with a certain pressure between the flange 120 and the insulating tube 110, and between the insulating tube 110 and the support member 130. These contact surfaces provide sufficient interfacial pressure and friction to ensure the connection strength of the three components. This prevents failure at the connection between the flange 120 and the insulating tube 110 during the operation of the composite insulator 100, and fully utilizes the structural strength of the composite insulator 100.

[0038] This application also provides a method for preparing a composite insulator 100, specifically including:

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

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

[0041] The support member 130 is a solid cylindrical structure. The length of the support member 130 is 10-20 mm longer than the length of the flange cylinder 121. Chamfers are made at both ends of the support member 130. The chamfers can play a guiding role in the diameter reduction, so that the support member 130 can be inserted into the inner cavity of the insulating tube 110 more smoothly, which significantly improves the assembly efficiency. In addition, the chamfers can also avoid structural wear caused by sharp edges, thus extending the service life of the composite insulator 100.

[0042] Furthermore, an umbrella skirt is prepared on the outer periphery of the insulating tube 110.

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

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

[0045] S3: Place two sealing rings around the outer periphery of the insulating tube 110, so that they are respectively located in the target crimping areas of the two flanges 120.

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

[0047] The flange 121 is provided with a target crimping area that mates with the insulating tube 110, for effective connection between the flange 121 and the insulating tube 110. The target crimping area is annular, located on the outer periphery of the flange 121 and coaxially arranged with the flange 121, that is, the target crimping area is the outer surface area of ​​a portion of the structure of the flange 121 along its axial direction.

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

[0049] S4: Fit the flange sleeves 121 of the two flanges 120 onto the outer periphery of both ends of the insulating tube 110, and make the end faces of the insulating tube 110 and the support 130 flush with the flange 122.

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

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

[0052] The crimping operation is achieved by a crimping device, which applies radial extrusion force within the target crimping area. This ensures that the flange cylinder 121, insulating tube 110, and support member 130 are subjected to uniform force throughout the crimping process, guaranteeing the reliability of their connection.

[0053] In one embodiment, when the length of the flange cylinder 121 exceeds a certain limit, multi-stage crimping is employed. The target crimping area includes several sub-crimping areas, with any two adjacent sub-crimping areas overlapping 0-20mm along the axial direction of the insulating tube 110, ensuring a continuous and gapless target crimping area across the entire flange cylinder 121. Crimping is performed in stages, with crimping operations conducted in only one sub-crimping area at a time, until all sub-crimping areas have been crimped.

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

[0055] The addition of reinforcing ribs 123 indirectly increases the contact area between the flange cylinder 121 and the flange plate 122, thereby improving the strength of the flange 120. Six or other numbers of reinforcing ribs 123 can be provided, as long as they enhance the overall stability of the flange 120.

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

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

[0058] Specifically, three test specimens were prepared using the above steps. A load was applied to each test specimen to conduct a load destructive test, and the destructive load, the destructive strength of the insulating tube 110, and the destructive mode were recorded, as shown in Table 1.

[0059] Table 1. Load failure test data record

[0060]

[0061] In the prior art, when the insulating tube and flange are glued together, the concentrated load on the insulating tube is 24kN, and the failure mode is based on glue failure. However, the test results show that after the insulating tube 110 and flange 120 are crimped together in this application, the external force that the insulating tube 110 can withstand is increased compared to the glued connection. The crimped product mainly suffers from the failure of the insulating tube 110, indicating that the crimped connection can fully utilize the strength of the insulating tube 110, further demonstrating the quality stability of the composite insulator 100 of this application.

[0062] The beneficial effects of this application are: the composite insulator of this application uses a support member to realize the crimping of the hollow insulating tube and the flange, which ensures the connection strength and sealing between the two, effectively avoids the failure of the composite insulator at the connection between the flange and the insulating tube, can give full play to the structural strength of the composite insulator, and compared with the traditional adhesive bonding technology, it saves the long time of adhesive curing process and improves production efficiency.

[0063] Meanwhile, the composite insulator of this application also has a sealing structure at the connection between the flange cylinder and the insulating tube at the end away from the flange, which can prevent external dust, moisture and other impurities from entering the interior of the insulating tube and ensure the normal operation of the composite insulator.

[0064] The above description is merely an embodiment of this application and does not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. A composite insulator, comprising an insulating tube, sheds located on the outer periphery of the insulating tube, and two flanges respectively disposed at both ends of the insulating tube, characterized in that, The insulating tube is a hollow round tube, and each end of the insulating tube is provided with a support member. The support member is a solid cylindrical structure. The support member is coaxially arranged with the insulating tube and extends inward from the end of the insulating tube. The outer diameter of the support member matches the inner diameter of the insulating tube. The flange is pressed onto the outside of the end of the insulating tube, so that the insulating tube, the support member and the flange are tightly connected.

2. The composite insulator as described in claim 1, characterized in that, The flange includes a flange cylinder and a flange plate. The flange cylinder is a hollow cylindrical structure, and the inner diameter of the flange cylinder matches the outer diameter of the insulating tube. The flange plate covers one end of the flange cylinder.

3. The composite insulator as described in claim 2, characterized in that, The flange cylinder has an inner rounded corner at the end away from the flange plate.

4. The composite insulator as described in claim 1, characterized in that, The support member has chamfers at both ends.

5. The composite insulator as described in claim 2, characterized in that, The length of the support member is 10 to 20 mm longer than the length of the flange.

6. The composite insulator as described in claim 1, characterized in that, The outer diameter of the support is 0.1 to 0.5 mm smaller than the inner diameter of the insulating tube.

7. The composite insulator as described in claim 2, characterized in that, The outer diameter of the insulating tube is 0.1 to 0.5 mm smaller than the inner diameter of the flange.

8. The composite insulator as described in claim 1, characterized in that, Both the insulating tube and the support are made of fiber-reinforced composite material.

9. The composite insulator as described in claim 2, characterized in that, A sealing structure is provided at the connection between the end of the flange cylinder away from the flange and the insulating tube. The sealing structure includes a sealing ring and a sealant. The sealing ring abuts against both the outer circumference of the insulating tube and the inner circumference of the flange cylinder. The sealant fills the gap between the flange cylinder and the insulating tube and covers the connection between the end face of the flange cylinder away from the flange and the insulating tube, thereby sealing the connection between the sealing ring, the flange cylinder, and the insulating tube.

10. The composite insulator as described in claim 2, characterized in that, The flange cylinder, the insulating tube, and the support are connected by crimping technology. The distance between the end of the target crimping area on the flange cylinder near the flange and the flange is 15-25mm, and the distance between the other end of the target crimping area away from the flange and the end face of the flange cylinder away from the flange is 5-10mm.

11. The composite insulator as described in claim 10, characterized in that, The target crimping area includes several sub-crimping areas, and any two adjacent sub-crimping areas overlap by 0 to 20 mm along the axial direction of the insulating tube.

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