Aging-resistant porcelain insulator
By setting alternating distributions of large-diameter and small-diameter sheds, flow guide grooves, and micro-nano-level honeycomb pit structures on porcelain insulators, combined with composite sealing rings and gradient anti-corrosion coatings, the problems of traditional porcelain insulators being susceptible to bird damage, flashover, poor sealing, and corrosion are solved, achieving long-term reliability and durability of insulators in complex environments.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- JIANGXI PINGXIANG XIANGSHENG CERAMIC IND CO LTD
- Filing Date
- 2025-07-22
- Publication Date
- 2026-05-29
AI Technical Summary
Traditional porcelain insulators are susceptible to bird damage, have a high risk of flashover due to surface contamination, poor sealing at the connection points leading to aging, insufficient corrosion resistance of the base, low rainwater drainage efficiency, and are prone to cracking of the porcelain body due to freeze-thaw cycles.
It adopts an alternating arrangement of large-diameter and small-diameter umbrella skirts with increasing skirt spacing, a flow guide groove design, and a micro-nano-level honeycomb pit structure, combined with a composite sealing ring, gradient anti-corrosion coating, and overvoltage protector to form a multi-dimensional structural design.
It effectively prevents birds from landing, quickly drains rainwater, enhances sealing and corrosion resistance, extends insulator life, and improves anti-pollution flashover capability and operational reliability.
Smart Images
Figure CN224304449U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of power transmission technology, and more specifically, to an aging-resistant porcelain insulator. Background Technology
[0002] In the field of power transmission, porcelain insulators, as key components ensuring the stable operation of transmission lines, have long faced challenges from complex environments. Traditional insulators suffer from susceptibility to bird damage, high risk of flashover due to surface contamination, poor sealing at connections leading to aging, and insufficient corrosion resistance of the base, all of which significantly impact the safety and reliability of power systems. Furthermore, overvoltage phenomena in the environment can cause irreversible damage to insulators, shortening their service life.
[0003] In the process of realizing this utility model, the inventors discovered the following problems with the existing technology: existing devices mostly use equally spaced umbrella skirts, which have low rainwater drainage efficiency and are prone to forming water accumulation layers between the umbrella skirts. Especially in cold regions, the ceramic body is prone to cracking due to freeze-thaw cycles; some products do not have drainage channels or the channels are not reasonably distributed, which cannot quickly drain surface sewage and aggravate dirt accumulation and electrochemical corrosion.
[0004] Therefore, an aging-resistant porcelain insulator is proposed to address the above problems. Utility Model Content
[0005] In order to overcome the above-mentioned defects of the prior art, the present invention provides an aging-resistant porcelain insulator to solve the problems mentioned in the background art.
[0006] To achieve the above objectives, this utility model provides the following technical solution: an aging-resistant porcelain insulator, comprising an insulator body, a skirt assembly coaxially disposed on the outer side of the insulator body, an upper metal attachment disposed on the top of the insulator body, and a lower base assembly disposed on the bottom of the insulator body; the skirt assembly includes large-diameter skirts and small-diameter skirts alternately disposed along the axial direction of the insulator body, and the spacing between adjacent skirts increases from the lower base assembly towards the upper metal attachment; the edge of the large-diameter skirt is provided with a downward-turned edge for bird protection, the turned edge forming an angle of 60°-75° with the horizontal plane.
[0007] Optionally, both the large-diameter umbrella skirt and the small-diameter umbrella skirt have radial guide grooves on their lower surfaces.
[0008] Optionally, the upper metal accessory includes a metal accessory body, the inner cavity of which is filled with an elastic cushioning material, and a circumferential composite sealing ring is provided at the connection interface between the metal accessory body and the insulator body. The composite sealing ring is composed of an inner second fluororubber ring, a middle stainless steel spring ring, and an outer first fluororubber ring. The multi-layer structure of the composite sealing ring prevents rainwater and moisture from penetrating into the connection interface, avoiding metal corrosion and insulation aging.
[0009] Optionally, the lower base assembly includes a metal base with a porous dome structure and an overvoltage protector embedded inside the metal base, wherein the outer surface of the metal base is provided with a gradient anti-corrosion coating.
[0010] Optionally, the guide channels are radially distributed at a 30° angle with the centers of the large-diameter umbrella skirt and the small-diameter umbrella skirt as the origin, and the depth of the guide channels decreases from the center to the outer edge. The guide channels are radially distributed for drainage and anti-fouling, and the depth decreases outward, so as to quickly guide rainwater, wash away dirt on the surface of the umbrella skirt, and maintain insulation performance.
[0011] Optionally, both the large-diameter umbrella skirt and the small-diameter umbrella skirt have a micro-nano-scale honeycomb-shaped pit structure beneath their surface glaze layers.
[0012] Optionally, the gradient anti-corrosion coating consists of, from the inside out: an arc-sprayed zinc-aluminum alloy layer, a plasma nitriding layer, and a polytetrafluoroethylene composite coating.
[0013] The technical effects and advantages of this utility model are as follows:
[0014] 1. Compared with existing technologies, this aging-resistant porcelain insulator incorporates components such as umbrella skirt assemblies, large-diameter umbrella skirts, small-diameter umbrella skirts, bird-proof structures, flow guide channels, and micro-nano-level honeycomb-shaped pit structures. The alternating distribution of large-diameter and small-diameter umbrella skirts along the insulator's axis, with increasing spacing from bottom to top, allows the flanges of the bird-proof structure to effectively prevent birds from landing. The flow guide channels direct rainwater to flow rapidly downwards in a 30° radial direction, and the micro-nano-level pit structures increase the hydrophobicity of the umbrella skirt surface. This multi-structural design comprehensively optimizes rainwater erosion paths, dirt adhesion probability, and bird activity interference, thereby enhancing the insulator's anti-flashover capability and surface self-cleaning performance.
[0015] 2. Compared with existing technologies, this aging-resistant porcelain insulator utilizes components such as an upper metal accessory, elastic buffer material, composite sealing ring, lower base assembly, overvoltage protector, and gradient anti-corrosion coating. The elastic buffer material fills the inner cavity of the metal accessory to absorb mechanical stress. The composite sealing ring (second fluororubber ring, stainless steel spring ring, and first fluororubber ring) provides multi-layer sealing at the connection interface. The overvoltage protector is embedded in a porous dome metal base. The gradient coating (zinc-aluminum alloy layer, nitriding layer, and polytetrafluoroethylene layer) covers the outer surface of the base. This combination enhances the sealing of the metal accessory connection interface, improves the mechanical strength and corrosion resistance of the base, and allows the overvoltage protector to respond in real time to abnormal line voltages. Thus, this device achieves multi-dimensional protection against mechanical stress impacts, environmental corrosion, and overvoltage hazards through material composites and structural reinforcement, extending the insulator's service life and improving operational reliability. Attached Figure Description
[0016] Figure 1 This is a schematic diagram of the overall structure of this utility model;
[0017] Figure 2 This is a partial structural schematic diagram of the present invention;
[0018] Figure 3 This is a schematic diagram of the main structure of the lower base assembly of this utility model;
[0019] Figure 4 This is a partial structural diagram of the umbrella skirt assembly of this utility model;
[0020] Figure 5 This is a schematic diagram of the main structure of the upper metal accessory of this utility model;
[0021] The attached figures are labeled as follows: 1. Insulator body; 2. Shelf assembly; 201. Large diameter shelf; 202. Small diameter shelf; 203. Flow guide groove; 3. Upper metal accessory; 301. Metal accessory body; 302. First fluororubber ring; 303. Stainless steel spring ring; 304. Second fluororubber ring; 4. Lower base assembly; 401. Metal base; 402. Overvoltage protector. Detailed Implementation
[0022] 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 of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0023] like Figures 1 to 4The illustrated aging-resistant porcelain insulator includes an insulator body 1. A skirt assembly 2 is coaxially arranged on the outer side of the insulator body 1. The skirt assembly 2 includes alternating large-diameter skirts 201 and small-diameter skirts 202 along the axis of the insulator body 1, with the spacing between adjacent skirts increasing from the lower base assembly 4 to the upper metal attachment 3. The edge of the large-diameter skirt 201 has a downward-curved bird-damage prevention structure, with the curved edge forming a 60°-75° angle with the horizontal plane. This effectively utilizes the variation in skirt spacing to optimize the electric field distribution, reducing the risk of partial discharge. The bird-damage prevention structure prevents birds from perching and nesting, reducing the probability of flashover and improving the safety of line operation.
[0024] like Figure 2 and Figure 4 As shown, both the large-diameter umbrella skirt 201 and the small-diameter umbrella skirt 202 have radially arranged guide grooves 203 on their lower surfaces. These guide grooves 203 are distributed radially at a 30° angle from the centers of the large-diameter and small-diameter umbrella skirts 201 and 202, with the groove depth decreasing from the center to the outer edge. Micro-nano-level honeycomb-shaped pit structures are also provided beneath the glaze layer on the surfaces of both the large-diameter and small-diameter umbrella skirts 201 and 202. The guide grooves 203 guide rainwater to slide off quickly, reducing surface contamination. The gradually changing groove depth design prevents water accumulation, and the honeycomb-shaped pit structure enhances surface roughness, improves glaze adhesion, slows down the aging process, and extends the service life of the insulator.
[0025] like Figure 1 and Figure 5 As shown, an upper metal accessory 3 is provided on the top of the insulator body 1. The upper metal accessory 3 includes a metal accessory body 301, the inner cavity of which is filled with elastic cushioning material. A surrounding composite sealing ring is provided at the connection interface between the metal accessory body 301 and the insulator body 1. This composite sealing ring is composed of an inner second fluororubber ring 304, a middle stainless steel spring ring 303, and an outer first fluororubber ring 302. The elastic cushioning material can absorb mechanical vibration energy and reduce stress concentration at the connection. The composite sealing ring combines the weather resistance of fluororubber with the elastic support of the stainless steel spring ring 303 to form a multi-layer sealing barrier, effectively preventing moisture and dirt from entering and ensuring long-term reliability of the connection interface.
[0026] like Figure 1 and Figure 3As shown, a lower base assembly 4 is provided at the bottom of the insulator body 1. The lower base assembly 4 includes a metal base 401 with a porous dome structure and an overvoltage protector 402 embedded inside the metal base 401. The outer surface of the metal base 401 is provided with a gradient anti-corrosion coating, which consists of, from the inside out: an arc-sprayed zinc-aluminum alloy layer, a plasma nitriding layer, and a polytetrafluoroethylene composite coating. The porous dome structure improves the mechanical strength and heat dissipation performance of the base, and the overvoltage protector 402 can quickly discharge transient overvoltage energy to protect the insulator body 1. The layers of the gradient anti-corrosion coating work together to comprehensively resist environmental erosion from substrate protection to surface anti-fouling, enhancing the durability of the base. Example
[0027] High-voltage transmission line scenario
[0028] In high-voltage transmission line scenarios, aging-resistant porcelain insulators are key components ensuring stable power transmission. The insulator body 1 serves as the core supporting structure, while the outer, coaxially arranged skirt assembly 2 plays a crucial role. The skirt assembly 2 includes alternating large-diameter skirts 201 and small-diameter skirts 202 along the axis of the insulator body 1, with the spacing between adjacent skirts increasing from the lower base assembly 4 towards the upper metal attachment 3. This design effectively disperses the impact of wind on the insulator in windy and rainy outdoor environments, while also allowing rainwater to drip more easily due to the varying spacing, reducing the time rainwater remains on the insulator surface and lowering the risk of tracking. The edges of the large-diameter skirts 201 feature downward-curved bird-proof structures. These curved edges form a 60°-75° angle with the horizontal plane, effectively preventing birds from perching and defecating on the skirts, thus avoiding bird droppings contaminating the insulator surface and maintaining the insulator's excellent insulation performance.
[0029] Both the large-diameter umbrella skirt 201 and the small-diameter umbrella skirt 202 have radially arranged guide grooves 203 on their lower surfaces. These grooves radiate outwards at a 30° angle from the centers of the large-diameter and small-diameter umbrella skirts 201 and 202, with the groove depth decreasing from the center to the outer edge. When rainwater falls on the umbrella skirts, the guide grooves 203 guide the rainwater to flow quickly down a specific path, preventing water accumulation on the lower surface of the umbrella skirts and further enhancing the insulator's anti-flashover capability. Simultaneously, the micro-nano-level honeycomb-like pit structure beneath the glaze layer on the umbrella skirt surface increases surface roughness, reduces the adhesion of dust and dirt, and slows down the aging rate of the insulator surface.
[0030] The upper metal accessory 3 includes a metal accessory body 301, whose inner cavity is filled with an elastic buffer material that can absorb the stress generated by conductor vibration, thermal expansion and contraction, etc. during the operation of the high-voltage transmission line, reducing mechanical damage to the insulator body 1. The surrounding composite sealing ring set at the connection interface between the metal accessory body 301 and the insulator body 1 is composed of an inner second fluororubber ring 304, a middle stainless steel spring ring 303, and an outer first fluororubber ring 302. It can effectively prevent external moisture, humidity, and corrosive gases from entering the connection interface, ensuring the sealing and reliability of the connection and extending the service life of the insulator.
[0031] The lower base assembly 4 includes a metal base 401 with a porous dome structure and an overvoltage protector 402 embedded inside the metal base 401. When the high-voltage transmission line is struck by lightning or experiences an operational overvoltage, the overvoltage protector 402 can quickly activate, limiting the overvoltage to a safe range and protecting the line and equipment from damage. The outer surface of the metal base 401 is provided with a gradient anti-corrosion coating, which consists of an arc-sprayed zinc-aluminum alloy layer, a plasma nitriding layer, and a polytetrafluoroethylene composite coating from the inside out. This coating effectively resists corrosive substances such as acid rain and salt spray in the outdoor atmosphere, preventing the metal base 401 from rusting and corroding, and ensuring the stability of the overall insulator structure.
[0032] The implementation principle of an aging-resistant porcelain insulator according to an embodiment of this application is as follows:
[0033] First, the insulator body 1 serves as the core load-bearing structure. The outer side of the coaxially arranged umbrella skirt assembly 2 is formed by alternating large-diameter umbrella skirts 201 and small-diameter umbrella skirts 202, with the spacing increasing from bottom to top, creating a gradient hydrophobic environment. The bird-proof structure with a 60°-75° chamfered edge of the large-diameter umbrella skirt 201 uses angle design to prevent birds from stopping and nesting, reducing bird droppings pollution. The 30° radially distributed guide grooves 203 on the lower surface of the umbrella skirt have a groove depth that decreases from the center to the outside, guiding rainwater to slide down quickly in the radial direction and avoiding surface water accumulation. The micro-nano honeycomb pit structure under the glaze layer increases the surface roughness and improves hydrophobicity, making it difficult for dirt particles to adhere.
[0034] Secondly, the inner cavity of the metal accessory body 301 of the upper metal accessory 3 is filled with elastic buffer material. When the insulator is subjected to external vibration or mechanical impact, the material deformation absorbs stress and prevents the body from cracking due to rigid connection. The composite sealing ring at the connection interface is composed of an inner second fluororubber ring 304, a middle stainless steel spring ring 303, and an outer first fluororubber ring 302. The spring ring provides pre-tightening force to ensure the sealing structure fits, the inner fluororubber ring isolates gas, and the outer fluororubber ring resists rainwater erosion, forming an "elastic support + multi-layer sealing" structure to prevent external moisture and dust from entering the connection gap and ensure long-term reliable connection of the interface.
[0035] Next, the metal base 401 of the lower base assembly 4 adopts a porous dome structure, which reduces the overall weight and disperses the bottom support stress through the dome curved surface, thereby improving mechanical stability. The overvoltage protector 402 embedded in the base monitors the line voltage in real time. When the system experiences lightning strikes or operational overvoltages, the protector quickly conducts discharge to limit the overvoltage to a safe range and prevent the insulator body 1 from being subjected to instantaneous high voltage breakdown. The combination of the porous structure and the protector realizes the functional integration of mechanical support and electrical protection.
[0036] Next, the gradient anti-corrosion coating on the outer surface of the 401 metal base is applied in three layers: the inner layer, an arc-sprayed zinc-aluminum alloy layer, uses the sacrificial anode principle to preferentially withstand electrochemical corrosion and protect the substrate; the middle layer, a plasma nitriding layer, forms a dense nitride hardened layer on the metal surface, improving wear resistance and chemical corrosion resistance; and the outer layer, a polytetrafluoroethylene composite coating, with its low surface energy characteristics, prevents the adhesion of corrosive media such as acids, alkalis, and salts, while also reducing dust adsorption. The three layers work progressively from electrochemical protection to physical isolation, adapting to complex corrosive environments such as coastal areas and chemical industrial zones, and extending the service life of the base.
[0037] Finally, the bird-proof, current-guiding, and self-cleaning structure of the umbrella skirt assembly 2 reduces surface dirt and electro-corrosion; the buffer seal of the upper accessory prevents mechanical damage and moisture intrusion; the overvoltage protection of the lower base prevents electrical aging; and the gradient coating resists environmental corrosion. The whole structure forms a three-dimensional aging-resistant system of "electrical insulation - mechanical support - environmental protection", which enables the insulator to effectively cope with multiple aging factors such as mechanical stress, electrical load, dirt deposition, and corrosive environment during long-term operation, and achieves high-reliability power transmission function.
Claims
1. An aging-resistant porcelain insulator, comprising an insulator body (1), characterized in that: The insulator body (1) is coaxially provided with a skirt assembly (2), the top of the insulator body (1) is provided with an upper metal accessory (3), and the bottom of the insulator body (1) is provided with a lower base assembly (4); the skirt assembly (2) includes a large-diameter skirt (201) and a small-diameter skirt (202) alternately arranged along the axis of the insulator body (1), and the spacing between adjacent skirts increases from the lower base assembly (4) to the upper metal accessory (3). The edge of the large-diameter skirt (201) is provided with a downward-turned bird protection structure, and the turn-up is at an angle of 60°-75° with the horizontal plane.
2. The aging-resistant porcelain insulator according to claim 1, characterized in that: The lower surfaces of both the large-diameter umbrella skirt (201) and the small-diameter umbrella skirt (202) are provided with radial guide grooves (203).
3. The aging-resistant porcelain insulator according to claim 1, characterized in that: The upper metal accessory (3) includes a metal accessory body (301), the inner cavity of which is filled with elastic buffer material, and a circumferential composite sealing ring is provided at the connection interface between the metal accessory body (301) and the insulator body (1). The composite sealing ring is composed of an inner second fluororubber ring (304), a middle stainless steel spring ring (303), and an outer first fluororubber ring (302).
4. The aging-resistant porcelain insulator according to claim 1, characterized in that: The lower base assembly (4) includes a metal base (401) with a porous dome structure and an overvoltage protector (402) embedded in the metal base (401). The outer surface of the metal base (401) is provided with a gradient anti-corrosion coating.
5. The aging-resistant porcelain insulator according to claim 2, characterized in that: The flow guide groove (203) is radially distributed at a 30° angle with the center of the large-diameter umbrella skirt (201) and the small-diameter umbrella skirt (202) as the origin, and the depth of the flow guide groove (203) decreases from the center to the outer edge.
6. The aging-resistant porcelain insulator according to claim 1, characterized in that: Both the large-diameter umbrella skirt (201) and the small-diameter umbrella skirt (202) have micro-nano-level honeycomb-shaped pit structures beneath their surface glaze layers.
7. The aging-resistant porcelain insulator according to claim 4, characterized in that: The gradient anti-corrosion coating consists of, from the inside out: an arc-sprayed zinc-aluminum alloy layer, a plasma nitriding layer, and a polytetrafluoroethylene composite coating.