A composite hollow insulator and an insulator wiring device

Abstract

This utility model relates to the field of insulator technology, and in particular to a composite hollow insulator and an insulator wiring device, comprising an insulator core, wherein a main corrosion-resistant layer, an auxiliary corrosion-resistant layer, a pressure-resistant layer, a load-bearing layer, and a processing layer are respectively bonded to the insulator core from the inside out; the main corrosion-resistant layer, the auxiliary corrosion-resistant layer, the pressure-resistant layer, the load-bearing layer, and the processing layer are all made by wet winding; the insulator has high production efficiency, low cost, light weight, small size, and is easy to install and transport.

Description

Technical Field

[0001] This utility model relates to the field of insulator technology, and in particular to a composite hollow insulator and an insulator wiring device. Background Technology

[0002] Hollow insulators play two fundamental roles in overhead power transmission lines: supporting the conductors and preventing current from returning to ground. Currently, there are two main types of hollow insulators in use: hollow porcelain insulators and hollow composite insulators. Porcelain insulators primarily use ceramic materials, which are inherently hard but also brittle. Their internal defects are difficult to detect, requiring deterioration testing and other maintenance, resulting in high costs. Conventionally wound hollow insulators often have more air bubbles and impurities in the core, leading to poor mechanical properties and reduced product quality. Long-term use can easily cause core deterioration, resulting in breakage of the hollow insulator. Furthermore, the upper end of the insulator needs a connector for connecting to the high-voltage line. The design of this connector must consider mechanical strength and connection stability to withstand long-term loads and stable operation.

[0003] Currently, there are two commonly used wiring devices. One is the through-hole connection, which is simple and quick to install, but has weak load-bearing capacity and poor cable stability. It is prone to swaying back and forth due to external weather conditions, causing friction between the through-hole and the cable, resulting in cable wear. The other is the bolt-fixed connection, which carries the risk of cable puncture and leakage.

[0004] Therefore, this application provides a composite hollow insulator and an insulator wiring device to solve the problems mentioned in the background art. Utility Model Content

[0005] The purpose of this invention is to provide a composite hollow insulator and an insulator wiring device to solve problems such as air bubbles in the existing insulator core, poor mechanical properties, and reduced finished product quality; as well as poor cable stability, easy loosening, and damage to the cable in the insulator wiring device.

[0006] To solve the above-mentioned technical problems, this utility model provides a composite hollow insulator and an insulator wiring device, including an insulator core, wherein a main corrosion-resistant layer, an auxiliary corrosion-resistant layer, a pressure-resistant layer, a load-bearing layer, and a processing layer are respectively bonded to the insulator core from the inside out; the main corrosion-resistant layer, the auxiliary corrosion-resistant layer, the pressure-resistant layer, the load-bearing layer, and the processing layer are all made by wet winding.

[0007] The further improvement of this utility model's technical solution lies in the following: the main corrosion-resistant layer is made of polyester surface felt; the number of layers of the main corrosion-resistant layer is 1-5; the auxiliary corrosion-resistant layer is made of polyester felt; the number of layers of the auxiliary corrosion-resistant layer is 0-4; the pressure-resistant layer is made of fiber yarn; the number of layers of the pressure-resistant layer is 2-15, and the circumferential winding angle is 80°-90°; the load-bearing layer is made of fiber yarn; the number of layers of the load-bearing layer is 2-20, and the circumferential winding angle is 30°-65°; the processing layer is made of fiber yarn; the number of layers of the processing layer is 5-30, and the circumferential winding angle is 80°-90°.

[0008] A further improvement of this utility model is that: the polyester surface felt of the main corrosion-resistant layer is wound on the mold, and a roller dipped in glue is used to press it to fully saturate the surface felt and completely remove the air bubbles in the surface felt; after the auxiliary corrosion-resistant layer polyester felt is wound, a roller is used to press the seam edge felt thoroughly and completely remove the air bubbles in the polyester felt.

[0009] A further improvement of this utility model is that a wiring mechanism is provided on the top of the insulator; the wiring mechanism includes a housing, and mounting holes are respectively provided through the two side walls of the housing at different angles. Bolt rods are respectively provided in the mounting holes. Arc-shaped first and second wire clamps are respectively provided in the wiring cavity of the bolt rods. The first and second wire clamps press the cable located in the wiring cavity, so that the cable bends and deforms into an S-shape.

[0010] A further improvement of the present invention is that the insulator includes an insulator core, which is a hollow structure; multiple shed bodies are evenly spaced on the outer wall of the insulator core, and the multiple shed bodies are coaxially arranged with the insulator core.

[0011] A further improvement of this utility model is that: an external thread is provided at the bottom of the insulator core body, and the external thread is connected to the high-voltage pole or tower; an internal thread is provided at the top, and the internal thread is connected to the wiring mechanism; an external thread post is provided at the center of the bottom surface of the wiring mechanism housing, and the external thread post is adapted to the internal thread of the insulator core body.

[0012] A further improvement of this utility model is that: the mounting hole on the left side wall of the housing body is located at one-third of the left side wall; the mounting hole on the right side wall of the housing body is located at one-third of the right side wall; and the two mounting holes are at the same height on the housing.

[0013] A further improvement of this utility model is that: the inner wall of the mounting hole is threaded, the bolt rod is adapted to the mounting hole, and the outer end of the bolt rod is provided with a bolt head, which is a hexagonal structure and has a cross groove on the top.

[0014] A further improvement of this utility model is that: the two bolt rods are located at one end of the housing and are respectively adapted to snap onto the first clamp and the second clamp; the first clamp and the second clamp are arc-shaped plate structures with an arc of 100°~180°, and the inner arc surfaces of the first clamp and the second clamp are respectively adapted to abut against the outer arc surfaces on both sides of the cable to compress the cable.

[0015] A further improvement of this utility model is that the shell, the first clamp and the second clamp are both made of polyamide containing 30% glass fiber, and the bolt rod is made of polyetheretherketone.

[0016] By adopting the above technical solution, this utility model has the following beneficial effects:

[0017] 1. This utility model provides a composite hollow insulator. The insulator core is produced by wet winding process. By winding glass fiber reinforcement material and using a small-angle winding process, the glass fiber winding yarn has good density, which enhances the axial performance of the core. The axial bending strength modulus is above 20GPa, which has high bending strength and good seismic and bending resistance. It still meets the requirements for use in relatively harsh environments. Due to the high content of glass fiber winding yarn, the toughness and hardness of the core are improved, avoiding core breakage caused by impact, collision, or compression due to transportation or other uncontrollable reasons, thus ensuring normal use in the future.

[0018] 2. This utility model provides a composite hollow insulator. The resin adhesive is vacuum-treated, and the main corrosion layer is pressed with a roller dipped in the adhesive to completely remove air bubbles from the surface felt. After the auxiliary corrosion-resistant polyester felt is wound, air bubbles are completely removed from the polyester felt using a roller, reducing air bubbles in the core and preventing core puncture due to impurities or air bubbles. This process is simple to operate, has high production efficiency, and low cost. It can achieve multi-axis production and can employ both external and internal curing processes. The composite insulator core produced by this process is lightweight and small in size, facilitating installation and transportation.

[0019] 3. The present invention provides a wiring device for an insulator. The two side walls of the housing of the wiring device are staggered and have through-holes. Bolt rods are respectively installed in the mounting holes. The two bolt rods move by controlling the position of the first clamp and the second clamp, thereby pushing the cable to bend and deform into an S-shape. By pressing the two clamps together, the cable is not easy to sway left and right, thus enhancing the stability of the cable.

[0020] 4. The present invention provides a wiring device for an insulator. The clamp is arc-shaped, which can fit the cable well, increase the force-bearing area, and because it is S-shaped in the linear direction of the cable, the cable is not easy to move in the linear direction, and it prevents the cable from loosening in the housing, while protecting the cable from damage.

[0021] 5. The wiring device for an insulator provided by this utility model has a housing, a first clamp and a second clamp made of polyamide containing 30% glass fiber; the bolt rod is made of polyetheretherketone, which has the characteristics of insulation, light weight, corrosion resistance and high strength. Attached Figure Description

[0022] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0023] Figure 1 This is a cross-sectional view of the hollow insulator core.

[0024] Figure 2 This is an overall schematic diagram of a wiring device for hollow insulators;

[0025] Figure 3 A schematic diagram of the hollow insulator core and the main body of the shed;

[0026] Figure 4 A schematic diagram of the umbrella skirt body and internal threads;

[0027] Figure 5 A schematic diagram of the wiring mechanism in its unwired state;

[0028] Figure 6 A schematic diagram of the wiring mechanism in the wire-threading state;

[0029] Figure 7 This is a cross-sectional view of the wiring mechanism after the wires have been threaded and the mechanism is clamped in place.

[0030] Reference numerals: 1. Insulator; 2. Connecting mechanism; 11. Insulator core; 12. Sheath body; 13. External thread; 14. Internal thread; 6. Cable; 21. Housing; 22. Connecting cavity; 23. Bolt shank; 24. Mounting hole; 25. Bolt head; 26. First clamp; 27. External thread post; 28. Second clamp; 31. Main corrosion-resistant layer; 32. Secondary corrosion-resistant layer

[0031] 33. Pressure-resistant layer; 34. Load-bearing layer; 35. Processing layer. Detailed Implementation

[0032] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0033] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0034] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0035] The present invention will be further explained below with reference to specific embodiments.

[0036] like Figure 1 As shown, this embodiment provides a composite hollow insulator, including an insulator core 11. The insulator core 11 is provided with a main corrosion-resistant layer 31, an auxiliary corrosion-resistant layer 32, a pressure-resistant layer 33, a load-bearing layer 34, and a processing layer 35, which are respectively bonded from the inside out. The main corrosion-resistant layer 31, auxiliary corrosion-resistant layer 32, pressure-resistant layer 33, load-bearing layer 34, and processing layer 35 are all formed by wet winding. This embodiment also provides a composite hollow insulator manufacturing process, including the following steps:

[0037] Step 1, Preparation: Mold preparation: Preheat the mold to 60℃ for 50 minutes, then evenly apply the release agent to the mold surface; add the resin to the raw material tank in advance, heat to 40℃, and perform vacuum degassing until there is less foam, then keep it sealed and stand for 60 minutes.

[0038] Step 2, Main corrosion-resistant layer 31 winding: Apply thermosetting resin adhesive evenly to the mold; the thermosetting resin includes epoxy resin, phenolic resin, unsaturated resin, polyurethane resin and the corresponding modified resins of the above resins; the thermosetting resin is epoxy resin; then rotate the mold, wrap the surface felt circumferentially around the mold, and use a roller dipped in adhesive to press and saturate the surface felt, and completely remove the air bubbles in the surface felt; wherein the surface felt is made of polyester surface felt, the overlap width is 5%, and the number of winding layers is 2.

[0039] Step 3, Auxiliary corrosion-resistant layer 32 winding: After the adhesive has been fully soaked, the polyester felt is wound around the mold in a circumferential direction. The seam felt is pressed through with a felt roller and all air bubbles in the polyester felt are completely expelled. The overlap width is 5%, the number of winding layers is 1, and the polyester felt is a polyester chopped strand continuous felt.

[0040] Step 4, Winding of pressure-resistant layer 33: Set the winding machine program and start winding the pressure-resistant layer on the corrosion-resistant layer 33 using a wet winding method. The winding method is circumferential winding; the number of circumferential winding layers is 3, the circumferential winding angle is 85°, and the tension of the winding fiber yarn is 15N.

[0041] Step 5, Winding of load-bearing layer 34: Set the winding machine program and start winding the load-bearing layer 34 on the pressure-resistant layer 33 using a wet winding method. The winding method is spiral winding; the number of spiral winding layers is 10, the spiral winding angle is 35°, and the tension of the winding fiber yarn is 15N.

[0042] Step 6, Processing layer 35 winding: Set the winding machine program, and start the processing layer winding on the load-bearing layer 34 using wet winding method. The winding method is circumferential winding; the number of circumferential winding layers is 22, the circumferential winding angle is 85°, and the tension of the winding fiber yarn is 15N;

[0043] Step 7: Turn on the oven to heat and cure the structural layer: the curing regime is: 60℃ / 1.5h, 90℃ / 1h, 130℃ / 1h; the heating rate is 2℃ / min.

[0044] Step 8: After curing, demold, polish and trim to complete product preparation.

[0045] The following image shows the performance test results of composite hollow insulator products:

[0046]

[0047] like Figure 1As shown, this embodiment provides a composite hollow insulator, comprising a main corrosion-resistant layer 31 made of polyester surface felt; the main corrosion-resistant layer 31 has 1-5 winding layers; an auxiliary corrosion-resistant layer 32 made of polyester felt; the auxiliary corrosion-resistant layer 32 has 0-4 winding layers; a pressure-resistant layer 33 made of fiber yarn; the pressure-resistant layer 33 has 2-15 winding layers with a circumferential winding angle of 80°-90°; a load-bearing layer 34 made of fiber yarn; the load-bearing layer 34 has 2-20 winding layers with a circumferential winding angle of 30°-65°; a processing layer 35 made of fiber yarn; the processing layer 35 has 5-30 winding layers with a circumferential winding angle of 80°-90°. By winding glass fiber reinforcement material and using a small-angle winding process, the glass fiber winding yarn has good density, which enhances the axial performance of the core. Due to the high content of glass fiber winding yarn, the toughness and hardness of the core are improved, avoiding problems such as core breakage caused by impact, collision, or compression due to transportation or other uncontrollable reasons, and ensuring normal use in the future.

[0048] like Figure 1 As shown, in this embodiment, the polyester surface felt of the main corrosion-resistant layer 31 is wound onto the mold. A roller dipped in adhesive is used to press and squeegee the felt to ensure it is fully saturated and all air bubbles are expelled. After the polyester felt of the auxiliary corrosion-resistant layer 32 is wound, a roller is used to press and squeegee the seam edge felt to ensure all air bubbles are expelled. By vacuuming the resin and using rollers or squeegees to squeegee the felt, air bubbles within the core are reduced, preventing the core from being punctured due to impurities or air bubbles. This ensures good sealing and prevents corrosion of the core due to the introduction of SF6 gas.

[0049] like Figures 2-7 As shown, the wiring device for the insulator provided in this embodiment includes an insulator 1, with a wiring mechanism 2 disposed on the top of the insulator 1. The wiring mechanism 2 includes a housing 21, which is a rectangular hollow cavity structure. Mounting holes 24 are provided through the offset sides of the housing 21. Bolt rods 23 are disposed within the mounting holes 24, and a first clamp 26 and a second clamp 28 are disposed at the inner ends of the bolt rods 23. By tightening the bolt rods 23 on both sides, the first clamp 26 and the second clamp 28 are moved forward, causing the cable 6 to bend and deform into an S-shape within the housing 21. In this embodiment, the cable 6 is passed through the wiring cavity 22. By tightening the bolt rods 23 on the sides of the housing 21, the first clamp 26 and the second clamp 28 are displaced, pressing the cable 6 and causing it to bend and deform into an S-shape. The cable 6 is less likely to move in the linear direction, and the cable 6 is prevented from loosening within the housing 21, thus improving the stability of the cable 6.

[0050] like Figures 2-4As shown, in this embodiment, the insulator 1 has an external thread 13 at its bottom and an internal thread 14 at its top. The external thread 13 is used for installation on a high-voltage pole or tower; the internal thread 14 is used for connection to the wiring mechanism 2. The wiring mechanism 2 has an external thread post 27 at its bottom, which is fitted with the internal thread 14. The external thread post 27 at the bottom is screwed to the internal thread 14 of the insulator 1. The insulator core 11 is a hollow structure, and the wiring cavity 22 of the wiring mechanism 2 is large, resulting in a lightweight overall structure that is easy to install and fix.

[0051] like Figures 2-7 As shown, in this embodiment, a bolt head 25 is provided at the outer end of the bolt rod 23. The bolt head 25 is hexagonal in shape and has a cross groove on the top. During installation, the bolt rod 23 is first turned by hand, which drives the first clamp 26 and the second clamp 28 to push the cable 6 to deform and fix it. Finally, the bolt head 25 is turned by wrench or Phillips screwdriver, which moves the entire bolt rod 23 in conjunction with the cable 6 to further reinforce it and thus enhance the cable 6's firmness.

[0052] like Figure 7 As shown, in this embodiment, the inner end of the bolt rod 23 is screwed with a first clamp 26 and a second clamp 28, which are arc-shaped with an arc angle of 100°~180°. By designing the first clamp 26 and the second clamp 28 as arc-shaped, they can fit the cable 6 well, increase the force-bearing area, which is beneficial to the stability of the cable 6, and at the same time protect the cable 6 from damage.

[0053] This utility model also provides the working principle of the insulator wiring device:

[0054] When using the insulator wiring device, the operator first screws the external thread post 27 of the wiring mechanism 2 to the internal thread 14 of the insulator 1, and then fixes the external thread 13 of the insulator 1 to the high-voltage pole or tower; by turning the bolt head 25 with a wrench or Phillips screwdriver, the bolt rod 23 on both sides of the housing 21 is rotated outward, causing the first clamp 26 and the second clamp 28 to move towards the two sides of the housing 21, so that the first clamp 26 and the second clamp 28 abut against the two sides, making the space of the wiring cavity 22 larger, facilitating the passage of the cable 6, and preventing the cable 6 from passing through the outside of the arc of the first clamp 26 and the second clamp 28; Cable 6 passes through the center of the wiring cavity 22. Then, by hand, one side of the bolt rod 23 on the housing 21 is screwed halfway into the wiring cavity 22. Then, by hand, the other side of the bolt rod 23 on the housing 21 is also screwed halfway in, ensuring that cable 6 deforms slowly. This is repeated two to three times. After the first clamp 26 and the second clamp 28 have completely tightened cable 6, the bolt head 25 is finally tightened with a wrench or Phillips screwdriver, which moves the entire bolt rod 23 to further reinforce cable 6. Cable 6 is bent and deformed into an S-shape in the wiring cavity 22, which achieves the purpose of fixing cable 6 and preventing loosening, while protecting cable 6 from damage.

[0055] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A composite hollow insulator, characterized in that, The insulator core (11) includes a main corrosion-resistant layer (31), an auxiliary corrosion-resistant layer (32), a pressure-resistant layer (33), a load-bearing layer (34), and a processing layer (35) respectively attached from the inside to the outside; the main corrosion-resistant layer (31), the auxiliary corrosion-resistant layer (32), the pressure-resistant layer (33), the load-bearing layer (34), and the processing layer (35) are all made by wet winding.

2. The composite hollow insulator according to claim 1, characterized in that, The main corrosion-resistant layer (31) is made of polyester surface felt; the number of winding layers of the main corrosion-resistant layer (31) is 1-5; the auxiliary corrosion-resistant layer (32) is made of polyester felt; the number of winding layers of the auxiliary corrosion-resistant layer (32) is 0-4; the pressure-resistant layer (33) is made of fiber yarn; the number of winding layers of the pressure-resistant layer (33) is 2-15, and the circumferential winding angle is 80°-90°; the load-bearing layer (34) is made of fiber yarn; the number of winding layers of the load-bearing layer (34) is 2-20, and the circumferential winding angle is 30°-65°; the processing layer (35) is made of fiber yarn; the number of winding layers of the processing layer (35) is 5-30, and the circumferential winding angle is 80°-90°.

3. A wiring device with an insulator as described in claim 1 or 2, characterized in that, A wiring mechanism (2) is provided on the top of the insulator (1); the wiring mechanism (2) includes a housing (21), and mounting holes (24) are provided through the two side walls of the housing (21) respectively. Bolt rods (23) are provided in the mounting holes (24). The bolt rods (23) are located in the wiring cavity (22) and arc-shaped first clamp (26) and second clamp (28) are provided respectively. The first clamp (26) and second clamp (28) press the cable (6) located in the wiring cavity (22) so that the cable (6) bends and deforms into an S shape.

4. The wiring device according to claim 3, characterized in that, The insulator (1) includes an insulator core (11), which is a hollow structure; multiple shed bodies (12) are evenly spaced on the outer wall of the insulator core (11), and the multiple shed bodies (12) are coaxially arranged with the insulator core (11).

5. The wiring device according to claim 3, characterized in that, The insulator core (11) has an external thread (13) at the bottom end, which is connected to the high-voltage pole or tower; the top end has an internal thread (14), which is connected to the wiring mechanism (2). The wiring mechanism (2) has an external thread post (27) at the center of the bottom surface of the housing (21), which is adapted to the internal thread (14) of the insulator core (11).

6. The wiring device according to claim 3, characterized in that, The mounting hole (24) on the left side wall of the housing (21) is located at one-third of the left side wall; the mounting hole (24) on the right side wall of the housing (21) is located at one-third of the right side wall; the two mounting holes (24) are at the same height on the housing (21).

7. The wiring device according to claim 3, characterized in that, The inner wall of the mounting hole (24) is threaded, the bolt rod (23) is adapted to the mounting hole (24), and the outer end of the bolt rod (23) is provided with a bolt head (25). The bolt head (25) is a hexagonal structure and has a cross groove on the top.

8. The wiring device according to claim 3, characterized in that, Two bolt rods (23) are located at one end of the housing (21) and are respectively adapted to snap onto the first clamp (26) and the second clamp (28); the first clamp (26) and the second clamp (28) are arc-shaped plate structures with an arc of 100°~180°. The inner arc surfaces of the first clamp (26) and the second clamp (28) are respectively adapted to abut against the outer arc surfaces on both sides of the cable (6) to press the cable (6).

Images