Composite Insulating Bushing Structure for Waterproof Busbar Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional insulating bushings for busbars exhibit poor flame retardancy, thermal resistance, and durability, leading to issues with shape deformation, manufacturing efficiency, and waterproof performance when exposed to outdoor environmental conditions.
Innovation Solution
An insulating bushing composed of unsaturated polyester and glass fabrics, with silicone resin components for gaskets and cover, providing improved thermal durability, structural integrity, and enhanced waterproof performance, along with a design that eliminates reinforcing members and cavities, ensuring better insulating and drainage characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a typical insulating bushing is produced from Nylon or polyamide, then it provides basic insulating properties, but it exhibits poor flame retardancy, thermal resistance, and shape stability due to low melting point
Solution Approach 1:
The patent uses a composite material system consisting of unsaturated polyester resin combined with glass fabrics (chopped glass fiber and glass mat). This composite provides superior thermal resistance, flame retardancy, and mechanical strength compared to conventional Nylon or polyamide materials, while maintaining good insulating properties. The glass fiber reinforcement prevents shape deformation at elevated temperatures.
2Ease of manufacture
If cavities and slits are formed in the insulating bushing, then material properties are accommodated, but manufacturing efficiency deteriorates and waterproof level reduces to IPX5
Solution Approach 1:
The patent employs a waterproof coating layer formed on the outer surface of the insulating bushing to provide IP65 waterproof protection. This coating eliminates the need for cavities and slits while maintaining material integrity and manufacturing efficiency. The coating creates a continuous waterproof barrier without compromising the structural requirements of the composite material.
3Reliability
If insulator or insulating tape is used to coat the busbar surface, then electrical interference is reduced, but bonding strength decreases over time due to friction and environmental exposure
Solution Approach 1:
The patent uses a composite material system consisting of unsaturated polyester resin combined with glass fabrics (chopped glass fiber and glass mat). This composite provides superior thermal resistance, flame retardancy, and mechanical strength compared to conventional Nylon or polyamide materials, while maintaining good insulating properties. The glass fiber reinforcement prevents shape deformation at elevated temperatures.
4Strength
If reinforcing members are added to the insulating bushing, then structural strength is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent incorporates glass fabrics (chopped glass fiber and glass mat) directly into the polyester resin matrix to create a fiber-reinforced composite structure. This provides localized strength enhancement exactly where needed within the bushing body, eliminating the need for separate reinforcing members. The fibrous reinforcement is distributed throughout the material, providing structural integrity without adding mechanical fasteners or additional components.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Disclosed herein is an insulating bushing adapted to protect a busbar and having improved waterproof performance. The insulating bushing includes: a first bushing provided with a first bushing passage through which the busbar passes; a second bushing provided with a first bushing-receiving portion receiving an upper portion of the first bushing inserted through a lower portion of the first bushing-receiving portion and a second bushing passage through which the busbar passes; and a cover coupled to an outer surface of the second bushing and provided with a cover passage through which the busbar passes, wherein the second bushing includes: a second bushing body; and a second bushing flange protruding from a lower portion of the second bushing body in a lateral direction thereof to surround the lower portion of the second bushing body and formed with a plurality of second bushing bolt-holes, the second bushing flange being composed of second bushing flange long-sides and second bushing flange short-sides with reference to a shape of the second bushing passage, the second bushing flange long-sides having an M shape with peaks and a valley.