Composite Insulating Bushing Structure for Outdoor Waterproofing
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Solution Overview
Problem
Conventional insulating bushings for busbars, especially those used outdoors, face issues with poor flame retardancy, thermal resistance, and manufacturing efficiency due to material properties, leading to inadequate waterproof performance and durability.
Innovation Solution
An insulating bushing design featuring a first bushing with an unsaturated polyester and glass fabric composition, a second bushing with a flange having an M-shaped configuration, and a silicone resin cover, which enhances mechanical and chemical properties, including waterproof performance, weather resistance, and flame retardancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a typical insulating bushing is produced from Nylon, polyamide, and similar materials, then it can be manufactured easily, but it exhibits poor flame retardancy, thermal resistance, and shape stability due to low melting point
Solution Approach 1:
The insulating bushing is produced from a composite material comprising polypropylene as the base resin and glass fiber as reinforcement. This composite structure provides superior flame retardancy, thermal resistance, and mechanical strength compared to conventional Nylon or polyamide materials, while maintaining manufacturability through standard injection molding processes.
2Stability of the object's composition
If cavities and slits are formed in the insulating bushing, then the material properties are accommodated, but manufacturing efficiency deteriorates and waterproof level decreases to IPX5
Solution Approach 1:
The invention eliminates the need for cavities and slits by using a solid, homogeneous composite structure. The polypropylene-glass fiber composite material inherently provides the necessary structural stability and dimensional control without requiring void spaces for material accommodation, thereby improving manufacturing efficiency and achieving superior waterproof performance (IP65 level).
3Reliability
If the insulator or insulating tape is used on the busbar surface, then electrical interference is reduced initially, but bonding strength reduces over time due to friction and environmental exposure
Solution Approach 1:
Instead of using short-lived insulating tapes or coatings that require periodic replacement, the invention employs a durable, integrated insulating bushing made from weather-resistant polypropylene-glass fiber composite. This single-component structure is designed to maintain its insulating properties and bonding strength over extended periods without degradation from friction or environmental exposure.
4Reliability
If a conventional insulating bushing design is used, then basic insulation is provided, but waterproof performance and weather resistance are insufficient for outdoor environments
Solution Approach 1:
The insulating bushing utilizes a polypropylene-glass fiber composite material that combines the electrical insulation properties of polypropylene with the mechanical strength and environmental resistance of glass fiber. This composite structure provides superior waterproof performance (IP65 rating) and weather resistance, making it suitable for outdoor installations while maintaining reliable electrical insulation.
Data Source
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.