Composite Polymer Insulator Joint Sleeve Assembly
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Solution Overview
Problem
Current manufacturing techniques for composite polymer insulators require bulky and expensive molds, and the molded sections with overlapping polymer surfaces are prone to damage from electrical activity and tears.
Innovation Solution
A method involving an elongate core with a midsection surrounded by a joint sleeve, where polymeric housings are molded to overlap and bond with the joint sleeve, eliminating the need for bulky molds and polymer-to-polymer joints, and forming polymer-to-metal bonded joints that are stronger and more durable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If polymer insulators are molded in multiple sections with overlapping polymer surfaces, then long insulators can be produced, but the overlapping sections are susceptible to damage from electrical activity and tears
Solution Approach 1:
A metal joint sleeve is introduced as an intermediary component between the two polymer housing sections. The joint sleeve receives both housing sections and provides a robust metal-to-polymer bonded joint, eliminating the vulnerable polymer-to-polymer overlap while enabling the production of long insulators through modular assembly
2Manufacturing precision
If bulky molds are used to produce long polymer insulators, then complete insulators can be molded in a single piece, but the manufacturing equipment becomes expensive and occupies large space
Solution Approach 1:
The insulator is segmented into modular components (core, housing sections, joint sleeve) that can be manufactured separately using smaller, less expensive molds and then assembled. This segmentation eliminates the need for bulky single-piece molds while maintaining insulator integrity through the robust metal joint sleeve connection
3Ease of manufacture
If polymer housings are molded to overlap each other directly, then assembly is simplified, but the polymer-to-polymer joint is vulnerable to electrical damage and tearing
Solution Approach 1:
The joint structure uses a composite material approach by combining metal (joint sleeve) with polymer (housing sections) to create a hybrid joint. This metal-to-polymer bonded joint provides both the simplicity of modular assembly and the superior strength and electrical durability that metal provides, eliminating the weaknesses of pure polymer-to-polymer joints
Data Source
AI summary
Embodiments of the invention are directed to a method for manufacturing a composite polymer insulator. The method includes: providing an elongate core having a core axis, the core including a first core main section, a second core main section, and a core midsection axially interposed between the first and second core main sections; and mounting a joint sleeve around the core midsection. The method further includes molding a polymeric first housing onto the core such that: the first housing surrounds the first core main section; and a joint section the first housing overlaps and bonds to the joint sleeve. The method further includes molding a polymeric second housing onto the core such that: the second housing surrounds the second core main section; and a joint section of the second housing overlaps and bonds to the joint sleeve.