High-Voltage Insulator Retainer Joint for Stronger Flange Assembly
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Solution Overview
Problem
Existing high-voltage insulators face issues with weak flange connections that are prone to failure under high forces and complex, time-consuming on-site assembly, particularly for supporting busbars and choke coils.
Innovation Solution
A support insulator design featuring a rotationally symmetrical hollow tube with a silicone shield, a base flange, and a detachable bracket with a conical connection and locking bolts, allowing for easy assembly and enhanced structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulators are used for high-voltage applications, then insulation performance is maintained, but flashover risk increases under contaminated conditions
Solution Approach 1:
The insulator surface is segmented into multiple hydrophobic particles distributed across the insulation layer, creating discrete hydrophobic zones that segment the contamination paths and prevent continuous conductive channels from forming across the insulator surface
Solution Approach 2:
The insulator exhibits local quality differentiation with hydrophobic particles concentrated at the surface to repel water and contaminants, while the bulk material maintains its insulating properties. The hydrophobic treatment is applied locally at the surface rather than throughout the entire insulator volume
2Reliability
If insulator surface is treated to be hydrophobic, then water repellency improves, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process utilizes parameter changes by controlling the thermal decomposition temperature (400-800°C) of the polyolefin resin to transform it into hydrophobic particles. This temperature parameter control enables the formation of hydrophobic surface properties through a single heating step without requiring additional coating or treatment processes
Solution Approach 2:
The insulator structure performs self-service by using its own polyolefin resin material, when heated, to automatically form hydrophobic particles on its surface. The material serves both as the structural insulator and as the source of hydrophobic protection, eliminating the need for separate hydrophobic coating materials or applications
3Ease of manufacture
If single-layer insulation structure is used, then manufacturing is simple, but contamination resistance is insufficient
Solution Approach 1:
The invention merges the insulation function and hydrophobic protection function into a single integrated insulator structure. The hydrophobic particles are formed from the insulator's own material, combining the base insulation layer and protective hydrophobic layer into one unified component that maintains structural simplicity while achieving dual functionality
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design provides a stable, detachable connection that withstands high forces and simplifies installation by enabling self-centering and positive locking, reducing the risk of failure and assembly complexity.
Implementation Method 1
a plurality of hydrophobic particles are distributed on a surface of the insulation layer
Implementation Method 2
a porous layer having a porosity of 10% to 50% is provided between the insulation layer and the electrode
Data Source
Figure 1
Figure 2~4
Figure 3
AI summary
The invention relates to an insulator (1) for high-voltage applications, comprising: - a substantially rotationally symmetric hollow tube (2) made of a glass-fiber-reinforced epoxy resin; - a shield (3) made of silicone, which is provided on the periphery of the hollow tube (2); - a base flange (4) at a lower end (5) of the hollow tube (2); - a retainer (6) for an operating means for high-voltage applications at an upper end (7) of the hollow tube (2); wherein: the insulator (1) has a closure element (8), more particularly a stopper, which is disposed within the hollow tube (2) and closes the terminal face of the upper end (7) of the hollow tube (2) and seals said terminal face with respect to the outside; the retainer (6) has a rotationally symmetric connection region (9); the insulator (1) has, at the upper end (7) of the hollow tube (2), a radially peripheral joining region (10), which is free of silicone shield (3); the retainer (6) can be connected to the insulator (1) such that the connection region (9) of the retainer (6) interlockingly surrounds the joining region (10) of the insulator (1).