Silicone Rubber Suspension Insulator Reducing Tower Load
Solution Overview
Problem
Conventional suspension insulators made of porcelain or glass are heavy, increasing the load on towers and are prone to faults, pollution, and disconnection due to high density and fragility.
Innovation Solution
A suspension insulator comprising a silicone rubber umbrella string arranged on a fiber-reinforced resin-based composite rod, which includes a core layer of fiber-reinforced resin and an outer silicone rubber layer, providing a lightweight and integral structure with improved mechanical strength and anti-pollution properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional porcelain or glass insulators are used, then mechanical strength and electrical insulation are ensured, but the weight is heavy which increases tower load
Solution Approach 1:
The patent employs composite materials consisting of a fiber-reinforced resin core layer and a silicone rubber outer layer. The fiber-reinforced resin provides high mechanical strength and structural support, while the silicone rubber layer contributes to electrical insulation and pollution resistance. This composite structure achieves the required mechanical strength and electrical performance with significantly reduced weight compared to traditional solid porcelain or glass insulators.
Solution Approach 2:
The patent changes the material parameters by transitioning from homogeneous dense materials (porcelain/glass) to a layered composite structure with different material properties. The core layer uses fiber-reinforced resin with high tensile strength, while the outer layer uses silicone rubber with flexible insulation properties. This parameter change in material composition and structure enables weight reduction while maintaining or improving mechanical and electrical performance.
2Reliability
If porcelain or glass insulators are used, then electrical insulation is provided, but they are prone to pollution accumulation and flashover
Solution Approach 1:
The patent changes the surface material parameter from traditional porcelain or glass to silicone rubber coating. Silicone rubber possesses hydrophobic properties that prevent water and pollution accumulation on the insulator surface. This material parameter change fundamentally alters the surface characteristics, making it resistant to pollution adhesion and reducing the risk of flashover in contaminated environments.
Solution Approach 2:
The silicone rubber outer layer serves as a protective coating that can be applied to the core structure. This layered approach allows the insulator to have a durable core with a renewable protective surface layer that resists pollution and can be maintained or replaced independently, improving overall reliability against environmental degradation.
3Stability of the object's composition
If porcelain or glass insulators are used, then structural integrity is maintained, but they are fragile and prone to disconnection
Solution Approach 1:
The patent uses a composite structure where the fiber-reinforced resin core provides high tensile strength and flexibility, eliminating the brittleness inherent in porcelain and glass. The fiber reinforcement (such as glass fibers, carbon fibers, or aramid fibers) embedded in the resin matrix creates a material that can withstand mechanical stress, impact, and vibration without fracturing, thereby preventing disconnection while maintaining structural integrity.
Solution Approach 2:
The patent fundamentally changes the mechanical parameters of the insulator material by transitioning from brittle ceramic/glass materials to a fiber-reinforced polymer composite. This parameter change in material ductility and toughness allows the insulator to deform elastically under stress rather than fracturing, significantly improving reliability and resistance to disconnection.
4Force
If heavy porcelain or glass insulators are used, then load-bearing capacity is ensured, but installation and removal become difficult
Solution Approach 1:
The fiber-reinforced resin core provides high strength-to-weight ratio, enabling the insulator to maintain adequate load-bearing capacity while significantly reducing overall weight. The composite construction allows for optimized material distribution, placing high-strength fibers only where mechanically critical, thereby achieving sufficient load capacity with minimal weight for easier handling and installation.
Data Source
AI summary
The present disclosure discloses a suspension insulator and a suspension insulator group. The suspension insulator comprises a silicone rubber umbrella string and a fiber-reinforced resin-based composite rod, wherein the silicone rubber umbrella string is arranged on the fiber-reinforced resin-based composite rod. Since the umbrella string is made of silicone rubber and is arranged on the fiber-reinforced resin-based composite rod, as compared with porcelain suspension insulator or glass suspension insulator, it has a low density and a light weight, and may reduce the load of the tower and is convenient to install and remove. The suspension insulator provided by the present disclosure is especially applicable to the field of power transmission.