Composite polymer insulators represent a significant advancement in electrical power systems due to their superior performance and durability compared to traditional ceramic or glass insulators. Here are some advanced insights into composite polymer insulators:

Core Material:

• Epoxy Resin: Epoxy resin is commonly used as the matrix material in composite polymer insulators due to its excellent electrical insulation properties, mechanical strength, and adhesion to reinforcement materials.
• Glass Fibers: These are typically used as the reinforcement material within the epoxy resin matrix. Glass fibers provide the insulator with high tensile strength, stiffness, and resistance to mechanical stresses. The type and orientation of glass fibers influence the insulator’s mechanical properties.
• Sizes: 16 mm, 18mm,20mm,24 mm, 28mm,32 mm, 34 mm,38mm,42mm and above

Composition of Fiberglass Core

The fiberglass core rod consists of fiberglass impregnated with resin. However, the specific type of resin and fiberglass, as well as the ratio of glass to resin, are not standardized. Instead, these factors are determined by the rod manufacturer. For instance, the choice of fiberglass and resin depends on the desired mechanical and electrical performance of the rod. A smaller outer diameter (OD) core rod is typically used for applications requiring high tensile strength, whereas a larger OD rod is necessary to withstand greater mechanical loads such as compression and cantilever forces.

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Options for Fiberglass Fibers

Both options meet or exceed the tests outlined in ANSI and IEC Standards:

1. E-Glass = Electrical Grade Fiberglass
   • Mainly used for manufacturing line post core rods.
   • Historically used in early-generation polymer types (suspension).
   • Prone to brittle fracture in suspension applications.
2. Corrosion Resistant E-Glass (CR-E or ECR) = Boron Free Fiberglass
   • Boron oxide is absent from the composition of glass fibers.
   • Engineered to eliminate brittle fracture issues.
   • Manufactured using the same process as standard E-Glass.
   • Offers mechanical and electrical properties equivalent to E-Glass.

Core Material Properties 

Housing (Silicone Rubber):

Silicone rubber is widely utilized as a critical raw material in composite insulators due to its exceptional electrical, mechanical, and environmental properties. Here’s a brief overview of why silicone rubber is favored in composite insulator manufacturing:

Components of Silicone Formulation

Base Material: The elastomer or pure silicone acts as the primary polymer, forming the backbone (Si-O) of the formulation. It is responsible for imparting hydrophobic properties, maintaining hydrophobicity throughout the insulator’s lifespan, facilitating hydrophobicity recovery, and encapsulating contaminants.

ATH (Aluminum Tri-Hydrate): This agent enhances arcing resistance within the formulation, aiming to improve tracking and erosion resistance properties.

Curing Agent: This catalyst initiates the cross-linking process, crucial for vulcanizing the silicone into its final cured state.

Colorants: Typically, silicone is transparent; however, grey colorants are added to the compound for aesthetic purposes.

Processing Aids / Mold Release Agents: These aids facilitate material flow within molds and ensure effective release properties during the manufacturing process.

Special Additives / Fillers: These components are supplier-specific and may include various additives and fillers tailored to enhance specific properties of the silicone formulation.

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Metal Fitting (End Fittings):

Metal end fittings, such as steel,Forged Steel,SGCI or aluminum, are attached to the ends of the insulator. These fittings provide mechanical attachment points for the insulator to be connected to transmission lines or other equipment.

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Raw Material Preparation:

• Step 1: Receive raw materials (e.g., silicone rubber, fiberglass rods, metal end fittings).
• Step 2: Inspect raw materials for quality and specifications.
• Step 3: Store raw materials in designated areas.

• Silicone Rubber Processing:

• Step 4: Mix silicone rubber with additives (cross-linking agents, fillers, Pigment).
• Step 5: Form silicone rubber into sheets or pellets.

• Fiberglass Rod Preparation:

• Step 6: Cut fiberglass rods to specified lengths.
• Step 7: Clean fiberglass rods for better Bonding.

• Metal Fitting Preparation:

• Step 8: Fabricate metal end fittings (SGCI or Forged steel).
• Step 9: Surface treat fittings for corrosion resistance.

• Injection and Curing:

• Step 10: Inject silicone rubber into Molds in Moulding Machine.
• Step 11: Apply pressure and heat to ensure proper bonding.
• Step 12: Cure assembled insulators (heat 145 degree – 165 degree and pressure).

• • Post-Curing and Finishing:
  • Step 13: Trim excess material and clean insulators.
  • Step 14: Conduct visual inspection for defects.

   

• Sealing Process:

• Step 17: •After the crimping Process Weather proof Silicone Sealant is applied to fill small Gap between weather shed & End fitting.

• Testing and Quality Control:

  • Step 18: Test insulators for electrical properties (dielectric strength, leakage current).
  • Step 19: Perform mechanical tests (tensile strength, bending).
  • Packaging and Shipping:
  • Step 20: Package insulators securely.
  • Step 21: Label packages with product information.
  • Step 22: Store or ship packaged insulators.
  • Documentation and Record Keeping:
  • Step 23: Maintain production records and quality assurance documents.
  • Step 24: Update quality management system with inspection results.