WO2019061635A1 - 一种长棒形瓷复合绝缘子及其制作方法 - Google Patents
一种长棒形瓷复合绝缘子及其制作方法 Download PDFInfo
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- WO2019061635A1 WO2019061635A1 PCT/CN2017/108247 CN2017108247W WO2019061635A1 WO 2019061635 A1 WO2019061635 A1 WO 2019061635A1 CN 2017108247 W CN2017108247 W CN 2017108247W WO 2019061635 A1 WO2019061635 A1 WO 2019061635A1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B17/00—Insulators or insulating bodies characterised by their form
- H01B17/38—Fittings, e.g. caps; Fastenings therefor
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B17/00—Insulators or insulating bodies characterised by their form
- H01B17/50—Insulators or insulating bodies characterised by their form with surfaces specially treated for preserving insulating properties, e.g. for protection against moisture, dirt, or the like
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B19/00—Apparatus or processes specially adapted for manufacturing insulators or insulating bodies
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- the invention relates to a long rod-shaped porcelain composite insulator for UHV transmission lines, and mainly relates to a long rod-shaped porcelain composite insulator with excellent mechanical and electrical properties and a preparation method thereof.
- the long rod-shaped porcelain insulator itself has non-breakable properties, but has self-cleaning and stain resistance and poor corrosion resistance under direct current conditions. Therefore, the excellent technical characteristics of long rod-shaped ceramic composite insulators are increasingly recognized and recognized, and the market demand is increasing rapidly year by year.
- the present invention aims to provide a long rod-shaped ceramic composite insulator and a manufacturing method thereof, and the long rod-shaped ceramic composite insulator has both mechanical properties of ceramic insulator and composite insulator.
- the silicone rubber material has strong resistance to flashover and can eliminate the brittle fracture and stringing accident of composite insulators, solve the problem of external insulation pollution of porcelain insulators, and is a new type of long rod-shaped porcelain insulator with excellent mechanical and electrical properties, suitable for various kinds. Extremely harsh working conditions.
- the technical solution adopted by the present invention is:
- the utility model relates to a long rod-shaped porcelain composite insulator, which comprises a porcelain rod insulator body, and an outer insulating umbrella skirt sheath is arranged outside the body, and ball socket type fittings are respectively glued on both ends of the body, and each ball socket type metal fitting is attached.
- the end of the outlet end has a circular arc shape and a rectangular groove is arranged outside the end portion; the direction of the rectangular groove is 0-60° with respect to the horizontal direction; the angle between the hole wall of the ball socket type fitting and the vertical direction is 0 ⁇ 7°.
- the outer side of the circular arc structure has a circular arc shape, and the inner portion has an outward convex arc structure.
- the structure of the outer shed skirt is arranged in a sequence of one large umbrella and two small umbrellas, and each umbrella formed by one large umbrella and two small umbrellas has a length of 60 mm.
- the outer shed skirt is a fluorosilicone rubber sheath.
- the outer shed skirt is mainly made of the following raw materials by weight: 100 parts of 110-2 methyl vinyl silicone rubber, 35 parts of fumed silica, 115 parts of aluminum hydroxide fine powder, color masterbatch 1.5 parts, 5 parts of zinc oxide, 1.6 parts of silane, 12 parts of silicone oil, 0.9 parts of triethanolamine, 5.5 parts of ⁇ -trifluoropropylmethylpolysiloxane, and 1.2 parts of bis-five vulcanizing agent.
- the method for manufacturing the above-mentioned long rod-shaped ceramic composite insulator comprising the following steps:
- step 1) The lead fittings obtained in step 1) are filled with lead-bismuth alloy at both ends of the porcelain rod insulator body to obtain a semi-finished product, and then the semi-finished rubber-filled position is pretreated;
- the pre-processing process is: first removing the surface of the semi-finished product Contamination and physical dust, spraying silane coupling agent on the surface, pre-baking in an oven at a temperature of 50 ° C, promoting the activity of the coupling agent, and taking it out when injecting;
- step 4) The semi-finished product obtained in step 3) is placed in a high-temperature and high-pressure cavity, and the outer diameter of the fitting of the fitting is closely aligned with the inner diameter of the cavity after the mold clamping, and the silicone rubber is uniformly extruded by the screw at a constant speed to fill the cavity of the cavity. Thereafter, it is held for 5 to 30 minutes under the action of clamping force of 140 to 200 ° C and 110 to 130 bar, and the shed skirt and the end seal are once vulcanized and molded, that is, the long rod-shaped porcelain composite insulator is obtained.
- silane coupling agent is prepared by mixing 1:1 volume of absolute ethanol with a mass fraction of 95 to 99.8% and butadiene-based triethoxysilane.
- the porcelain rod of the present invention has the advantages of: adopting a specific attachment structure to improve the bonding force between the shed and the attachment; and the outer edge of the insulator adopts a fluorosilicone shed to improve the stain resistance; Lead-bismuth alloy is used to improve the mechanical strength of the product.
- the coupling agent is used to improve the bonding strength between the shed and the porcelain core rod; the primary vulcanization molding process ensures the compactness and high strength of the fluorosilicone rubber.
- FIG. 1 is a schematic structural view of a ball and socket fitting of the present invention
- Figure 2 is a partial enlarged view of a portion A in Figure 1;
- Figure 3 is a schematic structural view of the outer shed skirt of the present invention.
- Figure 4 is a schematic view of a conventional end seal structure
- Figure 5 is a schematic view showing the end seal structure of the present invention.
- Embodiment 1 As shown in FIG. 1 to FIG. 5, the structure of the long rod-shaped ceramic composite insulator of the present invention is as follows: a ceramic rod insulator body is provided, and an outer insulating shed skirt is provided outside the body, respectively, at both ends of the body
- the rubber is equipped with a ball and socket type fitting, and the end of the outlet end of each ball and socket type fitting has a circular arc shape and a rectangular groove is provided outside the end; the direction of the rectangular groove is 30° with the horizontal direction; The angle between the wall of the fitting and the vertical direction is 5°.
- the outer side of the circular arc structure has a circular arc shape, and the inner part has an outward convex arc structure; the structure of the outer shed skirt is arranged in the order of a large umbrella and two small umbrellas, and one large umbrella and two small umbrellas Each set of umbrellas formed has a length of 60 mm.
- the outer shed skirt is made of a fluorosilicone rubber sheath.
- the method for manufacturing the above-mentioned long rod-shaped ceramic composite insulator comprising the following steps:
- the raw material of the base material comprises the following components by weight: 3 parts of black clay, 40 parts of industrial alumina, ⁇ 8 villages, 12 parts of Shuyang soil, 11 parts of Zuoyun soil, 12 parts of Qingcaoling, 15 parts of white clay, 10 parts of feldspar, 3 parts of Ninghai soil, 3 parts of Xinhui soil;
- step 1) The lead fittings obtained in step 1) are filled with lead-bismuth alloy at both ends of the porcelain rod insulator body to obtain a semi-finished product, and then the semi-finished rubber-filled position is pretreated;
- the pre-processing process is: first removing the surface of the semi-finished product Contamination and physical dust, spray silane coupling agent on the surface, put it into the oven preheated at 50 degrees Celsius, promote the activity of the coupling agent, and take it out when it is injected;
- the lead-bismuth alloy glue includes the following components: Sb by mass percentage 10%, Sn 4%, and the rest is Pb.
- step 4) The semi-finished product obtained in step 3) is placed in a high temperature and high pressure mold cavity, and the outer diameter of the fitting is used. Positioned closely with the inner diameter of the cavity after clamping, and the silicone rubber is evenly extruded by rotating the screw at a constant speed. After filling the cavity of the cavity, it is kept for 5 to 30 minutes under the action of clamping force of 140-200 ° C and 110-130 bar.
- the shed skirt and the end seal are once vulcanized to obtain the long rod-shaped porcelain composite insulator; wherein the outer shed sheath is mainly made of the following parts by weight: 110-2 methyl 100 parts of vinyl silicone rubber, 35 parts of fumed silica, 115 parts of aluminum hydroxide fine powder, 1.5 parts of color masterbatch, 5 parts of zinc oxide, 1.6 parts of silane, 12 parts of silicone oil, 0.9 parts of triethanolamine, ⁇ -trifluoro 5.5 parts of propylmethylpolysiloxane and 1.2 parts of bis-five vulcanizing agent.
- the outer shed sheath is mainly made of the following parts by weight: 110-2 methyl 100 parts of vinyl silicone rubber, 35 parts of fumed silica, 115 parts of aluminum hydroxide fine powder, 1.5 parts of color masterbatch, 5 parts of zinc oxide, 1.6 parts of silane, 12 parts of silicone oil, 0.9 parts of triethanolamine, ⁇ -trifluoro 5.5 parts of propylmethylpolysiloxane
- Embodiment 2 Basically the same as Embodiment 1, except that in the structure of the insulator: the direction of the rectangular groove is 60° with respect to the horizontal direction; the angle of the hole wall of the ball socket type fitting is 7° to the vertical direction.
- step 2) preparing the body of the ceramic rod insulator: slurrying the base material with 150% of the total weight of the base material to obtain a slurry;
- Step 4) The semi-finished product obtained in step 3) is placed in a high-temperature and high-pressure mold cavity, and the outer diameter of the fitting of the fitting is closely aligned with the inner diameter of the cavity after the mold clamping, and the silicone rubber is uniformly extruded by the screw at a uniform speed to fill the cavity. After the void, it was held for 5 min under the action of 140 ° C and 110 bar clamping force, so that the outer shed sheath and the end seal were once vulcanized.
- Embodiment 3 It is basically the same as Embodiment 1, except that in the structure of the insulator: the direction of the rectangular groove is 0° with respect to the horizontal direction; the angle of the wall of the ball socket type fitting accessory is 0° with the vertical direction.
- step 2) preparing the body of the ceramic rod insulator: pulping the base material with 200% of the total weight of the base material to obtain a slurry;
- Step 4) The semi-finished product obtained in step 3) is placed in a high-temperature and high-pressure mold cavity, and the outer diameter of the fitting of the fitting is closely aligned with the inner diameter of the cavity after the mold clamping, and the silicone rubber is uniformly extruded by the screw at a uniform speed to fill the cavity. After the void, it was held under the action of 200 ° C and 130 bar clamping force for 30 min, so that the outer shed sheath and the end seal were once vulcanized.
- the invention adopts a specific accessory structure to improve the bonding force between the shed skirt and the accessory, thereby improving the electrical performance; the outer edge of the insulator is made of a fluorosilicone rubber shed to improve its stain resistance; the lead-bismuth alloy is assembled and improved.
- the coupling agent is used to improve the bonding strength between the shed and the porcelain core rod; the primary vulcanization molding process ensures the compactness and high strength of the fluorosilicone rubber.
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Abstract
一种长棒形瓷复合绝缘子，包括瓷棒绝缘子本体（1），在本体（1）外设有外绝缘伞裙护套（2），在本体（1）的两端部分别胶装有球窝型金具附件（3），每个球窝型金具附件（3）的出口端的端部（32）呈圆弧形结构并且在该端部（32）的外面设有矩形槽（34）；矩形槽（34）方向与水平方向呈0～60°；球窝型金具附件（3）孔壁（31）与竖直方向夹角为0～7°。采用特定的附件结构，提高伞裙与附件的结合力；绝缘子外缘采用氟硅橡胶伞裙，提高其耐污性能；铅锑合金胶装，提高了产品的机械强度。采用偶联剂，提高伞裙与瓷芯棒的粘结强度；一次硫化成型工艺保证了氟硅橡胶的致密性以及较高的强度。
Description
本发明涉及特高压输电线路用长棒形瓷复合绝缘子，主要发明一种机械、电气性能优异的长棒形瓷复合绝缘子及其制备方法。
近年来，我国电力建设输电工程，交、直流特高压输电技术迅猛发展，但同时大气污染日益严重，线路污闪时有发生，对绝缘子电气特性提出了更高的要求。
长棒形瓷绝缘子自身具有不可击穿性，但是自洁耐污性能以及直流条件下耐腐蚀性能差。因此，长棒形瓷复合绝缘子优良的技术特性越来越被广泛认知和认可，市场需求量逐年快速增加。
发明内容
为了克服现有克服瓷绝缘子和复合绝缘子的缺陷和弊端，本发明的目的在于提供一种长棒形瓷复合绝缘子及其制作方法，该长棒形瓷复合绝缘子兼备瓷绝缘子机械性能可靠和复合绝缘子硅橡胶材料耐污闪能力强的特点，能杜绝复合绝缘子脆断和掉串事故，解决瓷绝缘子外绝缘污闪难题，是一种机械电气性能优异的新型长棒形瓷绝缘子，适用于各种极端恶劣的工况环境。
为了解决上述技术问题，本发明所采用的技术方案为：
一种长棒形瓷复合绝缘子，包括瓷棒绝缘子本体，在本体外设有外绝缘伞裙护套，在本体的两端部分别胶装有球窝型金具附件，每个球窝型金具附件的出口端的端部呈圆弧形结构并且在该端部的外面设有矩形槽；矩形槽方向与水平方向呈0～60°；球窝型金具附件孔壁与竖直方向夹角为0～7°。
进一步地，圆弧形结构外侧呈圆弧形，内部有向外凸的圆弧结构。
进一步地，所述外伞裙护套的结构为一个大伞两个小伞的顺序间隔排列，并且一个大伞两个小伞形成的每组伞的长度为60mm。
进一步地，所述外伞裙护套为氟硅橡胶护套。所述外伞裙护套主要是由如下重量份数的原料制成的：110-2甲基乙烯基硅橡胶100份、气相法白炭黑35份、氢氧化铝微粉115份、色母胶1.5份、氧化锌5份、硅烷1.6份、硅油12份、三乙醇胺0.9份、γ-三氟丙基甲基聚硅氧烷5.5份、双二五硫化剂1.2份。
上述长棒形瓷复合绝缘子的制作方法，该方法包括如下步骤：
1)制作金具附件：选用添加微量金属元素的耐候钢，通过锻造机加工工艺生产得到金具附件粗品，金具附件粗品的表面采用热浸锌工艺防腐，浸锌平均厚度大于90微米；将金具的出口端的端部设计变厚并成圆弧形，在该出口端位于用来外包胶的部位设计成矩形槽，最后逐个通过射线探伤和磁粉探伤剔除其内外部缺陷，即得到所述金具附件；
2)制作瓷棒绝缘子本体：将基料与基料总重量150～200％的水打浆得到浆料，经球磨、过筛、除铁、榨泥，在真空练泥机内挤制，电阴干，成型、干燥后得生坯，生坯经上釉、上砂、烧成得到瓷棒绝缘子本体；
3)在瓷棒绝缘子本体的两端用铅锑合金胶装步骤1)中制得的金具附件，得到半成品，然后对半成品包胶位置进行预处理；预处理的工序为：先去除半成品表面可见污染及物理灰尘，在表面喷涂硅烷偶联剂，放入温度50摄氏度的烘箱预烘，促进提高偶联剂活性，待注射时取出使用；
4)在步骤3)中得到的半成品放入高温高压的模腔内，采用金具附件外径与合模后模腔内径紧密切合方式定位，通过螺杆匀速旋转均匀挤出硅橡胶，充满模腔空隙后，在140～200℃和110～130bar锁模力的作用下保持5～30min，使伞裙护套和端部密封一次硫化成型，即得到所述长棒形瓷复合绝缘子。
进一步地，所述硅烷偶联剂是用质量分数95～99.8％的无水乙醇与丁二烯基三乙氧基硅烷1：1容积混合调配制成。
有益效果：与现有技术相比，本发明中瓷棒的优点是：采用特定的附件结构，提高伞裙与附件的结合力；绝缘子外缘采用氟硅橡胶伞裙，提高其耐污性能；铅锑合金胶装，提高了产品的机械强度。采用偶联剂，提高伞裙与瓷芯棒的粘结强度；一次硫化成型工艺保证了氟硅橡胶的致密性以及较高的强度。
图1为本发明球窝金具附件的结构示意图；
图2为图1中A处的局部放大图；
图3为本发明外伞裙护套的结构示意图；
图4为传统端部密封结构示意图；
图5为本发明端部密封结构示意图；
1-瓷芯棒，2-外绝缘伞裙护套，21-伞盘
3-金具附件，31-金具附件孔壁，32-金具附件出口端端部，33-内测圆弧结构，
34-矩形槽，4-铅锑合金胶合剂
下面结合附图和具体实施例对本发明作进一步的详细说明。
实施例1：如图1至图5所示，本发明长棒形瓷复合绝缘子的结构如下：包括瓷棒绝缘子本体，在本体外设有外绝缘伞裙护套，在本体的两端部分别胶装有球窝型金具附件，每个球窝型金具附件的出口端的端部呈圆弧形结构并且在该端部的外面设有矩形槽；矩形槽方向与水平方向呈30°；球窝型金具附件孔壁与竖直方向夹角为5°。圆弧形结构外侧呈圆弧形，内部有向外凸的圆弧结构；所述外伞裙护套的结构为一个大伞两个小伞的顺序间隔排列，并且一个大伞两个小伞形成的每组伞的长度为60mm。其中外伞裙护套采用氟硅橡胶护套。
上述长棒形瓷复合绝缘子的制作方法，该方法包括如下步骤：
1)制作金具附件：选用添加微量金属元素的耐候钢，通过锻造机加工工艺生产得到金具附件粗品，金具附件粗品的表面采用热浸锌工艺防腐，浸锌平均厚度大于90微米；将金具的出口端的端部设计变厚并成圆弧形，在该出口端位于用来外包胶的部位设计成矩形槽，最后逐个通过射线探伤和磁粉探伤剔除其内外部缺陷，即得到所述金具附件；
2)制作瓷棒绝缘子本体：将基料与基料总重量180％的水打浆得到浆料，经球磨、过筛、除铁、榨泥，在真空练泥机内挤制，电阴干，成型、干燥后得生坯，生坯经上釉、上砂、烧成得到瓷棒绝缘子本体；其中基料的原料包括如下重量份数的组分：黑粘土3份，工业氧化铝40份，樟村土8份，泾阳土12份，左云土11份，青草岭12份，白胶泥15份，长石10份，宁海土3份，新会土3份；
3)在瓷棒绝缘子本体的两端用铅锑合金胶装步骤1)中制得的金具附件，得到半成品，然后对半成品包胶位置进行预处理；预处理的工序为：先去除半成品表面可见污染及物理灰尘，在表面喷涂硅烷偶联剂，放入温度50摄氏度的烘箱预烘，促进提高偶联剂活性，待注射时取出使用；其中铅锑合金胶的包括如下成分：按质量百分比Sb 10％，Sn 4％，其余为Pb。
4)在步骤3)中得到的半成品放入高温高压的模腔内，采用金具附件外径
与合模后模腔内径紧密切合方式定位，通过螺杆匀速旋转均匀挤出硅橡胶，充满模腔空隙后，在140～200℃和110～130bar锁模力的作用下保持5～30min，使外伞裙护套和端部密封一次硫化成型，即得到所述长棒形瓷复合绝缘子；其中，所述外伞裙护套主要是由如下重量份数的原料制成的：110-2甲基乙烯基硅橡胶100份、气相法白炭黑35份、氢氧化铝微粉115份、色母胶1.5份、氧化锌5份、硅烷1.6份、硅油12份、三乙醇胺0.9份、γ-三氟丙基甲基聚硅氧烷5.5份、双二五硫化剂1.2份。
实施例2：与实施例1基本相同，所不同的是：绝缘子的结构中：矩形槽方向与水平方向呈60°；球窝型金具附件孔壁与竖直方向夹角为7°。
绝缘子的制作方法中：步骤2)制作瓷棒绝缘子本体：将基料与基料总重量150％的水打浆得到浆料；
步骤4)在步骤3)中得到的半成品放入高温高压的模腔内，采用金具附件外径与合模后模腔内径紧密切合方式定位，通过螺杆匀速旋转均匀挤出硅橡胶，充满模腔空隙后，在140℃和110bar锁模力的作用下保持5min，使外伞裙护套和端部密封一次硫化成型。
实施例3：与实施例1基本相同，所不同的是：绝缘子的结构中：矩形槽方向与水平方向呈0°；球窝型金具附件孔壁与竖直方向夹角为0°。
绝缘子的制作方法中：步骤2)制作瓷棒绝缘子本体：将基料与基料总重量200％的水打浆得到浆料；
步骤4)在步骤3)中得到的半成品放入高温高压的模腔内，采用金具附件外径与合模后模腔内径紧密切合方式定位，通过螺杆匀速旋转均匀挤出硅橡胶，充满模腔空隙后，在200℃和130bar锁模力的作用下保持30min，使外伞裙护套和端部密封一次硫化成型。
本发明长棒形瓷复合绝缘子的性能指标如下表所示：
硅橡胶与瓷件的剥离强度试验
由此可见，本发明采用特定的附件结构，提高伞裙与附件的结合力，进而提高电气性能；绝缘子外缘采用氟硅橡胶伞裙，提高其耐污性能；铅锑合金胶装，提高了产品的机械强度。采用偶联剂，提高伞裙与瓷芯棒的粘结强度；一次硫化成型工艺保证了氟硅橡胶的致密性以及较高的强度。
Claims (6)
- 一种长棒形瓷复合绝缘子，其特征在于，包括瓷棒绝缘子本体，在本体外设有外绝缘伞裙护套，在本体的两端部分别胶装有球窝型金具附件，每个球窝型金具附件的出口端的端部呈圆弧形结构并且在该端部的外面设有矩形槽；矩形槽方向与水平方向呈0～60°；球窝型金具附件孔壁与竖直方向夹角为0～7°。
- 根据权利要求1所述的长棒形瓷复合绝缘子，其特征在于，圆弧形结构外侧呈圆弧形，内部有向外凸的圆弧结构。
- 根据权利要求1所述的长棒形瓷复合绝缘子，其特征在于，所述外伞裙护套的结构为一个大伞两个小伞的顺序间隔排列，并且一个大伞两个小伞形成的每组伞的长度为60mm。
- 根据权利要求1所述的长棒形瓷复合绝缘子，其特征在于，所述外伞裙护套为氟硅橡胶护套。
- 根据权利要求1所述的长棒形瓷复合绝缘子的制作方法，其特征在于，该方法包括如下步骤：1)制作金具附件：选用添加微量金属元素的耐候钢，通过锻造机加工工艺生产得到金具附件粗品，金具附件粗品的表面采用热浸锌工艺防腐，浸锌平均厚度大于90微米；将金具的出口端的端部设计变厚并成圆弧形，在该出口端位于用来外包胶的部位设计成矩形槽，最后逐个通过射线探伤和磁粉探伤剔除其内外部缺陷，即得到所述金具附件；2)制作瓷棒绝缘子本体：将基料与基料总重量150～200％的水打浆得到浆料，经球磨、过筛、除铁、榨泥，在真空练泥机内挤制，电阴干，成型、干燥后得生坯，生坯经上釉、上砂、烧成得到瓷棒绝缘子本体；3)在瓷棒绝缘子本体的两端用铅锑合金胶装步骤1)中制得的金具附件，得到半成品，然后对半成品包胶位置进行预处理；预处理的工序为：先去除半成品表面可见污染及物理灰尘，在表面喷涂硅烷偶联剂，放入温度50摄氏度的烘箱预烘，促进提高偶联剂活性，待注射时取出使用；4)在步骤3)中得到的半成品放入高温高压的模腔内，采用金具附件外径与合模后模腔内径紧密切合方式定位，通过螺杆匀速旋转均匀挤出硅橡胶，充满模腔空隙后，在140～200℃和110～130bar锁模力的作用下保持5～30min，使伞裙护套和端部密封一次硫化成型，即得到所述长棒形瓷复合绝缘子。
- 根据权利要求5所述的长棒形瓷复合绝缘子的制作方法，其特征在于，所述硅烷偶联剂是用质量分数95～99.8％的无水乙醇与丁二烯基三乙氧基硅烷按照1：2～2：1容积混合调配制成。
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