Abstract
This study aimed to prepare a new lightweight ultra-high-voltage insulator core filler composite, which can solve the problem of bulkiness. In this study, rigid polyurethane foam pellets with different densities are used as lightweight fillers and polyurethane resins to compound lightweight composite materials. On accounting for working conditions, the density, insulation, heat resistance, water absorption and mechanical properties are tested. The compressive properties of composites are determined by a foam skeleton and a process. Among three kinds of composites, in which the composites with the best comprehensive performance are materials filled with pellets to a density of 0.15g·cm−3. The density, surface resistance, volume resistance, leakage current, initial decomposition temperature, water absorption, force, rupture displacement and limiting oxygen index (LOI) of composites are 0.665 g·cm−3, 1.17 × 1014 Ω, 9.68 × 1014 Ω·cm, 0.079 mA, 208 °C, 0.047%, 2262 N, 2.54 mm, and 23.3%, respectively. The ultra-high-voltage insulator core filler in this study can reduce the weight of the solid core insulator crossarm for Ultra-High Voltage (UHV) by 50–75%.
Highlights
The composite insulator employed in Ultra-High-Voltage (UHV) transmission systems is the internal insulation solid rod insulator, which is made of epoxy resin and glass fiber and obtained through pultrusion process [1–7]
The development of the material can reduce the weight of the composite insulator crossarm by 50–75% in the UHV environment, which improves the convenience of transportation and improves the safety of the installation process
The ductile polyurethane resin matrix was adopted to overcome the problem of brittleness existing with epoxy resin
Summary
The composite insulator employed in Ultra-High-Voltage (UHV) transmission systems is the internal insulation solid rod insulator, which is made of epoxy resin and glass fiber and obtained through pultrusion process [1–7]. The advantages of solid composite insulators are simple structure, excellent mechanical tensile strength, non-breakdown, and excellent stain resistance [8,9]. The insulating core is filled with an insulating medium as internal insulation, but which does not provide the mechanical strength. It is mainly composed of epoxy resin [16–21]. The development of the material can reduce the weight of the composite insulator crossarm by 50–75% in the UHV environment, which improves the convenience of transportation and improves the safety of the installation process. The vacuum casting process of the mandrel in advance can effectively reduce the internal defects of the mandrel, avoids the burning of the mandrel and the problem of cracking caused by the release of intense
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