Composite insulators are available for applications up to system voltages of 110 kV. The core of a composite insulator is a
pultruded fiber glass rod which provides a high mechanical strength. In a direct injection molding process a non-tracking, erosion
and UV resistant polymeric housing is molded directly onto the fiberglass rod. A corrosion resistant metal end fitting is crimped
onto each end of the rod to provide a high mecha nical strength. A new developed crimping control technology monitors the
assembly process of the metal fittings and ensures that crimping forces cause no damage to the fiberglass rod while achieving a
crimp that will withstand the highest possible mechanical loads. Sealed with a tracking and erosion resistant polyurethane barrier,
the core is protected from deterioration due to moisture ingress. Composite insulators are available as tension (suspension), line
post and station post insulators. For railway applications, tension and strut composite insulators are available in a large variety of
configurations.
Components and Materials
Polymer Weather sheds: the polymer weather shed material is a proprietary silicone-rubber compound for high-voltage insulator
applications. The sheds are manufactured using high-pressure injection moulding techniques to create a smooth surface reducing
the amount of pollution trap.
Fiberglass Core Rod: Insulators Core Rod is manufactured with electrical grade corrosion resistant epoxy rod. The materials used
are of the highest quality and are routinely tested to ensure the maximum performance characteristics. The suspension insulator's
fiberglass core rod is produced with boron-free, corrosion-resistant E-glass and epoxy resin. Line post insulators are manufactured
with electrical grade glass and epoxy resin. Silicon rubber shed housing
is mainly used to protect the core rod against rain or snow, providing necessary creepage distance and outer insulation, it adopts
high polymer silicon rubber as the basic material, assisted by fire retardant, coupling agent and other packing materials, through
high temperature and high pressure vulcanization, it has favorable hydrophobic nature and migratory aptitude, as well as fine
performances of corrosion resistance, anti aging, electric insulation, etc, besides, it also has rather high pollution flashover voltage.
Mechanical Ratings
Insulators are rated at a specified mechanical load of 70kN and are routinely tested. End fittings which are rated lower are marked
in specification.