In the early years, insulators were mostly used in electric poles. With the development of science and technology, many disc insulators were slowly developed at one end of the towers connected to high voltage power lines. They are used to increase the creepage interval and are usually made of glass or ceramic and are called insulators. The two basic roles of insulators in overhead transmission lines, namely to support the conductors and to prevent backflow of current, are to ensure that, in both cases, the insulators should not be subject to various electrical and mechanical stresses and faults due to changes in the environment and electrical load conditions, or that the insulators do not have a significant impact that would impair the use and full operation of the entire line.
Composite insulators are particularly suitable for dirty areas, high mechanical tensile loads, large spans, and compact lines. They are characterized by their lightweight, small size, low breakage, bending, high torsional strength, and high explosion resistance.
It consists of glass fibre epoxy resin tie rods, silicone rubber skirts and fittings. The silicone rubber umbrella skirt adopts the integral pressure injection process, which solves the key problem affecting the reliability of the electric breakdown of the composite insulator-interface. The connection between the glass tie rod and the metal fittings is made by a good crimping process. It is equipped with an automatic acoustic flaw detection system. With high strength, beautiful appearance, small volume, lightweight and galvanized metal fittings to prevent corrosion. Use, this product has a reliable structure, does not damage the mandrel, and can give full play to its mechanical strength.
Composite Insulator
Superior electrical performance, high mechanical strength, the internal bending strength of the epoxy glass fibre ties is twice that of ordinary steel and 8-10 times that of high strength ceramic materials, effectively improving the reliability of safe operation.
Good anti-fouling performance, strong anti-fouling flashing ability, wet withstand voltage and fouling withstand voltage is 2~2.5 times of similar creeping electric porcelain insulators, no need to clean, can be in the field of safe operation under heavy pollution environment.
- Small volume and lightweight (only 1/6-1/9 of porcelain insulators of the same voltage level), light and compact structure, easy to transport and install.
- Good waterproof performance of the silicone rubber umbrella skirt, the overall structure ensures that the internal insulation is not exposed to moisture, no preventive insulation monitoring tests are required, no cleaning is needed and the daily maintenance workload is reduced.
- Good sealing performance, strong resistance to galvanic corrosion, the umbrella skirt material resistance to leakage start-up to TMA 4.5 level, with good resistance to aging, corrosion, low temperature, can be applied to -40 ℃ ~ +5 ℃ area.
-Has strong impact and shock resistance, its good brittleness and creep resistance, not easy to break, bending, torsional strength, can withstand internal pressure, strong explosion-proof force, can be used with porcelain and glass insulators interactively.
- The mechanical and electrical properties of the composite insulator series are better than porcelain insulators and have a large operating safety margin. They are the newer products for power lines.
Taporel Electrical Insulation manufactures composite insulator fittings, power line fittings, and other fittings for transmission and distribution lines. Taporel Electrical Insulation produces all kinds of power fittings, including EYE and Clevis, ball and socket, hanging Ring, Y- head, T-head, steel foot, steel cap, flange, and other line accessories. Adhering to "Quality, Service, Integrity", we strictly follow standardized, scientific, and normalized management mode.
This article introduces composite insulators, highlighting their advantages over traditional glass and porcelain insulators. Made with a fiberglass core and polymer housing, composite insulators are lightweight, durable, and ideal for use in remote or harsh environments. Their design reduces maintenance due to water- and pollution-resistant properties, which lowers operational costs and improves efficiency for utility companies.
Composite insulators enhance safety by preventing sudden breakage and reducing the risk of electrical arcing. Environmentally, they contribute to energy efficiency and sustainability by requiring less frequent replacements and fewer resources over time. Although initially more expensive, their long-term savings and reliability make them a cost-effective choice. As energy grids evolve, composite insulators are becoming essential for building resilient, eco-friendly power infrastructures worldwide.
Composite insulators, also known as polymer insulators, are used on power lines to support and insulate the lines from each other and the ground. They prevent electricity from arcing or short circuiting, helping electricity flow smoothly across the grid.
Unlike traditional insulators, which are typically made from glass or porcelain, composite insulators are made of two main components:
Core Rod: A rod made of fiberglass that provides structural support.
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Housing: A protective outer layer made of a high-quality polymer, such as silicone rubber, which guards against weather and pollution.
These materials give composite insulators a unique set of advantages that have changed how engineers design power grids.
One of the biggest advantages of composite insulators is their lightweight structure. Compared to glass and porcelain insulators, composite ones are significantly lighter, which makes them easier and safer to transport and install. This benefit is especially important in hard-to-reach areas, such as mountainous regions or densely populated urban settings. Lightweight insulators reduce the need for heavy lifting equipment and speed up the installation process, which saves time and costs for utilities.
For example, in remote areas where large equipment is difficult to use, the light weight of composite insulators allows maintenance teams to perform installations and repairs with minimal resources. This advantage alone has led many power companies to switch to composite options for new installations and replacements.
Composite insulators are known for their durability, particularly in harsh environmental conditions. Traditional insulators, like glass and porcelain, are more susceptible to damage from factors like pollution, salt, and extreme weather. Composite insulators, on the other hand, are designed to withstand these conditions without compromising their performance.
The polymer housing on composite insulators is highly resistant to dirt and salt accumulation, making them ideal for areas with heavy pollution or coastal environments. Additionally, they can withstand extreme temperatures, whether in freezing winters or scorching summers, without cracking or degrading. This reliability helps reduce the number of power outages caused by environmental wear and tear, ensuring a more stable power supply.
Because of their durable construction, composite insulators generally require less maintenance than traditional insulators. For instance, the silicone rubber material used in composite insulators is hydrophobic, meaning it repels water. This property prevents water droplets from forming conductive paths on the insulator’s surface, which would otherwise increase the risk of short circuits. As a result, composite insulators maintain their insulating properties even in rainy or humid conditions.
Furthermore, the smooth surface of composite insulators makes it difficult for contaminants to stick, reducing the need for frequent cleaning. This feature is especially beneficial in industrial areas or cities with high pollution levels. By lowering maintenance requirements, composite insulators reduce operational costs for utility companies, making them an attractive long-term investment.
Safety is a top priority for power grids, and composite insulators offer several features that improve both operational safety and reliability. In the unlikely event that a composite insulator breaks, it tends to fail gradually rather than suddenly shattering, unlike glass or porcelain. This controlled degradation can give maintenance teams the time needed to replace the insulator without risking immediate power loss or posing danger to nearby workers.
Additionally, composite insulators are electrically nonconductive, which enhances safety. The materials used in their construction naturally resist electrical conductivity, which reduces the risk of power arcing and makes them safer in high-voltage applications. This safety factor is one of the key reasons why composite insulators are rapidly being adopted in modern power grid designs.
As countries aim to make their energy grids greener, composite insulators align well with these goals. By reducing power outages and minimizing energy loss through efficient insulation, composite insulators help power grids operate more efficiently, which ultimately lowers energy waste.
Additionally, their lower maintenance requirements mean fewer resources are used over time. Since composite insulators are lighter and easier to install, they require less fuel for transportation and less labor, contributing to a smaller carbon footprint. For utilities focused on sustainability, switching to composite insulators represents a step toward a more ecofriendly power grid.
While the initial cost of composite insulators may be comparable to or slightly higher than traditional insulators, the long-term savings are substantial. Thanks to their durability and low maintenance needs, composite insulators provide a significant return on investment over their lifespan. Power companies can save on frequent replacement costs, repair work, and cleaning expenses, making composite insulators an economically wise choice in the long run.
For example, a utility company that switched to composite insulators in high pollution regions found that their maintenance costs dropped by over 30%, as the insulators needed less frequent cleaning and showed fewer failures compared to traditional options.
As the world’s power demands grow and climate change intensifies, power grids will need to adapt quickly and efficiently. Composite insulators are a key part of this transition, offering a resilient, safe, and low maintenance solution that meets the needs of modern energy infrastructure. Already, many countries are replacing traditional insulators with composite ones to build stronger, more reliable power grids that can withstand the demands of a changing world.
With their proven track record of performance in various environments, composite insulators are likely to become the standard for power grids worldwide. Their innovative materials, ease of use, and cost effectiveness make them a crucial component in the global shift toward more resilient and sustainable energy networks.