Core Skeleton for Composite Hollow Insulators: Professional Customized High-Strength Fiberglass Wound Tube Solution

Product Overview

Our professionally manufactured fiberglass wound tubes, specially designed for composite hollow insulators, are core load-bearing insulating components that integrate high mechanical strength, excellent electrical performance, and superior weather resistance. Utilizing advanced computer-controlled winding processes and customized resin systems, we provide reliable internal support solutions for composite insulators of various voltage classes (10kV-1100kV).

 

Core Technical Characteristics

1. Outstanding Mechanical Properties

· High Strength-to-Weight Ratio Design: Axial tensile strength ≥600MPa, flexural strength ≥450MPa

· Precise Dimensional Control: Inner diameter tolerance ±0.1mm, wall thickness uniformity >95%

· Low Creep Characteristics: Deformation rate under long-term load <0.1%/year

 

2. Reliable Electrical Insulation

· High Dielectric Performance: Power frequency withstand voltage ≥30kV/mm, lightning impulse withstand level complies with GB/T 22079 standard

· Uniform Electric Field Distribution: Optimized dielectric constant (εr=4.0-5.5) and dissipation factor (tanδ≤0.5%)

· Partial Discharge Level: ≤3pC (at 1.1 times rated voltage)

 

3. Excellent Environmental Adaptability

· Wide Temperature Range Stability: Performance retention >90% in environments from -60℃ to +150℃

· UV Aging Resistance: Mechanical strength retention ≥85% after 3000 hours of QUV testing

· Chemical Corrosion Resistance: Withstands acid, alkali, and salt spray environments, suitable for harsh conditions such as coastal and industrial polluted areas

 

Professional Production Process

Raw Material System

· Reinforcement Material: Selection of E-CR glass fiber or high-strength S-glass fiber to provide the optimal strength-to-weight ratio

· Resin System: Customized epoxy/polyurethane/vinyl ester resin formulations to meet different operational requirements

· Interface Treatment: Special coupling agent treatment ensures strong fiber-resin interfacial bonding

 

Manufacturing Process

 

Raw Material Preparation → Fiber Impregnation → Program-Controlled Winding →

Sectional Curing → Machining → Surface Treatment →

Full-Dimension Inspection → Packaging and Dispatch

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Quality Assurance System

· Online Monitoring: Real-time monitoring of key parameters such as winding tension, resin content, and curing temperature

· Non-Destructive Testing: 100% ultrasonic flaw detection and X-ray inspection to ensure zero internal defects

· Type Testing: Comprehensive mechanical, electrical, and environmental performance tests conducted on each production batch

 

Customization Capability Showcase

1. Specification Parameter Customization Range

Parameter Customization Range Precision Grade

Inner Diameter Φ20-Φ800mm IT7 Grade

Wall Thickness Design 3-50mm ±0.2mm

Length Specification 500-12000mm ±1mm/m

End Structure Plain, Flange, Threaded, Grooved Machined per drawing

 

2. Special Function Designs

· Anti-Burst Structure: Multi-layer anti-burst design with safety factor ≥3.0

· Bird Protection Design: Special surface treatment to prevent bird droppings flashover

· Anti-Icing Flashover Performance: Hydrophobic surface treatment, HC1-HC6 grades available

· Seismic Design: Dynamic load simulation optimization, meeting requirements for seismic intensity of degree 8

 

Application Cases and Performance Verification

Successful Application Areas

· Transmission Lines: 110kV-1000kV composite insulator core rods

· Substations: GIS bushings, arrester external insulation cylinders

· Electrified Railways: 27.5kV catenary insulators

· Special Environments: High-altitude, heavily polluted, and strong UV radiation areas

 

Authoritative Certifications

· Passed all tests by the National Insulator and Arrester Quality Supervision and Inspection Center

· Complies with international and domestic standards such as IEC 61109 and GB/T 19519

· Obtained type test reports from third-party certification bodies (e.g., CQC, KEMA)

 

Technical Service System

1. Pre-Sales Technical Support

· Free provision of insulator structure optimization suggestions

· Assistance with mechanical simulation and electric field analysis

· Provision of samples for customer compatibility testing

 

2. Production Coordination Services

· Acceptance of small-batch trial orders (minimum order quantity negotiable)

· Flexible adjustment of production plans to align with customer R&D schedules

· Provision of video records of key production process milestones

 

3. After-Sales Guarantee

· Provision of detailed product installation guidance manuals

· Establishment of product lifecycle quality files

· Commitment to respond to technical inquiries within 48 hours

 

Our Core Advantages

20 Years of Focused Experience: Deeply engaged in the composite insulator field, serving over a hundred insulator manufacturing enterprises, with a profound understanding of industry technological development.

 

Full Industry Chain Control: From glass fiber selection to resin formulation R&D, from winding process optimization to post-treatment technology, achieving full-process independent control.

 

Digital Manufacturing: Implementation of MES (Manufacturing Execution System) enables full-process digital management from order to delivery, ensuring traceable quality.

 

R&D Innovation Capability: Establishment of joint laboratories with multiple universities for continuous development of next-generation high-performance composite material solutions.

 

Cooperation Process

1. Requirements对接: Provide technical parameters or drawings; we will deliver a preliminary solution within 24 hours.

2. Sample Confirmation: Free provision of samples, supporting on-site testing and verification.

3. Agreement Signing: Clarify technical standards, delivery timelines, and quality requirements.

4. Production and Delivery: Deliver according to agreed schedule, accompanied by a complete set of test reports.

5. Continuous Service: Establish long-term cooperative relationships and provide product upgrade support.

 

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Let Professionalism Achieve Reliability, Use Technology to Ensure Safety. We sincerely invite insulator manufacturing enterprises, power equipment companies, and research institutes to visit and explore the infinite possibilities of composite hollow insulator technology development together.

 

Welcome to request detailed technical documentation or schedule an on-site visit!