Patent Application
20240038418
The present invention relates to covers for insulators for power distribution lines, and more particularly, to covers and assemblies adapted for mitigating dry band arcing on polymeric insulators for power distribution lines.
Support structures, such as utility poles, are often used to suspend electrical lines, such as power distribution lines, above the ground. These support structures are generally located outdoors and may be of a variety of different configurations to suspend one or more lines. Composite polymer insulators are used to support electrical power conductors and to secure electrical power conductors to the support structures. In particular, composite polymer insulators are commonly used to support and attach high voltage (HV) power lines. As used herein, “high voltage” means a power line operating at a voltage of 69 kilovolts (kV) or greater. Composite polymer insulators typically include an elongate, electrically insulating core, an electrically insulating housing surrounding the core, and end fittings affixed to the ends of the core. See, e.g.,
The housing may also include radially outwardly projecting sheds. The sheds help to maximize the creep (or leakage) distance of the insulator by increasing the surface distance on the insulator from end to end and help remove environmental contaminants (e.g., salt, pollution, dust) from the insulator in wet conditions (e.g., rain). Creep or leakage distance represents the shortest distance along the surface of the insulator between the conductive ends of the insulator. Environmental contaminants can have a strong effect on insulator performance. The more surface contaminants on the insulator, the more likely leakage current will occur since many of the contaminants are conductive. It is desirable to have an insulator shape that will help prevent current from “leaking” along the surface of the insulator from live electrical circuits to ground. Current leakage may cause damage to and eventual failure of the insulator.
One problem with electrical lines as described above, particularly with power distribution lines that transmit electrical power at high voltages, is dry band arcing. Dry band arcing is a common phenomenon observed in the composite polymeric insulators for these power distribution lines, especially in contaminated (e.g., polluted, wet) service areas. When an insulator gets wet, a thin film of water can form on the surface and a small leakage current may start to flow. When this film of water evaporates due to a rise in atmospheric temperature, a “dry band” forms on the surface of the insulator. The dry band interrupts the current flow and a voltage gradient appears across the dry band. The voltage gradient exerts electrostatic stress across the surface and causes further water evaporation and an increase in the width of the dry band, thus creating a higher voltage gradient which causes minor arcing. Dry band arcing results in visible arcs and audible noise and can often generate customer complaints. These dry band arcing events can last from a few days to several weeks in certain environmental conditions, for example, during times of high dew/moisture.
Embodiments of the present invention are directed to covers that are adapted for use on polymeric insulators for power distribution lines to help mitigate dry band arcing from occurring along the insulator. In some embodiments, the covers help prevent a film of water from forming on the housing and/or annular sheds of the insulator, thereby helping to mitigate conditions that could cause dry band arcing. In addition, in some embodiments, the covers increase the creep or leakage distance along the surface of the insulator between the conductive ends of the insulator, thereby helping to mitigate current leakage that may cause damage to and/or eventual failure of the insulator.
Further embodiments of the present invention are directed to an assembly adapted for mitigating dry band arcing. The assembly includes a polymeric insulator for a power distribution line having a core, two end fittings affixed to opposing ends of the core, and a housing circumferentially surrounding the core. The housing including an upper end section and a lower end section each overlapping a respective end fitting, and a series of axially spaced apart annular sheds projecting radially outwardly from an outer surface of the housing. The assembly further includes a cover having a main body including a sidewall and a top wall, the sidewall and the top wall together define a cavity. A lower edge of the sidewall defines a lower opening and the top wall includes an upper opening, both the lower and upper openings being in communication with the cavity. At least a portion of the upper end section of the housing is received through the upper opening of the cover and one or more of the annular sheds are received within the cavity of the cover.
Further embodiments of the present invention are directed to a cover for an insulator for a power distribution line. The cover includes a main body including a sidewall and a top wall. The sidewall and the top wall together define a cavity. A lower edge of the sidewall defines a lower opening in communication with the cavity and a top surface of the top wall of the cover is tapered or angled. The cover further includes a collar extending upwardly from the top wall and an upper edge of the collar defines an upper opening in communication with the cavity. The upper opening is configured to receive at least a portion of a housing of the insulator and the cavity is configured to receive one or more annular sheds extending radially outwardly from the housing of the insulator.
Further embodiments of the present invention are directed to a method for mitigating dry band arcing on a polymeric insulator for a power distribution line. The method includes (a) providing a polymeric insulator for power distribution line having a core, two end fittings affixed to opposing ends of the core, and a housing circumferentially surrounding the core, the housing including an upper end section and a lower end section each overlapping a respective end fitting, and a series of axially spaced apart annular sheds projecting radially outwardly from an outer surface of the housing; (b) providing a cover having a main body including a sidewall and a top wall, the sidewall and the top wall together define a cavity, a lower edge of the sidewall defines a lower opening and the top wall having an upper opening, and the lower and upper openings being in communication with the cavity; (c) forcing the cover downwardly onto the housing of the insulator such that one or more annular sheds of the insulator is received into the cavity of the cover; and (d) continuing to force the cover downwardly until at least portion of the upper end section of the housing is received through the upper opening of the cover.
Further features, advantages and details of the present invention will be appreciated by those of ordinary skill in the art from a reading of the figures and the detailed description of the preferred embodiments that follow, such description being merely illustrative of the present invention.
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. In the drawings, the relative sizes of regions or features may be exaggerated for clarity. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
It will be understood that when an element is referred to as being “coupled” or “connected” to another element, it can be directly coupled or connected to the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly coupled” or “directly connected” to another element, there are no intervening elements present. Like numbers refer to like elements throughout. As used herein the term “and/or” includes any and all combinations of one or more of the associated listed items.
In addition, spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Embodiments of the present invention will now be discussed in greater detail below with reference to
As noted above, a known composite polymer insulator 100 is illustrated in
In some embodiments, the insulator 100 forms a part of an electrical power distribution system, such as a utility electrical power distribution system, for example. It will be appreciated that the insulator 100 may be used in any application or electrical power distribution system in which composite polymeric insulators of this type may be used. The support structure may take other forms and the configuration of the insulator 100 may be modified to accommodate different applications. For example, the insulator 100 may be incorporated into the system as a standoff insulator between a conductor and a bracket. In other embodiments, the insulator 100 may be secured by couplings to and between two elongate conductors (e.g., electrical power lines) such that the insulator 100 spans the distance between the conductors and mechanically spaces and electrically isolates the conductors from one another.
As shown in
The housing 112 circumferentially surrounds the core 110. The housing 112 includes an upper end section or joint section 114 and a lower end section or joint section 116. The upper joint section 114 overlaps end fitting 104 and the lower joint section 116 overlaps end fitting 106. A series of axially spaced apart, annular sheds or skirts 118 project radially outwardly from an outer surface of the housing 112. The housing 112 can be formed of any suitable dielectric or electrically insulating polymeric material, for example, silicone rubber, ethylene-vinyl acetate (EVA), ethylene propylene diene monomer (EPDM) rubber, or other suitable rubber or other elastomeric and/or polymeric material. These components of the insulator 100 will be well-known to those of ordinary skill in the art and need not be described in further detail herein.
In general, the end of the insulator 100 that is connected to a power line (e.g., the top end 102A) has a higher electrical energy (higher voltage) than the opposing lower voltage or grounded end of the insulator 100 (e.g., the bottom end 102B). In other words, the electrical stress on the insulator 100 decreases along the lengthwise axis L-L of the insulator as you travel from the higher energized (voltage) top end 102A to the lower voltage or grounded bottom end 102B. Dry band arcing is more likely to occur proximate to the higher energized top end 102A of the insulator 100.
A cover 200 for an insulator 100 according to embodiments of the present invention is illustrated in
As shown in
The lower edge of the sidewall 202 defines a lower opening 207 that communicates with the cavity 203. In some embodiments, the top wall 206 comprises an upper opening 205 that communicates with the cavity 203 as well. In some embodiments, the main body 201 further includes a collar 204 extending upwardly from the top wall 206. In some embodiments, the upper edge of the collar 204 defines the upper opening 205 that communicates with the cavity 203. In some embodiments, the upper opening 205 is sized and configured to form an interference fit with the upper joint section 114 of the insulator 100. In some embodiments, the cover 200 may be formed as a monolithic or unitary component. The cover 200 may be formed of silicone rubber, EVA, EPDM, or other suitable rubber or other elastomeric and/or polymeric material. In some embodiments, the cover 200 is formed via injection molding.
As shown in
As shown in
The cover 200 may be mounted on the insulator 100 to form the assembly 300 in the following manner. In some embodiments, the cover 200 is factory installed on an insulator 100. In other embodiments, the cover 200 is retrofittable in the field on a pre-existing insulator 100. Installation of the cover 200 in the factory will depend on the type of insulator 100; the cover 200 can either be installed before or after the end fittings 104, 106 are affixed to the core 110 of the insulator 100. For over-molded insulators, the cover 200 will be installed after the end fittings 104, 106 are affixed to the core 110 of the insulator 100 and the polymer housing 112 is molded around the core 110. For non-over-molded insulators (i.e., insulators in which the housing 112 is molded to the core 110 prior to the end fittings 104, 106 being assembled), prior to the end fittings 104, 106 being affixed to the core 110 of the insulator 100, the cover 200 is forced downwardly onto the housing 112 such that one or more annular sheds 118 is received into the cavity 203 and a portion of the upper end section 114 is received through the upper opening 205. As the upper end section 114 is received through the upper opening 205, an interference fit may be formed between the cover 200 and the insulator 100, and in some embodiments, between the upper end section 114 and the upper opening 205. The interference fit helps prohibit water from entering through the upper opening 205 of the cover 200 and onto the upper portion of the housing 112 and/or sheds 118. In some embodiments, the polymeric material that forms the cover 200 gives the cover 200 a certain degree of flexibility, such that the upper opening 205 having a smaller diameter may be deflected or stretched to enable insertion of the larger diameter upper end section 114 of the housing 112. Once the upper end section 114 is positioned within the upper opening 205 of the cover 200, the resilient nature of polymeric material of the cover 200 allows the upper opening 205 to recover toward its original diameter, thereby securing the cover 200 to the insulator 100. Retrofit installation of the cover 200 occurs after the end fittings 104, 106 are assembled, and can be accomplished by either stretching the cover 200 over the existing end fitting 104 affixed to the top end 110A of the core 110 or by utilizing a cover having a two-piece construction, for example, cover 400 which will be described in further detail below.
Referring to
The cover 400 differs from the cover 200 described herein in that the cover 400 comprises a two-piece construction. The two-piece construction allows for the cover 400 to be retrofit to pre-existing insulators 100, for example, insulators 100 already installed in the field. As shown in
In some embodiments, each member 400A, 400B includes a transition wall 411 comprising a plurality of securing features 410. The transition wall 411 is coupled to or integral with the sidewall 402, top wall 406, and collar 404 (where applicable). As discussed in further detail below, the transition wall 411 of each member 400A, 400B provides a contact surface for the members 400A, 400B to engage and be secured together on an insulator 100.
One of the members 400A is shown in
In some embodiments, the sidewall 402A includes one or more annular recesses 409A, 412A. The recesses 409A, 412A allow the cover 400 to conform to the sheds 118 on the insulator 100 and also provide additional creepage distance. The main body 401A (e.g., transition wall 411A) comprises a plurality of securing features 410 that are configured to engage corresponding securing features 410 on the other main body 401B. In some embodiments, the securing features 410 may comprise a snap-fit mechanism such as a ball or cylinder snap-in or a prolonged snap-in. In some embodiments, rivets or screws made from nonconductive materials may be used to secure the main bodies 401A, 401B of the cover 400 together. Alternatively, in some embodiments, the main bodies 401A, 401B of the cover 400 may be glued or otherwise sealed together. When the main bodies 401A, 401B of each member 400A, 400B (e.g., the transition walls 411) are engaged (i.e., secured together), the respective cavities 403A, 403B together define a main cavity 403 of the cover 400. Similar to the cavity 203 of cover 200 described herein, the main cavity 403 of cover 400 is adapted to receive one or more of the annular sheds or skits 118 of the insulator 100 (see, e.g.,
In some embodiments, the lower edges of the sidewalls 402A, 402B together define a lower opening 507 that communicates with the main cavity 403. In some embodiments, the top walls 406A, 406B cooperate together to define an upper opening 405 that communicates with the main cavity 403 as well. In some embodiments, the upper edges of the collars 404A, 404B cooperate together to define the upper opening 405 that communicates with the main cavity 403. Similar to the cover 200 described herein, in some embodiments, a top surface of the top wall 406A, 406B may be tapered or angled to allow for water and/or other environmental contaminants to flow off the cover 400 and away from the insulator 100. The cover 400 may be formed of silicone rubber, EVA, EPDM, or other suitable rubber or other elastomeric and/or polymeric material. In some embodiments, the cover 400 is formed via injection molding.
The cover 400 may be mounted on a pre-existing insulator 100 to form assembly 500 in the following manner. The two members 400A, 400B are aligned such that an inner surface of the respective top walls 406A, 406B are positioned above the uppermost shed 118 of the insulator 100 and the corresponding securing features 410 of each member 400A, 400B are in alignment. The two members 400A, 400B are forced (e.g., pressed or glued together) together such that the corresponding securing features 410 on the transition walls 411 engage and secure the two members 400A, 400B together. In some embodiments, the two members 400A, 400B are secured together with a room-temperature-vulcanizing silicone (RTV) sealant to help prevent moisture between the two members 400A, 400B. As shown in
When placed on the insulator 100 (e.g., as part of the assembly 500 shown in
Referring to
The assembly 600 differs from the assemblies 300, 400 in that the assembly 600 includes a three-piece cover 700. Similar to the two-piece cover 400 described herein, the three-piece construction of cover 700 allows for the cover 700 to be retrofit to pre-existing insulators 100, for example, insulators 100 already installed in the field.
As shown in
The lower edge of the sidewall 702 defines a lower opening 707 that communicates with the cavity 703. In some embodiments, the top wall 706 comprises an upper opening 705 that communicates with the cavity 703 as well. In some embodiments, the main body 701 further includes a collar 704 extending upwardly from the top wall 706. In some embodiments, the upper edge of the collar 704 defines the upper opening 705 that communicates with the cavity 703. In some embodiments, the top wall 706 or collar 704 includes an annular lip 709 around the upper opening 705. In some embodiments, the main body 701 of the cover 700 may be formed as monolithic or unitary component. The cover 700 may be formed of silicone rubber, EVA, EPDM, or other suitable rubber or other elastomeric and/or polymeric material. In some embodiments, the cover 700 is formed via injection molding. As shown in
As shown in
Each collar members 710A, 710B includes an arcuate sidewall 712A, 712B and a flanged edge 714A, 714B extending radially outwardly from a lower edge of the respective sidewall 712A, 712B. The arcuate sidewalls 712A, 712B of the collar members 710A, 710B are sized and configured to receive the upper end section 114 of the insulator 100 therebetween. The sidewalls 712A, 712B are also sized and configured to be received through the upper opening 705 of the main body 701. As described in further detail below, the flanged edges 714A, 714B of the collar members 710A, 710B are configured to engage or contact the lip 709 residing around the upper opening 705 of the main body 701.
The cover 700 may be mounted on a pre-existing insulator 100 to form the assembly 600 in the following manner. Similar to the cover 200 described herein, in some embodiments, the cover 700 is factory installed on an insulator 100. In other embodiments, the cover 700 is retrofittable in the field on a pre-existing insulator 100. Installation of the cover 700 in the factory will depend on the type of insulator 100; the cover 700 can either be installed before or after the end fittings 104, 106 are affixed to the core 110 of the insulator 100.
For non-over-molded insulators (i.e., insulators in which the housing 112 is molded to the core 110 prior to the end fittings 104, 106 being assembled), the sidewalls 712A, 712B of the two collar members 710A, 710B are aligned with at least a portion of the upper end section 114 of the housing 112 of the insulator 100 therebetween. The main body 701 is forced downwardly onto the housing 112 such that one or more annular sheds 118 is received into the cavity 703 and the sidewalls 712A, 712B of the collar members 710A, 710B, as well as a portion of the upper end section 114 of the housing 112 is received through the upper opening 705. The main body 701 is forced downwardly until the flanged edges 714A, 714B of the collar members 710A, 710B engage or contact the annular lip 709 of the main body 701. The top wall 706 and/or collar 704 of the main body 701 provide a radially inwardly force on the sidewalls 712A, 712B of the collar members 710A, 710B, thereby securing the upper end section 114 of the housing 112 between the sidewalls 712A, 712B.
For over-molded insulators, the cover 700 will be installed after the end fittings 104, 106 are affixed to the core 110 of the insulator 100 and the polymer housing 112 is molded around the core 110. The sidewalls 712A, 712B of the two collar members 710A, 710B are aligned with at least a portion of the upper end section 114 of the housing 112 of the insulator 100 therebetween. The cover 700 is stretched over the existing end fitting 104 affixed to the top end 110A of the core 110 and over the two collar members 710A, 710B. The main body 701 is forced downwardly until the flanged edges 714A, 714B of the collar members 710A, 710B engage or contact the annular lip 709 of the main body 701. The top wall 706 and/or collar 704 of the main body 701 provide a radially inwardly force on the sidewalls 712A, 712B of the collar members 710A, 710B, thereby securing the upper end section 114 of the housing 112 between the sidewalls 712A, 712B.
When placed on the insulator 100 (e.g., as part of the assembly 600 shown in
In some embodiments, similar to cover 200 described herein, the cover 700 may comprise one or more annular flanged edges that extend radially outwardly from the top wall 706 and/or from the lower edge of the sidewall to further increase the creep or leakage distance along the surface of the insulator 100, as well as help to direct the flow of any water and/or other environmental contaminants from the surface of the cover 700 further away from the insulator 100.
The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention. Therefore, it is to be understood that the foregoing is illustrative of the present invention and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the invention.
