Patent Description:
Electrical polymer insulators are used in power transmission and distribution systems to provide mechanical support for conductors and provide electrical insulation between the high voltage conductors and grounded tower structures. A corona protection device is located at the line end and/or the ground end of the insulator and eliminates the corona discharge from the insulator. Elimination of the corona discharge protects the surface of the insulator from polymeric material deterioration caused by electrical stress. Additionally, eliminating the corona discharge reduces television and/or radio noise created by the corona discharge. <CIT> discloses an integrated insulator seal and shield assembly. <CIT> discloses a composite insulator having end fittings with gaps.

One of the problems with conventional corona protection devices is the number of parts required to assemble the corona protection device, thereby increasing the manufacturing costs. In addition, some conventional corona protection devices require secondary operations and corresponding quality checks also increasing manufacturing costs. Another problem of conventional corona protection devices is incorrect installation in the field that can result in reduced performance and durability.

Accordingly, it has been determined by the present disclosure that there is a continuing need for integrated insulator sealing and shielding assemblies that overcome, alleviate, and/or mitigate one or more of the aforementioned and other deleterious effects of prior devices.

According to a first aspect of the present invention, there is provided an integrated insulator sealing and shielding assembly as set forth in independent claim <NUM>. Preferable and/or optional features are set forth in the dependent claims. The present disclosure provides an improved insulator sealing and shielding assembly.

The present disclosure also provides the insulator sealing and shielding assembly having a collar assembly disposed between a rubber housing and a metal end fitting.

The present disclosure further provides the insulator sealing and shielding assembly with a rubber housing tapered into a metal fitting to increase the compression connection therebetween.

The present disclosure still further provides the insulator sealing and shielding assembly with a plurality of radial weathersheds disposed along an exterior of the housing and the endmost weathershed adjacent to the collar assembly connected to the hardware.

The foregoing are basically attained by providing an insulator sealing and shielding assembly having a rubber housing with a plurality of weathersheds and a tapered end adjacent the metal fitting. Four sealing surfaces between the counterbore of the collar assembly and the rubber housing secure the connection therebetween creating an integral metal fitting and rubber housing.

An integrated insulator sealing and shielding assembly is also provided that includes a rubber housing having a plurality of radial weathersheds and a tapered end adjacent an endmost radial weathershed. The tapered end has an outer surface with a ring extending outward from the outer surface. The ring is compressible. A metal end fitting is disposed adjacent to the endmost radial weathershed and receives the tapered end. The tapered end is received in a counterbore in the metal end fitting. The counterbore has a sealing surface so that interference of the ring with the sealing surface creates a compressive sealing force to form a seal.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the rubber housing is made of rubber.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the sealing surface has a groove in the counterbore of the metal end fitting.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the groove is sized to receive the ring while the ring applies a compressive sealing force against the groove.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the sealing surface is a flat surface on the counterbore of the metal end fitting.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the ring protrudes from the tapered end so that the ring applies a compressive sealing force against the flat surface.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, at least one sealing surface that is a radial compression seal is located between a first frustum of the rubber housing and a second frustum of said counterbore.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the tapered end has an end that is opposite the endmost radial weathershed, and a portion of the tapered end between the ring and the end forms the first frustum.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the counterbore forms the second frustum to receive the first frustum of the tapered end.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the first frustum has a first angle that the tapered end forms with a line that is parallel with a center axis of the rubber housing and the second frustum has a second angle formed by a line parallel with a center axis of the metal housing and the counterbore.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the first angle is smaller than the second angle to create an increasing compressing force between the rubber housing and the counterbore.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the tapered end has an end that is opposite the endmost radial weathershed, and the counterbore forms a seal that is a joint between an end of counterbore and the end of the tapered end.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the tapered end has a raised rib that is a lowermost extension of the rubber housing on a side of the endmost weathershed adjacent the metal housing.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the raised rib abuts an outer portion of the counterbore to form a sealing surface.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the seal formed by the ring and the sealing surface is positioned on the tapered end of the rubber housing between the sealing surface formed by the raised rib that abuts the outer portion of the counterbore and another sealing surface that is a radial compression seal located between a first frustum of the rubber housing and a second frustum of said counterbore.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the tapered end has an end that is opposite the endmost radial weathershed, and the counterbore forms a seal that is the joint between an end of counterbore and the tapered end of the rubber housing.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the seal formed by the ring and the sealing surface is a third seal, and a first seal formed by a joint between an end of counterbore and the tapered end of the rubber housing, a second seal that is a radial compression seal located between a first frustum of the rubber housing and a second frustum of said counterbore, and a fourth seal that is a raised rib that is a lowermost extension of the rubber housing on a side of the endmost weathershed adjacent the metal housing that abuts an outer portion of the counterbore.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the third seal is between the second seal and the fourth seal.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the first seal is adjacent the second seal on a side that is opposite the third seal.

The above-described and other features and advantages of the present disclosure will be appreciated and understood by those skilled in the art from the following detailed description, drawings, and appended claims.

Referring to the drawings and in particular to <FIG>, an exemplary embodiment of an integrated insulator sealing and shielding assembly according to the present disclosure is shown and is generally referred to by reference numeral <NUM> ("assembly <NUM>"). Assembly <NUM> has a rubber housing <NUM> and two metal end fittings <NUM>.

Advantageously, assembly <NUM> includes an integrated sealing and corona shielding system with multiple integrated sealing features to optimize manufacturability through reduced part count and secondary operations over conventional designs. In particular, assembly <NUM> enables the utilization of advanced manufacturing assembly methods with integrated features to optimize quality and durability.

Referring to <FIG>, rubber housing <NUM> is a cylindrical rubber housing with a plurality of weathersheds <NUM>. Metal end fitting <NUM> is a metal end fitting with an integrated collar assembly <NUM>. Rubber housing <NUM> includes a plurality of radial weathersheds <NUM> distributed about rubber housing <NUM> in a columnar arrangement. An extended portion <NUM> of each metal end fitting <NUM> is disposed on an opposite side of collar assembly <NUM> relative to rubber housing <NUM>.

Ultimately, rubber housing <NUM> is adapted to be inserted into and connected to each metal end fitting <NUM> under pressure. Since each metal end fitting <NUM> and collar assembly <NUM> of <FIG> is identical, only one will be described in detail. However, metal end fitting <NUM> can have alternative configurations. In particular, extended portion <NUM> is shown as a "Ball end fitting" as representing the one of the many variations extended portion <NUM> can be, but extended portion <NUM> can be modified to alternatively have one of multiple different fittings (Ball, Y, clevis, etc.) that extends from collar assembly <NUM>. Further, metal end fitting <NUM> can have different configurations to accommodate different rod diameters of a rod <NUM> as well with scaled up versions of metal end fitting <NUM>.

Collar assembly <NUM> surrounds and protects an interface between metal end fitting <NUM> and rubber housing <NUM>, as shown in <FIG> and <FIG>. Collar assembly <NUM> also includes a counterbore <NUM> that receives tapered end <NUM>. Counterbore <NUM> is a passage adjacent to tapered end <NUM> of rubber housing <NUM>. This helps create the robust connection between collar assembly <NUM> and rubber housing <NUM>. Counterbore <NUM> is a main opening between rubber housing <NUM> and metal end fitting <NUM>. Rod <NUM> extends through rubber housing <NUM> and counterbore <NUM>. Rod <NUM> is a fiberglass rod, and, in particular, an epoxy based electrical grade corrosion resistant (E-CR) fiberglass rod. Rubber housing <NUM> is direct bonded polymer rubber molded onto rod <NUM> to form a direct bonded rubber to rod assembly. Rod <NUM> is related to a shielding portion of assembly <NUM>.

Tapered end <NUM> of rubber housing <NUM> is coupled to collar assembly <NUM> at a first seal <NUM> that is at a narrow junction between tapered end <NUM> and counterbore <NUM>. This is a lowermost area of counterbore <NUM>. Tapered end <NUM> is located adjacent a lowermost point of counterbore <NUM> for creating at least one sealing surface with collar assembly <NUM>. This junction or first seal <NUM> between tapered end <NUM> and collar assembly <NUM> represents one of four sealing surfaces securing assembly <NUM>. More specifically, the sealing surfaces are disposed between collar assembly <NUM> and a bottom end <NUM> of the rubber housing <NUM>. The junction of first seal <NUM> helps to create a seal between an outer surface of rubber housing <NUM> and counterbore <NUM> of metal end fitting <NUM>. Specifically, first seal <NUM> is the joint between end <NUM> of counterbore <NUM> and an end <NUM> of tapered end <NUM> of the rubber housing <NUM>.

Still referring to <FIG>, a second seal <NUM> is located slightly above first seal <NUM>. Second seal <NUM> is a radial compression seal created by pushing a first frustum <NUM> of the rubber housing <NUM> into a second frustum <NUM> of counterbore <NUM> imparting increasing compressing force between rubber housing <NUM> and the counterbore <NUM>. Referring to <FIG>, first frustum <NUM> has a first angle <NUM> that tapered end <NUM> forms with a line <NUM> that is parallel with a center axis A. Referring to <FIG>, second frustum <NUM> has a second angle <NUM> formed by a line <NUM> parallel with center axis C and counterbore <NUM>. First angle <NUM> is smaller than second angle <NUM> to create the increasing compressing force between rubber housing <NUM> and the counterbore <NUM> to form a radial compression seal located between first frustum <NUM> of rubber housing <NUM> and second frustum <NUM> of counterbore <NUM>.

Referring to <FIG>, a third seal <NUM> is located between second seal <NUM> and a fourth seal <NUM>. Third seal <NUM> is comprised of a ring <NUM> formed on rubber housing <NUM> and a sealing surface <NUM> of metal end fitting <NUM>. Tapered end <NUM> of rubber housing <NUM> has an outer surface <NUM>. Ring <NUM> is compressible and extends outward from outer surface <NUM>. Referring to <FIG>, ring <NUM> is an integrated compression sealing protrusion ring molded into the geometry of rubber of rubber housing <NUM>. Ring <NUM> forms a sealing barrier against sealing surface <NUM> of metal end fitting <NUM>. The ring seal feature of ring <NUM> will protrude from the surface of the polymer of rubber housing <NUM> and interference with sealing surface <NUM> of metal end fitting <NUM> will create a compressive sealing force of third seal <NUM>.

Referring to <FIG>, counterbore <NUM> may contain a groove <NUM> formed at sealing surface <NUM>. Groove <NUM> is sized and shaped to receive ring <NUM> as shown in <FIG>. Groove <NUM> mates with ring <NUM> to maintain ring <NUM> in place in groove <NUM> through initial assembly steps while ring <NUM> applies a compressive sealing force against groove <NUM> to create third seal <NUM>. However, referring to <FIG>, metal end fitting <NUM> can be modified to omit groove <NUM> so that sealing surface <NUM> is a flat surface <NUM>. In the modified metal end fitting <NUM> of <FIG>, ring <NUM> protrudes from tapered end <NUM> so that ring <NUM> applies a compressive sealing force against flat surface <NUM> to create third seal <NUM>.

Referring back to <FIG>, fourth seal <NUM> is located towards the top of collar assembly <NUM> at the junction of the rubber housing <NUM> and an outer portion <NUM> of the counterbore <NUM>. Fourth seal <NUM> is the lip seal defined by the intersection of a raised rib <NUM> on rubber housing <NUM> and an outer portion of counterbore <NUM> to provide an initial seal against moisture ingress. Raised rib <NUM> is the lowermost extension of rubber housing <NUM> on the side of endmost weathershed <NUM>' adjacent collar assembly <NUM>.

Referring to <FIG>, during assembly, rubber housing <NUM> is moved in a direction <NUM> into metal end fitting <NUM> by a force that allows movement of end <NUM> of tapered end <NUM> to abut end <NUM> of counterbore <NUM> to form first seal <NUM>, first frustum <NUM> into second frustum <NUM> to form second seal <NUM>, ring <NUM> into place to abut sealing surface <NUM> to form third seal <NUM>, and raised rib <NUM> to abut outer portion <NUM> of the counterbore <NUM> to form fourth seal <NUM>, as shown in <FIG>, to form assembly <NUM>.

The present disclosure describes one rod diameter and end fitting variation of many that are possible for assembly <NUM>. The present disclosure should not be limited thereby and each variation is covered by the present disclosure.

Advantageously, assembly <NUM> provides redundancy of sealing features to provide durability and robustness of the critical seal area.

Assembly <NUM> simplifies the manufacturability of metal end fitting <NUM> without the requirement of secondary operations such as cross drilling and reduces the assembly part count. Thus, assembly <NUM> optimizes the design, manufacturability, and quality of insulator sealing and shielding assemblies.

It should also be noted that the terms "first", "second", "third", "upper", "lower", and the like may be used herein to modify various elements. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated.

While the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated, but that the disclosure will include all embodiments falling within the scope of the appended claims.

Claim 1:
An integrated insulator sealing and shielding assembly (<NUM>) comprising:
a rubber housing (<NUM>) having a plurality of radial weathersheds (<NUM>) and a tapered end (<NUM>) adjacent an endmost radial weathershed (<NUM>), the tapered end (<NUM>) having an outer surface (<NUM>) with a ring (<NUM>) extending outward from the outer surface (<NUM>), the ring (<NUM>) being compressible;
a metal end fitting (<NUM>) disposed adjacent to the endmost radial weathershed (<NUM>) and receiving the tapered end (<NUM>), the tapered end (<NUM>) being received in a counterbore (<NUM>) in the metal end fitting (<NUM>), the counterbore (<NUM>) having a sealing surface (<NUM>) so that interference of the ring (<NUM>) with the sealing surface (<NUM>) creates a compressive sealing force to form a seal.