EC Insulator Jiangxi Co., Ltd. is one of the most reliable manufacturers and suppliers of ac polymer insulator in China. With abundant experience, we are committed to offering high quality custom service. Please feel free to wholesale premium ac polymer insulator made in China here from our factory.
Product Overview
EC Insulator designs and manufactures high-performance AC polymer insulators specifically built for AC overhead transmission lines and substation infrastructure. Unlike traditional porcelain insulators, our polymer options offer exceptional hydrophobic properties, strong resistance to pollution and UV damage, delivering consistent electrical insulation performance and robust mechanical support for medium and high-voltage AC power networks.
We have supplied these insulators for a wide range of AC power projects both domestically and internationally. For installations located in coastal salt-fog zones or areas with heavy industrial pollution, we can customize the creepage distance and shed profile to meet the requirements of different pollution classes. Our AC polymer insulators perform reliably even under challenging outdoor conditions including salt spray, industrial contamination and high-altitude environments.
When you provide specifications including required voltage grade, mechanical failing load, site pollution class and altitude parameters, our engineering team will develop a tailored insulator solution specifically matched to your project needs.
Key Features
Each AC polymer insulator incorporates three core components: a high-strength ECR fiberglass epoxy core rod, AC-grade HTV silicone rubber sheds, and hot-dip galvanized forged steel end fittings, all engineered to work in tandem for maximum reliability.
The HTV silicone rubber housing features excellent hydrophobic transfer capability, which significantly reduces pollution flashover risks when installed in polluted outdoor environments. The entire unit is substantially lighter than equivalent porcelain insulators, which cuts down on tower loading and simplifies on-site installation procedures for field crews.
All metal end fittings undergo rigorous hot-dip galvanizing treatment to deliver superior anti-corrosion performance for long-term outdoor service. The integral injection molding process eliminates internal gaps, preventing moisture ingress that could compromise performance. The hydraulic crimping connection between the core rod and fittings ensures consistent mechanical performance even under prolonged tension and vibration conditions.
Technical Specifications
|
Parameter |
Value |
|
Rated AC Voltage |
11kV,24kV,33kV,35kV,66kV,110kV,220kV |
|
Specified Mechanical Failing Load |
30kN – 210kN |
|
Operating Temperature |
-40°C ~ +60°C |
|
Core Rod Material |
High-strength ECR fiberglass epoxy rod |
|
Shed Material |
AC-grade HTV silicone rubber with hydrophobic migration performance |
|
Fitting Material |
Forged steel with full hot-dip galvanized finish |
|
Pollution Adaptability |
Customizable for pollution Class I, II, III, IV |
|
Partial Discharge |
≤5pC under standard test conditions |
|
Service Life |
20+ years under standard AC operating environments |
Important note: All test procedures are conducted in strict accordance with IEC 61109 and IEC 61952 standards. Full test reports and certification documentation will be provided alongside every shipment for your records.
Application
AC polymer insulators have extensive applications across AC overhead transmission and distribution lines, substation support insulation systems, suspension string and tension string assemblies. They serve as critical insulating components for both new construction and renovation projects of AC power grid infrastructure.
These insulators are particularly well suited for harsh operating sites including coastal salt-spray areas, regions with heavy industrial pollution, high-altitude mountain zones and humid climate environments. Important to note: DC composite insulators cannot be used as substitutes for AC applications, and AC insulators are similarly unsuitable for DC power scenarios.
Construction &Design
Our AC polymer insulators feature a proven, optimized structural design developed through years of field application. The ECR fiberglass epoxy core rod handles all tensile mechanical loads encountered during service. The silicone rubber housing is manufactured using integral injection molding, eliminating internal gaps that could allow moisture penetration over time.
End fittings are assembled using hydraulic crimping technology rather than adhesive bonding, which guarantees consistent mechanical capacity even under continuous vibration and tension. The shed profile has been optimized specifically for AC pollution characteristics, improving surface electric field distribution and limiting leakage current under contaminated conditions.
All structural dimensions conform to international AC insulator standards, ensuring full compatibility with standard tower hardware and grading ring configurations used in existing AC transmission projects worldwide.
Standards & Testing
Our AC polymer insulators are manufactured and tested in full compliance with IEC 61109 and IEC 61952 international standards, ensuring consistent quality across all production batches.
Every production batch undergoes a comprehensive suite of professional tests before leaving the facility: • AC power-frequency withstand test
• Lightning impulse withstand test
• Salt fog pollution aging test
• Hydrophobicity durability test
• Mechanical failing load test
• Galvanized layer thickness inspection
Complete factory test reports are included with every shipment for full quality transparency. For tender projects requiring third-party witness testing, we can arrange this service with adjusted production lead times to meet your project schedule requirements.
Customization & Optional Accessories
We offer comprehensive project-oriented customization services tailored to the specific requirements of AC power projects:
• Adjustable creepage distance to match different pollution grades and altitude conditions
• Custom end fitting types including ball-and-socket and clevis-and-tongue configurations
• Matched AC grading rings for 110kV / 220kV models to optimize electric field performance
• Anti-bird sheds and ice-optimized shed profiles for regions with special climatic conditions
• Custom mechanical load grades and string dimensions designed to meet specific tower span design requirements
Packaging & Delivery
All AC polymer insulators are packaged in ISPM 15 compliant standard wooden crates for international shipment. Each individual insulator is carefully wrapped in PE film to prevent scratches to the silicone rubber surface and abrasion to metal fittings during long-distance sea transportation.
Every product carries permanent markings indicating the AC voltage grade, mechanical load rating and batch number for complete traceability throughout its service life. Bulk AC project orders typically require 15-30 working days for production after deposit receipt. Small-batch sample orders can be completed and shipped within 10 working days.
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