Compared with traditional porcelain-jacket zinc oxide surge arresters, composite-jacket zinc oxide arresters offer several advantages, including compact size, lightweight design, excellent explosion-proof and sealing performance, larger creepage distance, strong resistance to pollution, simplified manufacturing processes, and a more robust structure. These benefits have made them highly popular among users. However, they also face challenges such as aging and electrical erosion of the jacket material. To address these issues, researchers are not only focusing on improving the characteristics of zinc oxide varistors but also exploring ways to enhance the aging and electrical corrosion resistance of the jacket insulation materials. Additionally, efforts are being made to optimize internal insulation structures and material properties to compensate for the limitations of organic composite materials. Zinc oxide (ZnO) surge arresters, developed in the 1970s, represent a new generation of protective devices. They primarily consist of zinc oxide varistors. Each varistor has a specific switching voltage, known as the varistor voltage. Under normal operating conditions (below the varistor voltage), the varistor exhibits high resistance, acting like an insulator. However, when exposed to an impact voltage exceeding the varistor voltage, the varistor rapidly conducts, creating a low-resistance path that allows the surge current to flow to ground. Once the overvoltage is removed, the varistor returns to its high-impedance state. This makes ZnO arresters effective in protecting electrical equipment from lightning strikes by limiting the voltage on power lines to safe levels. The structure of a composite-jacket zinc oxide arrester typically includes the following components: a. A series of zinc oxide varistor discs forming the valve core; b. Internal insulation and mechanical support made from glass fiber-reinforced thermosetting resin (FRP); c. An outer cover made of hot-vulcanized silicone rubber; d. Silicone sealant and adhesives for sealing; e. Inner electrodes, external terminals, and mounting hardware. Manufacturers may use different production methods and structural designs based on their technical capabilities. In this study, four representative structures were selected for comparative analysis to evaluate how different construction techniques affect the electrical and mechanical performance of composite-jacket zinc oxide arresters. These include: - Type A: Epoxy-glass prefabricated tubes - Type B: Resin-glass composite winding - Type C: Resin-glass composite winding with epoxy potting - Type D: Heat-shrinkable plastic sleeve combined with resin potting In addition to these types, other methods like SMC molding or high-temperature epoxy casting are also used, though they are not covered here. The outer jackets of these arresters are often prefabricated, allowing for optimal electrical and mechanical properties after two-stage vulcanization. The prefabricated umbrella sleeves are then bonded and sealed with the core using adhesives. To better understand the internal and external insulation performance, an insulating test piece was created by replacing the varistor disc with an insulating rod, forming a "mirror" arrester for comparison. Performance testing of these four types of arresters involved evaluating key parameters such as electrical and mechanical properties. Based on relevant standards, only certain tests were selected that directly relate to the internal structure of the arresters, as other tests were either less relevant or not closely tied to structural differences. One critical test is the 4/10 μs high-current impulse test, which measures the arrester’s ability to withstand large surges. For the 34×20.5 mm resistive elements commonly used in these arresters, the standard IEC level of 65 kA has been set as a target. Some manufacturers in China are still working towards meeting this benchmark. By analyzing these aspects, researchers aim to improve the reliability and efficiency of composite-jacket zinc oxide surge arresters, ensuring better protection for electrical systems under various environmental and operational conditions.
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