CROSS-LINKED POLYOLEFIN MATERIAL BLEND MOLDED ELECTRICAL TRANSMISSION INSULATING PRODUCTS
A new cross linked polyolefin material combination that is designed to replace current high-density polyethylene (“HDPE”) materials for use with molded or over-molded electrical transmission products. Such molded or over-molded electrical transmission products include, for example, vise-top pin insulators, line post insulators, F-neck, C-neck, and J-neck pin insulators of classes ANSI 55-3, 55-4, and 55-5, Spacer cable spacers, Brackets, hangers, Line post sensors, cable restraint insulators, and transmission style insulators.
1 . A method of making a molded electrical transmission product comprising the steps of:
a) providing a plurality of components in pellet form, said plurality of components including at least one low density cross-linkable polymer resin, at least one high density polymer, a cross-linking catalyst, and a color masterbatch;
b) combining the pellets using a gravimetric blender;
c) transferring the combined pellets to an injection-molding machine including a mixing screw and a mold;
d) melting the combined pellets;
e) mixing the melted and combined pellets into a uniform melt using the mixing screw; and
f) injection-molding the uniform melt to form an electrical transmission product in the mold.
2 . The method of claim 1 , further comprising the step of immersing the electrical transmission product in hot water to promote moisture curing.
3 . The method of clam 1 , further comprising the step of subjecting the electrical transmission product to steam to promote moisture curing.
4 . The method of claim 1 , wherein the at least one low density cross linkable polymer resin is a ethylene vinylsilane copolymer.
5 . The method of claim 1 , wherein the color masterbatch comprises at least one colorant and at least one stabilizer.
6 . The method of claim 5 , wherein the at least one stabilizer is selected from the group consisting of UV stabilizers, anti-oxidants, amine light stabilizers, and track resistance compounds.
7 . The method of claim 1 , wherein the at least one low density cross-linkable polymer resin is present at about 53% of the total compound, the at least one high density polymer is present at about 37% of the total compound, the cross-linking catalyst is present at about 5% of the total compound and the color masterbatch is present at about 5% of the total compound.
8 . The method of claim 1 , wherein the at least one high density polymer is a high density polyethylene.
9 . The method of claim 1 , wherein the at least one low density cross-linkable polymer resin is present in an amount from about 47.7% by weight of the total compound to about 58.3% by weight of the total compound, the at least one high density polymer is present in an amount from about 33.3% by weight of the total compound to about 40.3% by weight of the total compound, the cross-linking catalyst is present in amounts from about 4.5% by weight of the total compound to about 5.5% by weight of the total compound, and the color masterbatch is present in amounts from about 4.5% by weight of the total compound to about 5.5% by weight of the total compound.
10 . The method of claim 1 , wherein the electrical transmission product is selected from the group consisting of vise-top insulators; pin insulators; line post insulators; F-neck, C-neck, and J-neck pin insulators of classes ANSI 55-3, 55-4, and 55-5; spacer cable spacers; brackets; hangers; line post sensors; cable restraint insulators; and vertically mounted or horizontally mounted transmission products.
11 . The method of claim 1 , further comprising the step of providing a structural member, wherein the step of injection-molding the uniform melt includes placing at least a portion of the structural member into the mold of the injection molding machine.
12 . The method of claim 11 , wherein the structural member includes an insulating material.
13 . The method of claim 12 , wherein the structural member further includes a base.
14 . The method of claim 11 , wherein the structural member includes a fiberglass rod.
15 . The method of claim 11 , wherein the electrical transmission product is selected from the group consisting of vise-top insulators; pin insulators; line post insulators; F-neck, C-neck, and J-neck pin insulators of classes ANSI 55-3, 55-4, and 55-5; spacer cable spacers; brackets; hangers; line post sensors; cable restraint insulators; and vertically mounted or horizontally mounted transmission products.