Power Composites: Innovation Driving the High-Performance Development of Power Equipment

1. Introduction

In recent years, the Chinese government has vigorously promoted the intelligentization and efficiency transformation of the power system, issuing a series of policies and regulations, such as the "14th Five-Year Plan for Energy Development" and the "Action Plan for Carbon Peaking and Carbon Neutrality," which clearly stipulate the need to enhance the safety, durability, and environmental performance of power grid equipment. Meanwhile, State Grid Corporation of China and China Southern Power Grid have actively promoted UHV transmission projects and renewable energy grid integration, providing a broad market space for the application of power composites.

Traditional power equipment widely uses metals and ceramics, but they have certain limitations in terms of weight, corrosion resistance, and fatigue resistance. Composites, with their high strength, lightweight properties, and excellent insulation performance, are gradually replacing traditional materials and becoming indispensable in the power industry.

2. Fiber Mat Composite Laminates

Fiber mat composite laminates are insulating materials made from glass fiber mats, carbon fiber mats, or aramid fiber mats combined with high-performance resins (such as epoxy and phenolic resins) through high-temperature and high-pressure lamination. The core characteristics of this material lie in its excellent electrical insulation properties, ability to withstand high-voltage operation, low dielectric loss, and strong arc resistance. Additionally, its high strength and lightweight nature make it more versatile in power equipment applications. Compared to traditional ceramics and metals, fiber mat composite laminates have a lower density but exhibit good bending and tensile strength. They also demonstrate strong weather resistance and corrosion resistance, maintaining stable performance in damp, high-temperature, and corrosive environments.

Currently, this material is primarily used in transformer station insulating partitions, insulating support structures for high-voltage switchgear, and busbar supports. For instance, within high-voltage switchgear, composite laminates effectively reduce the risk of short circuits and enhance safety. Furthermore, traditional metal supports are prone to rusting due to moisture, while composite busbar supports not only offer strong insulation but also reduce corona discharge phenomena. Moving forward, as power distribution equipment evolves towards higher voltage levels, fiber mat composite laminates will trend towards higher voltage withstand capabilities, lighter weight, and greater environmental friendliness, such as through the adoption of nano-filled reinforced resin systems to enhance material heat resistance and aging resistance.

3. Composite Insulating Stress Members for UHV DC Power Transmission and Transformation

The application of UHV DC power transmission and transformation systems imposes extremely stringent performance requirements on materials. Composites, due to their high strength, fatigue resistance, and excellent insulation properties, have become one of the important materials for UHV power transmission equipment. These insulating stress members are typically manufactured using glass fiber-reinforced epoxy (GFRP) or carbon fiber-reinforced epoxy (CFRP), offering extremely high mechanical strength to withstand external forces such as strong winds and earthquakes. They are also resistant to pollution flashover and UV radiation, suitable for complex climatic conditions. Furthermore, these materials possess extremely high breakdown voltages, ensuring stable operation of transmission lines.

In terms of applications, composite pillar insulators in UHV DC transmission lines are lighter than traditional ceramic insulators and offer higher pollution flashover resistance. Additionally, composite cross-arms exhibit far greater strength than traditional steel cross-arms while significantly reducing weight, thereby lowering overall construction and maintenance costs. The application of composite insulating rods in the fixed support systems of power transmission and transformation equipment is also growing rapidly, effectively reducing energy losses due to corona discharge.

Currently, China is accelerating the construction of its UHV transmission network. It is estimated that by 2030, UHV DC transmission projects will cover multiple provinces and cities across the country, significantly increasing the market demand for composite insulating stress members. This trend will drive enterprises to continuously explore material optimization, manufacturing process innovation, and product upgrades.

4. Composite Molded Plates for Poles

Composite molded plates for poles are primarily used in high-voltage DC power transmission and distribution, fuel cells, and energy storage systems. Their manufacturing process involves high-temperature molding of carbon fibers, graphite powder, and thermoset resins, enabling them to maintain lightweight and high-strength characteristics while also possessing good electrical conductivity and insulation. This material optimizes current distribution, improves system efficiency, and exhibits excellent corrosion resistance and durability, suitable for high-humidity and high-temperature environments.

Specifically, this product is widely used as pole materials in energy storage systems such as lithium batteries and supercapacitors. Additionally, composite molded plates for poles are used in rectifying equipment at high-voltage DC converter stations to enhance energy conversion efficiency. In the hydrogen energy sector, fuel cell stacks also rely on composite molded plates for poles to improve durability and electrical conductivity.

Moving forward, the technological development of composite molded plates for poles will evolve towards lower contact resistance, higher electrical conductivity, and greater durability. For example, the adoption of nano-carbon material filling technology can further enhance the performance of these plates, broadening their application in energy storage and high-voltage power transmission and distribution.

5. Conclusion

Power composites play an increasingly important role in modern power transmission and transformation equipment due to their advantages of high strength, lightweight properties, excellent insulation, and strong weather resistance. In particular, the application of fiber mat composite laminates, composite insulating stress members for UHV DC power transmission and transformation, and composite molded plates for poles provides effective solutions for enhancing the safety, durability, and economy of power equipment.

With the rapid development of smart grids and renewable energy storage technologies, the application scenarios for power composites will further expand. In the future, combined with advanced manufacturing processes and novel material research and development, the power industry will advance towards a more efficient, safe, and environmentally friendly era with the assistance of composites.

The China Composites Industry Association has recently issued a public call for participation in the compilation of three group standards: "Fiber Mat Composite Laminates," "Composite Insulating Stress Members for UHV DC Power Transmission and Transformation," and "Composite Molded Plates for Poles." For related notices, please click the link below for more information:

Notice of the China Composites Industry Association on Soliciting Participants for the Compilation of Three Group Standards Including "Fiber Mat Composite Laminates"