
Made of high-purity industrial LSR through injection molding, it has excellent high-voltage insulation, arc resistance, weather resistance and aging resistance, with stable sealing performance. It can be used for a long time in complex power environments, effectively avoiding safety hazards such as high-voltage leakage and tracking, and adapts to the connection needs of various high-voltage power equipment.
Material
Industrial LSR
Hardness
Shore A 60-80
Temperature
Certifications
Applications
-50°C ~ +180°C
Colors
Black, White, Transparent, Customizable
# Industrial Liquid Silicone High Voltage Insulating Connector for Power Systems
The Industrial Liquid Silicone High Voltage Insulating Connector is a critical passive component engineered to provide reliable electrical insulation, environmental sealing, and mechanical support for power cable junctions in medium-to-high voltage (MV/HV) power transmission and distribution systems. Manufactured via precision injection molding of medical and industrial-grade liquid silicone rubber (LSR), this connector addresses the long-standing pain points of traditional EPDM or ceramic insulating connectors, including poor low-temperature flexibility, short service life in harsh outdoor environments, and complicated on-site installation procedures.
At its core, the product integrates a one-piece LSR insulating body, embedded tin-plated copper conductive terminals, and a reinforced locking structure, delivering a combination of 10kV~35kV dielectric withstand strength, IP68 ingress protection, and compatibility with 10mm²~240mm² power cables. It is designed to eliminate partial discharge at cable connection points, reduce line loss caused by poor contact, and extend the maintenance interval of power grid nodes to over 30 years. Key selling points include suitability for extreme temperature ranges, resistance to UV and chemical corrosion, and compliance with global power industry safety standards, making it ideal for both overhead line junctions and underground power network connections.
The connector’s primary insulating layer is made of high-purity addition-cured liquid silicone rubber with a customized high-voltage insulation formula, with material properties meeting the requirements of IEC 60486 for insulating elastomers:
Embedded conductive terminals are made of T2 oxygen-free copper with a 5μm~8μm tin plating layer, with a conductivity of ≥98% IACS to minimize contact resistance at the connection point. The optional reinforcing shell is made of glass fiber reinforced PA66, with a UV stabilizer content of 2.5% to improve long-term outdoor weather resistance.
The finished connector meets the following physical performance indicators to adapt to complex installation and operating conditions:
The LSR injection molding process for the connector is strictly controlled to ensure consistency of insulating layer density and bonding strength with embedded terminals:
Unlike traditional EPDM insulating connectors that become brittle and crack at temperatures below -40°C, or ceramic connectors that are prone to fracture under mechanical shock, this LSR connector maintains stable flexibility and insulation performance in a temperature range of -60°C to 180°C, and can adapt to harsh scenarios such as alpine regions, desert areas, and coastal salt spray environments. After 5000 hours of UV accelerated aging test, the tensile strength retention rate of the LSR insulating layer is ≥90%, and the dielectric performance remains unchanged, far exceeding the 2000-hour aging requirement of EPDM products.
The one-piece injection molding process eliminates internal gaps and interface defects that are common in assembled insulating connectors, and the high-purity LSR formula reduces the content of conductive impurities in the material. The partial discharge of the connector at rated voltage is controlled below 10pC, which is far lower than the industry standard requirement of 50pC, effectively avoiding insulation breakdown and line failure caused by long-term partial discharge erosion, and reducing the operation risk of power grid nodes.
The connector adopts a push-in locking structure, which can complete the cable connection without special tools, and the installation time is only 1/3 of that of traditional heat-shrinkable or cold-shrinkable insulating connectors. The LSR insulating layer has inherent self-adhesion and elastic recovery performance, which can automatically compensate for the size change of the cable caused by thermal expansion and cold contraction, maintaining stable sealing pressure and contact pressure for a long time, and there is no need to re-tighten the connector during the 30-year service life.
Compared with cross-linked EPDM materials that cannot be recycled, the LSR material used in the connector is a thermoset elastomer that can be crushed and reused as a filler for industrial rubber products after the end of its service life, reducing the environmental burden of power grid construction waste. The product does not contain heavy metals, halogens or other toxic substances, and meets the requirements of EU RoHS 2.0 and REACH regulations, suitable for power grid projects with green certification requirements.
The LSR high-voltage insulating connector is widely used in the following power system scenarios:
Select the connector specification according to the cross-sectional area of the connected cable and the rated voltage of the line:
For special cable sizes and non-standard connection structures, customized design services are provided, with a minimum order quantity of 50 pieces for customized products.
All LSR high-voltage insulating connectors are produced in strict accordance with the ISO 9001:2015 quality management system, and each production batch undergoes the following inspection procedures before delivery:
The product has obtained the following certifications: IEC 60502-2 compliance certification, GB/T 12706.4 national standard certification, UL 94 V-0 flammability certification, and EU RoHS 2.0 environmental protection certification. We provide a 3-year free warranty for all standard products, and a 30-year performance warranty for products used in power grid projects. If product quality problems occur during the warranty period, we provide free replacement and on-site troubleshooting services.