High-voltage insulating silicone rubber drives smart grid upgrades toward "efficiency, intelligence, and sustainability" through lightweight design and intelligent function integration. In UHV transmission, silicone composite insulators reduce tower loads significantly (1/5 to 1/3 the weight of ceramic insulators), cutting steel usage and construction costs. For example, in a 1000kV AC project, lines using silicone insulators lowered tower height by 15%, reduced concrete foundation volume by 20%, and saved approximately ¥800,000 per kilometer in total costs.

For intelligence, silicone rubber integrates sensors for condition monitoring. Conductive silicone coatings or embedded fiber-optic sensors on insulators enable real-time tracking of temperature, humidity, and partial discharges, enabling early warnings of aging or faults. A company’s "smart silicone insulator," deployed in 500kV substations, features temperature/humidity sensors (accuracy ±0.5℃) and partial discharge detection (sensitivity <1pC), slashing fault response times from hours to minutes versus traditional inspections.

Moreover, silicone rubber’s processability supports complex structure manufacturing. 3D printing directly shapes it into irregular insulators (e.g., live display devices, bird-deterrent units), shortening R&D cycles and reducing mold costs. A power equipment manufacturer used silicone 3D printing to cut development time for a new lightning-proof insulator from 6 months to 2 weeks, while lightweighting it by 25% via topology optimization, enhancing competitiveness.

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