Surge arresters and related assemblies and methods

A method of assembling a surge arrester, the method comprising:

• forming at least a portion of a cage by connecting a first end of each of a plurality of rods to a first end fitting;
• receiving a stack of a plurality of varistor elements between the plurality of rods such that a first end surface of the stack is at the first end fitting;
• connecting a second end of each of the plurality of rods to a second end fitting;
• forming a fill layer around the stack of the plurality of varistor elements and around the plurality of rods to thereby form a varistor assembly, wherein the fill layer completely surrounds an outer side surface of the stack extending between the first end surface of the stack and an opposite second end surface of the stack and extends between the first end fitting and the second end fitting, and wherein the fill layer completely surrounds each of the plurality of rods;
• and
• receiving the varistor assembly in a first channel of a polymer surge arrester body,
• wherein the polymer surge arrester body comprises an electrically insulating inner layer and an electrically conductive outer layer,
• wherein each of the plurality of rods is spaced apart from the polymer surge arrester body, and
• wherein the first channel has a first diameter that is greater than a second diameter of the stack.

A surge arrester comprising:

• a polymer body comprising:
• a first leg having a first channel defined therein;
• and
• a second leg perpendicular to the first leg and having a second channel defined therein, the second channel configured to receive a bushing;
• a varistor assembly in the first channel, the varistor assembly comprising:
• a plurality of varistor elements electrically connected in series and forming a stack of the plurality of varistor elements, wherein the stack has a first end surface, a second end surface, and an outer side surface extending between the first end surface and the second end surface;
• a first end fitting at the first end surface of the stack;
• a second end fitting at the second end surface of the stack;
• a plurality of rods disposed around the outer side surface of the stack, each of the plurality of rods comprising a first end that is connected to the first end fitting and a second end that is connected to the second end fitting;
• and
• a polymer fill layer between the outer side surface of the stack and the first leg of the body,
• wherein the polymer fill layer completely surrounds the outer side surface of the stack and extends between the first end fitting and the second end fitting,
• wherein the polymer fill layer completely surrounds each one of the plurality of rods,
• wherein the polymer body comprises an electrically insulating inner layer and an electrically conductive outer layer,
• wherein each of the plurality of rods is spaced apart from the polymer body, and
• wherein the first channel has a first diameter that is greater than a second diameter of the stack.