Electrical insulators with mechanical core and dielectric sheath

An electrical insulator for supporting an electrical conductor, comprising:

• a load sustaining mechanical core constructed of a dielectric material, and having a top end, a side, a bottom end with a mounting portion for coupling said mechanical core to a support member and a profiled core outer surface formed by said top end, said side and said bottom end, said profiled core outer surface comprising a first contour formed by said top end and said side of said mechanical core with a top groove formed therealong for supporting the electrical conductor, a second contour formed by said side of said mechanical core with a first groove formed therealong, a third contour located adjacent said second contour and formed by said side of of said mechanical core with a first radially extending rib, a fourth contour located adjacent said third contour of said mechanical core with a second groove formed therealong, and a fifth contour located adjacent said fourth contour of said mechanical core with a second radially extending rib;
• and
• an outer dielectric sheath overlying said profiled core outer surface, said dielectric sheath thinly coating said top groove, said first groove and said second groove of said mechanical core to form top, first and second recesses overlying said top groove, said first groove and said second groove, respectively, said dielectric sheath forming a first weathershed extending outwardly from said first rib of said mechanical core between said first groove and said second groove and a second weathershed extending outwardly from said second rib of said mechanical core adjacent said bottom end, said outer dielectric sheath having a profiled sheath outer surface with first and second contours overlying and being substantially identical in shape to said first and second contours of said mechanical core, respectively, a third contour formed by said first weathershed to overlie said third contour of said mechanical core such that said third contour of said profiled sheath outer surface has a different shape than said third contour of said mechanical core in that said first weathershed extends outwardly from said first rib at least three times farther than said dielectric sheath along said top, first and second grooves, a fourth contour overlying and being substantially identical in shape to said fourth contour of said mechanical core, and a fifth contour formed by said second weathershed to overlie said fifth contour of said mechanical core and having a different share than said fifth contour of said mechanical core in that said second weathershed extends outwardly from said second rib at least three times further than said dielectric sheath along said top, first and second grooves,
• said top groove of said mechanical core being a transverse top groove formed in said top end of said mechanical core so that the electrical conductor is adapted to be supported by said top end of said mechanical core when positioned within said first conductor receiving recess of said dielectric sheath, said first groove being a first side groove located between said top and bottom ends of said mechanical core, and said dielectric sheath thinly coats said first side groove of said mechanical core to form said first recess,
• said mounting portion of said mechanical core having an axially extending threaded bore.