Basin‐type insulators are made by epoxy resin composite materials. Curing defects are easily formed in basin‐type insulators, and degrade their insulating performances. High curing exothermic rates of epoxy resin composite materials have deemed as the main cause of curing defects formation. In this study, methyl tetrahydrophthalic anhydride (Me‐THPA) was used to extend the molecular chain of liquid epoxy resin to prepare epoxy resin composite materials with low curing exothermic rates. Curing exothermic properties, molecular weight distribution, curing stress, microstructures, and surface flashover characteristics of the composite materials were investigated. The results showed that chain‐extended epoxy resin had low curing exothermic rates. The curing stress of the chain‐extended epoxy resin composite materials was small. The curing defects forming in the composite materials were inhibited. Negative DC surface flashover characteristics of these composite materials were improved. Furthermore, variation of functional groups of the composite materials was studied before and after surface flashover tests. Results showed that the content of carbon–oxygen single bonds (–C–O) in the chain‐extended epoxy resin composite materials was observed to decrease. The –C–O bonds also affect the voltage withstand capability of the epoxy resin composite materials.
Phenolic resin systems generate water as a reaction by-product via condensation reactions during curing at elevated temperatures. In the fabrication of fiber reinforced phenolic resin matrix composites, volatile management is crucial in producing void-free quality laminates. A commercial vacuum-bag moldable phenolic prepreg system was selected for this study. The traditional single-vacuum-bag (SVB) process was unable to manage the volatiles effectively, resulting in inferior voidy laminates. However, a doublevacuum-bag (DVB) process was shown to afford superior volatile management and consistently yielded void-free quality parts. The DVB process cure cycle (temperature /pressure profiles) for the selected composite system was designed, with the vacuum pressure application point carefully selected, to avoid excessive resin squeeze-outs and achieve the net shape and target resin content in the final consolidated laminate parts. Laminate consolidation quality was characterized by optical photomicrography for the cross sections and measurements of mechanical properties. A 40% increase in short beam shear strength, 30% greater flexural strength, 10% higher tensile and 18% higher compression strengths were obtained in composite laminates fabricated by the DVB process.
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