Glass Fiber-Reinforced Phenol Formaldehyde Resin-Based Electrical Insulating Composites Fabricated by Selective Laser Sintering

Abstract

In this study, glass fiber (GF)/phenol formaldehyde resin (PF)/epoxy resin (EP) three-phase electrical insulating composites were fabricated by selective laser sintering (SLS) additive manufacturing technology and subsequent infiltration. In the three-phase composites, glass fibers modified by a silane coupling agent (KH-550) were used as reinforcements, phenol formaldehyde resin acted as the binder and matrix, and infiltrated epoxy resin was the filler. Mechanical and electrical properties such as tensile strength, bending strength, dielectric constant, electrical conductivity, and electric breakdown strength of the GF/PF/EP three-phase composite parts were investigated. The results indicated that after being infiltrated with EP, the bending strength and tensile strength of the GF/PF/EP composites increased by 30% and 42.8%, respectively. Moreover, the flexural strength and tensile strength of the GF/PF/EP composite increased with the increase of the glass fiber content. More importantly, the three-phase composites showed high electrical properties. Significant improvement in the dielectric constant, electric breakdown strength, and resistivity with the increase in the content of glass fiber was observed. This enables the prepared GF/PF/EP composites to form complex structural electrical insulation devices by SLS, which expands the materials and applications of additive manufacturing technology.

Phenol-Furfural Resin/Montmorillonite Based High-Pressure Green Composite from Renewable Feedstock (Saccharum munja) with Improved Thermo-Mechanical Properties

“…Phenol-formaldehyde (PF) resin, owing to its superb mechanical properties, chemical resistance, and thermal stability, has played an extensive role as engineered plastic in industry. PF resin is used on a large scale for the manufacturing of plywood where veneers or thin layers of wood are hot-pressed using PF as adhesive agents [ 6 , 7 ]. In the year 2004, the World Health Organization’s ‘International Agency for Research on Cancer’ marked formaldehyde as carcinogenic to humans.…”

PA12 Powder Recycled from SLS for FDM

“…Zhu et al [13] used a new method to prepare a high-performance SLS carbon fiber/polyamide 12/epoxy (CF/PA12/EP) ternary composite. Li et al [14] prepared a glass fiber/phenolic resin/epoxy resin (GF/PF/EP) three-phase electrical insulating composite material for SLS, and Yan et al [15] prepared a carbon fiber/polyamide-12 (CF/PA) composite powder. In SLS, the average total volume of manufactured parts is relatively small, between 5% and 15% of the volume of the manufactured article, which means that 85% to 95% of the material is not sintered and can theoretically be recycled [16].…”

“…Composite materials can be used for non-loaded bio-implant materials. Hao Li et al [14] used PA12 pellets and ABS pellets to produce filaments and printed test samples. Compared with amorphous ABS, FDM parts printed by semi-crystalline PA12 have better adhesive quality and higher tensile strength.…”

Reliability-Based Evaluation of the Suitability of Polymers for Additive Manufacturing Intended for Extreme Operating Conditions

“…With SLS, a powder bed fusion AM process, three-dimensional (3D) objects can be fabricated by adding powdered materials layer by layer according to computer-aided design (CAD) models [ 52 ]. The main advantage of SLS is that it can process an extensive scope of materials including polymers, metals, ceramics and composites.…”