This study aimed to prepare a new lightweight ultra-high-voltage insulator core filler composite, which can solve the problem of bulkiness. In this study, rigid polyurethane foam pellets with different densities are used as lightweight fillers and polyurethane resins to compound lightweight composite materials. On accounting for working conditions, the density, insulation, heat resistance, water absorption and mechanical properties are tested. The compressive properties of composites are determined by a foam skeleton and a process. Among three kinds of composites, in which the composites with the best comprehensive performance are materials filled with pellets to a density of 0.15g·cm-3. The density, surface resistance, volume resistance, leakage current, initial decomposition temperature, water absorption, force, rupture displacement and limiting oxygen index (LOI) of composites are 0.665 g·cm-3, 1.17 × 1014 Ω, 9.68 × 1014 Ω·cm, 0.079 mA, 208 °C, 0.047%, 2262 N, 2.54 mm, and 23.3%, respectively. The ultra-high-voltage insulator core filler in this study can reduce the weight of the solid core insulator crossarm for Ultra-High Voltage (UHV) by 50-75%.
Keywords: composite materials; lightweight; polyurethane; thermosets; ultra-high-voltage insulator core filler.