PRODUCTS

InsuVolt®

Cast and Molded Epoxy

InsulVolt®

InsulVolt® is a proprietary formulation of epoxy resins, hardeners, accelerators and fillers for cast and molded epoxy components used in electrical applications.

In addition to conventional casting, CK has the equipment and capability to perform epoxy automatic pressure gelation (APG). This process uses heat and pressure, usually with a steel mold, to achieve rapid cure time and superior surface quality. CK has produced weather cases of epoxy using APG, with individual part weights of up to more than 100 pounds. APG is best suited for parts with high production volume. CK has several large-capacity molding machines for performing APG. Another name used for APG is expose liquid injection molding (LIM).

We can assist in your effort to replace damaged or worn bushings. CK has the ability to reverse engineer, replicate and replace your original insulators, design and tested thru 69kV.

Bis-a and Cycloaliphatic Systems

CK’s cycloaliphatic resin systems produce insulators which are non-tracking, self-scouring and non-weathering for outdoor applications. C-K’s Bisphenol resin systems produce extremely high strength insulators.

Vacuum Casting

Many cast and molded epoxy parts are poured and processed in a vacuum to minimize voids and assure a strong bond between epoxy and metal. CK has extensive equipment for performing vacuum casting, including large capacity vacuum pumps and vacuum chambers. Finished parts are oven cured to achieve specified mechanical properties. Final operations include careful cleaning, inspection, and testing.

APG-Liquid Injection Molding

In addition to conventional and vacuum casting, CK has the equipment and capability to perform epoxy automatic pressure gelation (APG). This process uses heat and pressure, to achieve rapid cure time and productivity. CK has produced tens of thousands of bushings, spouts, and insulators using APG which is best suited for parts with a high production volume. CK has several large-capacity molding machines for perfuming APG.

Product Advantages

Many cast and molded epoxy parts are poured and processed in a vacuum to minimize voids and assure a strong bond between epoxy and metal. CK has extensive equipment for performing vacuum chambers. Finished parts are oven cured to achieve specified mechanical properties. A properly designed single epoxy casting or molding can often replace an assembly of parts of other materials such as porcelain, high-pressure laminates, tapes and metals. Final operations include careful cleaning, inspection, and testing. 

  Low-cost Part Replacement

  Weather Resistant

  Improved Quality

  Molded Void Free

Common Areas of Application

Molded Insulators for high, medium, and low voltage applications

      • Circuit Breakers
      • Switch Gear
      • Furnace, Power & Distribution Transformers
      • Standoff Insulators
      • Tap Changers
      • Custom Bushings
      • Power Supply Equipment
      • HV DC Equipment
      • Corrosion-Resistant Applications
      • Primary and Secondary Bushings
      • Roof Entrance Bushing
Technical Data

 InsulVolt

WHY CHOOSE CK COMPOSTIES

Over 65 Years of Experience

At CK Composites, our engineers and technicians are able to help customers in a wide range of industries solve problem applications using our line of custom composite solutions.

Made in the USA

Since the 1950's, we have been supporting the electrical, oil and gas, medical, defense, transportation and waste water industries with proven, innovative composites and engineering solutions.

Quality Assurance

Quality assurance procedures include testing and inspection of incoming raw materials, in-process inspection and both destructive and non-destructive material testing.

Precision Machining

We have a complete machine shop with precision milling, routing, turning and assembly capabilities. We ensure efficiently produce parts with the proper fit and finish required. 

InsulVolt

Application Examples

InsulVolt® Tap Changers

We manufacture a wide range of custom cast and molded tap changers for the electrical industry. Metal conductors and other metal inserts can be included as an integral part of the casting. 

InsulVolt® 6 Pt. Terminal Blocks

We manufacture a wide range of custom cast and molded tap changer panels for the electrical industry. Metal conductors and other metal inserts can be included as an integral part of the casting. 

InsulVolt® Insulators

CK Composites has manufactured tens of thousands of molded bushings, molded spouts, and molded insulators using APG which is best suited for parts with a high production volume. Liquid Injection Molding (LIM) allows the molding of complicated shapes, ranging up to fifty pounds in weight, and void free. These parts are ideal for power apparatuses and transformers for the electrical industry.

InsulVolt® Specialized Suspension Insulators

Manufactured specialized insulators for electrified railways.

InsulVolt

Manufacturing Process

The process of custom-engineering electrical components begins with the proprietary formulation of epoxy resin, hardeners, accelerators, and fillers, including our new toughened resin systems. Our polymer chemist can match your product needs with the strength, durability, and chemical resistance of the right resin system.

Electrical insulators from 5-69 kV in Bis-A or Cycloaliphatic epoxy resins are tested to ensure outstanding performance characteristics. Using computerized electrical field plot analysis, our engineers work with you to design your component, the mold, conductors, or other inserts to meet your quality requirements.