Manufacturing process for surge arrestor module using compaction bladder system

A method of producing a surge arrestor module, comprising:

• providing a plurality of MOV blocks arranged in a stack;
• surrounding the stack with an uncured epoxy-reinforced structural layer;
• after the applying, inserting the stack into a flexible bladder that is located in an outer tube structure;
• and
• curing the epoxy-reinforced structural layer with elevated temperatures while the flexible bladder applies radially aligned pressure to the stack and a tool applies axially aligned pressure to the stack, the radially aligned pressure being due to air pressure between an outer surface of the flexible bladder and an inner surface of the outer tube structure.

An apparatus for producing a surge arrestor module, comprising:

• an outer case structure having an inner surface and an outer surface, the inner surface forming a hollow region, the outer case structure including a port that provides access to the hollow region;
• a flexible bladder located within the hollow region, the flexible bladder being sized and configured to receive the surge-arrestor stack, the surge arrestor stack having a plurality of MOV blocks and a layer of epoxy-reinforced structural material on exterior surfaces of the plurality of MOV blocks;
• and
• a pressure source for delivering pressurized air into the hollow region of the outer case structure via the port, the pressurized air forcing the flexible bladder to compress against the surge-arrestor stack while the epoxy-reinforced structural material cures.

A method of producing a surge arrestor module, comprising:

• providing a plurality of MOV blocks arranged in a stack;
• applying an epoxy-fiberglass layer to surround an outer surface of the stack;
• placing the stack with the applied epoxy-fiberglass layer into a flexible bladder;
• applying heat to create a curing temperature that is greater than 200° F.;
• while the epoxy-fiberglass layer is curing around the outer surface of the stack, applying pressure to the flexible bladder to generate a compressive force to the epoxy-fiberglass layer and the stack;
• and
• after the curing, releasing the pressure to the flexible bladder, and removing the stack with the cured epoxy-fiberglass from the flexible bladder.