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Basalt fiber and its resin composites have gradually supplanted traditional steel and glass fiber composites due to their superior strength, heat resistance, and corrosion resistance. However, basalt fiber still has significant flaws that restrict the functionality and use of its composites, such as less active functional groups and poor resin adherence. This study examines the effects of sizing agent on the characteristics of basalt fiber/epoxy resin composites. Epoxy resin emulsion and acrylate emulsion are employed as the primary auxiliary film-forming agents in this study. Polyurethane emulsion with various content levels is also used. The findings indicate that a 1% wt. of polyurethane emulsion concentration produces the greatest results, increasing the composite’s flexural strength, flexural modulus, tensile strength, and interlaminar shear strength by 122%, 34.0%, 102%, and 10.2%, respectively. At the same time, the storage modulus and Tg of the material will decrease. In addition, the breakdown strength can be raised by 112%, and insulation parameters such as leakage current and dielectric loss factor can be decreased by 26.4% and 15.6%, respectively. The effect of sizing agent B is the best.

As basalt fiber has better mechanical properties and stability than glass fiber, cross arms made of continuous basalt-fiber-reinforced epoxy matrix composites are capable of meeting the mechanical requirements in the event of typhoons and broken lines in coastal areas, mountainous areas and other special areas. In this paper, continuous basalt-fiber-reinforced epoxy matrix composites were used to fabricate the core rods and composite cross arms. The results verified that basalt fiber composite cross arms can meet the strict requirements of transmission lines in terms of quality and reliability. In addition to high electrical insulation performance, the flexural modulus and the flexural strength of basalt fiber core rods are 1.8 and 1.06 times those of glass fiber core rods, respectively. Basalt fiber core rods were found to be much better load-bearing components compared to glass fiber core rods. However, the leakage current and the result of scanning electron microscopy (SEM) analysis reveal that the interface bonding strength between basalt fibers and the matrix resin is weak. A 3D reconstruction of micro-CT indicates that the volume of pores inside basalt fiber core rods accounts for 0.0048% of the total volume, which is greater than the 0.0042% of glass fiber rods. Therefore, improving the interface bond between basalt fibers and the resin can further improve the properties of basalt fiber core rods.