Xylok resin was synthesized from 1,4-bis(methoxymethyl)-benzene and phenol through a condensation reaction catalyzed by p-toluenesulfonic acid. The effects of molar ratio of phenol to 1,4-bis(methoxymethyl)-benzene, reaction time and washing process on the properties of Xylok resin were investigated. Xylok composite laminates reinforced by quartz cloth were fabricated by vacuum bag only (VBO) process. Softening point of Xylok resin and volatile content of prepreg and voids in composites were also studied to better control process defects in composite laminates. Void content was measured by image analysis and calculating parameters. Experimental results showed that the Xylok composite laminates manufactured by VBO process had good thermal and dielectric properties. The flexural strength and flexural modulus of laminates could be 733 MPa and 23 GPa, respectively.
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