Manufacturing Process

(1) Low pressure laminates :

Low pressure laminates typically use a glass mat substrate. Typical resins used in the low pressure laminate manufacturing process include polyester, vinyl ester, and epoxy. The process produces an excellent combination of mechanical strength, dielectric properties, and thermal performance. One advantage of the low pressure laminate manufacturing process is the ability to use a variety of fillers and additives to create a range of desirable properties from flame retardance to track resistance.

The manufacturing process for our low pressure thermoset laminate sheet materials begins with the selection of the proper resin formulation to provide the properties required for a specific application. Low pressure laminates are typically made following the same basic steps as follows:

The low pressure laminate manufacturing process is considered to be more cost effective than the high pressure laminate process due to the faster cycle time from the beginning of the process to the end of the process. With composite materials, there are always trade-offs among the properties of the various materials depending, in part, on the manufacturing process.

Characteristics		SMITHERM - SM14	SMITHERM - SP14
MICA TYPE		MUSCOVITE	PHLOGOPHITE
COLOUR		WHITE CREAM	BROWN
MICA CONTENT	% Min	90	90
RESIN CONTENT	% Max	10	10
DENSITY	Gm/cm3	2.0~2.2	2.0~2.2
HEAT RESISTING CONTINUOUS	°C	500	700
HEAT RESISTING INTERMITTENT	°C	800	1000
DIELECTRIC STRENGTH @23°C	KV/mm	>20	>18
EDGE STRENGTH	Kg / 0.1MM	1.3	0.9
TENSILE STRENGTH	N/mm2	140	100
FLEXURAL STRENGTH	N/mm2	180	150
WATER ABSORBATION	%	<1	<1
Data are average results of laboratory tests conducted under standard procedures and are subject to Variation, These do not constitute a warranty or representation for which we assume legal responsibility

(2) High pressure laminates :

High pressure laminates may use several substrates such as kraft paper, mica paper, canvas or linen (cotton) cloth, or glass cloth. Typical resins used in a high pressure laminate manufacturing process include phenolic, epoxy, melamine, silicone, and polyimide. The process produces outstanding mechanical strength, especially in compression. High pressure laminates also have excellent dielectric strength and related electrical properties. Each combination of substrate and resin provides a different set of properties

The manufacturing process for our high pressure thermoset laminate sheet material begins with the selection of the proper substrate and resin for the particular application. All high pressure thermoset laminates follow the same basic process as follows:

Though a longer process cycle than the low pressure laminate manufacturing process, the higher mechanical strengths and unique properties generally produced by the high pressure laminate manufacturing process allow for specific performance characteristics required by many demanding applications.

Material Description, Grade	Temp Class	General Description	Common Applications
Canvas Phenolic, NEMA CE	130 C	General purpose laminate primarily used for mechanical applications requiring basic dielectric properties.	Bearing housings, motor and generator wedges, wear plates, gears, and trunnions.
Linen Phenolic, NEMA LE	130 C	Fine weave cotton cloth laminate primarily used for mechanical applications requiring improved machining properties.	Gears, trunnions, terminal strips, and various punched parts.
Paper Phenolic,NEMA , X, XX, & XXX	130 C	Kraft paper based laminate primarily used in transformer applications requiring excellent dielectric properties with good oil compatibility.	Tap changer boards, terminal strips, fuse boards, phase barriers, lead clamps, and conduit tubes.
Arboron Paper Phenolic Laminate	105 C	General purpose paper phenolic laminate with arc resistant melamine surface.	Fuse support boards, terminal strips, transformer coil supports.
Glass Melamine, NEMA G-5 & G-9	130 C	Glass cloth based laminate with excellent dielectric and arc resistance properties. Very good mechanical strength.	Motor topsticks and wedges, switchgear terminal boards, and fuse insulators.
Glass Silicone, NEMA G-7	220 C	High temperature glass cloth laminate with excellent dielectric and arc resistance properties at elevated temperatures.	Electric furnace insulation components, circuit breaker arc chutes, bus tube clamps.
Glass Epoxy, NEMA G-10	130 C	General purpose glass cloth based laminate with excellent mechanical strength and good electrical properties. Not flame retardant and thus, a non-brominated material.	Motor and generator wedges, transformer coil supports, terminal boards. Material for non-brominated requirements.
Glass Epoxy, NEMA FR4	130 C	General purpose glass cloth based laminate with excellent mechanical strength and good electrical properties. Most commonly a brominated flame retardant resin system	Motor and generator wedges, transformer coil supports, terminal boards. Contains brominated flame retardants in most grades so care should be taken in using this material.
Glass Epoxy, NEMA G-11	180 C	High temperature version glass cloth based laminate with temperature resistance up to 180C. Excellent mechanical strength.	Motor and generator wedges, dry type transformer terminal boards.
Silicone Bonded Mica Laminate	500 C	Highest temperature thermoset laminate with very good mechanical and electrical properties.	Electric furnace insulation, high temperature appliance components, arc chutes.
Epoxy Bonded Mica Laminate	180 C	General purpose mica base laminate with excellent electrical properties. Limited mechanical strength versus glass laminates.	Resistor insulators, fuse element supports, dry type transformer insulation.