Document dYJv6Mp15gvZXe75jZOq4oDnR

Insulation PLAINTIFFS EXHIBIT E-45 JUar MU Directory IEncyclopedia Issue A complete, comprehensive source of information on insulation ?A*T 3--PRODUCT INFORMATION Section 3-18: Magnet Wire Xeu; Developments 4 DuPont has taken the wraps off its high temperature wire enamel previously known only as "ML" polymer and has revealed that the enamel is based on a polyimide poly mer. The enamel was the only ML product described in last year's issue bu; this issue also includes informa tion on polyimide coated glass fabrics (section 3-7) and polyimide varnish (section 3-12). Thus, insulation sys tems using all three materials can be developed. A composite film combin ing the advantages of a polyimide film next to the conductor and an outer polyvinyl formal film is also available. 4 Apparently, a great deal of prog ress has been made in the long search for a practical ceramic or glass in sulated wire for temperatures ap proaching or above the 500C level. At least two such radiation resistant products have been announced. Bv combining an inorganic material with a heat volatile organic polymer used as a binder, a wire coating is achieved which has the flexibility and strength needed for handling and winding. After volatizing the organic binder with heat, the fused inorganic film layer is left on the winding. The con ductor is an oxidation-resistant clad ding over copper. Author Credit This section was prepared by Harry L Saums, Consulting Engineer, Ana conda Wire & Cable Co., Muskegon, Mich., under the auspices of the Wire and Cable Division, National Electri cal Manufacturers Association. The listings of enameled wires and of fiber and paper-covered wires give the following information: A brief description of the composi tion of the insulating covering. This has been kept as simple as possible. In some cases the chemical composi tion has been defined in order to in sure identification of the insulator. Trade names such as "Formvar," "ML." etc., are used if these materials are available to all magnet wire makers. Usually the conductor is copper but in some cases nickel or silver-plated or clad copper is used and mentioned. No attempt has been made to indicate where aluminum can be used. Most of the insulations can be applied to aluminum conductors. Prospective users of aluminum magnet wires should discuss their problem with a magnet wire maker. Sfoadords and Specifications Round copper wires are made to comply (where applicable) with the latest issue of American Standards Specifications for soft or annealed copper wire number C7.1. Square and rectangular wires are made to comply (where applicable) with the latest issue of American Standards specifications for soft cop per wire number C7.9. The thermal classification is given using the nomenclature of the issue of AIEE No. 1 June 1957 entitled "General Principles upon which Tem perature Limits are Based in the Rat ing of Electric Equipment." For ex ample, 105C (class A). The assigned class is that believed to be accepted in the industry. In most cases the class assigned in the NEMA standard is used. If there is no NEMA standard, the class stated is from the published work of com petent authorities who have evaluated the wire in accordance with "Test Procedure for Evaluation of the Ther mal Stability of Enameled Wire" which is AIEE Publication No. 57. Or as provided in AIEE #1, the assignment is on the basis of experi ence in actual use. There is no central authority for the assigning of a temperature class to any magnet wire. Therefore, the information given for each wire is only the best data that can be ob tained. In some cases such as cotton, for example, the rating is specifically stated in AIEE #1. The ratings given are for use of the wire in free air. Higher tempera tures may be used in suitable gases, liquids, and solids. For example, wires used in hermetic motors may be oper ated at higher temperatures than the assigned class. Sealed systems em ploying air are subject to aging fac tors that depend upon the specific apparatus and the insulation svstem. Discussion of this is beyond the scope of this article. The publication number of the ap plicable NEMA standard is given. If the specification has been accepted by the American Standards Associa tion, the number and year of issue are stated. NEMA magnet wire standard num bers may apply to those which have been accepted by ASA and those which have met all NEMA require ments relating to these standards but have not been accepted bv ASA due to the time required for action but which are in a sufficiently advanced state of preparation by NEMA that they can be used. The Military Specification data are .. taken from the 15 December 1959 issue Amendment 1. This specificstion (MIL-W-583B) requires that all ; enameled wires intended for classes '' 130, 155, 180. and 200 be approved before production and delivery to the military agencies. This is done bv letter. The preproduction tests need not be repeated for individual lots. Wire makers can supply copies of their approval letters. The fact that this approval is necessary is stated jr for each wire to which it applies. Comment* Availability of the wires is given based on information taken from many sources. Magnet wire makers' catalogs, NEMA specifications, pub- 300 Insolation Directory/Encyclopedia Issue, May, 1962 r*!>vi,^vv'k;v>vK lished papers, and advertisements were consulted. Makers differ greatly in the kind and size of wires which they will furnish. The data given in the listing are generally those consid ered to be available from more than one maker. Wires which do not come within the listing may be available from some makers. Comments are given as to the in tended or established use of the wire. An effort has been made to keep the comments as short and concise as possible. Outstanding advantages and disadvantages are given. Tbe entire idea is to make the comments as short and useful as possible. It is impossible to answer every question that a user might desire to ask The present com plexity and size of the electrical in dustry are recognized by most magnet wire makers who offer technical in formation and service to engineers and manufacturers or users. Consult the maker of your choice. No attempt has been made to in clude the voluminous data regarding performance characteristics, dimen sions, and methods of tests. All of these data can be obtained by consulting the specifications or obtained from magnet wire makers. Actually, the characteristics of the wires described fit them for proper use in their respective fields. No one wire is completely best in all char' acteristics. Each may have one or more outstanding features. And no one wire can be used in all electrical devices. Packaging The packaging of magnet wires is now an extensive subject. Wires are offered on spools or reels and in pails and drums. In general, the round wires are put on spools in keeping with their size and other character istics. The smaller the wire, the smaller the spool. To conserve wind er's time, some round wires are pack aged in 100 pound pails or in drums containing as much as 800 pounds. Here too, the size of the wire is a governing factor in the selection of a usable pail or package. Square and rectangular wires are always put on reels. The most common reels are those with 12-inch and 24-inch flanges. Round wires are random wound on spools or reels. The round wires are put into the pails and on reels following a carefully designed pattern. In all cases the wire is so packaged that it will reach the user in good condition and be capable of proper removal from tbe package by the winding process. ENAMEL AND FILM C04TFD WIRE Acrylic r'Lecfojj"--Poet) Basic resin is a copolymer of acry lonitrile plus acrylate and phenolic resin. The enamel film is applied from an aqueous dispersion. Thermal Classification -- 105C (class A). NEMA Standard MW 4. Military Specification. Not specifi cally covered in MIL-W-583B. Avail able in round wires, grades single, heavy and triple. The insulating film is resistant to refrigerants and many solvents. It re sists refrigerant R-22 and is used in hermetic sealed motors where the re frigerant is in contact with the wire. The temperature rating given as 105C (class A) applies to use of the wire in air. In hermetic motors con taining refrigerants this rating may be exceeded. Ceileiose Loeqeer Coating resin is based on cellulose acetate. Thermal Classification--105C (class A) NEMA Standard--None. Military Specification--None. Not covered by MIL-W-583-B. Available in round wires, sizes 36 Awg and smaller. Coating thickness in 3 grades. Thinnest for paper-filled coils, medium thickness for general random winding, and thickest grade for severe winding conditions. Chief advantage is that film may be soldered through using alcohol rosin flux and tin-lead solders at moderate temperatures. Ceromic The inorganic insulating film is composed largely of metallic oxides. This is deposited on various conduc tors such as copper, nickel-clad cop per, or other metals over copper to prevent oxidation of the copper. Thermal Classification -- Depends 302 Insulation Directory/Encyclopedia Issue, May, 1962 upon the particular coating and con ductor. Some constructions mav be? operated as higb as 500C. NEMA Standard--None. Military Specification--None, sine not specifically covered in MIL-W- 583B. " ' Available in a limited range of j round wires. In general, sizes 20 Awg * and finer. No standards on insulation thicknesses have been developed. 2, Used where high temperature or * nuclear radiation may be present. Since this is a new development in : a field that is growing rapidly, the * user should obtain specific informa tion from the supplier. JjJ Ceremie-Coavenioa Typo f* The insulating film is an organic enamel with ceramic or glass mate- ; rials dispersed throughout. It is t smooth and glossv and generally re- sembles the familiar enamels. The conductor is an oxidation-resistant . cladding over copper. Thermal Classification -- 500C. No assigned class. -v NEMA Standard--None ( Military Specification--None Available in round sizes si 18 to sr40 Awg inclusive. Grades single. '* heavy, and triple in as-received con dition. - Windings are made with this wire . in the usual manner. The bobbins or * other parts of the insulation svstem must be inorganic. After the coil is * finished it is heated sufficiently to drive off all the organic portion of ^ the film and to sinter or fuse the ceramic particles into a continuous insulating film. The maximum tern- * perature reached is above the 500C j rating. > The wire can be used in anv elec-4 trical device where high temperature operation is needed. _ Ceramic with Polytotrotlooroothylono ^ Overcoat 3jf The insulation is a ceramic film j deposited on a conductor of copper,-* or copper protected by a coating of ? nickel or other metal. A coating of 2 polytetrafiuoroethylene ("Teflon"-Du- Pont) is applied as an overcoat. Thermal Classification--Class 220 C. NEMA Standard--MW-8. Military Specification -- MIL-W- Print ID/E 69 am Reader Service 1 *[. - -1* .'.i-1 1 v * mi < 1 .' 1 first composite enamel insulations. in previous listings. wrapped insulation but generally Thermal Classification -- 105C Thermal Classification--180C (class somewhat lower. (class A). NEMA Standard--MW-17. H) NEMA Standard--None Cotton Yarn Military Specification -- MIL-W- Military Specification--None The insulating covering is made of 583B. Class 105--types T, T2, T3, Availability is generally the same one or more servings of cotton yam. and T4. as for the standard polyvinyl formal Thermal Classification--If not im Available in round sizes, 8 Awg to (Formvar) wires in all shapes-- pregnated. 90C (class 0) ; if impreg 46 Awg, and in grades single, heavy, round, square, and rectangular--all nated. 105C (class A). and triple. grades and sizes. This is a very recent NEMA Standard--Round Wires-- ' This composite enameled wire com development- so specific statements of MW-U; Rectangular Wires--MW-12. r bines the characteristics of the two what can be secured cannot be made Military Specification -- MIL-W- resins. The nylon improves the wind- at this time. 583B--Class 90. types C. C2. r ability and the choice of impregnat This newly developed magnet wire Available in round sizes--4/0 Awg ing varnishes. The windings can be combines the good properties of both to 36 Awg and in ah sizes, square and dipped while hot into varnishes hav of the kinds of coating to present a rectangular. Single and double served. ing strong solvents. It is used prin unique magnet wire of high thermal This, the oldest magnet wire, is cipally in rotating equipment that stability. It has excellent heat and used where space separation of the requires the cured varnish to be hard solvent shock resistance. The thermo conductors is required and where and strong in order to withstand high plastic flow point is high. It has out complete penetration of insulating rotational speeds. standing resistance to burnout. It has varnishes, compounds, or oils is de Po/yviny/ forma/ with Polyvinyl Bufyral Overcoat /5a/f*6ood/gJ high resistance to hydrolysis. The polyvinyl formal on the outside con tributes the excellent windabilitv for sired. Gloss f/bar, Organic Said Composite enamel magnet wires which it is well known. The "ML" The insulating coating consists of having a polyvinyl formal film next undercoat contributes the thermal one or more servings of glass fibers to the conductor and a polyvinyl stability of this polymer. Mav be used bonded with an organic vamish. The butvral overcoat. in any electrical equipment. composition of the vamish varies but Thermal Classification -- 105C (class A). FIBER AMD COVERED WIRE & NEMA Standard--MW-19. Atbesfos fiber usually is based on phenolic resins. Thermal Classification--155C (class F). Military Specification--None. Insulation consists of a layer of NEMA Standard--Round Wires-- Available in round sizes, 10 to 44 resin impregnated asbestos fibers. The MW-41; Rectangular Wires--MW-42. Awg. Made in three grades or types. outer surface may be vamish treated Military Specification -- MIL-W- Grades 1. 2. and 3. The single, heavy, or coated with an adhesive. 583B. Class 130, types GV, G2V. and triple undercoats have a single Saturants for 130C (class B) are Available in round sizes 2/0 Awg overcoat making the total film thick phenolic or asphaltic. to 40 Awg and in all sizes, square and ness equal to heavy, triple, and quad Saturants for 180C (class H) are rectangular. Single and double served. ruple. silicone. This wire is used in a wide variety The overcoat is a thermoplastic The felted asbestos insulation is of apparatus designed to operate at resin used to cement or bond the turns applied to the conductor by employ the class temperature, 155C. The in a winding together. This can be ing adhesives, a card, and sizing dies. glass acts as a spacer between turns. done by heating the coil after it is Thermal Classification -- 130C Being varnished, it is readily treated wound by passing current through the (class B) with phenolic or asphaltic by impregnating varnishes. Insula coil. The wire can be wet with a sol varnish; 180C (class B) with sili tions made of glass fibers are avail vent while being wound. This acti cone varnish. able so that a suitable insulation sys vates the overcoat. The solvent escape NEMA Standard--None. tem can be made. can be improved by heating the coil. Military Specification -- MIL-W- The wire is particularly useful in Used in complicated coils which 583B, class 130, type AV. Note--this dry type transformers and in rotating must be self supporting. Also to elimi specification may require special han machines. nate bobbins in encapsulated coils. dling by the wire maker. Polyvinyl forme/ with "ML" Undercoat Available in round sizes #2 Awg to 25 Awg. Rectangular and square Glass fiber, Organic Bond With Disported Ceramic filler This composite film wire has a coat 2400 to 166.000 square mils. The insulation consists of one or ing of "ML" next to the conductor. The outer coating is of polvvinvl Used primarily in a-c generator stator windings or apparatus sub more servings bonded with a vamish in which ceramic or glass powder is formal. The film thickness propor jected to overioad. Coating is tough thoroughly dispersed. The conductor tions are about 259b "ML" and 75% polyvinyl formal. Here the polvvinvl formal coatings may be anv of those and withstands high pressures. Space factor similar to double cotton. Dielec tric strength comparable to served or is copper-core with an oxidation pro tective cladding. The varnish is com pletely fugitive when heated suffi- 312 Insulation Directory/Encyclopedia Issue, May, 1962 '' > > .. .................... ,, V or endure the winding hazards satis factorily. The table gives the useful combina tions stating the availability as round and rectangular wires including square as a rectangle. The data given under the individual listings apply to the combinations. In most cases where the individual wires are covered by the stated specifications the combina tions are also mentioned. UTZ WIRE Originally, as designed by Litz, this was a conductor consisting of a plurality of enameled strands trans posed continuously along its length. It was intended to be used in winding coils having the best time constant, ft). . The term is used today in refer ence to wires of this type and also wires with limited transposition of the strands. The enamel used is usually poly urethane because it is solderable. Two or more wires may he laid parallel or twisted and covered with textile threads such as rayon, nylon, silk. etc. Or the wires, if parallel, are covered with an enamel. No specifications, except those pri vately issued, are published. The wire is usually available in fine sizes and a few strands. It is used in winding coils intended for use at high frequencies. Acknowledgment In addition to author Harry L. Sauins of Anaconda Wire & Cable Co.. Muskegon, Mich., the editors are indebted to the fol lowing persons who voluntarily commented on. reviewed, or made suggestions for this section: H. F. White. Sprague Electric Co., Bennington, Vt.; Richard S. Hayes, The Okonite Co.. Passaic, NJ.; D. E. Wiesenberg and Ralph Hall, Phelps Dodge Copper Products Corp., Inca Mfg. Div., Fort Wayne. Ind.; and Charles L. Wiley, Gen eral Cable Corp., New York. SUPPLIER DIRECTORY LISTING NOTE: Numbers in parentheses following each product covered in this section correspond with the numbers shown in front of each supplier of products listed here (thus indicating which firms supply the product concerned). Only comoorty names ore listed here--see Port t, section 4-1. for addresses of suppliers. Bold face type indicates advertisers^-tee advertisers' listing at. boe* of book for page numaers of advertisements. Products Covered in His Section Enemel and Rim Coated Wire Actyuc~(6. 10, H, it K 22. 23) Aluminum ox>de (aluminum conauctor oni,j (19.22) Cellulose uccuer (7) Ceramic (12. 20. 2l. 2<. 25 . 26) Ceramic-conversion type (26) Ceramic with poiyimide (formerly fraoenemed "ML" resin) overcoat (2S, 26) Ceramic with polytetrafluoroethylene overcoat (2S. 26) Ceremic with siiicone overcoat (2S. 26) Chrome orioe fiiiea enemei. inorganic bond (22) Epoxy U. 2 6 ?. 8. 10. )!. 12. 18 , 20. 22. 23 . 30) Epoxy with seif-bonding epoxy overcoat ((, 6, II. 12, 20. 22: Epoxy modifiea with polyester (6. 22) Nylon (I. 6. 7. 8, 9. 10, II. 12. 13. U. IS. 18, 20 22. 23. 29. 30) Oleoresinous (I, 3, 6, 8. (0, II, 12. IX, 17, 18, 20. 22. 23. 29. 30) Poiyimide (formerly traaenamed "ML" resin) (5, 7. II. 12, ix. IS. 18. 22, 23. 25. 26. 29, 30) Polyester (l, 5. 6, 7 8. 10 U, 12 13, IX IS, 18, 20 22 , 23 , 25 , 29, 30) Polyester modified with DOlyurethene (6, 7, (0, II. IX. 18. 20. 22. 23. 29. 30} Polyester modified with polyurethane and with a polyester overcoat (I, 6, 7, 10, II. 12, 13, 18. 20 22. 23. 29) Polyester with eolyvinvl butyral overcoat (self-bonding) (6, 12. 13. 18.22.29) Polytetrafluoroethylene (3, *. 5, 6, 25. 26, 28, 30. 32) Polyurethane (I, 6. 7, 8. 10. II. 12. 13. IX, 15. (7, 18, 20. 22. 23. 26. 29. 30) Polyurethane with friction surface (7, 10, II. 13, 20) Polyurethane with nylon overcoat (l, 6, 7, 8. 10, II. 12, 13, IX. 18. 20, 22. 23 . 29. 30) Polyurethane with nylon and polyvinyl butyral over coats (7, !0. II. 12, 13, 18, 20. 22, 29) Polyurethane with polyvinyl bufvrel overcoat (self bonding) (6, 7, 10. II. 12. 13. IX. 18. 22. 29) Polyvinyl formal modified with phenol formaldt- hype (6. 10. II. 12. IX. 17. 18, 20. 22. 23 . 26. 29! Polyvinyl formal modified for hermetic use (I, 8, 10. H. 12. 13. IX, 18, 20. 22. 23) Polyvinyl formal with nvion overcoat (I. 6, 8. 10 fl 12. 13. IX. 18, 20. 22. 23. 29, 30) Polyvinyl formal with poiyvinvl butyral overcoa* (self-bonding) (I, 6. 10, II. 12. IX. 18. 20. 22, 29) Silicone modified with polyester (5, 6, IS) Silicone with polytetrafluoroethylene overcoat (S. 6) Pibet end Paper Coveted Wire Asbestos fiber, orgenic bond (13. 27. 31) Asbestos fiber, siiicone bond {13. 27. 31) Asbestos fiber with glass fiber reinforcement, Organic Dond (13, 27. 31) Asbestos fiber with glass fiber reinforcement, silicone bond (13. 27. 31) Asbestos fiber with second serving of glass fiber, orgenic bond (27. 31) Asbestos fiber with second serving of glass fiber, sificone bond (27 31) Cotton varn (I. 2, 6. 7. 10. II, 12, 13, IX. 16, 18 20 22. 23. 27) Giass fiber, organic bond (2, 6, 7, 10, 11, 12, 13, IX 16, 18. 23, 27) Glass fiber, silicone bond (2, 6. 7, 10. II, 12. 13, 18, 20. 27) Glass end polyester fibers, organic bond (6, 7. 10, 11. 12. 13. IX. 18. 20. 23) Glass and polyester fibers, silicone bond (6. 10. M, 12. 13. 18. 20) Nvion fiber (i, 6, 7. II. 12, IX. 18. 22) Paper teDe (2. 6. 7. 10. M, 12. M, 18 . 20. 22. 23) Paper teoe with second serving of cotton yarn (2, 6, 7. 10. II. 12. lx. 18. 20. 22) Silt yarn (6, 11, 18) Combination (Enemel end Film/Fibar end Paper) Covered Wire Giass fiber with purified asbestos paper cover (6) Oleoresinous enemel with asbestos fiber cover, organic bond (6. 7) Oleoresinous enamel with cotton yarn cover (I. 6. 7, 11. 12. IX. 18, 22) Oleoresinous enamel with glass fiber (6. 7, I!. IX, 18) Oleoresinous enamel with nvion fiber cover, organic bond (1.6. 7. M, !2. IX, f8. 22) Oleoresinous enames with paper tape covet (6 7 H. 12, IX, 18. 22) Oleoresinous enamel with silt yarn cover (I. 6 7 II. 18) Poiyimide (formerly tradenamed "ML" resin) with glass fiber, silicone pond (II, 12, 18. 20) Polyester film with purified asoestos paper cover (6. 7) 318 Insulation Directory/Encyclopedia Issue, May, 1962 Polyester modlfieo with poiyuretnene ana with a polyester overcoat with giats fibers, siiicone bona (7, II. 18, 23) Polyester modified with ooiyunetnane and with polyester overcoat with glass ano polyester fibers, siiicone bond (7, II, 16, 23) Polyvmyl formal enamel with asbestos fiber cove-, organic bona (6. 7, f3) Polyvinyl formal enamel with cotton yam cover 6, II. 12. 13, tx. 18.20. 22) Polyvinyl formal enemel with glass fiber cover. organic bona (6. II, 12, 13. IX, 18, 23) Polyvinyl formal enamel witn giass and poiyevttr fibers (II. 12. 13, IX, 18, 20) Poiyvinvl forme) enamel with paeer tape cover (6. tl. 12, H. 18 . 20. 22) Suppliers of Preceding Products 1--Acme Wi rt Co. 2--Alcoa, Rome Cabie Div. 3--ALPHA WIRE CORP.. SUBSIDIARY OF LORAL ELECTRONICS CORP. *--American Stanoerp w,r* S Cable Co. 5--AMERICAN SUPER-TEMPERATURE WIRES, INC.. A SUBSIDIARY Of HAVE INDUSTRIES. INC. 6--ANACONDA WIRE AND CABLE CO. 7--86LOEN MANUFACTURING CO. 8-- Chicago Magnet Wi'e Corp. 9-- Dielectric Materials Co. ID--THE ELECTRIC AUTOLITE CO.. WIRE AND CABLE DIV. 11-- ESSEX WIRE CORP.. MAGNET WIRE DIY. 12-- GENERAL CABLE CORP. 13-- General Electric Co.. Wire and Cable Dept, ix--General Motors Corp.. Packard Electric Div. 15-- HUOSON WIRE CO.. MAGNET WIRE DIV. 16-- Nenrjng Electrieel Works 17-- New Haven Wire S Cable Inc. IS--THE OKONITE CO.. KENNECOTT WIRE AND CABLE DIV. 19--Permalutter Inc. 2D--PHELPS DODGE COPPER PRODUCTS CORP.. INCA MFG. DIY. 21-- PHYSICAL SCIENCES CORP.. AFFILIATE OF PACKARD BELL ELECTRONICS 22-- REA MAGNET WIRE CO.. INC., SUBSIDIARY OF ALCOA 2D--Reynolds Metals Co. 2*--Secon Meteis Corp. 25-- Simpiei Wire i Cable Co., Hitemp Wires Co. Div. 26-- Sorague Electric Co., Soecial Products Oiv., Wire Dept. 27-- Stanoard Wire and Cabie Co. 28-- Thermal Wire of Americe 29-- Viking Wire Co.. Inc. 30-- Warren Wire Co. 31-- Westwood Cable Coro. 32-- World Wide Wire Inc. WANT ADDITIONAL COPIES OF THE INSULATION DIRECTORY ENCYCLOPEDIA? Us the handy order form on page 368.