Alpha-Core: Laminax Foil Conductors

	Alpha Core, Inc 6 Waterview Drive Shelton, CT 06484 USA 1-800-836-5920	Phone: 203-954-0050 Fax : 203-954-0051 E-mail:sales@alphacore.com
	Countless Applications in a Wide Range of Electrical and Electronic Industries
Flat Wire Custom Magnetic Cores Audio Products Alpha-Core Home Send e-Mail to Alpha-Core	The LAMINAX family of materials consists of metal foil and strip, partially or entirely enclosed in insulating film. At Alpha-Core, the materials are combined in a proprietary laminating process which will bond the most common dielectric, polyester film, to metal substrates, as well as to other film materials (e.g. polyimide "Kapton (tm)" film.) Unlike competing products which are based on pressure sensitive tape, in Laminax the bond is produced without the use of an adhesive, and this means that laminates are thinner for a given dielectric strength than otherwise possible. The absence of an adhesive also means that the film layer does not need to be removed for termination, since lead wires can be soldered cleanly to the base metal right through the film. And finally, cutters and taping machines never "gum up" with particles of pressure sensitive adhesive. Laminax products have countless applications in transformer and electronics industries, both as winding conductors and for electrostatic and grounding shields. They can be manufactured in a variety of styles, the most common of which are described below. Since our strength is custom products manufactured to your exact specifications, please regard the constructions shown as representative only. Products may be up to 4" wide, and can be supplied in coil form or cut to length as needed.
Series B	Backed Conductor The metal foil is bonded to the insulator. Dimensions and the width of margins may be varied as required. Film backed foil is used as a winding conductor in transformers and coils, replacing interleaved winding of two individual materials. It is also used as electrostatic and grounding shields in many types of equipment.
Series BM	Backed Multiple Conductor Two or more parallel foil or strip conductors are bonded to a common backing film. It is possible to combine several widths and thicknesses of metal in the same product. Typical applications are as low voltage power track in special lighting systems, and for signal pick up in rotating machinery via carbon brushes, etc.
Series EB	Enclosed Backed Conductor Enclosed Backed Multiple Conductor The conductors are totally enclosed by laminating a second film layer on top of type B or BM materials. All layers are bonded together, lead wires may be soldered onto the metal right through the polyester film.
Series C	Cuffed Conductor The insulating film is folded around and bonded to the foil material, leaving an open area on one side. Series C cuff conductors are most commonly used as winding conductors and for EMI and safety shields in bobbin wound and toroidal transformers.
Series EC	Enclosed Cuffed Conductor A second film strip is placed on top of the metal foil underneath the cuffed edges. The result is a totally enclosed, fully bonded product virtually without margins. EC style materials provide superior safety against shorted turns, and is used extensively as shields in toroidal transformers. [Patent No. 5,281,488].
Series J	Jacketed Conductor The jacket is folded around but not bonded to the foil strip. A strip of polyester film is placed inside and bonded to the jacket without adhering to the metal. The jacket material may be polyimide film enabling applications up to 180°C. This product works well in toroidal taping machines, and will withstand a great deal of punishment during winding. [Patent No. 5,281,488]
	Specifications
	Conductor Metals Copper is available from 1 to 20 mils thickness (0.025 to 0.5 mm). Standard thickesses are 1.0, 1.4, 2.0, 5.0 and 10.0 mils (0.025, 0.036, 0.051, 0.127 and 0.25mm). Other thicknesses may be supplied to order when certain minimums are met. Several sources are used. Alpha-Core can use other metals such as aluminum or ferro-magnetic materials as specified by customer. Copper Alloy 110 Thickness tolerance: plus and minus 0.0003" or 0.00762mm (ASTM B248) Slit width: plus and minus 0.005" or 0.13mm Dielectric Insulation Polyester is the most commonly specified insulation; it may be bonded to the base metal or used non-bonded for type J products. Standard thickness is 1.2 mil (0.030mm). Polyester may be doubled if required. Several sources are used. Trade Name: Mylar^TM, Melinex^TM, and others Thickness tolerance: plus and minus 5% Slit width: plus and minus 0.01" or 0.25mm Nominal Yield: 16,900 lb/inch² (SPC) Tensile Strength: 26,000 psi (MD, ASTM D882A) Elongation at Break: 110% (MD, ASTM D882A); 80% (TD); 1.39 g/cc (SPC) Typical Thermal Shrinkage: 5.5% (MD, Unrestrained); 4.0% (TD, 374°F, 5 mins) Dielectric Strength: 6,500 V/mil (ASTM D149-64) Dielectric Constant: 3.10 (100°C 50Hz); 3.30 (150°C 50Hz); 2.96 (23°C 50Hz) Surface Resistance: 10¹² ohm/sq. (ASTM 257-61, 500 Vdc, 25°C 95%RH); 10¹⁷ ohm/sq. (ASTM 257-61, 100 Vdc, 25°C 1000 sec) electrification UL Listing: E51840 (M), and others Alternatively, Polyimide and Aramid Paper insulation may be bonded to the foil or used non-bonded in J style applications. Polyimide (Kapton^TM) has a standard of 1 and 2 mils (0.025 and 0.051mm). Aramid Paper (Nomex^TM) has a standard of 2 and 5 mils (0.051 and 0.127mm). Specific Widths and Manufacturing Tolerances Widths of metal foil and insulating films are supplied as required. Special sizes on request. Lead wires attached as required. Maximum Conductor Width: 4.0 inches (102mm) Standard Length: 328 ft (100 meter) lengths with a 3" (76mm) diameter core. Also available cut to length from 0.5 to 36". (12.6mm to 914mm) Centering of Foil on Backings (Type B): 0.020" or 0.5mm either way. Width Tolerance of cuffed and sandwich products (types C and S): Width of metal foil + (2 x thickness of film). Minus 0 and plus 0.020" or 0.5mm.