From: Michael R. Kalish
Sent: Monday, January 31, 2005 8:27 AM
To: Thomas G. Meighan
Subject: FW: Prototype Bar Insulation Buildup

Attachments: TF VPI Mold.ppt; TF WP Bonded & Unbonded Stiffness.xls

Buddy,

Attached is the Drawing of the TF Winding Pack Prototype Bar


The TF Turn Insulation is as follows. The first layer of Kapton is directly applied to the conductor with the adhesive down .75" or 1" wide .002" thick Kapton tape may be used.  Then three 1/2 lap layers of glass are applied.  We should check the total build up to see how close to .049" is achieved.
			
One 1/2 Lap Layer Kapton	

	Kapton	0.002	
	Adhesive	0.0015	
	Kapton	0.002	
	Adhesive	0.0015	

Three 1/2 Lap Layers Glass	

	Glass		0.007	
	Glass		0.007	
	Glass		0.007	
	Glass		0.007	
	Glass		0.007	
	Glass		0.007	
		      0.049	Inches
		
The Ground Wrap includes no Kapton.  It is simply twenty-one 1/2 lap layers of .009" thick glass applied to bring the total ground wall thickness to 3/8".  If 9mil glass is unavailable we can achieve this build up with a greater number of layers of 7 mil glass. Again it is more important that the ground wall thickness is correct than that we achieve the prescribed # of layers.  We may have to adjust up or down based on experience.			
			
Twenty-one 1/2 Lap Layers Dry Glass		

		Glass		0.009	
x 21	  	Glass		0.009	
				0.375	Inches

We will continue the turn insulation another 1/2 inch past either end of the conductor.  These ends will be plugged with pieces of Teflon or possibly just stuffed with glass.  The purpose of this is to insulate the edges turn to turn so that we can successfully high pot this sample before during and after mechanical testing.  I'll get with you Monday and go over all of this with you.

Thanks,
Mike


Michael Kalish
Princeton Plasma Physics Laboratory
PO Box 451    Princeton, NJ    08543
Phone: (609) 243-2277
Fax:   (609) 243-3248

You can visit the home page of the
Princeton Plasma Physics Laboratory at
http://www.pppl.gov