Abstract A method of forming a laminate including providing an elongated laminate strip having a metal ply and a layer of a thermoplastic material bonded thereto with the metal ply and thermoplastic layer initially having a substantially equal width. Compressively reducing the thickness of the thermoplastic layer and simultaneously establishing transverse enlargement of the thermoplastic layer in both transverse directions to cause the thermoplastic layer to extend farther outwardly than the metal ply. The thickness reduction and transverse expansion may be effected at a laminate temperature of about 250* to 600* F. The reformed laminate may subsequently be coiled in order to establish an electrical coil having insulation between edges of adjacent wraps of the metal ply.
The method of claim 1 including said thermoplastic layer is adhesively bonded to said metal ply prior to effecting said reduction, reducing said thickness of said thermoplastic layer by about 2 to 10 percent, and transversely expanding said thermoplastic layer by about 3 to 25 percent.
Claim 2
Dependent Claim
42 words
The method of claim 1 including after establishing said reduction in thickness and said increase in transverse width winding said laminate to establish an electrical coil with said thermoplastic material serving to electrically insulate edges of adjacent wraps of said metal ply.