NCSX Coil Winding Development Program

Application of Epoxy/Fiberglass Modular Coil Molds

-Ventilation/Exhaust Issues

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NCSX Cross-section

Modular coils

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ModularModular Coil Fabrication

The modular coils will be wound in the TFTR Test Cell

Two winding stations

“VPI” Vacuum-Pressure

Impregnation station using

autoclave

VPI Exhaust ventilation

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FabricationFabrication Steps- part 2 VPI

Waffle Boards and fill ports (sprues) will be added to the modular coil bundle.

Tedlar insulation (non-stick) will then be over-wrapped.

The mold will then be installed around the turns (R&D program will define the VPI methodology) Mold shall be epoxy/glass fiber sprayed over Tedlar

insulation The shell is non-conductive and could remain

around coil The modular coil will then be vacuum

impregnated with the resin system approved by the NCSX Project based upon the R&D program

Once cured, the coil will be electrically tested and transferred to Field Period Assembly station

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NCSX Modular Coil

Typical Cross-section

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Two Phases of Work• Prototyping Development

– Components will be “table-top” sized, ~ 4 foot in length.

– Six to eight prototypes samples will be encased.

– We plan to do the work in a portable tent enclosure set up in the TFTR Test Cell.

– Modest amounts of material use.

• Modular coil molds.– Much larger enclosure needed.

– Each coil has +20 feet of coil.

– 19 coils to encase.

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Typical Application

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Materials- Spray Application• Materials being proposed

– Hetron 980/35 Resin System (Low Styrene Content Epoxy Vinyl Ester Resin)

• Promoter-Nuodex DMR Cobalt 6% Naphthenate

• Co-promoter-N, N-Dimethylaniline

• Catalysts- Cadox L-50a

– Acetone (for cleaning)

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Safety Concerns• Ventilation- good air flow• Personnel protective equipment

– Respirators

– Eye/face protection

– Gloves, coveralls, etc.

• Exhaust- via the elephant trunk system– HP concerns

– Environmental

– Flammability concerns

– Mixed waste