Muscovite and phlogopite splittings can be fabricated into various built-up mica products. Produced by mechanized or hand setting of overlapping splittings and alternate layers of binders and splittings, built-up mica is used primarily as an electrical insulation material. Mica insulation is used in high-temperature and fire-resistant power cables in aluminium plants, blast furnaces, critical wiring circuits (for example, defense systems, fire and security alarm systems, and surveillance systems), heaters and boilers, lumber kilns, metal smelters, and tanks and furnace wiring. Specific high-temperature mica-insulated wire and cable is rated to work for up to 15 minutes in molten aluminium, glass, and steel. Major products are bonding materials; flexible, heater, molding, and segment plates; mica paper; and tape.
Flexible plate is used in electric motor and generator armatures, field coil insulation, and magnet and commutator commutator core insulation. Mica consumption in flexible plate was about 21 tonnes in 2008 in the US. Heater plate is used where high-temperature insulation is required. Molding plate is sheet mica from which V-rings are cut and stamped for use in insulating the copper segments from the steel shaft ends of a commutator. Molding plate is also fabricated into tubes and rings for insulation in armatures, motor starters, and transformers. Segment plate acts as insulation between the copper commutator segments of direct-current universal motors and generators. Phlogopite built-up mica is preferred because it wears at the same rate as the copper segments. Although muscovite has a greater resistance to wear, it causes uneven ridges that may interfere with the operation of a motor or generator. Consumption of segment plate was about 149 t in 2008 in the US. Some types of built-up mica have the bonded splittings reinforced with cloth, glass, linen, muslin, plastic, silk, or special paper. These products are very flexible and are produced in wide, continuous sheets that are either shipped, rolled, or cut into ribbons or tapes, or trimmed to specified dimensions. Built-up mica products may also be corrugated or reinforced by multiple layering. In 2008, about 351 t of built-up mica was consumed in the US, mostly for molding plates (19%) and segment plates (42%).
