Granted Patent B2

US 8,802,230 · App. 12/642,334 · Granted Aug 12, 2014

Abstract

Claims (31)

1. An electrically-insulative coating for minimizing an electrical conductivity of a metal substrate, the electrically-insulative coating comprising:

a polymer of an inorganic metal salt, wherein said inorganic metal salt includes an element selected from Groups 3-11 of the periodic table of the elements; and

a powder component substantially dispersed in said polymer;

wherein said powder component is present in the electrically-insulative coating in an amount of from about 5 parts to about 80 parts by weight based on 100 parts by weight of the electrically-insulative coating;

wherein the electrically-insulative coating does not substantially degrade when exposed to from about 100 V to about 330 V at a temperature of from about −50° C. to about 500 ° C.;

wherein the electrically-insulative coating has a dielectric strength of at least about 2,000 volts alternating current per mil.

2. The electrically-insulative coating of claim 1 , wherein said powder component is present in the electrically-insulative coating in an amount of from about 5 parts to about 40 parts by weight based on 100 parts by weight of the electrically-insulative coating.

3. The electrically-insulative coating of claim 1 , wherein said powder component includes an oxide.

4. The electrically-insulative coating of claim 1 , wherein said powder component includes a nitride.

5. The electrically-insulative coating of claim 1 , wherein said powder component includes a first constituent having an average particle size of from about 1 nm to about 100 nm and a second constituent having an average particle size of from about 0.1 μm to about 50μm.

6. An electrically-insulative coating system comprising:

a metal substrate having multiple surfaces; and

an electrically-insulative coating disposed on at least one surface of said metal substrate and comprised of;

a polymer of an inorganic metal salt, wherein said inorganic metal salt includes an element selected from Groups 3-11 of the periodic table of the elements; and

a powder component substantially dispersed in said polymer;

wherein said powder component is present in said electrically-insulative coating in an amount of from about 5 parts to about 80 parts by weight based on 100 parts by weight of said electrically-insulative coating;

wherein said electrically-insulative coating does not substantially degrade when exposed to from about 100V to about 330V at a temperature of from about −50° C. to about 500° C.;

wherein said electrically-insulative coating has a dielectric strength of at least about 2,000 volts alternating current per mil.

7. The electrically-insulative coating system of claim 6 , wherein said electrically-insulative coating has a thickness of from about 0.1μm to about 500 μm.

8. The electrically-insulative coating system of claim 6 , wherein said electrically-insulative coating does not substantially separate from said metal substrate when said metal substrate is folded.

9. The electrically-insulative coating system of claim 6 , wherein said electrically-insulative coating is disposed on two surfaces of said metal substrate.

10. The electrically-insulative coating system of claim 6 , wherein said metal substrate is lamination steel configured for use within an electric motor.

11. The electrically-insulative coating system of claim 6 , wherein said metal substrate is copper wire configured for use as a stator winding of an electric motor.

12. A method of forming an electrically-insulative coating on a metal substrate to thereby minimize an electrical conductivity of the metal substrate, the method comprising:

polymerizing an inorganic metal salt to form a liquid polymer, wherein the inorganic metal salt includes an element selected from Groups 3-11 of the periodic table of the elements;

substantially dispersing a powder component in the liquid polymer;

after substantially dispersing, applying the liquid polymer including the powder component to the metal substrate;

after applying, drying the liquid polymer including the powder component to sufficiently transition the liquid polymer to a solidified gel and thereby form the electrically-insulative coating on the metal substrate.

13. The method of claim 12 , wherein substantially dispersing is further defined as mixing the powder component in the liquid polymer in an amount of from about 5 parts to about 80 parts by weight of the powder component based on 100 parts by weight of the liquid polymer.

14. The method of claim 12 , wherein applying is selected from the group comprising dip-coating, spin-coating, spraying, inkjet printing, roll-coating, plate printing, and combinations thereof.

15. The method of claim 12 , further including stamping the metal substrate after sufficient drying.

Assignments (8)