High-temperature, Electrically-insulating Coating for Magnet Wires

In this SBIR project, Aegis Technology proposes to develop a high-temperature, electrically-insulating coating for magnet wires used in electro-mechanical and power conversion components. The development of such coating will enable the resultant components and systems to operate at high temperatures, high power densities and high frequencies, offering the advantages such as high efficiency, small size and light weight. In this Phase I, we are to demonstrate a novel magnet wire insulation concept based on a Si3N4-based ceramic coating material, which can be cost-effectively processed by a polymer-based precursor. With a proper control of processing, it is likely to form a nanocrystalline-microstructure coating with a thickness varying from a few nanometers (thin film) to a few micrometers (thick film). With such a ceramic coating, the insulation properties, thermal stability and mechanical strength can be substantially enhanced, making the resultant magnet wires can work reliably high temperatures far exceeding than 300 C.