A method of coating a substrate includes adding ion erosion resistant particles, conductive particles, and a binder to an electrophoretic solution in an electrophoretic deposition apparatus including the substrate and a cathode spaced from the substrate. A current is applied to the substrate and cathode to deposit a first layer coating including the erosion resistant particles, the conductive particles, and the binder onto the substrate. The method further includes adding a low work function material to an electrolyte solution in an electrolytic deposition apparatus including the substrate and a cathode spaced from the substrate. A current is applied to the substrate and the cathode to deposit a second layer coating including the low work function material onto the substrate.

A method of coating a substrate includes adding ion erosion resistant particles, conductive particles, and a binder to an electrophoretic solution in an electrophoretic deposition apparatus including the substrate and a cathode spaced from the substrate. A current is applied to the substrate and cathode to deposit a first layer coating including the erosion resistant particles, the conductive particles, and the binder onto the substrate. The method further includes adding a low work function material to an electrolyte solution in an electrolytic deposition apparatus including the substrate and a cathode spaced from the substrate. A current is applied to the substrate and the cathode to deposit a second layer coating including the low work function material onto the substrate.

There is provided an insulated electric wire formed by covering a rectangular conductor wire having a rectangular cross-sectional shape with an insulating film. The insulating film is formed of an inner layer covering a surface of the rectangular conductor wire, and an outer layer covering a surface of the inner layer. A thickness (t.sub.1) of a section of the inner layer, which covers one short side of two facing short sides of the same length of a rectangular cross section of the rectangular conductor wire, is greater than a thickness (t.sub.2) (including that t.sub.2=0) of a section of the inner layer which covers the other short side. An elastic modulus and/or a yield stress of the inner layer are less than an elastic modulus and/or a yield stress of the outer layer.

There is provided an insulated electric wire formed by covering a rectangular conductor wire having a rectangular cross-sectional shape with an insulating film. The insulating film is formed of an inner layer covering a surface of the rectangular conductor wire, and an outer layer covering a surface of the inner layer. A thickness (t.sub.1) of a section of the inner layer, which covers one short side of two facing short sides of the same length of a rectangular cross section of the rectangular conductor wire, is greater than a thickness (t.sub.2) (including that t.sub.2=0) of a section of the inner layer which covers the other short side. An elastic modulus and/or a yield stress of the inner layer are less than an elastic modulus and/or a yield stress of the outer layer.

The present invention is directed towards an electrodepositable coating composition comprising a cationic electrodepositable binder; a phyllosilicate pigment; and a dispersing agent. Also disclosed are methods of making the electrodepositable coating composition, coatings derived therefrom, and substrates coated with the coatings derived from the electrodepositable coating composition.

In various aspects, the processes disclosed herein may include the steps of inducing an electric field about a non-conductive substrate, and depositing functionalized nanoparticles upon the non-conductive substrate by contacting a nanoparticle dispersion with the non-conductive substrate, the nanoparticle dispersion comprising functionalized nanoparticles having an electrical charge, the electric field drawing the functionalized nanoparticles to the non-conductive substrate. In various aspects, the related composition of matter disclosed herein comprise functionalized nanoparticles bonded to a surface of a non-conductive fiber, the surface of the non-conductive fiber comprising a sizing adhered to the surface of the non-conductive fiber. This Abstract is presented to meet requirements of 37 C.F.R. §1.72(b) only. This Abstract is not intended to identify key elements of the processes, and related apparatus and compositions of matter disclosed herein or to delineate the scope thereof.

The invention relates to a composition and a process for the deposition of conductive polymers on dielectric substrates. In particular, the invention relates to a composition for the formation of electrically conductive polymers on the surface of a dielectric substrate, the composition comprising at least one polymerizable monomer which is capable to form a conductive polymer, an emulsifier and an acid, characterized in that the composition comprises at least one metal-ion selected from the group consisting of lithium-ions, sodium-ions, aluminum-ions, beryllium-ions, bismuth-ions, boron-ions, indium-ions and alkyl imidazolium-ions. The acid is typically a high molecular weight polymeric acid having molecular weight of at least 500,000 Da including, for example, polystyrene sulfonic acid having a molecular weight of approximately 1,000,000 Da.

The invention relates to a composition and a process for the deposition of conductive polymers on dielectric substrates. In particular, the invention relates to a composition for the formation of electrically conductive polymers on the surface of a dielectric substrate, the composition comprising at least one polymerizable monomer which is capable to form a conductive polymer, an emulsifier and an acid, characterized in that the composition comprises at least one metal-ion selected from the group consisting of lithium-ions, sodium-ions, aluminum-ions, beryllium-ions, bismuth-ions, boron-ions, indium-ions and alkyl imidazolium-ions. The acid is typically a high molecular weight polymeric acid having molecular weight of at least 500,000 Da including, for example, polystyrene sulfonic acid having a molecular weight of approximately 1,000,000 Da.

Self-healing polymers used to fabricate electrical devices or to coat electrical devices that have a metal or polymer substrate. The self-healing polymers can be made from modified polymers including polyurethanes, polyureas, polyamides and polyesters and, optionally, cross-linking agents and one or more catalysts. The self-healing polymers can be used to make cable ties, tape, conduit fittings and explosion-proof sealant materials.

The present invention is directed towards an electrodepositable coating composition comprising a polybutylene oxide polymer, an ionic film-forming polymer having functional groups, and a curing agent that is reactive with functional groups on the film-forming polymer. Also disclosed are methods of making the electrodepositable coating composition. Also disclosed are substrates treated with the electrodepositable coating composition.