A composition comprising a reactive organic matrix and majority amount of large conductive particles referred to as the primary filler and a minority amount of significantly smaller conductive particles, referred to as the secondary filler. The primary filler and secondary filler are dispersed in a reactive organic matrix and the secondary filler comprises particles with anti-settling characteristics to prevent the primary filler particles from settling without compromising the overall conductivity of the composition.

In an embodiment, a thermoplastic composite comprises a thermoplastic polymer; and a dielectric filler having a multimodal particle size distribution; wherein a peak of a first mode of the multimodal particle size distribution is at least seven times that of a peak of a second mode of the multimodal particle size distribution; and a flow modifier.

A conductor assembly including an electrically conductive material defining a longitudinal axis, a microporous membrane surrounding the electrically conductive material defining a series of pores, and a ceramic material within at least a first portion of the series of pores.

A medium voltage electric cable is disclosed the cable comprising: a conductor; an inner semi-conductive layer arranged in a radially outer position with respect to the conductor; an insulating layer arranged in a radially outer position with respect to the inner semi-conductive layer and directly contacting the inner semi-conductive layer; an outer semi-conductive layer arranged in a radially outer position with respect to the insulating layer and directly contacting the insulating layer; a wire metal screen arranged in a radially outer position with respect to the outer semi-conductive layer; a filler layer arranged in a radially outer position with respect to the wire metal screen and interpenetrating within the wire metal screen, the filler layer being made from an extruded elastomeric low smoke zero halogen (LSOH) composition comprising a polyethylene homopolymer and/or copolymer having a density lower than 0.93 g/cm.sup.3 and a metal hydroxide; and an outer sheath arranged in a radially outer position with respect to the filler layer and directly contacting the filler layer, the outer sheath being made from a low smoke zero halogen (LSOH) composition comprising a polymer mixture of an EVA polymer and polyethylene homopolymer and/or copolymer having a density lower than 0.93 g/cm.sup.3, the polymer mixture being charged with a metal hydroxide and a phyllosilicate clay.

An electromagnetic coil that can withstand high temperatures and operate efficiently and methods of making the same are provided. In preferred embodiments the electromagnetic coil comprises: a bobbin made entirely of ceramic; a coiled conductor wrapped around the bobbin; a potting resin applied to the coiled conductor during winding wherein, the resin is a siloxane polymer mixed with a metal oxide or a cyanate ester; and an overwind made of glass fiber yarn.

A method of manufacturing an insulated conductive component having an electrically conductive element is provided. The method includes applying a first layer of a first material comprising a thermally conductive ceramic on a portion of the conductive element, and applying a second layer of a second material comprising a polymeric resin over the first layer. The method includes curing the conductive element to infuse the second material into the first material to define an electrically insulative, thermally conductive coating on the portion of the electrically conductive element.

Various applications of the teachings of the present disclosure include a powder coating formulation suitable for producing an insulation system of an electrical machine. The formulation may include: a curable resin mixture; and spherical SiO.sub.2 filler particles having a maximum particle diameter of 100 μm.

An insulating film includes: a resin consisting of a polyimide, a polyamide-imide, or a mixture thereof; and α-alumina single crystal particles having an average particle diameter in a range of 0.3 μm or more and 1.5 μm or less, in which an amount of the α-alumina single crystal particles is in a range of 8% by volume or more and 80% by volume or less. An insulated conductor includes: a conductor; and an insulating film provided on a surface of the conductor, in which the insulating film consists of the insulating film. A metal base substrate includes a metal substrate, an insulating film, and a metal foil which are laminated in this order, in which the insulating film consists of the insulating film.

An insulated electrical cable includes: a conductor; and an insulating layer that is laminated on an outer peripheral surface of the conductor and includes a polyimide as a main component, wherein the insulating layer includes a plurality of pores, and wherein a porosity of the insulating layer is greater than or equal to 25% by volume and less than or equal to 60% by volume.

Disclosed is a polymer-ceramic composite, comprising: ceramic particles within a polymer matrix; wherein greater than or equal to about 70% of the ceramic particles by volume experience ceramic particle to ceramic particle contact; wherein a dielectric strength of the composite is greater than or equal to about 300 kilovolts per millimeter; and wherein a thermal conductivity of the composite is greater than or equal to about 10 watts per meter kelvin.