I need help from a materials engineer or chemist or electronics engineer or mechanical engineer to find the best thermoset powder coating for electrical insulation in a 2 mil (50.8 microns) thick coating.
1. To be incorporated into a final paste/ink for a screen print capacitor dielectric.
2. Dielectric strength rated at better than 1500V/mil and preferable as high as 4000V/mil
3. Supplied as a thermoset or thermoplastic powder normally used for electrostatic coating
4. Available in small quantities (not only 55 gal drum, etc.)
5. Need to be able to apply in 2 coats of 1 mil each.
6. Cost including shipping and other fees must not be higher than $50/lb.
I expect to re-list this project so that each time I get the "best" spec then others will have an opportunity to get paid for an even better spec as long as all the requirements are met.
The material's spec.s must be better than 3M 6233P which is rated at about 1400-1500 volts/mil. It might not matter if the coating is not usually used in a coating as thin as 2 mil as long as I can use it at that thickness for this application. Ideally the powder coating should be rated at 4000 volts/mil or better. I've seen electrical insulation liquid coatings rated that high but I haven't been able to find a thermoset powder coating rated that high. It must be a thermoset or thermoplastic powder coating normally applied through an electrostatic coating process and not a spray bottle and not a liquid. An exception would be if a dried solidified coating of said liquid were porous enough to allow entrained gases to exit and if it could be re-melted in a vacuum press at a temperature no higher than 400F.
In the final application the selected powder may get additional additives as necessary for:
UV blocking/stabilizing (to assist with corona degradation protection),
degassing (to remove micro bubbles),
higher dielectric constant,
higher dielectric strength,
corona degradation protection,
anti "electrical treeing"
The powder coating must be available for immediate shipping to Texas, USA either from the factory or a distributor. If you send me some company's spec only to have that company (for example) tell me they will only send the product to authorized contractors or only to have them tell me that I have to purchase a minimum of a 55 gal drum then you will not be awarded the money. I need only small quantities for initial research. Also, you cannot tell me that I must purchase directly from yourself either unless you agree to maintain the price.
Please do not bid on this project until you have already found something that meets the spec and I expect to award as soon as you confirm you found something.