BACKGROUND

Technological Field

The present disclosure relates to dielectric device, and more particularly to polymer ceramic hybrid dielectric.

Description of Related Art

High-voltage power distribution systems require electrical insulators that combine high dielectric strength with high thermal conductivity in a flexible (bendable) structure. High thermal conductivity yet low dielectric constant, high dielectric strength combined with mechanical flexibility, and the ability to form defect-free structures at reasonably large scale while maintaining their long-term integrity and dielectric properties even in high-humidity environments are all desirable characteristics.

The conventional methods and systems have generally been considered satisfactory for their intended purpose. However, there is still a need in the art for a dielectric material having improved electrical and thermal conductivity. There also remains a need in the art for such a material and components that are economically viable. The present disclosure may provide a solution for at least one of these remaining challenges.

SUMMARY

A conductor includes 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, and can further include a non-porous layer surrounding the microporous membrane. A sealant material can be located within at least a second portion of the series of pores. The first portion of the series of pores is significantly smaller than the second portion of the series of pores.

The microporous membrane can include a polymeric matrix and a spherulitic structure. At least a portion of the series of pores of the microporous membrane can be aligned orthogonal to the longitudinal axis. The microporous membrane can include a thermoplastic fluoropolymer material, such as PEEK, PTFE or PVDF or a silicone material. The ceramic material can includes a boron nitride or aluminum nitride.

A method of manufacturing an electrical conductor includes depositing a microporous membrane over electrically conductive material such that a series of pores are formed within the microporous membrane, filling at least a first portion of the series of pores with a ceramic material, and filling at least a second portion of the series of pores with a polymeric electrically insulating sealant. Filling the first portion of the series of pores can include atomic layer deposition, which is plasma enhanced. The method further including exposing the microporous membrane to a plasma mixture containing a ceramic precursor.

These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings.

