Patent ID: 8448334

Claim:
A method of forming a self-healing electrical insulation coating on a length of magnet wire for use in an electrical device, the magnet wire being intended to be shaped and placed on a supporting element of the device and having a surface to be located against a device surface along the length of magnet wire or against the surface of another magnet wire, the method comprising; providing each magnet wire with a single layer of an electrically insulating material as a continuous electrical insulation layer coextensive with the surface of the magnet wire, the insulating material further comprising a substantially uniform dispersion of capsules of an electrical insulation precursor material, the electrical insulation precursor material being polymerizable to an electrical insulator following exposure to a polymerization initiator, the capsules being smaller than the thickness of the insulating layer and of a quantity for releasing electrical insulation precursor material where a crack may be subsequently formed in a portion of the insulation layer; and, thereafter, shaping the magnet wire for placement in the electrical device, the shaping causing a mechanical stress at a location in the insulation layer, the capsules being composed to break and release precursor material at a stress location at which an electrical resistance-reducing crack is formed in the insulation layer, reducing the electrical resistance of the insulating material at such location; the released precursor being polymerized at crack locations by a polymerization initiator after the magnet wire has been placed in the electrical device and before the electrical device is approved for use.