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Dip coating was employed to apply low temperature co-firing ceramic (LTCC) zinc molybdate coatings to the surfaces of Ni-coated Cu conductor wires. Zinc molybdate ceramic powders were synthesized via a solid state route; ceramic suspensions for dip coating were prepared by mixing the LTCC powders in an organic solution. By optimizing the dip coating parameters and subsequent heat treatment, ceramic films, with a typical insulation thickness of 47.3 &#x03BC;m and dielectric strength of 24.2 kV&#x00B7;mm<sup>-1</sup>, were formed on the surfaces of Ni test discs. The processing parameters were transferrable to the coating of Ni-coated Cu wires; the resulting wires exhibited an insulation thickness of 40.3 &#x03BC;m and breakdown voltage of 798 V.

Development of low temperature co-fired ceramic (LTCC) coatings for electrical conductor wires