Electrically-insulative coating, coating system and method

An electrically-insulative coating system comprising:

• a metal substrate having multiple surfaces;
• and
• an electrically-insulative coating disposed on at least one surface of said metal substrate and comprised of;
• a polymer of an inorganic metal salt, wherein said inorganic metal salt includes an element selected from Groups 3-11 of the periodic table of the elements;
• and
• a powder component substantially dispersed in said polymer;
• wherein said powder component is present in said electrically-insulative coating in an amount of from about 5 parts to about 80 parts by weight based on 100 parts by weight of said electrically-insulative coating;
• wherein said electrically-insulative coating does not substantially degrade when exposed to from about 100V to about 330V at a temperature of from about −50° C. to about 500° C.;
• wherein said electrically-insulative coating has a dielectric strength of at least about 2,000 volts alternating current per mil.

A method of forming an electrically-insulative coating on a metal substrate to thereby minimize an electrical conductivity of the metal substrate, the method comprising:

• polymerizing an inorganic metal salt to form a liquid polymer, wherein the inorganic metal salt includes an element selected from Groups 3-11 of the periodic table of the elements;
• substantially dispersing a powder component in the liquid polymer;
• after substantially dispersing, applying the liquid polymer including the powder component to the metal substrate;
• after applying, drying the liquid polymer including the powder component to sufficiently transition the liquid polymer to a solidified gel and thereby form the electrically-insulative coating on the metal substrate.