CERAMIC INSULATOR AND METHODS OF USE AND MANUFACTURE THEREOF

• US 20110048371A1
• Filed: 07/21/2010
• Published: 03/03/2011
• Est. Priority Date: 01/07/2008
• Status: Active Grant

• Current Assignee: Advanced Green Innovations, LLC
• Original Assignee: McAlister Technologies, LLC
• Inventors: McAlister, Roy E.
• Granted Patent: US 8,192,852 B2
• Time in Patent Office: Days
• US Class Current: 123/297
• CPC Class Codes: C03C 10/0045 containing SiO2, Al2O3 and MgO as main constituents
• CPC Class Codes: C03C 10/0054 containing PbO, SnO2, B2O3
• CPC Class Codes: C03C 10/16 Halogen containing crystalline phase
• CPC Class Codes: C03C 2218/345 Surface crystallisation
• CPC Class Codes: C03C 4/16 for dielectric glass
• CPC Class Codes: C04B 2235/3201 Alkali metal oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3203 Lithium oxide or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3206 Magnesium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3409 Boron oxide, borates, boric acids, or oxide forming salts thereof, e.g. borax
• CPC Class Codes: C04B 2235/445 Fluoride containing anions, e.g. fluosilicate
• CPC Class Codes: C04B 2235/787 Oriented grains
• CPC Class Codes: C04B 35/195 Alkaline earth aluminosilicates, e.g. cordierite or anorthite
• CPC Class Codes: C04B 40/00 Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability active ingredients C04B22/00 - C04B24/00; hardening of a well-defined composition C04B26/00 - C04B28/00; making porous, cellular or lightening C04B38/00; mechanical aspects B28, e.g. conditioning the materials prior to shaping B28B17/02
• CPC Class Codes: C04B 40/0071 making use of a rise in pressure
• CPC Class Codes: F01N 5/02 the devices using heat
• CPC Class Codes: F02B 2075/125 Direct injection in the combustion chamber for spark ignition engines, i.e. not in pre-combustion chamber
• CPC Class Codes: F02M 21/0215 Mixtures of gaseous fuels; Natural gas; Biogas; Mine gas; Landfill gas
• CPC Class Codes: F02M 21/0275 for in-cylinder direct injection, e.g. injector combined with spark plug
• CPC Class Codes: F02M 2200/9038 Coatings
• CPC Class Codes: F02M 31/20 for cooling F02M31/005 takes precedence; use of cold F02M17/52; cooling of charging-air or of scavenging-air F02B29/04
• CPC Class Codes: F02M 33/08 : returning to the fuel tank
• CPC Class Codes: F02M 51/0671 : the armature having an elongated valve body attached thereto
• CPC Class Codes: F02M 51/0685 : the armature and the valve being allowed to move relatively to each other or not being attached to each other
• CPC Class Codes: F02M 53/043 : with cooling means other than air cooling
• CPC Class Codes: F02M 57/005 : the devices being sensors
• CPC Class Codes: F02M 57/06 : the devices being sparking plugs
• CPC Class Codes: F02M 61/12 : characterised by the provision of guiding or centring means for valve bodies
• CPC Class Codes: F02M 61/16 : Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
• CPC Class Codes: F02M 61/1893 : Details of valve member ends not covered by groups F02M61/1866 - F02M61/188
• CPC Class Codes: F02P 23/02 : Friction, pyrophoric, or catalytic ignition
• CPC Class Codes: H01B 19/00 : Apparatus or processes specially adapted for manufacturing insulators or insulating bodies manufacture of porcelain for electric insulation C04B33/26
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies
• CPC Class Codes: Y02T 10/30 : Use of alternative fuels, e.g. biofuels
• CPC Class Codes: Y10T 29/49227 : Insulator making

Abstract

One embodiment of the present disclosure is directed to an insulator comprising a ceramic composition, wherein the ceramic composition comprises about 25-60% SiO₂; 15-35% R₂O₃, wherein the R₂O₃ is 3-15% B₂O₃ and 5-25% Al₂O₃; 4-25% MgO+0-7% Li₂O, wherein the total of MgO+Li₂O is between about 6-25%; 2-20% R₂O, wherein the R₂O is 0-15% Na₂O, 0-15% K₂O, 0-15% Rb₂O; 0-15% Rb₂O; 0-20% Cs₂O; and 4-20% F; crystalline grains, wherein the crystalline grains are substantially oriented to extend in a first direction to provide improved insulating properties in a direction perpendicular to the first direction, wherein the first direction is circumferential and the direction perpendicular to the first direction is radial; and a first zone and a second zone, wherein the first zone is in compression and the second zone is in tension.

Claims

1. An insulator comprising:

a ceramic composition,

wherein the ceramic composition comprises crystalline grains and wherein the crystalline grains are substantially oriented to extend in a first direction to provide improved insulating properties in a direction perpendicular to the first direction.

2. The insulator of claim 1 wherein the ceramic composition comprises:

about 25-60% SiO₂;

15-35% R₂O₃, wherein the R₂O₃ is 3-15% B₂O₃ and 5-25% Al₂O₃;

4-25% MgO+0-7% Li₂O, wherein the total of MgO+Li₂O is between about 6-25%;

2-20% R₂O, wherein the R₂O is 0-15% Na₂O, 0-15% K₂O, 0-15% Rb₂O;

0-15% Rb₂O;

0-20% Cs₂O; and

4-20% F).

3. The insulator of claim 2, wherein the first direction is circumferential and the direction perpendicular to the first direction is radial.

4. The insulator of claim 3 further comprising a first zone and a second zone wherein the first zone is in compression and the second zone is in tension.

5. The insulator of claim 4 wherein the first zone is adjacent an outer surface of the insulator.

6. The insulator of claim 5 wherein the first zone comprises more crystal grains per volume that the second zone.

7. The insulator of claim 5 wherein the crystal grains of the first zone have a packing efficiency less than the crystal grains of the second zone.

8. The insulator of claim 5 wherein the first zone comprises diffused ions, sputtered surfaces, or a dopant.

9. The insulator of claim 4 wherein the insulator has a dielectric strength of greater than about 1.2 KV/0.001″

at a temperature from about −

30°

C. to 450°

C.

10. The insulator of claim 4 wherein the insulator has a dielectric strength of greater than about 1.9 KV/0.001″

at a temperature from about −

30°

C. to 450°

C.

11. The insulator of claim 4 wherein the insulator has a dielectric strength of greater than about 2.5 KV/0.001″

at a temperature from about −

30°

C. to 450°

C.

12. The insulator of claim 4 wherein the insulator has a dielectric strength of greater than about 3 KV/0.001″

at a temperature from about −

30°

C. to 450°

C.

14. A fuel injector-igniter comprising the insulator of claim 4.

13. An insulator comprising:

a ceramic composition, wherein the ceramic composition comprises;

about 25-60% SiO₂;

15-35% R₂O₃, wherein the R₂O₃ is 3-15% B₂O₃ and 5-25% Al₂O₃;

4-25% MgO+0-7% Li₂O, wherein the total of MgO+Li₂O is between about 6-25%;

2-20% R₂O, wherein the R₂O is 0-15% Na₂O, 0-15% K₂O, 0-15% Rb₂O;

0-15% Rb₂O;

0-20% Cs₂O; and

4-20% F;

crystalline grains, wherein the crystalline grains are substantially oriented to extend in a first direction to provide improved insulating properties in a direction perpendicular to the first direction, wherein the first direction is circumferential and the direction perpendicular to the first direction is radial; and

a first zone and a second zone, wherein the first zone is in compression and the second zone is in tension.

15. A method of modifying one or more properties of a substantially amorphous material comprising:

providing a substantially amorphous material;

selectively inducing a phase change in a first zone of the material without substantially inducing a phase change in a second zone of the material.

16. The method of claim 15 wherein the step of selectively inducing a phase change in a first zone of the material comprises inducing crystallization in the first zone.

17. The method of claim 16 wherein the step of inducing crystallization comprises seeding at least a portion of the first zone.

18. The method of claim 16 wherein the step of inducing crystallization comprises providing a nucleating agent to at least a portion of the first zone.

19. The method of claim 16 wherein following the step of selectively inducing a phase change in a first zone of the material, the first zone of material is under compression and the second zone of the material is under tension.

20. The method of claim 15 wherein following the step of selectively inducing a phase change in a first zone of the material, the first zone of material has an index of refraction different from the second zone of the material.

21. The method of claim 15 wherein following the step of selectively inducing a phase change in a first zone of the material, the first zone of material has a chemical or corrosion resistance different from the second zone of the material.

22. The method of claim 19 wherein the material is a ceramic.