Ceramic insulator and methods of use and manufacture thereof

• US 8,192,852 B2
• Filed: 07/21/2010
• Issued: 06/05/2012
• Est. Priority Date: 01/07/2008
• Status: Expired due to Fees

• Current Assignee: Advanced Green Innovations, LLC
• Original Assignee: McAlister Technologies, LLC
• Inventors: McAlister, Roy E.
• Primary Examiner(s): McNeil, Jennifer
• Assistant Examiner(s): Katz, Vera
• Application Number:
  US12/841,135
• Publication Number:
  US 20110048371A1
• Time in Patent Office: 685 Days
• Field of Search: None
• US Class Current: 428/701
• 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, 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,

wherein the first direction is circumferential and the direction perpendicular to the first direction is radial.

2. The insulator of claim 1 further comprising a first zone and a second zone wherein the first zone is in compression and the second zone is in tension.

3. The insulator of claim 2 wherein the first zone is adjacent an outer surface of the insulator.

4. The insulator of claim 3 wherein the first zone comprises more crystal grains per volume that the second zone.

5. The insulator of claim 3 wherein the crystal grains of the first zone have a packing efficiency less than the crystal grains of the second zone.

6. The insulator of claim 3 wherein the first zone comprises diffused ions, sputtered surfaces, or a dopant.

7. The insulator of claim 2 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.

8. The insulator of claim 2 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.

9. The insulator of claim 2 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.

10. The insulator of claim 2 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.

11. A fuel injector-igniter comprising the insulator of claim 2.

12. 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.