Refractory Composite Composition for Arc-Chute Thermal Shock Resistance
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Solution Overview
Problem
Existing refractory materials, such as reinforced cement-based composites and ceramics, fail to provide simultaneous high mechanical resistance, refractoriness, thermal shock resistance, and machinability for complex shapes in extreme electric operation conditions, particularly in high-voltage applications like arc-chutes.
Innovation Solution
A refractory composite material based on corundum, quartz, and sodium aluminate (NaAl11O17 or Na2O·11Al2O3) is developed, which includes a slurry comprising water-melted alumina, reactive alumina, microsilica, flux oxides, and organic additives, allowing for the creation of items with improved thermal and electric insulation properties through a process involving silicone moulds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforced cement-based composite materials are used, then mechanical resistance is improved, but resistance to electric arc in high voltage conditions deteriorates
Solution Approach 1:
The patent uses a composite material consisting of alumina particles (3-5 mm diameter) embedded in a silicate-based binding matrix. This composite structure combines the high mechanical strength of alumina with the electrical insulation and thermal stability of silicates, creating a material that resists both mechanical stress and electric arc in high voltage conditions.
2Reliability
If ceramic materials are used, then resistance to electric arc is improved, but machinability and forming capability deteriorate
Solution Approach 1:
The patent employs a silicate-based binding matrix that remains plastic and workable at processing temperatures, allowing the material to be molded into complex shapes using silicone molds. The binding agents maintain formability while the alumina particles provide the required electrical and thermal properties, enabling both complex geometry fabrication and high-voltage resistance.
3Temperature
If materials with high refractoriness are used, then thermal resistance is improved, but resistance to thermal shocks deteriorates
Solution Approach 1:
The patent creates a heterogeneous structure where alumina particles of specific size (3-5 mm) are distributed within a silicate matrix. This local arrangement allows different regions to respond differently to thermal stress: the alumina particles provide high-temperature stability while the silicate matrix accommodates thermal expansion differences, enabling the material to withstand rapid temperature changes without cracking.
4Adaptability or versatility
If complex shapes are manufactured, then adaptability is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent uses silicone molds as an intermediary tool to form the composite material. The silicone material's flexibility allows it to capture complex geometries with high precision, while the composite's plastic state during processing enables it to take the mold's shape accurately. After curing, the material maintains dimensional stability, ensuring manufacturing precision even for complex forms.
Data Source
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AI summary
Refractory composite material based on Al2O3 in the form of corundum, SiO2 in the form of quartz and sodium aluminate having the formula NaAl11O17 or Na2O- 11Al2O3, method for preparing the same, use thereof for preparing manufactured items, as well as manufactured items made thereby and use thereof.