Tin Oxide Electrode Composition for Glass Melting
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Solution Overview
Problem
Existing tin oxide-based electrodes for glass melting applications face challenges with low thermal stability, unsuitable electrical resistivities, and macroscopic internal cracks, making it difficult to form industrial-grade electrodes with improved mechanical and optical performance.
Innovation Solution
A tin oxide-based electrode composition with a majority component of SnO2, including additives such as CuO and ZnO in specific weight percentages, and a resistivity modifying species like Sb2O3, is used to form electrodes with enhanced stability and electrical properties, avoiding excessive CuO and ZnO content to prevent cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If higher amounts of CuO and ZnO are used to improve densification, then density improves, but thermal stability deteriorates and macroscopic internal cracks occur
Solution Approach 1:
The patent applies parameter changes by precisely controlling the amounts of CuO and ZnO additives within narrow ranges (CuO: 0.05-0.2%, ZnO: 0.2-1.55%) to achieve optimal densification while preventing thermal instability and macroscopic cracking. This quantitative parameter optimization resolves the contradiction between densification and thermal stability.
2Force
If higher amounts of CuO and ZnO are used to improve densification, then density improves, but electrical resistivity becomes unsuitable (too high)
Solution Approach 1:
The patent uses parameter changes by optimizing the CuO and ZnO content within specific ranges to simultaneously achieve proper densification and suitable electrical resistivity. The controlled additive amounts prevent excessive resistivity while maintaining density, resolving this technical contradiction.
3Force
If higher amounts of CuO and ZnO are used to improve densification, then density improves, but manufacturing precision deteriorates due to unstable firing shrinkage
Solution Approach 1:
The patent applies parameter changes by controlling CuO and ZnO within narrow ranges (0.05-0.2% CuO, 0.2-1.55% ZnO) to achieve stable firing shrinkage and consistent manufacturing precision while maintaining adequate densification. This resolves the contradiction between densification and manufacturing precision.
4Stability of the object's composition
If incremental modifications to additive ratios are made to improve stability, then thermal stability improves, but electrical properties and density deteriorate
Solution Approach 1:
The patent applies parameter changes by optimizing not just additive ratios but also absolute amounts within specific ranges (0.05-0.2% CuO, 0.2-1.55% ZnO, 0.7-1.2% Sb2O3). This comprehensive parameter optimization achieves thermal stability while maintaining suitable electrical properties and density, resolving the contradiction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition results in electrodes with high density, low porosity, and suitable electrical resistivity, free of macroscopic internal cracks, suitable for industrial-sized glass melting applications, offering improved thermal stability and corrosion resistance.
Implementation Method 1
the tin oxide-based compositions include various components that assist in densification
Implementation Method 2
a resistivity modifying species... within a range between about 0.5 wt% and about 1.5 wt%
Data Source
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Figure 5~6
AI summary
A tin oxide-based electrode formed from a composition including a majority component comprising tin-oxide (SnO2), and additives comprising CuO, ZnO, and a resistivity modifying species. The total amount of CuO and ZnO is not greater than about 0.3 wt%, and the ZnO is present in an amount within a range between about 0.1 wt% and about 0.19 wt%.