Tin Oxide Electrode Corrosion Resistance via Zirconia Solid Solution
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Solution Overview
Problem
Current tin oxide-based electrodes for glass melting and refractory applications lack improved mechanical and optical performance, durability, and corrosion resistance, which are essential for high-performance glass components and displays.
Innovation Solution
A tin oxide-based electrode composition with SnO2 as the primary component, supplemented with Sb2O3, Nb2O5, Ta2O5, CuO, ZnO, Mn2O3, ZrO2, HfO2, and TiO2, where ZrO2 forms a solid solution with SnO2, acting as a corrosion inhibitor, and CuO, ZnO, Mn2O3 as sintering aids, enhancing durability and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional tin oxide-based electrodes are used for glass melting, then basic electrode function is maintained, but corrosion resistance and mechanical durability are insufficient
Solution Approach 1:
The patent applies composite materials by combining tin oxide base material with multiple oxide additives (zirconia, hafnia, titania, and transition metal oxides) to create a composite electrode composition. This composite structure provides enhanced corrosion resistance through the synergistic effects of different oxides, where zirconia/hafnia/titania form a protective refractory phase while transition metal oxides control resistivity and sintering behavior, resolving the contradiction between improved reliability and composition complexity.
Solution Approach 2:
The patent employs parameter changes by precisely controlling the weight percentages of each oxide component (e.g., zirconia at 1-10 wt%, hafnia at 1-10 wt%, titania at 1-10 wt%, with transition metal oxides at 0.1-5 wt%). These specific compositional parameters optimize the balance between corrosion resistance, electrical resistivity, and mechanical properties, allowing the electrode to maintain basic function while achieving superior corrosion protection without excessive complexity.
2Duration of action of stationary object
If electrode composition is simplified, then manufacturing is easier, but corrosion resistance and lifespan are reduced
Solution Approach 1:
The patent uses parameter changes by defining specific concentration ranges for each oxide component that optimize both performance and manufacturability. The controlled addition of zirconia (1-10 wt%), hafnia (1-10 wt%), and titania (1-10 wt%) within these parameter ranges ensures extended electrode lifespan through improved corrosion resistance while maintaining reasonable manufacturing complexity through standardized compositional specifications.
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 demonstrates improved corrosion resistance, sublimation resistance, and maintained density, extending the electrode's lifespan and performance in glass melting applications, with ZrO2 and HfO2 additions optimizing resistivity and corrosion protection.
Implementation Method 1
The ZrO2 or combination of ZrO2 with HfO2 and/or TiO2 forms a solid solution with the tin oxide
Implementation Method 2
CuO, ZnO, Mn2O3, or a combination thereof in an amount of not greater than 1.0% of the total composition by weight, as sintering aid
Data Source
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AI summary
In one embodiment a tin oxide based electrode is disclosed. The tin oxide- based electrode includes a base material of tin oxide, a resistivity modifier, a sintering aid, and a corrosion inhibitor. The corrosion inhibitor forms a solid solution with the base material and has a melting point not less than about 1700°C and a partial pressure of not greater than about 1.0E-7 atmospheres atl500°C. The corrosion inhibitor further includes 0 - 4.0wt% ZrO2 based on the total weight of the composition.