CN102712540B - 陶瓷绝缘体及其使用和制造方法 - Google Patents

陶瓷绝缘体及其使用和制造方法 Download PDF

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Publication number
CN102712540B
CN102712540B CN201080048878.2A CN201080048878A CN102712540B CN 102712540 B CN102712540 B CN 102712540B CN 201080048878 A CN201080048878 A CN 201080048878A CN 102712540 B CN102712540 B CN 102712540B
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Prior art keywords
isolator
fuel
dielectric
area
dielectric strength
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Expired - Fee Related
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CN201080048878.2A
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CN102712540A (zh
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罗伊·E·麦卡利斯特
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McAlister Technologies LLC
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McAlister Technologies LLC
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Priority claimed from US12/581,825 external-priority patent/US8297254B2/en
Priority claimed from US12/653,085 external-priority patent/US8635985B2/en
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Publication of CN102712540A publication Critical patent/CN102712540A/zh
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B19/00—Apparatus or processes specially adapted for manufacturing insulators or insulating bodies
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M51/00—Fuel-injection apparatus characterised by being operated electrically
    • F02M51/06—Injectors peculiar thereto with means directly operating the valve needle
    • F02M51/061—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means
    • F02M51/0625—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures
    • F02M51/0664—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures having a cylindrically or partly cylindrically shaped armature, e.g. entering the winding; having a plate-shaped or undulated armature entering the winding
    • F02M51/0671—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures having a cylindrically or partly cylindrically shaped armature, e.g. entering the winding; having a plate-shaped or undulated armature entering the winding the armature having an elongated valve body attached thereto
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C10/00—Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition
    • C03C10/0036—Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition containing SiO2, Al2O3 and a divalent metal oxide as main constituents
    • C03C10/0045—Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition containing SiO2, Al2O3 and a divalent metal oxide as main constituents containing SiO2, Al2O3 and MgO as main constituents
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C10/00—Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition
    • C03C10/0054—Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition containing PbO, SnO2, B2O3
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C10/00—Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition
    • C03C10/16—Halogen containing crystalline phase
    • C—CHEMISTRY; METALLURGY
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    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C4/00—Compositions for glass with special properties
    • C03C4/16—Compositions for glass with special properties for dielectric glass
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    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
    • C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
    • C04B35/195—Alkaline earth aluminosilicates, e.g. cordierite or anorthite
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    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
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    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/0071—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability making use of a rise in pressure
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F02M21/02—Apparatus for supplying engines with non-liquid fuels, e.g. gaseous fuels stored in liquid form for gaseous fuels
    • F02M21/0203—Apparatus for supplying engines with non-liquid fuels, e.g. gaseous fuels stored in liquid form for gaseous fuels characterised by the type of gaseous fuel
    • F02M21/0215—Mixtures of gaseous fuels; Natural gas; Biogas; Mine gas; Landfill gas
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    • F02M21/00—Apparatus for supplying engines with non-liquid fuels, e.g. gaseous fuels stored in liquid form
    • F02M21/02—Apparatus for supplying engines with non-liquid fuels, e.g. gaseous fuels stored in liquid form for gaseous fuels
    • F02M21/0218—Details on the gaseous fuel supply system, e.g. tanks, valves, pipes, pumps, rails, injectors or mixers
    • F02M21/0248—Injectors
    • F02M21/0275—Injectors for in-cylinder direct injection, e.g. injector combined with spark plug
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M31/00—Apparatus for thermally treating combustion-air, fuel, or fuel-air mixture
    • F02M31/20—Apparatus for thermally treating combustion-air, fuel, or fuel-air mixture for cooling
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M33/00—Other apparatus for treating combustion-air, fuel or fuel-air mixture
    • F02M33/02—Other apparatus for treating combustion-air, fuel or fuel-air mixture for collecting and returning condensed fuel
    • F02M33/08—Other apparatus for treating combustion-air, fuel or fuel-air mixture for collecting and returning condensed fuel returning to the fuel tank
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M51/00—Fuel-injection apparatus characterised by being operated electrically
    • F02M51/06—Injectors peculiar thereto with means directly operating the valve needle
    • F02M51/061—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means
    • F02M51/0625—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures
    • F02M51/0664—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures having a cylindrically or partly cylindrically shaped armature, e.g. entering the winding; having a plate-shaped or undulated armature entering the winding
    • F02M51/0685—Injectors peculiar thereto with means directly operating the valve needle using electromagnetic operating means characterised by arrangement of mobile armatures having a cylindrically or partly cylindrically shaped armature, e.g. entering the winding; having a plate-shaped or undulated armature entering the winding the armature and the valve being allowed to move relatively to each other or not being attached to each other
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M53/00—Fuel-injection apparatus characterised by having heating, cooling or thermally-insulating means
    • F02M53/04—Injectors with heating, cooling, or thermally-insulating means
    • F02M53/043—Injectors with heating, cooling, or thermally-insulating means with cooling means other than air cooling
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M57/00—Fuel-injectors combined or associated with other devices
    • F02M57/06—Fuel-injectors combined or associated with other devices the devices being sparking plugs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
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    • F02M61/04—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00 having valves, e.g. having a plurality of valves in series
    • F02M61/10—Other injectors with elongated valve bodies, i.e. of needle-valve type
    • F02M61/12—Other injectors with elongated valve bodies, i.e. of needle-valve type characterised by the provision of guiding or centring means for valve bodies
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F02M61/18—Injection nozzles, e.g. having valve seats; Details of valve member seated ends, not otherwise provided for
    • F02M61/1893—Details of valve member ends not covered by groups F02M61/1866 - F02M61/188
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C2218/00—Methods for coating glass
    • C03C2218/30—Aspects of methods for coating glass not covered above
    • C03C2218/345—Surface crystallisation
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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Abstract

本公开的一个实施例涉及一种绝缘体，所述绝缘体包括陶瓷组合物、结晶晶粒、以及第一区域和第二区域，其中所述陶瓷组合物包含约25-60％SiO2；15-35％R2O3，其中R2O3为3-15％B2O3和5-25％Al2O3；4-25％MgO+0-7％Li2O，其中MgO+Li2O总共为约6-25％之间；2-20％R2O，其中R2O为0-15％Na2O、0-15％K2O、0-15％Rb2O；0-15％Rb2O；0-20％Cs2O；以及4-20％F；其中所述结晶晶粒基本上取向为在第一方向上延伸，以在与所述第一方向垂直的方向上提供改进的绝缘性质，其中所述第一方向为周向，且与所述第一方向垂直的方向为径向；其中所述第一区域处于压缩中，且所述第二区域处于张紧中。

Description

陶瓷绝缘体及其使用和制造方法
相关申请的交叉引用
本申请要求如下申请的优先权和权益：2009年8月27日提交的名称为“OXYGENATED FUEL PRODUCTION”的美国临时申请No.61/237,425；2009年8月27日提交的名称为“MULTIFUEL MULTIBURST”的美国临时申请No.61/237,466；2009年8月27日提交的名称为“FULL SPECTRUMENERGY”的美国临时申请No.61/237,479；2009年10月19日提交的名称为“MULTIFUEL STORAGE，METERING AND IGNITION SYSTEM”的美国专利申请No.12/581,825；2009年12月7日提交的名称为“INTEGRATED FUEL INJECTORS AND IGNITERS AND ASSOCIATED METHODS OF USE AND MANUFACTURE”的美国专利申请No.12/653,085；2009年12月7日提交的名称为“INTEGRATED FUEL INJECTORS AND IGNITERS AND ASSOCIATED METHODS OF USE AND MANUFACTURE”的PCT申请No.PCT/US09/67044；2010年2月13日提交的名称为“FULLSPECTRUM ENERGY AND RESOURCE INDEPENDENCE”的美国临时申请No.61/304,403；以及2010年3月9日提交的名称为“SYSTEM ANDMETHOD FOR PROVIDING HIGH VOLTAGE RF SHIELDING，FOR EXAMPLE，FOR USE WITH A FUEL INJECTOR”的美国临时申请No.61/312,100。这些申请的每一个以全文引用的方式并入本文。
技术领域
如下公开总体上涉及改进的材料，包括改进的介电绝缘体。
背景技术
长期需要可交换地使用甲烷、氢或甲烷及氢的混合物作为低温液体或压缩气体代替火花点火式发动机中的汽油。但是该目标还未令人满意地实现，因此，尽管甲烷的成本和可再生氢的许多形式的成本比汽油低得多，绝大多数机动车辆仍使用汽油。类似地，长期以来的目标是可交换地使用甲烷、氢或甲烷及氢的混合物作为低温液体和/或压缩气体代替压缩点火式发动机中的柴油燃料，但该目标被证实为甚至更难，且大多数柴油发动机仍使用污染性的且更昂贵的柴油燃料。
常规的火花点火系统包括高电压、但低电离能的包括空气和燃料的混合物。约0.05至0.15焦耳的常规火花能量级对于以12∶1或更低的压缩比运行的装配火花塞的正常吸气式发动机而言是典型的。在火花隙中的更高环境压力下，必须增加产生这种电离的足够电压。需要更高电压的因素包括更低的空气-燃料比和更大的火花隙(如点火可能所需)、有效压缩比的增加、增压、和对进入燃烧室的的空气的阻抗量的降低。常规火花点火系统不能提供足够的电压产生以在发动机(如压缩比为16∶1至22∶1的柴油发动机)中可靠地提供火花点火，且常常不能将足够的电压提供给为了增加的动力产生和改进的燃油经济而增压的无节气门发动机。这些问题也困扰替代或混合燃料发动机。
不能在火花隙提供足够的电压大多是由于点火系统部件(如火花塞瓷和火花塞线)的介电强度不足。施加至基本上在燃烧室的壁上的常规火花塞的高电压导致燃烧的均匀空气-燃料混合物的热损失，所述燃烧的均匀空气-燃料混合物在燃烧室的所有表面处或接近燃烧室的所有表面，所述燃烧室包括活塞、汽缸壁、汽缸盖和阀门。这种热损失降低了发动机效率，并可劣化燃烧室部件，所述燃烧室部件易受如下的影响：氧化、腐蚀、热疲劳、由于热膨胀、变形、翘曲而导致的增加的摩擦、以及由于被过热或氧化的润滑膜的活性损失而导致的磨损。
另外，现代发动机缺乏具有足够的介电强度和耐久性的电绝缘部件，所述足够的介电强度和耐久性用于保护必须承受高电压的循环施加、电晕放电、和由于冲击、振动和高温和低温的快速热循环所导致的叠加的劣化的部件。类似地，现代柴油发动机的燃烧室设计为具有用于“铅笔”型直接燃料喷射器的极小直径的端口，所述“铅笔”型直接燃料喷射器必须安装在典型的顶阀式发动机头的复杂且紧密拥挤的进气阀和排气阀运行机构内。进入燃烧室的典型的柴油燃料喷射器的端口直径限于约8.4mm(0.331”)。除了这种严重的空间限制之外，对于大多数百万英里寿命要求，热的润滑油在阀盖内的发动机头环境中不断喷溅而将燃料喷射器组件加热至超过115℃(240°F)，这阻止了常规风冷电磁阀设计的应用。
非常需要克服将柴油发动机运行局限于压缩点火的要求、具有窄的十六烷值和粘度的柴油燃料的使用、以及消除粒子和水的严格要求。存在具有少得多的替代成本的更丰富的燃料选择的可能，其中所述燃料具有十六烷值和/或辛烷值的较大差异以及杂质，如水、氮气、二氧化碳、一氧化碳和各种颗粒。
为了提供从对化石燃料的经济依赖性的平稳过渡，非常需要能够可交换地使用常规柴油燃料或汽油以及可再生燃料，如氢、甲烷或燃料酒精。在通过如下方式使用柴油燃料的情况中需要改进的绝缘体：当柴油燃料进入燃烧室时，将足够的等离子体能量施加至柴油燃料以引起柴油燃料分子的极快速的蒸发和裂解或细分，并产生点火离子以由此克服压缩点火的难以克服的问题和局限。
因此，本领域需要改进的绝缘体和材料以及制造和使用方法，例如，用于多燃料发动机的点火系统部件中的具有改进耐久性和介电强度的材料。
附图说明
图1为根据本公开的一个实施例构造的一体化喷射器/点火器的示意性横截面侧视图。
图2为根据本公开的一个实施例构造的喷射器的横截面局部侧视图。
图3A为根据本公开的一个实施例构造的绝缘体或介电体的侧视图，且图3B为基本上沿着图3A的线3B-3B获得的横截面侧视图。
图4A和4B为基本上沿着图2的线4-4获得的横截面侧视图，其示出了根据本公开的另一实施例构造的绝缘体或介电体。
图5A和5B为根据本公开的另一实施例在所需区域中使用压缩应力形成绝缘体或介电体的系统的示意性说明。
图6为根据本公开的一个实施例构造的喷射器/点火器的示意性横截面侧视图。
图6A和6B为图6的主体602的横截面侧视图，其示出了根据本公开的另一实施例构造的绝缘体或介电体。
具体实施方式
本申请以全文引用的方式并入2008年1月7日提交的名称为“MULTIFUEL STORAGE，METERING，AND IGNITION SYSTEM”的美国专利申请No.12/006,774(现在为美国专利No.7,628,137)的主题。本申请以全文引用的方式并入同时于2010年7月21日提交的如下美国专利申请的每一个的主题，所述美国专利申请的名称如下：“INTEGRATED FUELINJECTORS AND IGNITERS AND ASSOCIATED METHODS OF USE ANDMANUFACTURE”(代理人案号No.69545-8031US)；“FUEL INJECTORACTUATOR ASSEMBLIES AND ASSOCIATED METHODS OF USE ANDMANUFACTURE”(代理人案号No.69545-8032US)；“INTEGRATED FUELINJECTORS AND IGNITERS WITH CONDUCTIVE CABLE ASSEMBLIES”(代理人案号No.69545-8033US)；“SHAPING A FUEL CHARGE IN ACOMBUSTION CHAMBER WITH MULTIPLE DRIVERS AND/ORIONIZATION CONTROL”(代理人案号No.69545-8034US)；“METHODAND SYSTEM OF THERMOCHEMICAL REGENERATION TO PROVIDEOXYGENATED FUEL，FOR EXAMPLE，WITH FUEL-COOLED FUELINJECTORS”(代理人案号No.69545-8037US)；以及“METHODS ANDSYSTEMS FOR REDUCING THE FORMATION OF OXIDES OFNITROGEN DURING COMBUSTION IN ENGINES”(代理人案号No.69545-8038US)。
为了全面了解获得根据本发明的上述细节和其他优点和目的的方式，将参照本发明的具体实施例提供本发明的更详细的描述。
在如下描述和附图中提出某些细节以提供对本公开的各种实施例的深入了解。然而，其他细节描述了公知的结构和系统。应理解，提供如下提出的若干细节，从而以足以使相关领域技术人员能够制造和使用所公开的实施例的方式描述如下实施例。然而，如下描述的多个细节和优点对于实施本公开的某些实施例可能不是必需的。附图所示的许多细节、尺寸、角度、形状和其他部件仅说明了本公开的特定实施例。因此，在不偏离本公开的精神和范围下，其他实施例可具有其他细节、尺寸、角度和部件。另外，本领域普通技术人员将理解本公开的另外的实施例可在无若干如下所述的细节下实施。
在整个说明书中，提及“一个实施例”或“实施例”意指关于所述实施例描述的特定部件、结构或特性包括于本公开的至少一个实施例中。因此，在整个说明书各处的短语“在一个实施例中”或“在实施例中”的出现不必需均指同一实施例。此外，特定部件、结构或特性可在一个或多个实施例中以任何合适的方式组合。本文提供的标题仅为了方便，且不解释所要求保护的本公开的范围或含义。
图1为根据本公开的一个实施例构造的一体化喷射器/点火器110(“喷射器110”)的示意性横截面侧视图。图1所示的喷射器110被构造为将不同的燃料喷入燃烧室104中，并基于燃烧室104中的燃烧性质和条件适应性地调节燃料喷射或爆炸的方式和/或频率。如在下文详细解释，喷射器110可优化喷入的燃料以进行快速点火和完全燃烧。除了喷射燃料之外，喷射器110包括被构造为点燃喷入的燃料的一个或多个一体化点火部件。同样，喷射器110可用于将常规内燃机转化为能够以多种不同的燃料运行。
根据所示实施例的一个方面，主体112的至少一部分由一种或多种介电材料117制成，所述一种或多种介电材料117适于使高能点火能够燃烧不同的燃料，包括未精制燃料或低能量密度燃料。这些介电材料117可提供高电压的足够电绝缘，所述高电压用于产生、分离和/或递送用于点火的火花或等离子体。在某些实施例中，主体112可由单个介电材料117制成。然而，在其他实施例中，主体112可包括两种或更多种介电材料。例如，中间部分116的至少一部分可由具有第一介电强度的第一介电材料制成，且喷嘴部分118的至少一部分可由具有第二介电强度的介电材料制成，所述第二介电强度大于所述第一介电强度。具有相对更强的第二介电强度的第二介电材料可保护喷射器110免于热冲击和机械冲击、污染、电压跟踪等。合适的介电材料的例子，以及这些材料在主体112上的位置在下文详细描述。
介电部件
在一方面，图2为喷射器210的横截面局部侧视图。图2所示的喷射器210示出了根据本公开的数个实施例可使用的介电材料的数个部件。所示喷射器210包括数个部件，所述数个部件在结构和功能上可至少通常类似于参照图1如上描述的喷射器的对应部件。例如，喷射器210包括主体212，所述主体212具有从中间部分216延伸的喷嘴部分218。喷嘴部分218延伸至发动机头207中的开口或进口209。许多发动机(如柴油发动机)具有进口209，所述进口209具有极小的直径(例如直径大约为7.09mm或0.279英寸)。对于本公开所设想的燃料物质(例如，比柴油燃料的能量密度低大约3,000倍的燃料)的火花点火或等离子体点火，这种小空间具有提供足够的绝缘的难度。然而，如下文所详细描述，本公开的喷射器具有主体212，所述主体212具有介电材料或绝缘材料，所述介电材料或绝缘材料可为点火线提供足够的电绝缘，以产生用于在极小空间中产生、分离和/或递送点火活动(例如火花或等离子体)的所需高电压(例如60,000伏)。这些介电材料或绝缘材料也被构造用于获得稳定性和抵抗由于循环暴露于由燃烧所产生的高温高压气体而导致的氧化或其他劣化的保护。而且，如下文所详细解释，这些介电材料可被构造为一体化从燃烧室至传感器的光或电通讯通路，如转换器、测量仪器(instrumentation)、滤波器、放大器、控制器和/或计算机。此外，所述绝缘材料可在密封位置与主体212的金属基部分214钎焊或扩散结合。
螺旋缠绕的介电部件
根据图2所示的喷射器210的主体212的另一方面，包括喷射器210的中间部分216和/或喷嘴部分218的介电材料示于图3A和3B中。更具体地，图3A为绝缘体或介电体312的侧视图，且图3B为基本上沿着图3A的线3B-3B获得的横截面侧视图。尽管图3A所示的主体312具有通常圆柱形的形状，但在其他实施例中，主体312可包括其他形状，包括例如，从主体312向燃烧室界面331延伸的喷嘴部分。一起参照图3A和3B，在所示实施例中，介电体312由螺旋或缠绕的基层328组成。在某些实施例中，基层328可为人造云母或天然云母(例如无针孔云母纸)。然而，在其他实施例中，基层328可由其他材料组成，所述其他材料适于提供与相对较薄的材料相关的足够的介电强度。在所示的实施例中，基层328的一侧或两侧由相对较薄的介电涂层330覆盖。涂层330可由高温高纯度聚合物制成，所述高温高纯度聚合物如Teflon NXT、Dyneon TFM、聚对亚苯基二甲基HT、聚醚砜和/或聚醚醚酮。然而，在其他实施例中，涂层330可由其他材料制成，所述其他材料适于充分密封基层328。
基层328和涂层330可被紧紧缠绕成螺旋形状而形成管，由此提供组合的基层328和涂层330的片的连续层。在某些实施例中，可使用合适的粘合剂(例如陶瓷接合剂)以缠绕结构结合这些层。在其他实施例中，可用聚合物、玻璃、热解法二氧化硅或其他合适的材料浸渍这些层，以使主体312能够以紧紧缠绕的管状而被卷绕。而且，主体312的片或层可通过连续施用不同的膜而被分离。例如，主体312的层之间的分离膜可包括聚对亚苯基二甲基N膜层、聚对亚苯基二甲基C膜层、聚对亚苯基二甲基HT膜层、和/或通过施用其他材料选择而分离的层，所述其他材料选择例如薄氮化硼、聚醚砜或聚烯烃(如聚乙烯)或其他合适的分离材料。这种膜分离也可通过温度或压力测量仪器纤维(包括例如单晶蓝宝石纤维)而实现。这种纤维可通过激光加热基座生长技术而制得，并随后用全氟乙烯丙烯(FEP)或具有类似折射率值的其他材料涂布，以防止能量从所述纤维渗漏至围绕这种纤维的潜在吸收的膜中。
当涂层330以相对较薄的膜(例如0.1至0.3mm)施用时，涂层330可提供在-30℃(例如-22°F)直至约230℃(例如450°F)下大约2.0至4.0千伏/0.001″的介电强度。本发明人已发现，具有更大厚度的涂层330可能不提供足够的绝缘以提供点火活动的所需电压。更具体地，如下表1所反映，具有更大厚度的涂层具有显著降低的介电强度。当需要在燃烧室产生点火活动(例如火花或等离子体)之时，这些降低的介电强度可能不足以防止绝缘体312的弧穿和电流泄漏。例如，在具有高压缩压力的许多发动机(如典型的柴油发动机或增压式发动机)中，引发点火活动(例如火花或等离子体)所需的电压为大约60,000伏特或更高。包括管状绝缘体的常规介电体可仅提供500伏特/.001″，且无法充分容纳这种所需电压，所述管状绝缘体仅具有0.040英寸或更大的有效壁厚并由常规绝缘体制成。
表1：所选配方的介电强度比较
图3A和3B所示的绝缘体主体312的实施例可在-30℃(例如-22°F)直至大约450℃(例如840°F)的温度下提供大约3,000伏/0.001″的介电强度。而且，涂层330还可用作基材328的密封剂，以防止燃烧气体和/或其他污染物进入主体312。涂层330还可提供足够不同的折射率，以改进延伸通过主体312的光学通讯器的光透射通过主体213的效率。
根据所示实施例的另一特征，主体312在基层328的片或层之间包括纵向延伸通过主体312的多个通讯器332。在某些实施例中，通讯器332可为导体，如高电压火花点火线或电缆。这些点火线可由金属线制成，所述金属线用经氧化的铝绝缘或涂布，由此在所述线上提供氧化铝。由于通讯器332在相应的基层328之间纵向延伸通过主体312，因此通讯器332不参与径向向外延伸通过主体312的任何充电(charge)。因此，通讯器332不影响或劣化主体312的介电性质。除了递送用于点火的电压之外，在某些实施例中，通讯器332还可被操作性地联接至一个或多个致动器和/或控制器，以驱动用于燃料喷射的流量阀。
在其他实施例中，通讯器332可被构造为将燃烧数据从燃烧室传输至一个或多个转换器、放大器、控制器、滤波器、测量仪器、计算机等。例如，通讯器332可为光学纤维或由光学层或光学纤维形成的其他通讯器，所述光学层或光学纤维如石英、氟化铝、ZBLAN氟化物、玻璃、和/或聚合物、和/或适于通过喷射器传输数据的其他材料。在其他实施例中，通讯器332可由合适的传输材料制成，所述传输材料例如锆、钡、镧、铝和钠氟化物(ZBLAN)、以及陶瓷或玻璃管。
介电部件的晶粒取向
再次参照图2，根据图2所示的喷射器210的另一实施例，主体212的介电材料(例如中间部分216和/或喷嘴部分218)可被构造为具有特定的晶粒取向，以获得能够承受与本公开相关的高电压的所需介电性质。例如，晶粒结构可包括周向排列以及围绕管状主体212成层的结晶晶粒，由此在外表面形成压缩力，所述压缩力由表面下张力平衡。更具体地，图4A和4B为基本上沿着图2的线4-4获得的介电体412的横截面侧视图，所述介电体412根据本公开的另一实施例构造。首先参照图4A，主体412可由具有高介电强度的陶瓷材料制成，所述陶瓷材料如石英、蓝宝石、玻璃基质和/或其他合适的陶瓷。
如在示出的实施例中所示，主体412包括在通常同一方向上取向的结晶晶粒434。例如，晶粒434取向为每个单独的晶粒434具有在围绕主体412通常周向延伸的方向上排列的纵向轴线。具有在所述取向上成层的晶粒434的主体412在主体412的几乎任何厚度中提供优良的介电强度。这是因为成层的长的平直晶粒不提供从主体412径向向外的良好导电通路。
图4B示出了在主体412的特定区域中的压缩力。更具体地，根据图4B所示的实施例，主体412已被处理，以在与主体412的外部外表面437和内部外表面438相邻的一个或多个压缩区域435(即包括取决于晶粒434的取向的压缩力的区域)中至少部分排列晶粒434。主体412还在压缩区域435之间包括晶粒434的非压缩区域436。非压缩区域436在主体412的中间部分提供平衡张力。在某些实施例中，压缩区域435中的每一个可每体积包括更多的晶粒434以获得压缩力。在其他实施例中，压缩区域435中的每一个可包括晶粒434，所述晶粒434已被影响以保持局部无定形结构，或已通过产生无定形结构或结晶晶格而被改性，所述无定形结构或结晶晶格具有比非压缩区域436的晶粒434更小的充填效率。在另外的实施例中，由于离子注入、溅镀的表面层和/或一种或多种物质向表面中的扩散使得表面具有比主体412的非压缩区域436更低的充填效率，可导致外表面437和内表面438处于压缩中。在图4B所示的实施例中，在主体412的外部表面437和内表面438处的压缩区域435提供了更高的各向异性介电强度。
图4B所示的实施例的一个益处在于，由于在压缩区域435和非压缩区域436中充填效率的所述差异，导致在压缩中的表面处于压缩中并变得显著更耐久且抗断裂或劣化。例如，这种压缩力发展至少部分防止了可能在主体412中形成导电通道并由此降低主体412的介电常数的物质(例如具有溶解物质的电解质(如水)、富碳材料等)的进入。这种压缩力发展也至少部分防止了主体412源于热冲击和/或机械冲击的劣化，所述热冲击和/或机械冲击来自每个燃烧活动的暴露于快速变化的温度、压力、化学降解剂和冲力。例如，特别构造图4B所示的实施例以获得主体412的持久电压容纳、增加的抗断裂强度，所述断裂是由于高载荷力(包括点载荷)以及低循环疲劳力或高循环疲劳力导致的。
与压缩区域435结合的取向的结晶晶粒434的另一益处在于，晶粒434的所述构造提供了用于容纳在主体412上设立的电压的最大介电强度。例如，所述构造在大于1mm或0.040英寸厚的部分中提供了高达2.4KV/.001英寸的显著的介电强度提高。相比于不具有这种新的晶粒特性并具有仅大约1.0至1.3KV/.001英寸的介电强度的相同陶瓷组合物，这些为明显更高的值。
用于制备具有压缩表面特征的如上所述的绝缘体的数个方法如下详细描述。在一个实施例中，例如，根据本公开的一个实施例构造的绝缘体可由美国专利No.3,689,293所公开的材料制成，所述专利以全文引用的方式并入本文。例如，绝缘体可由包含如下成分的材料制成(以重量计)：25-60％SiO2、15-35％R2O3(其中R2O3为3-15％B2O3和5-25％Al2O3)、4-25％MgO+0-7％Li2O(MgO+Li2O总共为约6-25％之间)、2-20％R2O(其中R2O为0-15％Na2O、0-15％K2O、0-15％Rb2O)、0-15％Rb2O、0-20％Cs2O，并具有4-20％F。更具体地，在一个实施例中，说明性配方由43.9％SiO2、13.8％MgO、15.7％Al2O3、10.7％K2O、8.1％B2O3和7.9％F组成。然而，在其他实施例中，根据本公开的实施例构造的绝缘体可由这些构成材料的更高或更低百分比制成，以及由不同的材料制成。
根据本公开的一个实施例，将构成绝缘体的成分球磨并在合适的密闭坩埚中熔化，已使得所述合适的密闭坩埚对形成所述绝缘体的构成成分的配方不渗透且无反应性。所述成分保持在大约1400℃(例如2550°F)一段时间，所述时间确保彻底混合熔化的配方。熔体随后冷却，并与添加剂一起再次球磨，所述添加剂可选自粘合剂、润滑剂和助燃剂。所述成分随后以各种所需的形状(包括例如管)挤出，并加热至约800℃(1470°F)在转化温度以上一定时间。在转化温度以上加热促进了氟云母晶体成核。挤出的成分随后可被进一步加热，并在约850-1100℃(1560-2010°F)下压力成型或挤出。所述第二加热导致正在形成的晶体变得成形(如上文通常所述)，以使在所得产品的优选方向上的介电强度最大化。
随着晶粒的体积充填效率增加和相应的密度增加，这种材料的结晶，包括例如包含K2Mg5Si8O20F4的组成的云母玻璃，产生放热释热。转化活动，如成核、放热释热速率、结晶表征和结晶温度，随着绝缘体的氟含量和/或B2O3含量而变化。因此，通过控制这些变量而加工所述绝缘体使得能够改进产率、拉伸、疲劳强度和/或介电强度、以及增加所述绝缘体的耐化学性。
这提供了最大介电强度的重要的新的各向异性结果，所述各向异性结果可通过定向成型设计和获得，所述定向成型包括将前体管挤出为更小直径或更薄壁的管材以产生细长的和/或取向的晶体晶粒，所述细长的和/或取向的晶体晶粒对于成型和成层以或多或少地围绕所需特征的代表性群体是典型的，所述所需特征例如通过顺应用于实现这种热成型或挤出的心轴而产生的内径。
根据另一实施例，至少部分取向和/或压缩根据所示实施例的图4A/B的晶粒434的方法可通过将B2O3和/或氟加入表面而实现，所述表面需要在成型和热处理的产品的基材中变得受到压缩应力以对抗平衡拉伸应力。B2O3、氟或类似的促动剂的这种添加可以以类似于掺杂剂的方式完成，所述掺杂剂被加入并扩散至半导体中的所需位置。这些促动剂也可作为通过喷溅、气相沉积、涂漆和/或洗涤而施用的组分配方的富集配方而施用。此外，这些促动剂通过反应物呈递(presentation)和缩合反应制得。
在需要变得压缩负载的表面处或接近需要变得压缩负载的表面增加材料的B2O3和/或氟含量引起氟云母晶体的更快速的成核。相比于配方的非压缩基材区域，所述成核导致更大数量的更小晶体与扩散添加的材料竞争。因此，所述过程在非压缩基材区域中提供了比在压缩区域中更大的充填效率，所述压缩区域更接近接收B2O3、氟和/或其他促动剂(产生另外的氟云母晶体的成核)的富集的表面。因此，所需的表面压缩预负载加强了对抗点火活动和化学试剂的部件。
根据在相应的基材中产生或增强由张力平衡的压缩力的另一方法包括加热待设置为压缩的目标区域。可充分加热目标区域以将晶体再溶解为无定形结构。然后可将基材淬火以充分保持无定形结构的显著部分。取决于涉及的部件类型，这种加热可在炉中。这种加热也可为通过来自电阻加热源或反应加热源的辐射，以及通过电子束或激光。所述过程的另一变型为通过如下方式提供增加数量的更小晶体或晶粒以产生所需的压缩应力：热处理和/或将结晶成核和生长刺激剂(例如B2O3和/或氟)加入部分溶解的区域以快速提供重结晶。
制造系统
图5A示意性地示出了根据本公开的另一实施例的用于实施方法的系统500a，所述方法包括熔化和挤出以形成在所需区域中具有压缩应力的绝缘体。更具体地，在所示的实施例中，系统500a包括可由耐火金属、陶瓷或热解石墨材料制成的坩埚540a。坩埚540a可包括合适的转化涂层，或不渗透且无反应性的内衬，如铂的薄选择或铂族防护涂层。坩埚540a装载有如上通常所述的配方的装料541a(例如含有如下物质的装料：大约25-60％SiO2、15-35％R2O3(其中R2O3为3-15％B2O3和5-25％Al2O3)、4-25％MgO+0-7％Li2O(其中MgO+Li2O总共为约6-25％之间)、2-20％R2O(其中R2O为0-15％Na2O、0-15％K2O、0-15％Rb2O)、0-15％Rb2O和0-20％Cs2O、以及4-20％F)，或用于制备云母玻璃的合适配方，如具有K2Mg5Si8O20F4的大概组成的材料。
所述坩埚可在保护气氛中加热并熔化装料541a。例如，坩埚540a可经由任何合适的加热方法(包括例如电阻加热、电子束加热、激光加热、感应加热、和/或通过来自由这种能量转化技术加热的源的辐射)来加热装料541a。在合适的混合和熔化而产生基本上均匀的装料541a之后，封盖或封帽542a将压力施加至坩埚540a中的装料541a。气源543a还可将惰性气体和/或工艺气体施用至由封帽542a密封的坩埚540a中。调压器544a可调节坩埚540a中的压力，以使得熔化的装料541a流入模头组件545a中。模头组件545a被构造为形成管状介电体。模头组件545a包括接收阳心轴547a的阴套筒546a。模头组件545a还包括一个或多个加固翼片式支架548a。成型的管材流动通过模头组件545a进入第一区域549a，在所述第一区域549a中所述成型的管材被冷却以作为无定形材料固化并开始氟云母晶体的成核。随后模头组件545a使所述管材前进至第二区域550a，以通过降低所述管材的壁厚而进行进一步细化，从而进一步促进氟云母晶体的结晶。
图5B示意性地示出了根据本公开的另一实施例的用于实施方法的系统500b，所述方法也包括熔化和挤出以形成在所需区域中具有压缩应力的绝缘体。更具体地，在所示的实施例中，系统500b包括可由耐火金属、陶瓷或热解石墨材料制成的坩埚540b。坩埚540b可包括合适的转化涂层，或不渗透且无反应性的内衬，如铂的薄选择或铂族防护涂层。坩埚540b装载有如上通常所述的配方的装料541b(例如含有如下物质的装料：大约25-60％SiO2、15-35％R2O3(其中R2O3为3-15％B2O3和5-25％Al2O3)、4-25％MgO+0-7％Li2O(其中MgO+Li2O总共为约6-25％之间)、2-20％R2O(其中R2O为0-15％Na2O、0-15％K2O、0-15％Rb2O)、0-15％Rb2O和0-20％Cs2O、以及4-20％F)，或用于制备云母玻璃的合适配方，如具有K2Mg5Si8O20F4的大概组成的材料。
系统500b还可包括封盖或封帽542b，所述封盖或封帽542b包括反射组件543b和加热器544b。系统500b可在保护气氛中(如在真空中或使用在坩埚540b和封盖542b之间的惰性气体)加热并熔化装料741b。例如，系统500b可经由坩埚加热器545b、封盖加热器544b和/或经由任何合适的加热方法(包括例如电阻加热、电子束加热、激光加热、感应加热和/或通过来自由这种能量转化技术加热的源的辐射)来加热装料541b。在合适的混合和熔化而产生基本上均匀的装料541b之后，封盖542b将压力施加至坩埚540b中的装料541b。气源546b还可将惰性气体和/或工艺气体施用至由封帽542b在密封界面547b处密封的坩埚540b中。调压器可调节坩埚540b中的压力，以使得熔化的装料541b流入模头组件549b中。模头组件549b被构造为形成管状介电体。模头组件749b包括接收阳心轴551b的阴套筒550b。模头组件549b还可包括一个或多个加固翼片式支架552b。成型的管材501b流动通过模头组件549b进入第一区域553b，在所述第一区域553b中所述成型的管材501b被冷却以作为无定形材料固化并开始氟云母晶体的成核。
随后旋转模头组件549b的至少一部分(包括具有成核的氟云母玻璃的成型的管材501b)，或将其移动至与第二模头组件对齐的位置502b。圆筒555b将成型的管材501b从第一区域556b推动至第二区域557b。在第二区域557b中，所述第二模头组件可再加热成型的管材501b以加速晶体生长，因为其进一步细化以继续产生如上所述的优选取向的晶粒。随后使成型的管材501b前进至第三区域558b以进行进一步的晶粒细化和取向。第三区域558b的所选接触区域有时可撒上或涂布晶粒成核促进剂，包括例如AlF3、MgF2和/或B2O3。在第三区域558b中，通过降低成型的管材501b的壁厚而进一步细化成型的管材501b，以甚至进一步促进氟云母晶体的结晶，并因此在根据如上所述的晶粒结构的区域中产生所需的压缩力，以及在如上所述的区域中产生平衡张力。之后，成型的管材501b可沉积在用于移动所述成型的管材501b的输送机559b上，所述成型的管材501b包括由受到压缩应力且不渗透的表面所形成的特别高的物理强度和介电强度。
用于制备具有这些改进介电性质的绝缘管材的可选择的系统和方法可使用公开于美国专利No.5,863,326(其以全文引用方式并入本文)中的压力梯度，以产生所需形状、粉末压制和烧结过程。另外的系统和方法可包括公开于美国专利No.5,549,746(其以全文引用方式并入本文)中的单晶转化方法，以及公开于美国专利3,608,050(其以全文引用方式并入本文)中的成型方法，以将多晶材料转化为具有高得多的介电强度的基本上单晶材料。根据本公开的实施例，仅具有大约0.3至0.4KV/.001″的介电强度的多晶材料(例如氧化铝)向单晶材料的转化可获得至少大约1.2至1.4KV/.001″的介电强度。所述改进的介电强度允许在各种应用中使用根据本公开的喷射器，所述应用包括例如，具有进入燃烧室的极小端口的高压缩柴油机，以及高增压发动机和高增压涡轮增压发动机。
根据用于形成具有高介电强度的绝缘体的本公开的另一实施例，绝缘体可由表2所示的任意组合物形成。更具体地，根据本公开的数个实施例，表2提供了以氧化物计的大概重量百分比组成的说明性的配方选择。
表2：说明性的介电组合物
可在大约1300-1400℃下在覆盖的坩埚中球磨并熔化可提供最终氧化物组成百分比的所选物质前体(如表2所示的材料)大约4小时，以提供均匀溶液。随后可铸塑所述熔体以形成管，所述管随后在大约500-600℃下退火。管可随后在大约750℃下被进一步热处理大约4小时，随后撒上成核刺激剂(如B2O3)。所述管可随后在大约1100至1250℃下重整，以刺激成核并产生所需的晶体取向。这些管还可被进一步热处理大约4小时，以提供至少大约2.0至2.7KV/.001″的介电强度。
在另外的实施例中，所述均匀溶液可被球磨，并提供有用于环境温度挤出的合适的粘合剂和润滑添加剂，以制备良好的管材表面。随后，所得管材可用含有成核刺激剂(如B2O3)的膜涂布并进行热处理，以提供至少大约1.9至2.5KV/.001″的介电强度和改进的物理强度。取决于保持管材的合适尺寸(包括例如，被挤出的管材的“圆度”或管材的轮廓)的能力，可提供更高的热处理温度进行更短时间以提供类似高介电强度和高物理强度性质。
用于制备如上所述的介电材料的系统和方法的实施例有利于材料的各种组合的改进的介电强度，由此解决了燃烧低能量密度燃料所需的高电压容纳的极困难的问题。例如，具有高介电强度材料的喷射器可为极稳定的，并能够使用由固体、液体和蒸气的低温混合物变化至过热柴油燃料、以及其他类型的燃料的燃料进行运行。
在另一方面，本文公开的高强度介电材料实施例还使利用可长时间储存的各种烃类的新方法能够通过发动机-发电机-热交换器的各种组合和应用提供热量和电力，以用于紧急救援和赈灾目的，包括冷冻储存和制冰以及纯水和/或安全水和杀菌装置以支持医疗努力。可加热低蒸气压和/或粘性燃料物质以产生足够的蒸气压和降低的粘度，从而快速流动并产生迅速完成分层或成层装料燃烧过程的具有高面积体积比的燃料喷射爆炸。举例而言，大块石蜡、压缩纤维素、稳定化的动物油脂或植物油脂、焦油、各种聚合物(包括聚乙烯)、蒸馏残余物、等外柴油和其他长烃类烷烃、芳族化合物和环烷烃可被储存于适于灾难响应的区域中。提供长期储存益处的这些说明性燃料选择不能被常规燃料增碳或喷射系统使用。然而，本实施例提供了待加热的这种燃料，包括提供在热交换器中使用来自热力发动机的热冷却剂或排气流以产生足够的温度(例如大约150-425℃(300-800°F)之间)，从而提供本文公开的喷射器的直接喷射以在喷射和等离子体注入点火时极快完成燃烧。
参照图6，在另一实施例中公开了燃料喷射器装置。该实施例提供了：(1)是现有柴油燃料喷射器的高达3000倍的燃料流量，以使得能够使用低成本燃料，如填埋气、厌氧消化甲烷、以及氢和其他燃料物质以及大量非燃料物质(如水蒸气、二氧化碳和氮气)的各种混合物；(2)当这种燃料被注入燃烧室时所述燃料的等离子体点火；以及(3)在调整时柴油燃料喷射器的替换。
燃料喷射器600使用陶瓷绝缘体主体602，所述陶瓷绝缘体主体602在导电电极603和绝缘体602的外表面(如图600和602所示)之间在小于1.8mm(0.071”)厚的部分中，在兆赫直流电下提供超过80,000伏特的介电容纳。
在施加高频电压以在电极626之间建立离子电流或离子振荡的情况中，铜或银的导电层603的孔620可通过另外的电镀而增大，以提供更大的高频电导率。在替代形式中，可将绞合线编织物置于芯中的光学纤维上方以降低电阻损失。
绝缘体602由玻璃制成，所述玻璃具有配方1的以重量百分比计的大概组成。
配方1：
为了制备绝缘体602，将组合物球磨，在合适的坩埚(如铂、二氧化硅、氧化镁或氧化铝材料选择)中熔融，并挤出、压缩模塑或铸塑为适于再加热并成型为具有近净形状和尺寸的部件的块体(mass)。
在该实施例的一个方面，以重量计的合适的组成(如配方2所列)在覆盖的铂、氧化铝、氧化镁或二氧化硅坩埚中在约1350℃至1550℃之间的温度下熔融。
配方2：
管状轮廓可由在约1050℃至1200℃之间的温度下热成型的熔体或稍微冷却的材料挤出。铸塑以提供用于热挤出为管材或其他轮廓或者用于锻造成具有近净形状和尺寸的部件所需的体积的块体被缓慢冷却。将这种块体加热至用于热成型的合适温度，如约1050℃至1250℃之间，并通过挤出而成型为所需的轮廓形状和尺寸，如可通过包括耐火材料(例如铂、钼或石墨)的合适的模头所制得的那样。挤出的轮廓被撒上一种或多种合适的结晶成核剂(如BN、B2O3、AlF3、B、AlB2、AlB12或AlN)，以在所得表面区域中产生比在中心区域中更大数量的小晶体而由此降低体积充填效率，以在表面区域中提供压缩应力并在中心区域中提供拉伸应力。
如果需要，压缩应力的另外发展可通过伸长外层中的晶体而产生，所述伸长通过当挤出制品被强制形成更小的横截面(这导致这种伸长)时由模头所引起的变形和牵引进行。
更复杂的形状和形式可在超合金或石墨模具组件中压缩模塑或成型，所述超合金或石墨模具组件已被撒上合适的结晶成核剂(如B2O3或BN)以在近表面区域中产生类似的压缩应力。
在先申请需要化学配方与热处理的组合以制备可加工材料。该实施例实现了相反目的，使得其制得由于表面区域过硬而无法加工的不能被加工的制品，表面区域过硬而无法加工源于由拉伸应力平衡的压缩应力，所述拉伸应力在具有压缩应力的区域之间或与具有压缩应力的区域相邻的中心部分区域中。
该实施例克服了固有的现有技术缺点，包括制得这样的材料，所述材料被设计为在接近切削工具施加应力的区域有意裂化以使得能够逐渐形成碎片而提供可加工性。然而，允许可加工性的这种特性裂纹形成固有地允许诸如有机化合物的物质(包括发动机润滑剂、表面活性剂、手部脂肪和汗液)不利地进入所述裂纹。有机材料最终趋于脱氢或以其他方式变成供碳体，所述供碳体随后变成导电通道以及被引入所述裂纹的各种电解质而危害可加工陶瓷制品的介电强度，这最终导致电压容纳失败。本实施例补救了这些缺点。
在该实施例的另一方面，用于如图6的绝缘体602(示为管)的部件的另一合适的配方具有配方3所列的大概重量百分比：
配方3
形成具有图602所示的横截面的绝缘体602，其包括孔603和槽或通道604。在最接近燃烧室的区域，通道604通过逐渐变细进入弹性体管材正常封闭和密封的直径而被封闭，如图604所示。在绝缘体管602被挤出之后，通过将氢通过孔603而将所述绝缘体管602冷却至约650℃，这还原了氧化铜和/或氧化银而产生铜和/或银及铜的合金的金属表面。在产生导电金属603的合适厚度之后，通过合适的源(如来自围绕602的感应加热管的辐射)或通过氧化焰(如过剩的氧气-氢气火焰)加热管602的外表面，并将合适的结晶和/或细化试剂提供至所述表面以在绝缘体管602的内部内的区域中产生由张力平衡的压缩应力。
绝缘体602可通过挤出或热锻成型为管，并包括槽或通道604，所述槽或通道604用于燃料从合适的计量阀(如盘606)通过，所述计量阀对孔口608为常闭的。孔口608通过通道610连接至环形槽，所述环形槽将燃料递送至通道604，如所示。孔口608可具有合适的密封部件(如所示的O型环612)以确保在盘606对所述孔口为常闭位置时燃料流动的无泄漏关闭。
合适的套筒618可为高强度聚合物，如聚酰胺酰亚胺(Torlon)或具有Kapton、玻璃纤维或石墨增强的热固性复合材料，或者，合适的套筒618可为铝、钛或钢合金。套筒618包括合适的安装部件616，所述安装部件616使得能够快速夹固以更换在主体发动机中的之前使用的柴油燃料喷射器。密封件622可为弹性体，如FKM、Viton或氟硅氧烷弹性体，以相对燃烧室中所产生的气体密封618，并防止发动机润滑剂通入燃烧室中。
在运行中，燃料通过合适的配件652进入以冷却螺线管线圈658。在所需燃料喷射之前，在螺线管线圈658设立电流以吸引阀盘606远离环-盘磁体642。在替代方式中或另外地，当阀606打开而允许燃料流动通过区域662以经过孔口408进入通道604并到达经过密封件622的区域以打开弹性体套筒630，且允许燃料闯入电极626与通过部分620的燃烧室进入端口之间的区域时，压缩合适的盘簧646，如图6所示。弹性体套筒630对绝缘体602的圆柱形部分为常闭的，所述绝缘体602的圆柱形部分延伸超过套筒604的端部，如所示。
在选择螺线管组件而不是压电、气动、液压或机械连接用于致动阀606的应用中，通过将24至240VDC施加至绝缘线圈658而提供铁磁阀606的极快速作用运行。这可达到如下目的：在约3％至21％工作周期(取决于运行模式)中短时间产生格外高的电流和阀致动力，以能够由于热传递至燃料而冷却螺线管部件，当所述燃料通过阀606的狭槽或通道607至孔口608时，所述燃料从配件652流动以冷却线圈658，如所示。
燃料通过通道604被递送至弹性体管阀630，所述弹性体管阀630对绝缘体602为正常密封的。通过打开阀606而导致的通道604中燃料的加压迫使管阀630打开，燃料通过呈现的环形开口喷射至燃烧室中。
用于所述应用的铜磁线的合适绝缘包括在所选铜线上的聚酰亚胺漆和铝镀层，其中所述铝镀层被氧化或部分氧化而产生氧化铝。这种铝镀层和氧化也可与聚酰亚胺或聚酰胺酰亚胺或聚对亚苯基二甲基绝缘膜组合使用。具有铁磁部件666、650和662的所示组件将由线圈664产生的磁通量引导通过铁磁阀606，以使得阀606能够极快速作用。
绝缘体656可由本文给出的任意配方制得，并提供由合适的绝缘线施加的高压的容纳，所述合适的绝缘线被插入接收器660中以接触导体603，由此提供对合适源(如压电或感应变压器)的连接。可通过锻造、钎焊、焊接或者通过合适的密封剂(如环氧树脂)使绝缘体656对铁磁套筒650密封，如所示，并且绝缘体602包括铁磁盘666和662，如所示。
在希望在接触区域654处将绝缘体656线钎焊或焊接至650的情况中，可通过氧化铜和/或氧化银(如在配方3中所提供)的掩蔽或局部氢还原将相应的接触区域656金属化。或者，可通过其他合适的技术(包括喷溅或气相沉积)电镀合适的金属区域。
因此，如图6A所示，测量仪器(如光学纤维624)可被绝缘体602保护通过电极部分626和628至燃烧室670的界面。
图6B显示了燃料入口配件652的可选择的取向，以及用于产生温度压力数据并通过光纤624将这些数据递送至微处理器的设置，所述光纤624通过高压导体603的芯部，如所示。由合适的源(如变压器、电容器或压电发电机)供给的高电压通过绝缘线和介电护罩施加至端部625，并通过导电管或表面603传导至电极626，以在延续至部件628的电极626之间的环形区域中产生等离子体，所述部件628适于以所需的方式将燃料注入燃烧室中，并围绕和保护光纤624，如所示。
可选择的实施例
在其他实施例中，如上原理可适用于能够相变的其他材料，包括非陶瓷材料或其他化学。例如，在其中相变可在材料的选择性区域中选择性地引入的任意材料中，可应用如上原理以引发相变，并由此在所选区域中或在材料整体中改性材料的性质。同样，可应用如上原理以制备具有所需性质的材料，包括但不限于绝缘体。例如，在能够相变(如果使所述材料体积膨胀，所述相变将改变所述材料的密度)的材料中，可通过选择性地引发相变而不允许明显的体积变化而将如上所述的相同的压缩力和张力引入所述材料中。以此方式，可通过例如防止裂纹由于材料中的压缩力和张力而传播通过所述材料来加强材料。
类似地，在其他材料中，相变可用于改变其他性质。例如，在相变改变折射率的系统中，可将相变选择性地引入选择性的区域以改变那些区域中的折射率。以此方式，基于所引发的相变，可在单个材料中在材料的横截面上改变折射率。在另一实例中，如果相变改变材料中的抗化学性或抗腐蚀性，则材料的所选区域的抗腐蚀性或抗化学性可通过在那些所选区域中选择性地引发相变而改性。
在另一方面，火焰处理或热处理可用于改进材料的如上性质或其他性质。火焰处理或热处理可包括使用氢炬、感应加热或电阻加热、或本领域已知的任意其他方法，包括这样的技术，所述技术将材料内的具体位置作为目标，以通过例如选择施加辐射的特定波长而选择用于在材料内或在材料表面处进行处理的区域。
火焰处理或热处理可用于处理材料表面，包括使表面光滑以防止可能减弱所述材料的应力梯级或为了其他优点。例如，当加热时，由于材料内的共价键和/或离子键而导致的表面张力可使表面光滑，由此减少或消除了材料表面上的应力梯级或其他缺陷。
由于如上所列的原因，火焰处理或热处理也可用于引发材料中的相变。例如，如果材料包括氧化硼，则可使用还原火焰来产生富硼区域。随后，可使用氧化焰以将硼氧化而产生更有效的成核剂和/或提高选择用于成核/相变的材料的具体区域的能力。该过程可适用于易受火焰处理或热处理影响的材料的任意组分，包括任意金属化合物。类似地，取决于材料或区域的具体组成，火焰处理或热处理可用于直接改性材料或材料中的区域。火焰处理或热处理可产生更多的晶体晶粒(如上所述)，和/或产生用于处理的目标区域的改进选择，由此进一步改进材料耐久性、介电强度和/或其他性质。在另一方面，火焰处理或热处理可用于通过蒸发和/或去活化所选区域中的核而防止在经火焰处理或热处理的区域中的成核或其他变化。
在其他实施例中，其他性质可通过选择性引发相变而进行改性。这些性质包括表面张力、摩擦、折射率、音速、弹性模量和热导率的改性。
显而易见的是，在不偏离本发明的范围下可进行各种改变和修改。例如，介电强度或其他性质可被改变或变化以包括可选择的材料和加工方法，或者可包括与所示和所描述的那些不同的构造，而仍然在本公开的精神内。
除非上下文明确要求，否则在整个说明书和权利要求书中，词语“包含”等以包括的方式而不是排除或穷举的方式进行解释，即以“包括但不限于”的方式进行解释。使用单数或复数的词语也分别包括复数或单数。当权利要求书参照两个或更多个项目使用词语“或”时，该词语覆盖所述词语的所有如下解释：列表中的任意项目、列表中的所有项目，和列表中的项目的任意组合。
可组合如上所述的各种实施例以提供另外的实施例。在本说明书中引用和/或在申请数据表中所列的所有美国专利、美国专利申请公布、美国专利申请、外国专利、外国专利申请和非专利公布均以全文引用的方式并入本文。如果需要，可用各种构造以及各种专利、申请和公布的概念修改所述公开的方面，以提供所述公开的另外的实施例。
根据如上详细描述，可对本公开进行这些和其他改变。通常，在如下权利要求书中，所用的术语不应解释为将本公开限制为说明书和权利要求书中公开的具体实施例，而是应解释为包括根据权利要求书操作的所有系统和方法。因此，本发明不由本公开限制，相反，本发明的范围由如下权利要求书广义地确定。

Claims (11)

1.一种绝缘体，包括：
陶瓷组合物，
其中所述陶瓷组合物包含结晶晶粒，且其中所述结晶晶粒基本上取向为在第一方向上延伸，以在与所述第一方向垂直的方向上提供改进的绝缘性质；
其中所述陶瓷组合物包含：
25-60％SiO2；
15-35％R2O3，其中所述R2O3为3-15％B2O3和5-25％A12O3；4-25％MgO+0-7％Li2O，其中MgO+Li2O总共为6-25％之间；
2-20％R2O，其中所述R2O为0-15％Na2O、0-15％K2O和0-15％Rb2O；
0-15％Rb2O；
0-20％Cs2O；和
4-20％F，
其中所述第一方向为周向，且与所述第一方向垂直的方向为径向。
2.根据权利要求1所述的绝缘体，其中所述绝缘体还包括第一区域和第二区域，所述第一区域处于压缩中，且所述第二区域处于张紧中。
3.根据权利要求2所述的绝缘体，其中所述第一区域与所述绝缘体的外表面相邻。
4.根据权利要求3所述的绝缘体，其中所述第一区域每体积包含比所述第二区域更多的晶体晶粒。
5.根据权利要求3所述的绝缘体，其中所述第一区域的晶体晶粒具有比所述第二区域的晶体晶粒更小的充填效率。
6.根据权利要求3所述的绝缘体，其中所述第一区域包含扩散离子、喷溅表面或掺杂剂。
7.根据权利要求2所述的绝缘体，其中所述绝缘体在-30℃至450℃的温度下具有大于1.2KV/0.001英寸的介电强度。
8.根据权利要求2所述的绝缘体，其中所述绝缘体在-30℃至450℃的温度下具有大于1.9KV/0.001英寸的介电强度。
9.根据权利要求2所述的绝缘体，其中所述绝缘体在-30℃至450℃的温度下具有大于2.5KV/0.001英寸的介电强度。
10.根据权利要求2所述的绝缘体，其中所述绝缘体在-30℃至450℃的温度下具有大于3KV/0.001英寸的介电强度。
11.一种一体化的燃料喷射器/点火器，包括权利要求2所述的绝缘体。
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CA2772043A1 (en) 2011-03-24
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US8192852B2 (en) 2012-06-05
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