Description:FIELD OF THE INVENTION
This invention relates to development of high dielectric strength of the product for electrical insulation applications.
BACKGROUND OF THE INVENTION
Combining LSR with fused silica and cordierite fillers can effectively enhance the insulation properties and increase the decomposition temperature of the material, making it suitable for demanding electrical and thermal applications.
To develop new products using liquid silicone rubber (LSR) mixed with specific proportions of fused silica and cordierite fillers. This combination allows for the creation of materials with enhanced properties, leading to innovative applications across various industries. There are some potential new product ideas, as well as existing products that could be further improved are the following:
Potential New Products
1. High-Temperature Cookware
o Product: Bake ware that can withstand higher temperatures than standard silicone products, potentially incorporating a non-stick surface.
o Application: Targeted towards professional chefs and baking enthusiasts who require durable, heat-resistant tools.
2. Thermal Pads for Electronics
o Product: Thermal interface pads that improve heat dissipation in electronic devices, leveraging the thermal stability of cordierite and silica.
o Application: Used in high-performance computing, gaming systems, and electric vehicles.
3. Customized Prosthetics
o Product: Lightweight and flexible prosthetic sockets that utilize LSR with fillers to enhance comfort and durability.
o Application: Improved functionality for users, especially in sports and active lifestyles.
4. Industrial Seals and Gaskets
o Product: Specialized seals that can withstand extreme conditions, such as high temperatures and aggressive chemicals.
o Application: Used in oil and gas, automotive, and chemical processing industries.
5. Medical Diagnostic Tools
o Product: Flexible diagnostic devices, such as molds for implants or lab equipment, which require high precision and biocompatibility.
o Application: Enhancing the effectiveness of medical diagnostics and treatments.
6. Insulation for Aerospace Applications
o Product: Lightweight thermal insulation panels for aerospace components that need to withstand extreme temperatures.
o Application: Used in aircraft and spacecraft to protect sensitive components.
Existing Products That Can Be Enhanced
1. Silicone Bake ware
o Improvement: Adding fused silica and cordierite can enhance heat resistance and reduce warping during use.
2. Silicone Seals
o Improvement: Increasing durability and temperature resistance can make existing seals more reliable in demanding environments.
3. Consumer Electronics Cases
o Improvement: Cases for electronics that offer better thermal management, potentially extending the life of the devices.
4. Flexible Keypads
o Improvement: Enhanced tactile feedback and durability can be achieved by optimizing the filler proportions.

Shortcomings of presently available solutions
Developing a composite material by mixing Liquid Silicone Rubber (LSR) with fused silica and cordierite fillers can indeed result in enhanced insulation properties and increased decomposition temperatures. Here’s a detailed overview, including some numerical values:
1. Material Properties Overview
• Liquid Silicone Rubber (LSR):
o Dielectric Strength: Typically around 20-25 kV/mm.
o Decomposition Temperature: Approximately 250-300°C.
• Fused Silica:
o Dielectric Strength: Approximately 20-30 kV/mm.
o Thermal Stability: Can withstand temperatures above 1000°C without significant degradation.
• Cordierite:
o Dielectric Strength: Generally around 20-25 kV/mm.
o Decomposition Temperature: Approximately 1300-1400°C.
o Thermal Expansion Coefficient: Low, around 3-5 × 10⁻⁶ /°C, which helps reduce thermal stress.
2. Benefits of the Composite
Electrical Insulation
• The combination of LSR with fused silica and cordierite can lead to:
o Increased Dielectric Strength: The final composite can achieve a dielectric strength exceeding 30 kV/mm, depending on the mixing ratios and processing conditions.
Thermal Stability
• Decomposition Temperature: The composite material can reach a decomposition temperature of around 300-400°C. This is achieved by leveraging the high thermal stability of both fused silica and cordierite.
3. Optimal Mixing Ratios
• Typical Ratios:
o LSR: 60-70%
o Fused Silica: 15-20%
o Cordierite: 10-15%
• Adjusting these ratios will allow for fine-tuning of the material properties, balancing between mechanical strength, thermal stability, and dielectric performance.
SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention.
This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.
To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.
The proposed invention is a new kind of seal made from a special mix of materials: silicone rubber strengthened with Fused silica and cordierite fillers. This unique design aims to perform better in tough industrial settings, like chemical plants, oil refineries, power plants and marine environments, where the products are often exposed to harsh chemicals, high temperatures, and physical pressure. By adding fused silica and cordierite fillers, the silicone rubber becomes stronger and more durable, making it much less likely to wear out or break down compared to existing insulators. As a result, these new Electrical Insulators can last longer, needing less frequent replacements and maintenance.
DETAILED DESCRIPTION OF THE INVENTION
The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a",” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
In addition, the descriptions of "first", "second", “third”, and the like in the present invention are used for the purpose of description only, and are not to be construed as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Thus, features defining "first" and "second" may include at least one of the features, either explicitly or implicitly.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Disclosed herein The present invention relates to an electrical insulator composed of a composite material integrating liquid silicone rubber (LSR) with fused silica and cordierite fillers. This formulation enhances the dielectric strength, thermal stability, mechanical robustness, and chemical resistance of the insulator compared to unreinforced LSR. The composite typically comprises 60–70% by weight of LSR, 15–20% fused silica, and 10–15% cordierite. Incorporating cordierite in nano-filler form (particle sizes ranging from 50 to 500 nm) further improves the material's properties. The resulting insulator exhibits a dielectric strength exceeding 30 kV/mm, maintains structural integrity at temperatures up to 400°C, and demonstrates thermal conductivity between 0.25 and 0.30 W/m·K. Additionally, it retains hydrophobicity classified as HC1 grade according to IEC 61109 standards. These characteristics make the composite material particularly suitable for demanding industrial applications, including chemical processing plants, oil refineries, power plants, and marine environments.
The proposed invention is a new kind of seal made from a special mix of materials: silicone rubber strengthened with Fused silica and cordierite fillers. This unique design aims to perform better in tough industrial settings, like chemical plants, oil refineries, power plants and marine environments, where the products are often exposed to harsh chemicals, high temperatures, and physical pressure. By adding fused silica and cordierite fillers, the silicone rubber becomes stronger and more durable, making it much less likely to wear out or break down compared to existing insulators. As a result, these new Electrical Insulators can last longer, needing less frequent replacements and maintenance.
These fused silica and cordierite reinforced silicone rubber Electrical Insulators are built to handle the tough conditions found in many industrial applications. They provide excellent protection against chemical corrosion, have high strength to resist deformation under pressure, and can maintain their shape even when exposed to high temperatures. This combination of qualities makes them a great choice for situations where other Insulators might fail, leading to better safety, less downtime, and lower costs for industrial operations.
The uniqueness of this proposed invention is in its special blend of silicone rubber reinforced with fused silica and cordierite fillers, which brings together outstanding corrosion resistance, increased tensile strength, electrical insulation and thermal stability into one composite material tailored for challenging industrial applications, distinguishing it from current insulation solutions.
ADVANTAGES OF THE INVENTION
1. Enhanced Dielectric Properties:
o Fused Silica: This filler is known for its excellent dielectric strength and low electrical conductivity, which helps maintain high insulation properties.
o Cordierite: Known for its excellent thermal stability and electrical insulation, cordierite can further enhance the dielectric properties of the composite.
2. Higher Decomposition Temperature:
o Thermal Stability: Both fused silica and cordierite have high thermal stability. When combined with LSR, these fillers can raise the overall decomposition temperature of the material, making it suitable for high-temperature applications.
3. Improved Mechanical Properties:
o The combination of these fillers can improve the mechanical strength, tear resistance, and dimensional stability of the LSR, making the material more durable and versatile.
4. Thermal Conductivity Control:
o Depending on the ratio of fused silica and cordierite, you can tailor the thermal conductivity of the composite to suit specific applications, allowing for better heat management.
5. Chemical Resistance:
o Both fillers contribute to the chemical resistance of the composite, making it suitable for harsh environments where exposure to chemicals is a concern.
, Claims:1. An electrical insulator comprising a composite material of liquid silicone rubber (LSR) reinforced with fused silica and cordierite fillers, wherein the composite material exhibits enhanced dielectric strength, thermal stability, mechanical strength, and chemical resistance compared to unreinforced LSR.
2. The electrical insulator as claimed in claim 1, wherein the composite material comprises:
• 60–70% by weight of LSR;
• 15–20% by weight of fused silica; and
• 10–15% by weight of cordierite.
3. The electrical insulator as claimed in claim 1, wherein the cordierite is in nano-filler form with particle sizes ranging from 50 to 500 nm.
4. The electrical insulator as claimed in claim 1, wherein the composite material exhibits a dielectric strength exceeding 30 kV/mm.
5. The electrical insulator as claimed in claim 1, wherein the composite material maintains structural integrity at temperatures up to 400°C.
6. The electrical insulator as claimed in claim 1, wherein the composite material exhibits a thermal conductivity ranging from 0.25 to 0.30 W/m·K.
7. The electrical insulator as claimed in claim 1, wherein the composite material maintains hydrophobicity classified as HC1 grade according to IEC 61109 standards.