AU654435B1 - Process for environmentally safe disposal of used fluorescent lamp potted ballast assemblies and the like, with component part reclamation and/or recycling - Google Patents

Description

AUSTRALIA

Patent Act 6 54435 COMPLETE SPECIFICATION

(ORIGINAL)

Class Int. Class Application Number: Lodged: Complete Specification Lodged: Accepted: Published: S 555 S 5555

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*5 55 Priority: Related Art: Names(s) of Applicant(s): ANTHONY NARDELLA Actual Inventor(s): Anthony Nardella Our Address for service is: PHILLIPS ORMONDE FITZPATRICK Patent and Trade Mark Attorneys 367 Collins Street MELBOURNE, Australia 3000 Complete Specification for the invention entitled: PROCESS FOR ENVIRONMENTALLY SAFE DISPOSAL OF USED FLUORESCENT LAMP POTTED BALLAST ASSEMBLIES AND THE LIKE, WITH COMPONENT PART RECLAMATION AND/OR RECYCLING Our Ref: IRN 326514 The following statement is a full description of this invention, including the best method of perfori ing it known to applicant(s): 1 2210x

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120503 PROCESS FOR EN4VIRONMIENTALLY SAFE DISPOSAL OF USED FLUORESCENT LAM4P POTTED 8ALLAST ASSEMlBLIES AN'D THE LIKE, WITO COMPON4ENT PART RECLAMATION ANn/OR RECYCLINlG The present invention relates to processes for disposing of composite potted electrical component assemblies and the like with environmental safety and cost efficiency, and with safe component and part reclamation and/or recycling where desired, being more particularly concerned with used fluorescent light ballast assemblies often containing only select components, such as capacitors, with environmientally hazardous constituents such as pcb's (polychlorinated biphenyls) and the like.

Background of Invention The problem of disposing of used fluorescent light ballast assemblies has plagued commercial and other institutions for some years, particularly in view of relatively recent state and federal regulations governing~ perpetual legal responsibility for their disposal and the 2 environmiental safety of th9 waste prcdu,,cts of such disposal.

The concomitant problem of enabling conservation or salvaging of those valuable components and materials not presenting hazai~d difficulties by reclamation and reuse, refurbishing and/oc recycling of the valuable materials therein (metals, wires and windings, plastics, etc.) often must be ignored in the light of this perpetual environmental.

safety responsibility, leading to expensive incineration or other blanket waste of the total products as in land fill, etc., just because hazards may exist only in Limited parts there)f It is just such a circumstance that exists with used fluorescent light ballasts containing potted asse mblies of electrical components and the like embedded in the potting and wherein only a very small weight or volume percentage ot the product may involve highly environmentally hazardous materials; the *remainder or bulk of the product, however, 0****being admirably suited for valuable reclamation and/or recycling, leading none-the-less to the current-day practice of wasting the whole opportunity for such reclamation and/or 0 recycling in incinerating or breaking up and/or burying the c~.rnplete produtt Juzt because, for ex~ample, the capacitor compon~ent thereof may contain the before-mentioned hazardous pcb's or the like.

Objects of Invention Xt is an object of the present invention, accordingly, to provide a now and improved process for the disposal of such used potted ballasts and the like that provides totally adequate security and low cost efficiency for the perpetual environmiental safety in the disposal of the potentially hazardous component or materials thereof, while simultaneously enabling safe and substantially pristine condition reclamation and/or recycling of the remilning *0:060 major components of the product.

,Go:* An additional object is to provide such a novel process with the added'advantage, of cost benefit over the above- :00 described current-day disposal practices.

see other and further objects will be explained hereinafter and are more particularly delineated in the appended claims.

see 0 4 Summary In sumvtary, however, from one of its broader viewpoints, the invention embraces a process for the environmentally safe and economical disposal of used fluorescent lamp potted ballast housing assemblies and the like, that comprises, removing from the housing the potted assembly with its embedded electrical component assemblies including a component such as a capacitor contalning environmentally hazardous material such as pcb's; after or before such removing Immersing the potted 4,,sembly in a cryogenic bath and freezing the same to the extent of rendering the potting sufficiently brittle to fragment into fine pieces upon being impactedi impacting the potting thoroughly to fragment the same into small pieces and cleanly to remove substantially all traces of the potting from all the electrical components and parts embedded thereiz. and without imparting damage to sAid components and parts; disconnecting the said component containing the 0 41 environmentally hazardous material; and incinerating only *e the said component containing the environmentally hazardous V000, 0 0 0e ase 0* material, leaving all other comiponents and parts including said housing and pottin6 fragmenits for salvage, re-use and/or recycling as desired and appropriate. Preferred and best mode embodiments are later described.

Drawings The invention wiill now be explained in connection with the accompanying drawings, Fig. I of which Is an isome~tric view of a (used) fluorescent lighting ballast containing an outer sheece metal housing and an inner potted electrical assembly, The integral wiring used to connect the ballast to the lamp sockets and the power supply is also schematically shown.

Fig. 2 is a similar view of the ballast with the sheet metal cover removed. The asphaltic potting compound.

essentially takes the form of the sheet metal housing into which it is po~tred during tche manufacturing process. tt is this configurationi that is subjected to the cryogenic bath.

*?Fig. 3 illustrates a quantity of potted ballasts stacked in a wire basket which fits into an insulated a d 6 container partially filled with a cryogenic fluid, typically liquid nitrogen.

Fig. 4 shows the condition of the frozen and embrithled ballast assembly after it has been immerged in thie cryogenic bath for the prescribed time interval and removed, and is now struck several blows by schematically illustrated hammering or similar impacting, fragmenting the enbrittlod potting.- Fig. 5 illustrates the separation of the components af ter the impacting step of Fig. 4, showing the substantially pristine and undamaged components and asphaltic potting compound suitable for reclamation, with the capacitor only'requiring environmentally safe disposal, being preferably incinerated.

Figs. GA, 6B and 7 Illustrate modified impacting anid pulverizing techniques, Figs. 6A and B showing roller crushing, and Fig: 7, compacting.

0 D* fescription of Preferred Embodiment 1Referring to Fig. 1, connecting electrical wires W, are 0 a cut from the ballast using wire cutters, and stored for reclamation as scrap copper. The removal of the painted sheet metal cover H is facilitated by countersinking or drilling the staked holes 9, which also form the means by which the ballast Is attached to the lighting fixture using screws or other suitable fasteners- The cover is separated from the ballast and removed using simple hand tools, revealing the potted ballast P, Fig. 2, with the embedded electrical components, shown as a transformer T, a-starter and a capacitor C that, as before described, may be the only component harboring environmentally dangerous materials.

Several of the potted assemblies P, as shown in Fig. 3, are then placed mna wire basket B, which fits into a liquid-tight, insulated container R subjected to a meauired flow or quantity of a cryogenic fluid, so labelled,.

typically liquid nitrogen. The quantity of cryogenic fluid required is a function of the heat of vaporizatic'n of the see fluid used and Lhe weight (or, more accuratelyt the total 0 specific heat) of the ballasts, as well as the basket and inner surfaces of the containor. Upon the closing of the s container by the insulated cover 1, the potted ballast assemblies P become rapidly cooled and embrittied. After a suitable immersion time, sufficient to embrittle the potting compound not only externally but thoroughly internally to its core where it has attached to the embedded components, the assemblies are removed from the cryogenic fluid and impacted with one or more blows with a hammering device or suitable instrument capable of delivering the required fragmenting impact, shown in Fig. 4 as eff~cted by A hammer 0 as where manual operation is employedl it being understood that suitable well-known impacting or crushing apparatus may be used for automated or production line operation, including alternatIve systems later 4iscussed.

The brittle potting compound fragments and pulverizes into random-shaped particles ranging in size from fine •OOOq particulates to chunks as large as a one inch cube, shown in a collected pile ,EP In Fig. 5, with the previously potted electrical components (transformer T, -starter S, capacitor C) t* emerging trom the potting compound in a relatively pristine and undamaged condition, essentially free from the potting 0 0000 0 00 4 compound, with small residual particles of compound of no consequence.

Ar, an illustration, for a common right rectangular parallelopiped asphialtic potted fluorescent light ballast as abown, about 6' x 3" xc 2" In dimensions, immersion in a liquid nitrogen bath, with a nominal temperature of -320*F for approxcimately eight minutes has been found satisfactory to cool the care to a temperature of approximately Although higher tomperaturds shorter immersion times) will yield useful results, the lower temperature provides a longer working time after the ballast is removed fromn the bath, but before it is impacted.

Several blows'with a hammter or sjmilar impacting tool, at an energy level of ten to twenty toot pounds, more or less, are then sufficient thoroughly to Eracture andfragment the potting compound into Irregular random-sized pieces and particulated, effectively to separate the potting compound from the previously potted components, and the myriad of interconnecting wires W, terminal lugs etc.j which may be separated for sal~vage, as well.

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to0 While plastic or rubber-mnetal parts have heretofore been separated and recovered intact by a measure of cryogenic fratzing, as, for example, in U.S. Patent Nlo.

1,976,204, in accordance with the present invention, the freezing is carried to the extent sufficient to guarantee both the total pulverizing destruction of the potting, and its substantially total and clean separation from the parte it enclosed and to which it had conformed and adhered in the potting process.

At this stage, moreover, the unpotted and excposad electrical components in the core are also frozen, requiring care to avoid hand burns in cutting and removing the electrical connectlons to the capacitor C, so that such maey be disconnected and freed for Its preferred safe incineration or other safe digposal, Fig. S.

The remaining different methal and wire parts (copper, alumainum, steefi) and the transformer T and other components, and any other paper or plastic separators or other parts (not shown) have been thus recovered in clean condition for ~*:independent collection and ultimate salvage and/or

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recycling. The fragmnted asphalt P' may itself be swept down a chute into a barrel fcaL its reclamation, if desired.

For a conventional Eour pound ballast assembly of this character, only about 51 of the total weight is attributable to the capacitor C. About 95% of the energy and effluent otherwise required for complete incineration of the total ballast, as is common current practice, is thus conserved.

The costs of cryogenic freezing, pulverizing and component eparahion underlying the process is easily absorbed in the ,oat-savlng of incinerating only the hazardous vapacitor, even assuming little or no profit in used component salvage.

Enviro-nental~ly safe and economic disposal is thus achieved.

In addition t& hammering techniques for imupactin'g, crushing and removing the potted compound, as before stated, other techniques for accomplishing this result may-als9o be used as shown in Figs. 6A, Go and 7. In Ehe embodiment of :Fi~gs. 6A and 6B, Che Impacting is effected by a roller., system which crushes the potted material when the frozen ballast ia placed between sets of rollers R' with fixed or so*oadjustable spring ot other pressures, as at In Fig. 69, the rollers R' on the top and to the right are crushing the potted materials ae the embrittled ballast P is moved along the rollers, left to right. Potting material them falls into a receptacle D through the bottom rollers. In Fig. 1, on the other hand, the potted ball-st assembly is placed in a piston or spring actuated compactor, the surfaces C' of which strike and compress the ends or sides of tLhe embrittled potted ballast P with predetermined pressures.

The compactor surfaces shatter the potted coverin without damaging the components embedded therein; and the fragmented potting may again be swept away to a receptacle.

While the use oE adequate cryogenic freezing and then Impactlng is the preferred and most rapid form of potting fragmentation and substantially total removal from the :electrical components, and without damaging or defacing the a.

components, some potting compounds may lend themselves to S other total removal processes including ultrasonic cracking a.or chemical removal, f£.r example. The hazard-materialesee containing component(s)-to-be-incinerated or otherwise *d saEely disposed of, moreover, may be other thnn the 0 *SQe S. a. 13 capacitor; and the geometry of the housing and assembiy, and even type of electrical assembly and product to be dispoted of may be different, as well.

Further modifications,including, if more convenient, freezing the potted assembly while still in the cover housing M and then removing therefrom, will occur to those skilled iin this art, and such are considered to fall within the spirit and scope of the invention as defined in the appended claims.

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Claims (5)

1. 2. A process as claimed in claim I and in which the said other components and parti comprise wires, different metal parts, a transformer and a starter which are disassembled and separated by different metals, wires, and similar part materials for independent recycling.
2. 3. A process ri claimed in claim 1I and in which said potting is oE an asphalt-tar type and the cryogeni',: freezing Is effected over the, complete potted assembly to ensure that the core of the assembly :achieves a temperature oE about -50F to attain suf icient brittleness to enable small impact fragmentation of potting particles and substant11.Iy ~total removal of potting particles from the electrical componentt and parts once embedded °.ren a Itherein. e 0 C b> *0 a O 4 16
3. 4. A process for the environmentally and safe and economical disposal of used potted assemblies containing embedded electric components and parts Including one or more components containing environmentally hazardous material, that comprises, immersing the potted assembly In a cryogenic bath and freezing the same to the adequate extent of rendering the potting sufficiently brittle to fragment inko fine pieces upon being impacted; impacting the frozen brittle potting thoroughly to crush and fragment the same into such small pieces and cleanly to remove substantially all traces of the pottin from all the electrical components and parts embedded therein a .J without imparting substantial damage to said components and parts; S. disconnecting the said one or more components containing environmentally hazardous minterial; and incinerating or burying only such one or more 'S components, leaving all the other components ahd parts Including the potting fragments for recycling 0 a 1 0 0 so 0"! o• 0 and/or salvage as desired and appropriate ~px~c6S as iaied n clim 1 and inl whiob aid i.mpacting 1s e ftgc ted by On i ma rting r~i-ruhigand co~co *too4 18
4. 6. A proqena f~or the sivirthittt.i1Ily slid suEe avid ~i~io~ivj.disposal ot ussed pokted arsembiLes co~~e~i~~qemedded electrlc compr -it-4 avid parts Iticludlig one ot more containing etiviraiimeitni.y hiatt1Inij mateil, Lhnt comnpri.seg, Inniereiny Mia potted Assemibly Wi a cryogeitc bathi *ml~ Freezlig thte esaine 1-o One adeq'.iabe exletit oE rvdeiiiq the~ pottiti su~licier'tly brlttle to !r~sivistil: litio Elitie pieces uponi beivig impacted,, tmp~.actLii thn frozent britle pottIng thiorouJgly Eo Criilli alit fragliellt 1:1e qsimer 11to sulch ~Small~ pleces atir) cleatily to terdove g'zbotaititl.y all traces or, the pittl-.Uv Cram all the els3cttca-l cuinpolialitS Blvd parts embederdi~c Merein alid without imparting nailietrintLO dnnl..1 nid crolioantu ni por'ts; belore or *E'ter ontd fteenitg, 41dPetntfag tiae sold one or more iOmPOnenItu ot Poltts contaning eutvirotitentsa1ly ibiraadoul; ntuaerioJ; and intineraiteg or burying only cuch one or see:%q~~mp~i~t ""*o11"U -OX Pr't t, Lrsiv( tn ;11.1I the other componevitn and parta ineliudtnF the pottt~nt Eromento for recycling @6CC sandtor on~ane noavsid Lf desi red and oppropriativ. DATED: 26 April 1993 PHILLIPS ORMONDE FITZPATRICK Attorneys for: ANTHONY NARDELLA oil% 0 *00
5. 064. ABSTRACT A process for the environmentally safe di~posa1 of used fluorescent lamp potted ballast aesemblies and the like, with the potential for component part reclamation and/or recycling, involving preferred cryogenic freezing of the potted assembly to the extent that the frozen potting becomes sufficiently brik.tle throughout to enable it to be pulverized away in small particles, cleanly from all the components, with only that component with a hazardous material needing to be incinerated or otherwise environmentally safely disposed of, and with all the othe~r *components and parts in condition for salvages re-use, and/or reclamation.