US20100180914A1 - Conductor cleaning system and method - Google Patents
Conductor cleaning system and method Download PDFInfo
- Publication number
- US20100180914A1 US20100180914A1 US12/608,079 US60807909A US2010180914A1 US 20100180914 A1 US20100180914 A1 US 20100180914A1 US 60807909 A US60807909 A US 60807909A US 2010180914 A1 US2010180914 A1 US 2010180914A1
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- United States
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- cleaning solution
- cleaning
- conductor
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- naoh
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Links
- 238000004140 cleaning Methods 0.000 title claims abstract description 144
- 239000004020 conductor Substances 0.000 title claims abstract description 97
- 238000000034 method Methods 0.000 title claims description 15
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 15
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 15
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical group [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 claims description 63
- CIWBSHSKHKDKBQ-JLAZNSOCSA-N Ascorbic acid Chemical compound OC[C@H](O)[C@H]1OC(=O)C(O)=C1O CIWBSHSKHKDKBQ-JLAZNSOCSA-N 0.000 claims description 18
- 238000000576 coating method Methods 0.000 claims description 14
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 10
- 229960005070 ascorbic acid Drugs 0.000 claims description 9
- 235000010323 ascorbic acid Nutrition 0.000 claims description 9
- 239000011668 ascorbic acid Substances 0.000 claims description 9
- 239000000203 mixture Substances 0.000 claims description 9
- 239000003518 caustics Substances 0.000 claims description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 6
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical class [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 5
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 claims description 5
- 229910052681 coesite Inorganic materials 0.000 claims description 5
- 229910052906 cristobalite Inorganic materials 0.000 claims description 5
- 239000000377 silicon dioxide Substances 0.000 claims description 5
- 229910052682 stishovite Inorganic materials 0.000 claims description 5
- 229910052905 tridymite Inorganic materials 0.000 claims description 5
- 239000003112 inhibitor Substances 0.000 claims description 4
- 239000012459 cleaning agent Substances 0.000 claims description 3
- 238000001139 pH measurement Methods 0.000 claims description 3
- 230000003213 activating effect Effects 0.000 claims description 2
- 230000015556 catabolic process Effects 0.000 claims description 2
- 238000006731 degradation reaction Methods 0.000 claims description 2
- 230000000593 degrading effect Effects 0.000 claims description 2
- 230000002708 enhancing effect Effects 0.000 claims description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 claims 2
- 239000002253 acid Substances 0.000 claims 1
- 229910000831 Steel Inorganic materials 0.000 abstract description 5
- 239000010959 steel Substances 0.000 abstract description 5
- 241001474033 Acar Species 0.000 abstract description 2
- PUZPDOWCWNUUKD-UHFFFAOYSA-M sodium fluoride Chemical compound [F-].[Na+] PUZPDOWCWNUUKD-UHFFFAOYSA-M 0.000 description 16
- 239000011248 coating agent Substances 0.000 description 9
- 229910018137 Al-Zn Inorganic materials 0.000 description 7
- 229910018573 Al—Zn Inorganic materials 0.000 description 7
- 239000011775 sodium fluoride Substances 0.000 description 7
- 235000013024 sodium fluoride Nutrition 0.000 description 7
- 230000006835 compression Effects 0.000 description 6
- 238000007906 compression Methods 0.000 description 6
- 230000007797 corrosion Effects 0.000 description 6
- 238000005260 corrosion Methods 0.000 description 6
- 230000008569 process Effects 0.000 description 5
- 238000013019 agitation Methods 0.000 description 4
- 230000009286 beneficial effect Effects 0.000 description 4
- 239000000356 contaminant Substances 0.000 description 4
- 238000009434 installation Methods 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 239000004115 Sodium Silicate Substances 0.000 description 3
- 229910052593 corundum Inorganic materials 0.000 description 3
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 3
- 229910052911 sodium silicate Inorganic materials 0.000 description 3
- 229910001845 yogo sapphire Inorganic materials 0.000 description 3
- UXVMQQNJUSDDNG-UHFFFAOYSA-L Calcium chloride Chemical compound [Cl-].[Cl-].[Ca+2] UXVMQQNJUSDDNG-UHFFFAOYSA-L 0.000 description 2
- 230000005587 bubbling Effects 0.000 description 2
- 239000001110 calcium chloride Substances 0.000 description 2
- 229910001628 calcium chloride Inorganic materials 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 230000001419 dependent effect Effects 0.000 description 2
- 230000000994 depressogenic effect Effects 0.000 description 2
- 238000003756 stirring Methods 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 229910001335 Galvanized steel Inorganic materials 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 239000008397 galvanized steel Substances 0.000 description 1
- XLYOFNOQVPJJNP-ZSJDYOACSA-N heavy water Substances [2H]O[2H] XLYOFNOQVPJJNP-ZSJDYOACSA-N 0.000 description 1
- 150000004679 hydroxides Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B13/00—Accessories or details of general applicability for machines or apparatus for cleaning
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
- B08B3/04—Cleaning involving contact with liquid
- B08B3/10—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
- B08B3/12—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration by sonic or ultrasonic vibrations
- B08B3/123—Cleaning travelling work, e.g. webs, articles on a conveyor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
- B08B3/04—Cleaning involving contact with liquid
- B08B3/10—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
- B08B3/102—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration with means for agitating the liquid
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
- C11D7/00—Compositions of detergents based essentially on non-surface-active compounds
- C11D7/02—Inorganic compounds
- C11D7/04—Water-soluble compounds
- C11D7/06—Hydroxides
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
- C11D7/00—Compositions of detergents based essentially on non-surface-active compounds
- C11D7/02—Inorganic compounds
- C11D7/04—Water-soluble compounds
- C11D7/10—Salts
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
- C11D7/00—Compositions of detergents based essentially on non-surface-active compounds
- C11D7/02—Inorganic compounds
- C11D7/04—Water-soluble compounds
- C11D7/10—Salts
- C11D7/14—Silicates
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
- C11D2111/00—Cleaning compositions characterised by the objects to be cleaned; Cleaning compositions characterised by non-standard cleaning or washing processes
- C11D2111/10—Objects to be cleaned
- C11D2111/14—Hard surfaces
- C11D2111/20—Industrial or commercial equipment, e.g. reactors, tubes or engines
Definitions
- the present invention relates generally to a conductor cleaning system, and more particularly to a system for cleaning aluminum strands of all aluminum and steel reinforced electrical conductors, such as ACSS, ACSR, ACAR, and AAA.
- the present invention provides a conductor cleaning system capable of cleaning external and internal strands of a conductor without unstranding the conductor.
- a conductor cleaning system includes a container adapted to receive a portion of a conductor to be cleaned, a housing adapted to receive and support the container, and a cleaning solution contained in the container for cleaning the portion of the conductor.
- the cleaning solution is adapted to clean the conductor without reacting with or damaging the conductor.
- a cleaning solution adapted to clean electrical conductors without damaging galvanization coatings or degrading aluminum contained in the coatings or conductor has a composition, by approximate weight percent, of 0.985 to 8.97 NaOH, 0.49 to 1.45 NaF, and 89.7 to 98.5 H 2 O
- a method of cleaning an electrical conductor includes providing a conductor cleaning system having a container and an agitator. The method further includes providing a cleaning solution for cleaning of the electrical conductor, introducing the cleaning solution into the container, positioning an electrical conductor in the cleaning solution disposed in the container, and activating the agitator, thereby agitating the cleaning solution and enhancing its ability to clean the electrical conductor.
- FIG. 1 is a perspective view of a conductor cleaning system according to an embodiment of the invention
- FIG. 2 shows a vibrator housing of the conductor cleaning system of FIG. 1 ;
- FIG. 3 shows an eccentric weight for use in a vibrator of the conductor cleaning system of FIG. 1 ;
- FIG. 4 shows a battery and receptacle for the conductor cleaning system of FIG. 1 ;
- FIG. 5 shows a control panel for the conductor cleaning system of FIG. 1 ;
- FIG. 6 shows the conductor cleaning system of FIG. 1 being carried
- FIG. 7 shows the conductor cleaning system of FIG. 1 in use
- FIGS. 8-10 show the conductor cleaning system of FIG. 1 supported in an upright position by supports
- FIG. 11 shows the conductor cleaning system of FIG. 1 fitted with bi-pods
- FIG. 12 shows a tri-pod for supporting the conductor cleaning system of FIG. 1 ;
- FIG. 13 is a perspective view of a conductor cleaning system according to an embodiment of the invention.
- FIG. 14 is a graph showing pH v. cleaning sequence.
- FIG. 1 an exemplary conductor cleaning system according to the present invention is illustrated in FIG. 1 and shown generally at reference numeral 10 .
- the system 10 includes a container, such as tube 11 operably connected to an agitator, such as vibrator 12 , FIG. 2 , contained in a vibrator housing 13 , and a control panel 14 for controlling the system 10 .
- the container 11 may be disposable or permanently attached to the system 10 .
- the vibrator housing 13 is adapted to receive and support the container 11 , and includes an attachment rail 16 to allow the system 10 to be attached to a support for easy operation or to allow a user to easily carry the system 10 .
- Other attachments such as a hook-type attachment may also be used to attach the system 10 to a bucket of a bucket truck or other suitable support.
- a standing base 17 is disposed at one end of the housing 13 to allow the system 10 to be positioned in a stand-up position such that the tube 11 is in a vertical position.
- the base 17 may be adapted to accept supports to further stabilize the system 10 in the vertical position, as shown in FIGS. 8-10 .
- Guide straps 18 and 19 are attached to opposing ends 20 and 21 of the housing 13 to provide guides and supports for the tube 11 , and a retaining strap 22 is positioned between the guide straps 18 and 19 to lock the tube 11 into position.
- a support 23 is also positioned on a bottom of the housing 13 to further position and lock the tube 11 into position. As shown, the support 23 is V-shaped; however, any suitable geometry may be used to position and lock the tube 11 in position.
- the vibrator housing 13 includes a control system 30 having an electric motor 31 , a timer circuit 32 , a voltage regulator 33 , and the vibrator 12 .
- the vibrator 12 includes an eccentric weight 15 , like that shown in FIG. 3 , to emit vibrations into the tube 11 , thereby agitating a cleaning solution contained therein. While a vibrator is being described herein, it should be appreciated that other types of agitators may be used, for example, ultrasonic, bubbling air, and stirring.
- the motor 31 and vibrator 12 cause the system 10 to vibrate at a specified rate by spinning the eccentric weight 15 at a desired speed. It should be appreciated that the speed of the motor 31 and size of the eccentric weight 15 may be changed to optimize the conductor cleaning efficiency. It should be appreciated that other forms of vibrators/agitators may be used, such as ultrasonic.
- the system 10 is powered by a battery 36 .
- the battery 36 is contained in a battery receptacle 37 of the base 17 .
- the battery 36 may be replaceable or rechargeable and allows the system 10 to be portable for conductor cleaning both at ground level and at elevated levels.
- the control panel 14 is electrically connected to the control system 30 and includes a power switch 38 , a timer 39 , a start button 40 , and a buzzer 41 .
- the power switch 38 turns the system 10 on to a ready state so that the system 10 is ready to clean a conductor.
- the timer 39 allows a user to choose how long the cleaning process is going to last. The amount of time chosen is dependent on the level of contaminants and corrosion products on the surface of the conductor, temperatures, and other factors.
- the start button 40 turns the cleaning process on when depressed, and the buzzer 41 lets a user know when the cleaning process has ended.
- the cleaning solution is contained in the tube 11 to allow an end of a conductor to be cleaned properly while reducing spills and splashes.
- the cleaning solution is designed and optimized to permit cleaning of aluminum strands of conductors without unstranding the conductor. Namely, the cleaning solution is designed to permit internal and external cleaning of aluminum strands of the conductor without reacting and damaging the galvanization of galvanized steel strands; to not react with or degrade aluminum strands after the cleaning process is complete; to clean over a wide range of temperatures; to not react with inhibitor compounds used in compression connector installation; and to be environmentally acceptable.
- the cleaning solution uses a caustic solution of sodium hydroxide (NaOH) as a cleaning agent due to the tri-hydrated oxide of aluminum found in corrosion products being soluble in this type of solution. It should be appreciated that other suitable caustic hydroxides may be used.
- the caustic level of the solution is equal to, or less than, that of standard household cleaners.
- a low concentration of sodium fluoride (NaF) enhances the solubility of the aluminum oxides and reduces the time needed to complete the cleaning.
- the predominant reactions occurring during cleaning are as follows:
- reaction products are essentially stable and do not react with Al and the corrosion layer Al 2 O 3 . Only NaOH chemically attacks both Al and Al 2 O 3 . Examples of cleaning solutions are shown in the Table below.
- Temper- Cleaning Effectiveness Rated 0 to 5 with 5 Being the Best ature With Agitation Without Agitation (C.) 1 Min 2.5 Min 5 Min 1 Min 2.5 Min 5 Min 0 3 4 4 1 1 2 25 4 5 5 2 3 4 50 5 5 5 5 5 5 70 5 5 5 5 5 5 5 5 5 5
- agitation may be used, such as ultrasonic, bubbling air, stirring, etc.
- the pH is a concern due to EPA regulations for handling chemical solutions.
- various chemicals could be used to lower the pH of the solution. For example, it was found that a CaCl 2 solution could lower the pH from 13.0 to 12.4. However, the CaCl 2 solution tends to leave a residue.
- ascorbic acid provided many benefits that the other chemicals did not.
- the ascorbic acid was beneficial for both lowering the pH and for protecting the Al—Zn coating.
- An acceptable range, by approximate weight percent, of ascorbic acid was found to be 0.193 to 3.54. This results in a cleaning solution having a composition, by approximate weight percent, of (0.193 to 3.54) ascorbic acid+(1.87 to 1.93) NaOH+(1.40 to 1.45)NaF+(93.28 to 96.43) H 2 O.
- a cleaning solution without ascorbic acid maintains a fairly constant pH across the cleaning sequences.
- the ascorbic modified cleaning solution steadily decreases in pH until the cleaning solution becomes ineffective (indicated by the sudden drop off in pH).
- a user cleaning multiple conductors can monitor the pH of the ascorbic modified solution and easily determine a normal range of drop in pH either visually by graphing pH measurements prior to and after each cleaning, as done in FIG. 14 , or by calculating the drop in pH for each cleaning using the pH measurements and then determining a normal range of drop in pH. If during a cleaning, a drop in pH of the cleaning solution exceeds the normal range, then the user knows to dispose of the spent cleaning solution and replace it with new cleaning solution.
- the tube 11 is inserted through the guide straps 18 and 19 of the vibrator housing 13 and secured in position by the retaining strap 22 and support 23 .
- the tube 11 may be disposable or permanently attached to the system 10 .
- the tube 11 may be pre-filled with the cleaning solution and a plug 42 would be inserted into an end of the tube 11 to prevent spilling of the solution.
- the tube would then be attached to the system 10 and carried, as shown in FIG. 6 , to the conductor cleaning site. After use, the tube 11 would be removed from the system 10 and the tube and cleaning solution would be properly disposed of.
- the tube 11 In the case of a permanent tube, the tube 11 would be attached to the system 10 and carried to the conductor cleaning site.
- the cleaning solution could be poured into the tube 11 and sealed therein by the plug 42 prior to delivery to the cleaning site, could be delivered to the site in another container and then poured into the tube at the site, or could be in powder form which would be mixed with water at the site.
- a conductor 43 is inserted into the tube 11 so that the cleaning solution contained therein may clean the strands of the conductor 43 .
- a baffle 44 may be inserted into the end of the tube 11 to prevent splashing during the cleaning process.
- the system 10 may be supported in various ways to relieve the burden, on the user, of supporting the system 10 .
- supports may be attached to the base 17 , FIGS. 8-10 .
- legs 46 are directly attached to the base 17 .
- Legs 46 may be secured to the base 17 using fasteners.
- removable legs 47 are secured to the base 17 by pins 48 . This allows the legs 47 to be removed when supporting the system 10 in a vertical position is not necessary.
- foldable legs 50 are secured to the base 17 by supports 49 which allow the legs 50 to pivot between a use position and a non-use position about pin 51 .
- a bi-pod having legs 53 and 54 may be attached to strap 18 .
- the legs 53 and 54 may be moved between a use position and a non-use position to allow the system 10 to be supported in a non-vertical position.
- a tri-pod 60 may also be used to support the system 10 .
- the tri-pod 60 includes adjustable legs 61 , 62 , and 63 to allow for adjustment on uneven surfaces. The system 10 is then hung from the tri-pod 60 using the attachment rail 16 .
- system 110 includes a container 111 operably connected to a vibrator contained in a vibrator housing 113 , a control panel 114 , an attachment rail 116 , a base 117 , and retaining straps 118 , 119 , and 122 .
- the container 111 of system 110 is a trough-like container to allow cleaning of a conductor 143 at a point intermediary of opposing ends of the conductor 143 without cutting. This allows the conductor 143 to be cleaned at locations where compression fittings, such as repair sleeves and T-connections, are being installed along the conductor 143 .
- the container 111 In use, the container 111 is positioned at a point along the conductor 143 where cleaning is desired and moved into engagement with the conductor 143 . Seals 160 and 161 permit the conductor 143 to be pressed into the container 111 until the conductor 143 is immersed in the cleaning solution. The seals 160 and 161 prevent the cleaning solution from leaking between the container 111 and the conductor 143 .
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- Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Wood Science & Technology (AREA)
- Organic Chemistry (AREA)
- Cleaning By Liquid Or Steam (AREA)
- Cleaning And De-Greasing Of Metallic Materials By Chemical Methods (AREA)
Abstract
A conductor cleaning system for cleaning aluminum strands of all aluminum and steel reinforced conductors, such as ACSS, ACSR, ACAR, and AAA. The conductor cleaning system having a container adapted to receive a portion of a conductor to be cleaned, a housing adapted to receive and support the container, and a cleaning solution contained in the container for cleaning the portion of the conductor. The cleaning solution being adapted to clean the conductor without reacting with or damaging the conductor.
Description
- This application is a Continuation-In-Part of U.S. patent application Ser. No. 12/357,610 filed on Jan. 22, 2009.
- The present invention relates generally to a conductor cleaning system, and more particularly to a system for cleaning aluminum strands of all aluminum and steel reinforced electrical conductors, such as ACSS, ACSR, ACAR, and AAA.
- In current power transmission systems, failures can pose a significant risk to the reliability of the system. There are several factors that contribute to these failures—one such factor is the failure of compression connectors.
- Current data suggests that a primary root cause for failures in compression connectors is improper installation. Examples of improper installation include lack of compound, alignment, wrong die, and poor cleaning of the aluminum strands of the conductor prior to installation of compression connectors. Research indicates that corrosion products and other contaminants (resulting from years of exposure to the environment) left on the conductors during splice assembly can raise the resistance of the splice-conductor joint (this is also true of new conductors which have oxidation and contaminants thereon). Cyclical variations of load current feeding through the increased resistance of the splice-conductor joint causes thermal expansion/contraction that eventually reduces the grip of the splice to a point where it can no longer hold the conductor.
- Currently, compression connector installers clean the aluminum strands with a wire brush, which results in ineffective cleaning of the strands, leaving corrosion products and other contaminants behind. Further, the installer cannot clean internal strands using the wire brush unless the installer takes the time to unstrand the conductor. Unfortunately, unstranding is impractical in most field conditions and can increase the risk of damage to the individual strands.
- Accordingly, there is a need for a conductor cleaning system that can effectively clean both outer and inner strands of a conductor without the need to unstrand the conductor.
- These and other shortcomings of the prior art are addressed by the present invention, which provides a conductor cleaning system capable of cleaning external and internal strands of a conductor without unstranding the conductor.
- According to one aspect of the present invention, a conductor cleaning system includes a container adapted to receive a portion of a conductor to be cleaned, a housing adapted to receive and support the container, and a cleaning solution contained in the container for cleaning the portion of the conductor. The cleaning solution is adapted to clean the conductor without reacting with or damaging the conductor.
- According to another aspect of the present invention, a cleaning solution adapted to clean electrical conductors without damaging galvanization coatings or degrading aluminum contained in the coatings or conductor has a composition, by approximate weight percent, of 0.985 to 8.97 NaOH, 0.49 to 1.45 NaF, and 89.7 to 98.5 H2O
- According to another aspect of the present invention, a method of cleaning an electrical conductor includes providing a conductor cleaning system having a container and an agitator. The method further includes providing a cleaning solution for cleaning of the electrical conductor, introducing the cleaning solution into the container, positioning an electrical conductor in the cleaning solution disposed in the container, and activating the agitator, thereby agitating the cleaning solution and enhancing its ability to clean the electrical conductor.
- The subject matter that is regarded as the invention may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which:
-
FIG. 1 is a perspective view of a conductor cleaning system according to an embodiment of the invention; -
FIG. 2 shows a vibrator housing of the conductor cleaning system ofFIG. 1 ; -
FIG. 3 shows an eccentric weight for use in a vibrator of the conductor cleaning system ofFIG. 1 ; -
FIG. 4 shows a battery and receptacle for the conductor cleaning system ofFIG. 1 ; -
FIG. 5 shows a control panel for the conductor cleaning system ofFIG. 1 ; -
FIG. 6 shows the conductor cleaning system ofFIG. 1 being carried; -
FIG. 7 shows the conductor cleaning system ofFIG. 1 in use; -
FIGS. 8-10 show the conductor cleaning system ofFIG. 1 supported in an upright position by supports; -
FIG. 11 shows the conductor cleaning system ofFIG. 1 fitted with bi-pods; -
FIG. 12 shows a tri-pod for supporting the conductor cleaning system ofFIG. 1 ; -
FIG. 13 is a perspective view of a conductor cleaning system according to an embodiment of the invention; and -
FIG. 14 is a graph showing pH v. cleaning sequence. - Referring to the drawings, an exemplary conductor cleaning system according to the present invention is illustrated in
FIG. 1 and shown generally atreference numeral 10. Thesystem 10 includes a container, such astube 11 operably connected to an agitator, such asvibrator 12,FIG. 2 , contained in avibrator housing 13, and acontrol panel 14 for controlling thesystem 10. Thecontainer 11 may be disposable or permanently attached to thesystem 10. - The
vibrator housing 13 is adapted to receive and support thecontainer 11, and includes anattachment rail 16 to allow thesystem 10 to be attached to a support for easy operation or to allow a user to easily carry thesystem 10. Other attachments such as a hook-type attachment may also be used to attach thesystem 10 to a bucket of a bucket truck or other suitable support. A standingbase 17 is disposed at one end of thehousing 13 to allow thesystem 10 to be positioned in a stand-up position such that thetube 11 is in a vertical position. Thebase 17 may be adapted to accept supports to further stabilize thesystem 10 in the vertical position, as shown inFIGS. 8-10 .Guide straps opposing ends housing 13 to provide guides and supports for thetube 11, and aretaining strap 22 is positioned between theguide straps tube 11 into position. Asupport 23 is also positioned on a bottom of thehousing 13 to further position and lock thetube 11 into position. As shown, thesupport 23 is V-shaped; however, any suitable geometry may be used to position and lock thetube 11 in position. - As shown in
FIG. 2 , thevibrator housing 13 includes acontrol system 30 having anelectric motor 31, atimer circuit 32, avoltage regulator 33, and thevibrator 12. Thevibrator 12 includes aneccentric weight 15, like that shown inFIG. 3 , to emit vibrations into thetube 11, thereby agitating a cleaning solution contained therein. While a vibrator is being described herein, it should be appreciated that other types of agitators may be used, for example, ultrasonic, bubbling air, and stirring. Together, themotor 31 andvibrator 12 cause thesystem 10 to vibrate at a specified rate by spinning theeccentric weight 15 at a desired speed. It should be appreciated that the speed of themotor 31 and size of theeccentric weight 15 may be changed to optimize the conductor cleaning efficiency. It should be appreciated that other forms of vibrators/agitators may be used, such as ultrasonic. - Referring to
FIG. 4 , thesystem 10 is powered by abattery 36. Thebattery 36 is contained in abattery receptacle 37 of thebase 17. Thebattery 36 may be replaceable or rechargeable and allows thesystem 10 to be portable for conductor cleaning both at ground level and at elevated levels. - As illustrated in
FIG. 5 , thecontrol panel 14 is electrically connected to thecontrol system 30 and includes apower switch 38, atimer 39, astart button 40, and abuzzer 41. Thepower switch 38 turns thesystem 10 on to a ready state so that thesystem 10 is ready to clean a conductor. Thetimer 39 allows a user to choose how long the cleaning process is going to last. The amount of time chosen is dependent on the level of contaminants and corrosion products on the surface of the conductor, temperatures, and other factors. Thestart button 40 turns the cleaning process on when depressed, and thebuzzer 41 lets a user know when the cleaning process has ended. - The cleaning solution is contained in the
tube 11 to allow an end of a conductor to be cleaned properly while reducing spills and splashes. The cleaning solution is designed and optimized to permit cleaning of aluminum strands of conductors without unstranding the conductor. Namely, the cleaning solution is designed to permit internal and external cleaning of aluminum strands of the conductor without reacting and damaging the galvanization of galvanized steel strands; to not react with or degrade aluminum strands after the cleaning process is complete; to clean over a wide range of temperatures; to not react with inhibitor compounds used in compression connector installation; and to be environmentally acceptable. - The cleaning solution uses a caustic solution of sodium hydroxide (NaOH) as a cleaning agent due to the tri-hydrated oxide of aluminum found in corrosion products being soluble in this type of solution. It should be appreciated that other suitable caustic hydroxides may be used. The caustic level of the solution is equal to, or less than, that of standard household cleaners. A low concentration of sodium fluoride (NaF) enhances the solubility of the aluminum oxides and reduces the time needed to complete the cleaning. The predominant reactions occurring during cleaning are as follows:
-
2Al+2NaOH+2H2O→2NaAlO3+3H2. - The reaction products are essentially stable and do not react with Al and the corrosion layer Al2O3. Only NaOH chemically attacks both Al and Al2O3. Examples of cleaning solutions are shown in the Table below.
-
Solution No. Composition Caustic Level 1 NaOH + H2O High 2 NaOH + NaPO4•12H2O + NaF + Medium H2O 3 NaOH + NaPO4•12H2O + NaF + Medium-Low H2O 4 NaOH + NaF + H2O Low - In testing, all of the above solutions provided good to excellent cleaning results. For example, in one test, a cleaning solution having a low level of causticity and relatively simple composition was chosen. The cleaning solution had the following concentrations:
- Sodium Hydroxide (NaOH)=20 g (approx. weight percent=1.93)
- Sodium Fluoride (NaF)=15 g (approx. weight percent=1.45)
- Water (H2O)=1 L. (approx. weight percent=96.62)
- It should be appreciated that other concentrations could be used depending on the application. For example, it was found that solutions having approximate weight percent ranges of 0.985 to 8.97 NaOH, 0.49 to 1.45 NaF, and 89.7 to 98.5H2O were acceptable. The chemicals were mixed in the water until completely dissolved. It was determined that the level of cleaning and the time to achieve that level were dependent on the solution temperature and the amount of agitation provided to the solution by the
vibrator 12. This can be seen in the table below. -
Temper- Cleaning Effectiveness Rated 0 to 5 with 5 Being the Best ature With Agitation Without Agitation (C.) 1 Min 2.5 Min 5 Min 1 Min 2.5 Min 5 Min 0 3 4 4 1 1 2 25 4 5 5 2 3 4 50 5 5 5 5 5 5 70 5 5 5 5 5 5
It should be appreciated that other forms of agitation may be used, such as ultrasonic, bubbling air, stirring, etc. - When using a cleaning solution with ACSS and other conductors having aluminum incorporated into the steel core's zinc coating, care must be taken to prevent damaging the aluminum in the Al—Zn coating that protects the steel strands of the electrical conductor. The Al—Zn coating protects the steel strands from corrosion and degradation of the coating would be detrimental to the life of the electrical conductor. As a result, it was determined that the use of an inhibitor in the cleaning solution would be beneficial.
- It was found that an inhibitor such as sodium silicate (Na2O(SiO2)x(H2O)x) protected the Al—Zn coating while allowing the cleaning solution to adequately clean the electrical conductor. It was further found that a approximate weight percent range of 0.15 to 1.42 of sodium silicate was acceptable. When mixing the sodium silicate with the cleaning solution it was found that a solution, by approximate weight percent, of (0.15 to 1.42) Na2O(SiO2)x(H2O)x+(1.90 to 1.93) NaOH+(1.43 to 1.45)NaF+(95.24 to 96.47) H2O adequately cleaned the electrical conductors and protected the Al—Zn coating.
- In addition to preventing damage to the Al in the Al—Zn coating, the pH is a concern due to EPA regulations for handling chemical solutions. Thus, it is beneficial to maintain the cleaning solution below a pH of 12.5. It was found, that various chemicals could be used to lower the pH of the solution. For example, it was found that a CaCl2 solution could lower the pH from 13.0 to 12.4. However, the CaCl2 solution tends to leave a residue.
- It was further found that the use of ascorbic acid provided many benefits that the other chemicals did not. For example, the ascorbic acid was beneficial for both lowering the pH and for protecting the Al—Zn coating. An acceptable range, by approximate weight percent, of ascorbic acid was found to be 0.193 to 3.54. This results in a cleaning solution having a composition, by approximate weight percent, of (0.193 to 3.54) ascorbic acid+(1.87 to 1.93) NaOH+(1.40 to 1.45)NaF+(93.28 to 96.43) H2O.
- In addition to lowering the pH and protecting the Al—Zn coating, when using the ascorbic acid, it was unexpectedly found that after a certain number of cleanings the pH of the cleaning solution dramatically fell off (See
FIG. 14 ), thereby indicating the need to change the cleaning solution before cleaning any more conductors. This is extremely beneficial because by simply monitoring the pH of the solution, a user knows exactly when to change out the solution for optimum cleaning. - As can be seen from
FIG. 14 , a cleaning solution without ascorbic acid maintains a fairly constant pH across the cleaning sequences. On the other hand, the ascorbic modified cleaning solution steadily decreases in pH until the cleaning solution becomes ineffective (indicated by the sudden drop off in pH). As such, a user cleaning multiple conductors can monitor the pH of the ascorbic modified solution and easily determine a normal range of drop in pH either visually by graphing pH measurements prior to and after each cleaning, as done inFIG. 14 , or by calculating the drop in pH for each cleaning using the pH measurements and then determining a normal range of drop in pH. If during a cleaning, a drop in pH of the cleaning solution exceeds the normal range, then the user knows to dispose of the spent cleaning solution and replace it with new cleaning solution. - In use, the
tube 11 is inserted through the guide straps 18 and 19 of thevibrator housing 13 and secured in position by the retainingstrap 22 andsupport 23. As discussed, thetube 11 may be disposable or permanently attached to thesystem 10. In the case of a disposable tube, thetube 11 may be pre-filled with the cleaning solution and aplug 42 would be inserted into an end of thetube 11 to prevent spilling of the solution. The tube would then be attached to thesystem 10 and carried, as shown inFIG. 6 , to the conductor cleaning site. After use, thetube 11 would be removed from thesystem 10 and the tube and cleaning solution would be properly disposed of. - In the case of a permanent tube, the
tube 11 would be attached to thesystem 10 and carried to the conductor cleaning site. The cleaning solution could be poured into thetube 11 and sealed therein by theplug 42 prior to delivery to the cleaning site, could be delivered to the site in another container and then poured into the tube at the site, or could be in powder form which would be mixed with water at the site. - Referring to
FIG. 7 , once at the conductor cleaning site, aconductor 43 is inserted into thetube 11 so that the cleaning solution contained therein may clean the strands of theconductor 43. Abaffle 44 may be inserted into the end of thetube 11 to prevent splashing during the cleaning process. With theconductor 43 positioned in the cleaning solution, thepower switch 38 is moved to the on position and thetimer 39 is moved to a desired time limit. The duration of vibration is determined by the user depending on the present temperature and the amount of deposits on the conductor surfaces. Thestart button 40 is then depressed and the motor rotates theeccentric weight 15 of thevibrator 12, thereby causing vibrations to agitate the cleaning solution to ensure that internal and external strands of the conductor are cleaned. - As discussed, during the cleaning cycle of the conductor, the
system 10 may be supported in various ways to relieve the burden, on the user, of supporting thesystem 10. For example, if the system is to be supported in a vertical position, supports may be attached to thebase 17,FIGS. 8-10 . As shown inFIG. 8 ,legs 46 are directly attached to thebase 17.Legs 46 may be secured to the base 17 using fasteners. As illustrated inFIG. 9 ,removable legs 47 are secured to thebase 17 bypins 48. This allows thelegs 47 to be removed when supporting thesystem 10 in a vertical position is not necessary. As shown inFIG. 10 ,foldable legs 50 are secured to thebase 17 bysupports 49 which allow thelegs 50 to pivot between a use position and a non-use position aboutpin 51. - Other support methods may also be employed. For example, in
FIG. 11 , abi-pod having legs strap 18. Thelegs system 10 to be supported in a non-vertical position. As shown inFIG. 12 , a tri-pod 60 may also be used to support thesystem 10. As shown, the tri-pod 60 includesadjustable legs system 10 is then hung from the tri-pod 60 using theattachment rail 16. - Referring to
FIG. 13 , aconductor cleaning system 110 is shown. Likesystem 10,system 110 includes acontainer 111 operably connected to a vibrator contained in avibrator housing 113, acontrol panel 114, anattachment rail 116, abase 117, and retainingstraps system 10, thecontainer 111 ofsystem 110 is a trough-like container to allow cleaning of aconductor 143 at a point intermediary of opposing ends of theconductor 143 without cutting. This allows theconductor 143 to be cleaned at locations where compression fittings, such as repair sleeves and T-connections, are being installed along theconductor 143. - In use, the
container 111 is positioned at a point along theconductor 143 where cleaning is desired and moved into engagement with theconductor 143.Seals conductor 143 to be pressed into thecontainer 111 until theconductor 143 is immersed in the cleaning solution. Theseals container 111 and theconductor 143. - The foregoing has described a conductor cleaning system. While specific embodiments of the present invention have been described, it will be apparent to those skilled in the art that various modifications thereto can be made without departing from the spirit and scope of the invention. Accordingly, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation.
- We claim:
Claims (18)
1. A cleaning solution adapted to clean electrical conductors, comprising: a caustic composition including a hydroxide cleaning agent.
2. The cleaning solution according to claim 1 , wherein the hydroxide cleaning agent is sodium hydroxide (NaOH).
3. The cleaning solution according to claim 1 , wherein the caustic composition, by approximate weight percent, comprises 0.985 to 8.97 NaOH.
4. The cleaning solution according to claim 1 , wherein the caustic composition further includes NaF to enhance the solubility of aluminum oxides and reduce the time needed to complete a cleaning of an electrical conductor.
5. The cleaning solution according to claim 1 , wherein the caustic composition, by approximate weight percent, comprises 0.49 to 1.45 NaF.
6. A cleaning solution adapted to clean electrical conductors without damaging galvanization coatings or degrading aluminum contained in the coatings or conductor, the cleaning solution having a composition comprising, by approximate weight percent, 0.985 to 8.97 NaOH, 0.49 to 1.45 NaF, and 89.7 to 98.5H2O.
7. The cleaning solution according to claim 6 , further including, by approximate weight percent, 0.15 to 1.42 Na2O(SiO2)x(H2O)x.
8. The cleaning solution according to claim 7 , wherein the cleaning solution comprises, by approximate weight percent, 0.15 to 1.42 Na2O(SiO2)x(H2O)x, 1.90 to 1.93 NaOH, 1.43 to 1.45 NaF, 95.24 to 96.47H2O.
9. The cleaning solution according to claim 6 , further including, by approximate weight percent, 0.193 to 3.54 ascorbic acid.
10. The cleaning solution according to claim 9 , wherein the cleaning solution comprises, by approximate weight percent, 0.193 to 3.54 ascorbic acid, 1.87 to 1.93 NaOH, 1.40 to 1.45 NaF, 93.28 to 96.43H2O.
11. The cleaning solution according to claim 6 , further including an inhibitor to prevent degradation of aluminum in the galvanization coatings or the conductor.
12. The cleaning solution according to claim 6 , further including an acid to control pH of the cleaning solution such that the pH is maintained below 12.5.
13. A method of cleaning an electrical conductor, comprising:
(a) providing a conductor cleaning system having:
(i) a container; and
(ii) an agitator;
(b) providing a cleaning solution for cleaning of the electrical conductor;
(c) introducing the cleaning solution into the container;
(d) positioning an electrical conductor in the cleaning solution disposed in the container; and
(e) activating the agitator, thereby agitating the cleaning solution and enhancing its ability to clean the electrical conductor.
14. The method according to claim 13 , wherein the cleaning solution comprises, by approximate weight percent, 0.15 to 1.42 Na2O(SiO2)x(H2O)x, 1.90 to 1.93 NaOH, 1.43 to 1.45 NaF, 95.24 to 96.47H2O.
15. The method according to claim 13 , wherein the cleaning solution comprises, by approximate weight percent, 0.193 to 3.54 ascorbic acid, 1.87 to 1.93 NaOH, 1.40 to 1.45 NaF, 93.28 to 96.43H2O.
16. The method according to claim 13 , further including the step of checking the pH of the cleaning solution before and after cleaning the electrical conductor.
17. The method according to claim 16 , further including the step of replacing the cleaning solution with a new cleaning solution when the pH of the cleaning solution indicates that the cleaning solution is ineffective in cleaning the electrical conductor.
18. A method of determining when to replace a cleaning solution in a conductor cleaning system with a new cleaning solution, comprising:
(a) measuring a pH of the cleaning solution prior to and after each cleaning of multiple electrical conductors;
(b) calculating a drop in pH of the cleaning solution for each cleaning using the pH measurements taken prior to and after each cleaning of the electrical conductors;
(c) determining a range of drop in pH using the calculated drops in pH for each cleaning; and
(d) replacing the cleaning solution with the new cleaning solution when a calculated drop in pH exceeds the determined range of drop in pH.
Priority Applications (9)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/608,079 US20100180914A1 (en) | 2009-01-22 | 2009-10-29 | Conductor cleaning system and method |
CA2689897A CA2689897C (en) | 2009-01-22 | 2010-01-12 | Conductor cleaning system and method |
CA2821473A CA2821473C (en) | 2009-01-22 | 2010-01-12 | Conductor cleaning system and method |
AU2010200197A AU2010200197B2 (en) | 2009-01-22 | 2010-01-18 | Conductor cleaning system and method |
EP10151246A EP2210677B1 (en) | 2009-01-22 | 2010-01-20 | Cleaning solution and cleaning method for an electrical conductor |
ES10151246T ES2384831T3 (en) | 2009-01-22 | 2010-01-20 | Dissolution and cleaning procedure for an electric conductor |
AT10151246T ATE551128T1 (en) | 2009-01-22 | 2010-01-20 | CLEANING SOLUTION AND PROCESS FOR ELECTRICAL CONDUCTORS |
US13/903,062 US20130255730A1 (en) | 2009-01-22 | 2013-05-28 | Conductor cleaning system and method |
US13/903,080 US20130255726A1 (en) | 2009-01-22 | 2013-05-28 | Conductor cleaning system and method |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/357,610 US8839804B2 (en) | 2009-01-22 | 2009-01-22 | Conductor cleaning system |
US12/608,079 US20100180914A1 (en) | 2009-01-22 | 2009-10-29 | Conductor cleaning system and method |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/357,610 Continuation-In-Part US8839804B2 (en) | 2009-01-22 | 2009-01-22 | Conductor cleaning system |
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US13/903,080 Division US20130255726A1 (en) | 2009-01-22 | 2013-05-28 | Conductor cleaning system and method |
US13/903,062 Division US20130255730A1 (en) | 2009-01-22 | 2013-05-28 | Conductor cleaning system and method |
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US20100180914A1 true US20100180914A1 (en) | 2010-07-22 |
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Family Applications (3)
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US12/608,079 Abandoned US20100180914A1 (en) | 2009-01-22 | 2009-10-29 | Conductor cleaning system and method |
US13/903,062 Abandoned US20130255730A1 (en) | 2009-01-22 | 2013-05-28 | Conductor cleaning system and method |
US13/903,080 Abandoned US20130255726A1 (en) | 2009-01-22 | 2013-05-28 | Conductor cleaning system and method |
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US13/903,062 Abandoned US20130255730A1 (en) | 2009-01-22 | 2013-05-28 | Conductor cleaning system and method |
US13/903,080 Abandoned US20130255726A1 (en) | 2009-01-22 | 2013-05-28 | Conductor cleaning system and method |
Country Status (6)
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US (3) | US20100180914A1 (en) |
EP (1) | EP2210677B1 (en) |
AT (1) | ATE551128T1 (en) |
AU (1) | AU2010200197B2 (en) |
CA (2) | CA2689897C (en) |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11191886B2 (en) * | 2013-06-14 | 2021-12-07 | The Cleveland Clinic Foundation | Motion-assisted systems, devices and methods for minimizing obstruction of medical devices |
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Also Published As
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US20130255726A1 (en) | 2013-10-03 |
AU2010200197A1 (en) | 2010-08-05 |
AU2010200197B2 (en) | 2011-10-06 |
US20130255730A1 (en) | 2013-10-03 |
ATE551128T1 (en) | 2012-04-15 |
EP2210677B1 (en) | 2012-03-28 |
CA2689897C (en) | 2013-11-19 |
CA2689897A1 (en) | 2010-07-22 |
CA2821473A1 (en) | 2010-07-22 |
EP2210677A1 (en) | 2010-07-28 |
ES2384831T3 (en) | 2012-07-12 |
CA2821473C (en) | 2014-09-30 |
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AS | Assignment |
Owner name: ELECTRIC POWER RESEARCH INSTITUTE, INC., NORTH CAR Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:PHILLIPS, ANDREW J., DR.;STEWART, ANDREW H.;NINGILERI, SHRIDAS;AND OTHERS;SIGNING DATES FROM 20091103 TO 20091130;REEL/FRAME:023610/0899 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |