Rare Earth Coated Conductors for Ice Resistance

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Solution Overview

Problem

Existing coatings for overhead power transmission conductors fail to effectively prevent ice accumulation and wear while providing adequate insulating properties, especially in outdoor environments.

Innovation Solution

A conductor coated with a rare earth material composition, including elements like Lanthanum, Cerium, and Neodymium, applied using a cold spray deposition process, which provides hydrophobic and anti-icing properties, enhancing adhesion and stability through additives like aluminum or zinc.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing coatings are applied to conductors, then insulating properties are provided, but ice accumulation and wear resistance are insufficient

Engineering Contradiction:

Improveice resistanceVSAvoidice accumulation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters of the coating by incorporating rare earth materials (such as cerium oxide, lanthanum oxide) with specific hydrophobic properties. This compositional parameter change enables the coating to repel water and ice effectively, resolving the ice accumulation problem while maintaining insulating properties.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite coating materials combining rare earth compounds (e.g., cerium oxide, lanthanum oxide) with hydrophobic agents and binders. This composite structure provides multiple functions simultaneously: insulation from the base coating, ice resistance from rare earth hydrophobic properties, and enhanced durability. The composite material approach resolves the contradiction by integrating multiple protective functions in one coating system.

Inventive Principle:

Principle #40Composite materials

2Strength

If existing coatings are applied to conductors, then basic protection is provided, but wear resistance from environmental factors is insufficient

Engineering Contradiction:

Improvewear resistanceVSAvoidenvironmental wear

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The composite coating system incorporates rare earth materials known for their chemical stability and hardness, combined with durable binders and protective additives. This creates a coating with enhanced mechanical strength and resistance to environmental wear factors such as UV radiation, oxidation, and physical abrasion, directly addressing the wear resistance requirement.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The rare earth materials in the coating, particularly cerium oxide, provide protective oxidation resistance by forming stable oxide layers that prevent further oxidation of the conductor surface. This protective mechanism enhances the coating's ability to resist environmental degradation and extend service life.

Inventive Principle:

Principle #38Strong oxidants (Accelerated oxidation)

3Reliability

If existing coatings are applied to conductors, then some insulating properties are provided, but adequate insulation for outdoor environments is insufficient

Engineering Contradiction:

Improveinsulating propertiesVSAvoidenvironmental degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The composite coating formulation combines insulating base materials with rare earth compounds that provide enhanced electrical insulation properties and environmental stability. The rare earth materials contribute to maintaining insulation performance under outdoor conditions by providing resistance to moisture penetration, UV degradation, and thermal cycling, thus ensuring adequate insulation reliability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the coating's electrical and physical parameters by incorporating rare earth materials with high dielectric strength and environmental stability. These parameter changes enhance the coating's ability to maintain insulating properties in harsh outdoor environments, preventing electrical breakdown and degradation over time.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The rare earth coating significantly inhibits ice buildup and offers corrosion resistance, improving the structural integrity of conductors in outdoor environments by providing effective hydrophobic and anti-icing properties.

Implementation Method 1

the rare earth material in the coating composition provides sufficient hydrophobic properties as well as sufficient anti-icing properties

Methodology Applied

Scientific EffectHydrophobic effect: Hydrophobe

Implementation Method 2

the conductor is coated with the coating composition utilizing a cold spray deposition process

Methodology Applied

Scientific EffectCold spray deposition: Deposition (physical)

Data Source

PatentUS10068683B1Rare earth materials as coating compositions for conductors

Publication Date: 2018.09.04 SOUTHWIRE CO LLC

AI summary

A conductor includes a core with at least one conductive filament, and a coating deposited on a surface of the core. The coating is made of a rare earth material that includes at least one rare earth element selected from the group consisting of Lanthanum (La), Cerium (Ce), Praseodymium (Pr), Neodymium (Nd), Promethium (Pm), Samarium (Sm), Europium (Eu), Gadolinium (Gd), Terbium (Tb), Dysprosium (Dy), Holmium (Ho), Erbium (Er), Thulium (Tm), Ytterbium (Yb), Lutetium (Lu), Scandium (Sc) and Yttrium (Yt).