Electrolytic Cathode Conducting Bar Corrosion Resistance

Solution Overview

Problem

Existing cathodes for electrolytic processes face challenges with weld corrosion and significant voltage drops due to the use of copper or alternative metals, leading to increased operating costs and structural weaknesses.

Innovation Solution

A stainless steel conducting bar with a copper or copper alloy conducting member attached via welds on the inside surface, forming a tubular shape through roll forming, which enhances conductivity and reduces corrosion susceptibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If a copper conducting bar is used, then electrical conductivity is improved, but corrosion resistance deteriorates due to acid mist

Engineering Contradiction:

Improveelectrical conductivityVSAvoidcorrosion resistance

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The conducting bar is divided into two distinct parts: a stainless steel core providing corrosion resistance and a copper coating providing electrical conductivity. This segmentation allows each material to perform its optimal function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure combining stainless steel and copper materials. The stainless steel core provides mechanical strength and corrosion resistance, while the copper coating provides high electrical conductivity, creating a material system that exhibits properties superior to either individual material alone.

Inventive Principle:

Principle #40Composite materials

2Reliability

If copper is replaced with alternative metals, then corrosion resistance is improved, but electrical conductivity deteriorates causing voltage drop

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidelectrical conductivity

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The conducting bar is divided into two distinct parts: a stainless steel core providing corrosion resistance and a copper coating providing electrical conductivity. This segmentation allows each material to perform its optimal function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure combining stainless steel and copper materials. The stainless steel core provides mechanical strength and corrosion resistance, while the copper coating provides high electrical conductivity, creating a material system that exhibits properties superior to either individual material alone.

Inventive Principle:

Principle #40Composite materials

3Use of energy by moving object

If copper coating is applied on stainless steel, then electrical conductivity is improved, but coating separation occurs due to corrosion

Engineering Contradiction:

Improveelectrical conductivityVSAvoidcoating adhesion

Core Design Contradiction:

Use of energy by moving objectVSStability of the object's composition

Solution Approach 1:

A nickel intermediate layer is applied between the stainless steel core and copper coating before final assembly. This preliminary action creates a stable foundation that prevents future coating separation, addressing potential adhesion issues before they occur during operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The nickel layer serves as an intermediary between the stainless steel core and copper coating. This intermediate material facilitates strong bonding between the two dissimilar metals, preventing coating separation while maintaining both corrosion resistance and electrical conductivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If three-part welding process with nickel alloy is used, then weld reliability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveweld resistance to corrosionVSAvoidwelding process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The nickel intermediate layer serves as a mediator that enables direct welding between stainless steel and copper components. This intermediate material is compatible with both metals, allowing for simpler welding processes while maintaining high weld reliability and corrosion resistance.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution provides a durable and cost-effective cathode with reduced corrosion and voltage drop, maintaining structural integrity while minimizing copper usage, thus lowering operational costs.

Implementation Method 1

the conducting bar has a conducting member attached thereto to increase the conductivity of the conducting bar

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

The conducting member is welded to an inside surface of the conducting bar

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS11136683B2Cathode and method of manufacturing

Publication Date: 2021.10.05 GLENCORE TECHNOLOGY PTY LTD

AI summary

A method is disclosed for manufacturing a cathode for electrolytic processes, the cathode comprising a conducting bar and a plate attached to the conducting bar, wherein the conducting bar has a conducting member attached thereto to increase the conductivity of the conducting bar.