Cathode Plate Edge Protector with Overmolded Corner Cap

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Solution Overview

Problem

Cathode plates in electrowinning processes experience excessive copper buildup at the edges, making it difficult to move or remove copper sheets, which is addressed by using non-conductive edge protectors, but existing technologies require continuous improvement.

Innovation Solution

The method involves manufacturing an edge protector by inserting retention plates into slits of edge strips, using a plug to abut the ends of the strips, and overmolding corner caps to create a robust and flexible edge protector that prevents copper buildup and enhances handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If plastic edge protectors are placed on cathode plate edges to prevent copper buildup, then copper deposition at edges is reduced, but the manufacturing complexity and assembly difficulty increase

Engineering Contradiction:

Improvecopper buildup at edgesVSAvoidedge protector structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The edge protector is divided into multiple functional segments: edge strips with slits that wrap around the plate edges, corner caps that fit into corner slots, and retention plates that secure the components. This segmentation allows each part to perform its specific function while simplifying the overall assembly process through modular construction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The corner caps are designed to nest into corner slots formed by the edge strips, creating a compact integrated structure. The retention plates are inserted into slots in the edge strips, allowing one component to be nested within another. This nesting reduces the overall complexity by eliminating separate fastening mechanisms.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If edge protectors are made robust to prevent copper accumulation, then effectiveness increases, but ease of manufacture decreases

Engineering Contradiction:

Improveedge protector effectivenessVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The edge strips are made from flexible non-conductive material that can be bent and wrapped around the cathode plate edges. This flexibility allows the strips to conform to the plate geometry and be easily installed without requiring complex forming operations or multiple rigid components, thereby maintaining manufacturing simplicity while ensuring effective edge coverage.

Inventive Principle:

Principle #30Flexible shells and thin films

3Strength

If corner caps are overmolded for strength, then structural integrity improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improvecorner cap integrityVSAvoidovermolding alignment

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The corner slots are pre-formed by the edge strips before the corner caps are installed. This preliminary action creates a ready-made receptacle that guides the corner cap into proper alignment during installation. The pre-formed slots eliminate the need for precise alignment during the overmolding process, as the corner caps simply need to fit into the existing slot geometry.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS9863050B2Cathode plate edge protector and methods of manufacture

Publication Date: 2018.01.09 CLIM A TECH IND

AI summary

A method of manufacturing an edge protector for a cathode plate includes inserting a first retention plate into a slit in a first edge strip, proximate an end of the first edge strip. The first retention plate is also inserted into a slit in a second edge strip, proximate a first end of the second edge strip. Additionally, the first retention plate is inserted into a gap of a first plug, such that the first plug abuts both the end of the first edge strip and the first end of the second edge strip. A corner cap is then overmolded on the end of the first edge strip, the first plug, and the first end of the second edge strip.