Sacrificial Electrode Flange Structure for Leak-Safe Pipe Replacement
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Solution Overview
Problem
Existing sacrificial electrodes in electrolysis systems require cumbersome and costly replacement due to welding, and their detachment leads to electrolyte leakage and increased risk of corrosion in adjacent conductive pipes.
Innovation Solution
A sacrificial electrode design featuring a body disposed within conductive or non-conductive pipes with a detachable mounting flange sandwiched between flanges, eliminating the need for additional fixing parts and allowing easy replacement, reducing electrolyte leakage and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sacrificial electrode is welded to conductive pipe, then electrode is securely fixed and provides corrosion protection, but replacement becomes time-consuming and costly requiring cutting and rewelding
Solution Approach 1:
The sacrificial electrode is segmented into a removable mounting portion and a sacrificial body portion. The mounting portion is detachably connected to the conductive pipe while the body portion remains as the sacrificial element, allowing the body to be replaced without replacing the entire electrode assembly or performing welding operations.
Solution Approach 2:
The electrode transitions from a static welded configuration to a dynamic removable configuration. The mounting portion can be detached and reattached, enabling easy replacement of the sacrificial body while maintaining secure electrical and mechanical connection during operation.
2Reliability
If sacrificial electrode is directly welded to pipe, then secure electrical connection is achieved, but electrode cannot be easily removed for replacement
Solution Approach 1:
The electrode is divided into a mounting portion that provides the electrical connection interface and a separate sacrificial body portion. This segmentation allows the mounting portion to remain permanently connected to the pipe while the body portion can be easily removed and replaced.
Solution Approach 2:
The mounting portion acts as an intermediary between the conductive pipe and the sacrificial body. It provides the electrical connection to the pipe while serving as a removable interface that facilitates easy replacement of the body without direct welding or permanent attachment.
3Ease of repair
If detachable mounting structure with multiple pipe couplings is used, then electrode can be freely detached and replaced, but number of fixing parts increases leading to electrolyte leakage risk and cumbersome replacement
Solution Approach 1:
The mounting portion combines multiple functions into a single integrated component: it provides mechanical attachment to the pipe, electrical connection to the sacrificial body, and sealing to prevent electrolyte leakage. This eliminates the need for separate pipe couplings and fixing parts.
Solution Approach 2:
The mounting portion serves multiple purposes simultaneously: it acts as a mechanical fastener, an electrical conductor, and a sealing element. This multi-functionality reduces the total number of components needed while maintaining ease of detachment and replacement.
4Ease of repair
If multiple dedicated fixing parts are required for detachable connection, then electrode can be freely replaced, but risk of electrolyte leakage increases
Solution Approach 1:
The mounting portion integrates the sealing function directly into the attachment mechanism. The same component that provides mechanical detachment capability also ensures electrolyte sealing, eliminating gaps or interfaces where leakage could occur.
Solution Approach 2:
The mounting portion incorporates a flexible sealing element or gasket that conformally seals the interface between the electrode assembly and the pipe. This flexible sealing mechanism maintains reliability while allowing for easy detachment and replacement.
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
Facilitates easy and cost-effective replacement of sacrificial electrodes, minimizing electrolyte leakage and electrolytic corrosion in conductive pipes by ensuring a sealed and electrically connected arrangement between adjacent pipes.
Implementation Method 1
a mounting flange (14) extending from the body (12) so as to be detachably sandwiched in a sealed manner between the flanges (52A, 54A) of the adjacent conductive and non-conductive pipes (52, 54)
Implementation Method 2
a conductive member (16) configured to electrically connect the mounting flange (14) to the conductive pipe (52)
Implementation Method 3
The leakage current in the electrolyte in the non-conductive pipe (54) may flow through the conductive member (16) of the sacrificial electrode (10) into the conductive pipe (52), leading to sacrificial electrolytic corrosion of the body (12) of the sacrificial electrode (10)
Data Source
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AI summary
The present invention relates to a sacrificial electrode (10) for arrangement between adjacent conductive and non-conductive pipes (52, 54) to flow electrolyte to or from electrolysis cells, adjoining ends of the pipes (52, 54) being provided with flanges (52A, 54A), respectively. The sacrificial electrode (10) comprises a body (12) configured to be disposed within the non-conductive pipe and/or the conductive pipe (52, 54), a mounting flange (14) extending from the body (12) so as to be detachably sandwiched in a sealed manner between the flanges (52a,54a) of the adjacent conductive and non-conductive pipes (52, 54), and a conductive member (16) configured to electrically connect the mounting flange (14) to the conductive pipe (52).