Thermoplastic Insulation Bonding on Electrode Plates
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Solution Overview
Problem
Existing methods for fastening electrically insulating thermoplastic profiles and plates to electrode plates in electrochemical processes are prone to premature loosening due to shrinkage and uneven pressure distribution, leading to corrosion and inefficient metal precipitation.
Innovation Solution
A method and device that apply controlled pressure and temperature to ensure a durable bond between thermoplastic profiles and electrode plates, using hoses to maintain pressure during the melting and cooling process, and employing grafted polymers for chemical adhesion, while regulating pressure and temperature to prevent shrinkage and air entrapment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermoplastic profiles are fastened to electrode plates using conventional methods, then the insulating material provides electrical insulation, but the profiles become loose before the electrode plate is worn out
Solution Approach 1:
The patent applies controlled temperature and pressure parameters during the fastening process. The electrode plate is heated to a specific temperature range, and controlled pressure is applied to the thermoplastic profile during cooling to ensure proper bonding. This parameter control prevents premature loosening while maintaining the service life of the profile.
Solution Approach 2:
The electrode plate surface is pre-heated before the thermoplastic profile is applied. This preliminary heating action prepares the surface for optimal bonding, ensuring that the profile adheres properly from the start and prevents early loosening during operation.
2Strength
If pressure is applied to fasten thermoplastic profiles, then bonding strength is improved, but uneven pressure distribution causes shrinkage and poor adhesion
Solution Approach 1:
A compression element is introduced as an intermediary between the pressure source and the thermoplastic profile. This element distributes the applied pressure evenly across the profile surface, preventing localized shrinkage and ensuring uniform bonding strength without compromising adhesion quality.
Solution Approach 2:
The compression element applies pressure locally at multiple points across the thermoplastic profile surface. This localized pressure distribution ensures even bonding throughout the profile while preventing excessive shrinkage in any single area, maintaining manufacturing precision.
3Strength
If the electrode plate is heated to melt thermoplastic, then bonding is enhanced, but air entrapment occurs between the profile and plate surface
Solution Approach 1:
The electrode plate surface is pre-heated before the thermoplastic profile is placed on it. This preliminary heating action melts the thermoplastic gradually from the contact points, allowing air to escape before the profile fully bonds, thus preventing air entrapment while maintaining strong adhesion.
Solution Approach 2:
The heated electrode plate surface acts as an intermediary that controls the melting and bonding process. By providing controlled heat, it allows the thermoplastic to melt and flow, expelling air gradually, and then solidify to create a strong bond without trapped air pockets.
4Reliability
If thermoplastic profiles are used for insulation, then electrical insulation is provided, but corrosion occurs in the sloshing zone where electrolyte contacts the plate
Solution Approach 1:
The thermoplastic profile serves multiple functions simultaneously: it provides electrical insulation for the electrode plate and acts as a protective barrier against corrosion in the sloshing zone. This multi-functionality eliminates the need for separate protective components while maintaining both insulation and corrosion resistance.
Solution Approach 2:
The solution uses a composite structure where the thermoplastic profile combines insulating properties with corrosion resistance. The thermoplastic material itself forms a protective layer that prevents electrolyte contact with the metal plate in the sloshing zone, while maintaining electrical insulation throughout the profile.
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 achieves a durable and even fastening of thermoplastic profiles and plates, preventing premature loosening and ensuring optimal contact pressure, which enhances the longevity of electrode plates and improves the efficiency of metal precipitation processes.
Implementation Method 1
the area on the electrode plate where the plastic body is applied is heated to a temperature at or above the melting point of the plastic body, b) the plastic body is placed on the heated surface of the electrode plate, and the surface of the thermoplastic body that is in contact with the heated surface of the electrode plate melts
Implementation Method 2
a force is applied to the plastic body that pushes the plastic body against the surface of the electrode plate, where the pressure force is formed by one or more hoses
Implementation Method 3
the plastic body and the electrode plate are cooled down, while the pressure force is maintained until the shape of the thermoplastic is stable
Data Source
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AI summary
The present invention relates to a method of attaching one or more electrically insulating thermoplastic bodies to an electrode plate for precipitation of metal from an electrolyte comprising the following steps: a) the area of the electrode plate where the plastic body is applied is heated to a temperature at or above the melting point of the plastic body, b) the body is placed on the heated surface of the electrode plate, and the surface of the thermoplastic body which is in contact with the heated surface of the electrode plate melts, c) the plastic body applies a pressure force which forces the plastic body against the surface of the electrode plate, where the pressure force preferably is formed by one or more hoses and d) the plastic body and the electrode plate are cooled down while the pressure force is maintained until the form of the thermoplastic is stable. The present invention additionally includes a device comprising: means for holding and positioning the electrode plate to the desired position (s), means for heating one or more selected areas of the surface of the electrode plate, means for placing one or more electrically insulating thermoplastic bodies on the selected areas of the electrode plate, one or more hoses arranged to apply pressure to the electrically insulating thermoplastic bodies on the selected areas of the electrode plate, and means for cooling the thermoplastic bodies, preferably the cooling channels in the device and / or water flow in the hoses.