PLATE EDGE PROTECTOR
20220298662 · 2022-09-22
Inventors
Cpc classification
International classification
Abstract
An edge protector 1 mountable to a cathode plate 2, the edge protector 1 comprising a set of elongate channels 3. Each elongate channel 10, 20, 30 defining a slot. The set of elongate channels 3 including a first and second channel 10, 20 adapted to receive and cover respective side edges 4a, 4c of the cathode plate 2, and a third channel 30 adapted to receive and cover a lower edge 4b of the cathode plate 2. The first, second and third channels 10, 20, 30 being channels of a first, second and third body 12, 22, 32 respectively. Wherein, the edge protector 1 further includes a first and a second insert 40a-b. The first insert 40a being adapted to be inserted into or over a feature 14 of a first end 16a of the first body 12 and a feature 24a of a first end 26a of the second body 22 to form a first corner 6a. The second insert 40b being adapted to be inserted into or over a feature 24b of a second end 26b of the second body 22 and a feature 34 of a first end 36a of the third body 32 to form a second corner 6b. The first and second corners 6a-b are overmoulded with a first and second mouldable material respectively. The first corner 6a being separately overmoulded to the second corner 6b.
Claims
1. An edge protector mountable to a cathode plate, the edge protector comprising a set of elongate channels, each elongate channel defining a slot, the set of elongate channels including a first and second channel adapted to receive and cover respective side edges of the cathode plate, and a third channel adapted to receive and cover a lower edge of the cathode plate, the first, second and third channels beings channels of a first, second and third body, respectively, wherein the edge protector further includes: a first and second insert, the first insert being adapted to be placed into or over a feature of a first end of the first body and a feature of a first end of the second body to form a first corner, the second insert being adapted to be placed into or over a feature of a second end of the second body and a feature of a first end of the third body to form a second corner; and first and second corner over moldings adapted to seal the first and second corners, the first corner over molding being separate to the second corner over molding.
2. The edge protector as claimed in claim 1, wherein, the first, second and third channels (channels) have a transverse cross section which is substantially cruciform in shape.
3. The edge protector as claimed in claim, wherein, the cruciform shape includes four ends, the four ends including an open end which is adapted to receive the cathode plate and three closed ends, the three closed ends including a first closed end opposite the open end and two side ends, the two side ends each adapted to receive a seal.
4. The edge protector as claimed in claim 1, wherein the first and second inserts each include a slot adapted to receive the cathode plate.
5. The edge protector as claimed in claim 1, wherein the first corner over moldings is formed in an over molding process in which injected plastic melts an outer surface of the first body, therefore fixing the first body to the first insert rotationally and axially.
6. The edge protector as claimed in claim 1, wherein the first and second bodies are formed in an over moulding of the first and second corners whereby the respective outer surfaces of the first and second bodies are melted.
7. The edge protector as claimed in claim 1, wherein the first and second corners include the first body aligned or oriented at an angle of between 80 and 100 degrees relative to the alignment or orientation of the second body, and the second body is aligned or oriented at an angle of between 80 and 100 degrees relative to the alignment or orientation of the third body.
8. The edge protector as claimed in claim 1, wherein all of the components of the edge protector are made of plastic.
9. The edge protector as claimed in claim 1, wherein the feature of the first end of the first body is substantially in the form of a cylinder.
10. The edge protector as claimed in claim 1, wherein the first insert includes an interference or press fit into the feature of the first body.
11. The edge protector as claimed in claim 1, wherein the first channel is substantially uniform along its length.
12. The edge protector as claimed in claim 1, wherein a transverse cross section of the first channel is substantially identical to a transverse cross section of each of the second and third channels.
13. The edge protector as claimed in claim 1, wherein the open end of each of the first, second and third channels includes a taper from a larger thickness of the channel to a smaller thickness of the channel at an open edge of each of the channel, the open end of each of the channel being adapted to receive the cathode plate.
14. The edge protector as claimed in claim 1, wherein the first and third bodies include holes adapted to line up with holes in the cathode plate such that bolts can be inserted through the holes in the first and third bodies and the cathode plate.
15. (canceled)
16. A method of manufacturing an edge protector for a cathode plate as claimed in claim 1, comprising the steps of: (a) receiving and covering the respective side edges of the cathode plate with the first and second elongate channels; (b) receiving and covering a lower edge of the cathode plate with the third elongate channel; (c) placing the respective first and second inserts into or over the respective feature of the first and second ends of the respective first and second bodies to form the corresponding first and second corners; (d) placing the second insert into or over the feature of the second end of the second body and the feature of a first end of the third body to complete the second corner; and (e) over molding the first and second corners to seal the first and second corners.
17. A method as claimed in claim 16, further comprising the step of: (f) inserting a brace into the first second and third channels and slots to hold a longitudinal axis of the first body at 90 degrees to a longitudinal axis of the second body and the longitudinal axis of the second body at 90 degrees to a longitudinal axis of the third body whilst the first and second corners are over-molded.
18. A method as claimed in claim 17, further comprising the step of: (g) injecting a suitable plastic into spaces between the two halves of the mould and the first corner in an over-molding process forming the first molded body.
19. A method as claimed in claim 18, further comprising the step of: (h) melting the plastic outer surfaces of the bodies, therefore fixing the bodies to the first insert rotationally and axially.
20. A method as claimed in claim 19, further comprising the step of: (i) placing the second corner between two halves of a mold and injecting plastic into spaces between the two halves of the mold and the second corner in an over molding process forming a second molded body.
21. A method as claimed in claim 20, further comprising the steps of: (j) injecting the plastic to melt the outer surfaces of the first, second and third bodies and fixing same to the second insert rotationally and axially; and (k) removing the brace from the first, second and third channels and slots.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] The invention may be better understood from the following non-limiting description of preferred embodiments, in which:
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DETAILED DESCRIPTION OF THE DRAWINGS
[0054] Preferred features of the present invention will now be described with particular reference to the accompanying drawings. However, it is to be understood that the features illustrated in and described with reference to the drawings are not to be construed as limiting on the scope of the invention.
[0055] An edge protector 1 mountable to a cathode plate 2, the edge protector 1, 101, 201, 301 comprising a set of elongate channels 3, 103. Each elongate channel 10, 20, 30, 110, 120, 130 defining a slot. The set of elongate channels 3 including a first and second channel 10, 20, 110, 120 adapted to receive and cover respective side edges 4a, 4c of the cathode plate 2, and a third channel 30, 130 adapted to receive and cover a lower edge 4b of the cathode plate 2. The first, second and third channels 10, 20, 30, 110, 120, 130 being channels of a first, second and third body 12, 22, 32, 112, 122, 132 respectively. Wherein, the edge protector 1 further includes a first and second insert 40a-b, 140a-b. The first insert 40a, 140a being adapted to be placed into or over a feature 14 of a first end 16a of the first body 12, 112 and a feature 24a of a first end 26a of the second body 22, 122 to form a first corner 6a. The second insert 40b being adapted to be placed into or over a feature 24b of a second end 26b of the second body 22, 122 and a feature 34 of a first end 36a of the third body 32, 132 to form a second corner 6b. The first and second corners 6a-b are overmoulded with a first and second mouldable material respectively. The first corner 6a being separately overmoulded to the second corner 6b.
[0056] Like features may be referenced with the same reference number. For example, the first and second corners 6a-b in each of a first, second, third and fourth embodiment are slightly different in some embodiments but are all referenced 6a-b. Furthermore, like features may be referenced with like reference numbers. A first, second, third and fourth embodiment of the invention include combinations of two versions of the first, second and third channels 10, 20, 30, 110, 120, 130 (channels) and two versions of the first and second inserts 40a-b, 140a-b (inserts). The first embodiment of the invention includes a first version version of the channels 10, 20, 30 shown in
[0057] The following passages refer to any one of a first, second, third or fourth embodiment of the invention. The first and third bodies 12, 32, 112, 132 are identical. The first, second and third channels 10, 20, 30, 110, 120, 130 are substantially the same. The channels 10, 20, 30, 110, 120, 130 have an inner transverse cross-section which is substantially cruciform shape 10a, 110a (as seen in
[0058] The following passages refer to either the first or second embodiment of the invention. The cruciform shape includes four ends; a top end 10b, two side ends 10c-d and a bottom end 10e. The top end 10b includes tapers 10f angled outwards from a smaller width base 10bi of the top end 10b to a larger width top 10bii of the top end 10b. The larger width top 10bii of the top end 10b includes radiused edges 10g. The two side ends 10c-d include radiused upper edges 10h with larger radii and radiused lower edges 10i with smaller radii. Furthermore, lowers faces 10j of the two side ends 10c-d include tapers 10n. The tapers 10n extend inwards from a smaller width inner side 10ci of each of the two side ends 10c-d to a larger width outer side 10cii of the two side ends 10c-d. The top end 10b and two side ends 10c-d are enclosed. The bottom end 10e is open or not enclosed by the first, second and third bodies. The bottom end 10e includes tapered faces 10k extending from a smaller width base 10ei of the bottom end 10e to a larger width top 10eii of the bottom end 10e. The tapered faces 10k of the bottom end 10e include edges 10m on the smaller width base 10ei which are adapted to contact the large faces of the cathode plate 2 when the cathode plate 2 is inserted into the channels 10, 20, 30. The edges 10m limit the flow of a solution into the channels 10, 20, 30.
[0059] The following passages refer to either the third or fourth embodiment of the invention. The cruciform shape includes four ends; a top end 110b, two side ends 110c-d and a bottom end 110e. The top end 110b includes cylindrical slots 110f cut into two upper corners 110bi of the top end 110b. The top end 110b is adapted such that edges 4a-c of the cathode plate 4a-c do not contact the bodies 112, 122, 132 when the cathode plate 2 is inserted into the edge protector 1. The adaptions include the cylindrical slots 110f. The top end 110b includes a top 110bii. The bottom end 110e includes tapered faces 110k extending from a smaller width base 110ei of the bottom end 110e to a larger width top 110eii of the bottom end 110e. The tapered faces 110k of the bottom end 110e include edges 110m on the smaller width base 110ei which are adapted to contact the large faces of the cathode plate 2 when the cathode plate 2 is inserted into the channels 110, 120, 130. The edges 110m limit the flow of a solution into the channels 110, 120, 130. The two side ends 110c-d are substantially rectangular slots.
[0060] Unless otherwise stated, the following passages refer to any of the first, second, third and fourth embodiments of the invention. The edge protector 1, 101, 201, 301 and cathode plate 2 are adapted for insertion into the solution. The solution may include any metal. Preferably, the solution includes either copper, zinc or cobalt. The copper, zinc or cobalt may be in an oxidised form or in the form of another compound including copper, zinc or cobalt. A plate portion 2a of the cathode plate is made of either stainless steel or aluminium. The tapers 10k, 10n described above may also include curved faces and curved tapers.
[0061] The features 14, 24a-b, 34 of the first, second and third bodies 12, 22, 32, 112, 122, 132 (bodies) are substantially identical. The features 14, 24a-b, 34 of the first or second embodiment of the invention are shown in
[0062] End faces 11 of the ends of the bodies 10, 20, 30, 110, 120, 130 are substantially flat. The bodies 12, 22, 32, 112, 122, 132 further include holes 72 in the ends of the channels 10, 20, 30, 110, 120, 130 without the features 14, 24a-b, 34. The holes 72 are located in the second end 16b of the first body 12, 112 and second end 36b of the third body 32, 132. Outer surfaces 70 of the bodies 12, 22, 32, 112, 122, 132 are rounded. A transverse cross-section of the outer surfaces 70 of the bodies 12, 22, 32, 112, 122, 132 are in the shape of a rectangle with rounded corners.
[0063] The following refers to the first and second inserts 40a-b according to the first and third embodiments of the invention. The first and second inserts 40a-b (inserts) are in the shape of a 90 degree elbow. The first and second inserts 40a-b are identical. The inserts 40a-b each include a slot 41. The slot 41 is a rectangular slot with a closed end 42a and an open end 42b. The open end 42b is adapted to receive the cathode plate 2. The slot 41 is within 20% of the thickness of the top end 10b and bottom end 10e of the first, second and third channels 10, 20, 30, 110, 120, 130. The inserts 40a-b are adapted such that when they are inserted into the first, second and third channels 10, 20, 30, 110, 120, 130 a top 42ai of the closed end 42a of the slot 41 is within 5 mm of lining up with the top 10bii, 110bii of the top end 10b, 110b of the first, second and third channels 10, 20, 30, 110, 120, 130. Preferably, within 2 mm of lining up. The closed end 42a of the slots 41 of the inserts 40a-b have radiused edges. The slots 41 include a 90 degree bend. The slots 41 are adapted to be aligned with the top and bottom ends 10b, 10e, 110b, 110e of the channels 10, 20, 30, 110, 120, 130 when the inserts 40a-b are inserted into the bodies 12, 22, 32, 112, 122, 132.
[0064] The 90 degree elbow of the inserts 40a-b include two arms 43a-b. The two arms 43a-b orientated at 90 degrees to each other. Each of the two arms 43a-b include a feature 44a-b (insert feature). The features 44a-b are in the form of cylinders 44a-b. The cylinders 44a-b are adapted for insertion into the features 14, 24a, 24b, 34 of the bodies 12, 22, 32, 112, 122, 132. At inner ends 48a-b of the cylinders 44a-b the inserts 40a-b include a surface 49a-b which is adapted to contact the ends of the bodies 12, 22, 32, 112, 122, 132 when the inserts 40a-b are inserted into the features 14, 24a, 24b, 34 of the bodies 12, 22, 32, 112, 122, 132.
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[0066] A first cylinder 44b of a second insert 40b is then inserted into the feature 24b of the second end 26b of the second body 22, 122. A second cylinder of the second insert 40b is then inserted into the feature 34 of the first end of the third body 32, 132. This completes the second corner 6b.
[0067] A brace 80 is then inserted into the channels 10, 20, 30, 110, 120, 130 and slots 41 as seen in
[0068] Therefore, the first and second mouldable materials may be a suitable plastic, such as PVC or ABS. The first and second mouldable materials may be different materials. Preferably, the first and second mouldable materials are the same material.
[0069] The first and second moulded bodies 50, 60 (moulded bodies) are substantially in the form of a 90 degree elbow. The moulded bodies 50, 60 cover substantially all of an outer surface 7a-b of the first and second corners 6a-b. The moulded bodies 50, 60 each include a slot 52, 62 aligned with the open end 42b of the slots 41 of the inserts 40a-b and the top end 10b of the channels 10, 20, 30, 110, 120, 130 as seen in
[0070] The first body 12, 112 further includes a hole 72 in a second end 16b of the first body 12, 112. The third body 32, 132 further includes a hole 72 in a second end 36b of the third body 12, 112. The holes 72 may have a diameter of between 3 mm and 11 mm.
[0071] Preferably, the holes 72 have a diameter of between 5 mm and 9 mm. The cathode plate 2 is adapted for inserting into the edge protector 1, 101, 201, 301. The cathode plate 2 includes holes 82 on a top end 83a of the cathode plate 2. After the cathode plate 2 is inserted into the edge protector 1, 101, 201, 301, bolts are inserted through the holes 72 in the first and third bodies 12, 32, 112, 132 and through the holes 82 in the cathode plate 2. These bolts fix the edge protector 1, 101, 201, 301 to the cathode plate 2. The edge protector 1, 101, 201, 301 further includes four retainers 90a-d. The retainers 90a-d are inserted into the two side ends 10c-d of the first and third channels 10, 30. The retainers 90a-d are adapted for insertion into the two side ends 10c-d of the first and third channels 10, 30 before or after the cathode plate 2 is inserted into the edge protector 1, 101, 201, 302. The retainers 90a-d apply additional force and friction from the bodies 12, 22, 32, 112, 122, 132 onto the plate portion 2a of the cathode plate 2 to keep the cathode plate 2 from moving relative to the edge protector 1, 101, 201, 301.
[0072] The cathode plate 2 further includes rectangular shaped cut outs 85a-b in the cathode plates 2 lower corners 86a-b. The cut outs 85a-b ensure the corners 86a-b of the cathode plate 2 can be inserted into the edge protector 1, 101, 201, 301 without interference by build up of material in corners 41a of the slots 41 of the inserts 40a-b.
[0073] The following passage refers to inserts 140a-b included in the second and fourth embodiments of the invention.
[0074] Throughout the specification and claims the word “substantially” refers to greater than 80% by mass. Throughout the specification and claims the word “comprise” and its derivatives are intended to have an inclusive rather than exclusive meaning unless the contrary is expressly stated or the context requires otherwise. That is, the word “comprise” and its derivatives will be taken to indicate the inclusion of not only the listed components, steps or features that it directly references, but also other components, steps or features not specifically listed, unless the contrary is expressly stated or the context requires otherwise.
[0075] In the present specification, terms such as “apparatus”, “means”, “device” and “member” may refer to singular or plural items and are terms intended to refer to a set of properties, functions or characteristics performed by one or more items or components having one or more parts. It is envisaged that where an “apparatus”, “means”, “device” or “member” or similar term is described as being a unitary object, then a functionally equivalent object having multiple components is considered to fall within the scope of the term, and similarly, where an “apparatus”, “assembly”, “means”, “device” or “member” is described as having multiple components, a functionally equivalent but unitary object is also considered to fall within the scope of the term, unless the contrary is expressly stated or the context requires otherwise.
[0076] Orientational terms used in the specification and claims such as vertical, horizontal, top, bottom, upper and lower are to be interpreted as relational and are based on the premise that the component, item, article, apparatus, device or instrument will usually be considered in a particular orientation, typically with the second body 22,122 lowermost.
[0077] It will be appreciated by those skilled in the art that many modifications and variations may be made to the methods of the invention described herein without departing from the spirit and scope of the invention.