Edge protector systems for cathode plates and methods of making same

Abstract

Cathode plate edge protector systems formed by secondary and tertiary molding processes, in which fluid plastic is molded around and/or introduced into previously manufactured plastic edge protectors. A U-shaped edge protector system is formed by bevel-cutting abutting ends of edge protector strips, securing the strips in the desired configuration a molding jig, and molding corner pieces around the abutting ends. The system is then removed from the jig and slip-installed over the two sides and the bottom edge of a cathode plate. In an optional tertiary molding process, fluid plastic may be introduced into the remaining void between the edge protector system and the cathode plate. Another edge protector system is formed by mounting edge protector strips on opposing side edges of a cathode plate, damming the open ends, and introducing fluid plastic in the contained voids between the strips and the cathode plate.

What is claimed is: 
     
       1. A U-shaped edge protector system for a cathode plate, comprising:
 a. a first side edge strip and a second side edge strip, each of said side edge strips having an upper end and a lower end, and, an inner, open side portion extending therebetween, said lower end having a bevel termination; 
 b. a bottom edge strip having an first end with a bevel termination in mating engagement with said bevel termination of said first side edge strip forming a first juncture, and having a second end with a bevel termination in mating engagement with said bevel termination of said second side edge strip forming a second juncture, said bottom edge strip having an inner, open side portion extending between said first end and said second end; 
 c. a first molded corner piece, said first corner piece being molded over said first juncture; and, 
 d. a second molded corner piece, said second corner piece being molded over said second juncture, forming a unitary structure. 
 
     
     
       2. An edge protector system as in  claim 1  including a cathode plate, said cathode plate having a top edge, a bottom edge, and first and second side edges extending therebetween, said side edges including a plurality of plate apertures arranged in spaced relation, and further including first and second retainer strips, said retainer strips each including a plurality of registration pins depending from the underside thereof, said registration pins being arranged in spaced relation for insertion into said plate apertures, whereby said open side portions of said first edge strip and said second edge strip are respectively slip installed over said first retainer and said second retainer strip until said bottom edge of said cathode plate is inserted into said portion of said bottom edge strip. 
     
     
       3. An edge protector system as in  claim 2  in which said cathode plate includes a hanger bar attached along said top edge, and further including a pair of hook holes extending through said cathode plate adjacent said top edge. 
     
     
       4. An edge protector system as in  claim 2  in which said cathode plate is made from stainless steel. 
     
     
       5. An edge protector system as in  claim 1  in which said first and second corner pieces are molded from liquid plastic. 
     
     
       6. An edge protector system as in  claim 1  in which said first and second corner pieces include a right-angle corner plug located at a terminus of said open side portion of said bottom edge strip. 
     
     
       7. An edge protector system for a cathode plate, comprising:
 a. a side edge strip having an open upper end and an open lower end, and an inner, open side portion extending therebetween, said open side portion including an inner cavity having a volume; 
 b. a cathode plate, said cathode plate having a top edge, a bottom edge, and a side edge extending therebetween said side edge including a plurality of plate apertures extending through said plate and arranged in spaced relation therealong, said side edge filling a portion of said volume of said inner cavity, and said open side portion enclosing said apertures; and, 
 c. a locking body formed from a fluid curable into a hardened form, whereby said upper end of said side edge strip is temporarily fitted with a dam and said lower end of said side edge strip temporarily fitted with an injection mold fitting, and said locking body is injected in a fluid form through said injection mold fitting into the remaining unfilled portion of said volume and into said apertures, said fluid thereafter curing into a hardened form to secure said cathode plate and said side edge strip together. 
 
     
     
       8. An edge protector system as in  claim 7  in which said locking body is made from an injection molded plastic. 
     
     
       9. An edge protector system as in  claim 7  in which said inner cavity includes a plate recess sized and configured to receive said side edge of said cathode plate, and a strip recess having an upper portion and a lower portion in communication with said plate recess, said apertures in said cathode plate lying within said plate portion between said upper portion and said lower portion of said strip recess. 
     
     
       10. An edge protector system as in  claim 7 , in which said dam and said injection mold fitting are removed after said fluid is at least partially cured, and in which said locking body fills said open upper and lower ends of said side edge strip. 
     
     
       11. An edge protector strip system as in  claim 7  in which said side edge strip is generally rectangular in transverse, cross-section. 
     
     
       12. An edge protector strip system as in  claim 7  in which said side edge strip is circular in transverse, cross-section. 
     
     
       13. An edge protector system for a cathode plate, comprising:
 a. a first side edge strip and a second side edge strip, each of said side edge strips having an upper end and a lower end, and an inner, open side portion extending therebetween, each of said open side portions including an inner cavity having a volume; 
 b. a cathode plate, said cathode plate having a top edge, a bottom edge, and first and second side edges extending therebetween, each of said first and second side edges including a plurality of plate apertures extending through said plate and arranged in spaced relation therealong, said first side edge filling a portion of said volume of said inner cavity of said first side edge strip, and said open side portion of said first side edge strip enclosing said apertures along said first side edge, said second side edge filling a portion of said volume of said inner cavity of said second side edge strip, and said open side portion of said second side edge strip enclosing said apertures along said second side edge and, 
 c. a locking body formed from a fluid curable into a hardened form, said locking body being injected in a fluid form into the remaining unfilled portion of each of said volumes and into each of said apertures, said fluid thereafter curing into a hardened form to secure said cathode plate together with each of said first and said second side edge strips. 
 
     
     
       14. A U-shaped edge protector system for a cathode plate, comprising:
 a. a cathode plate, said cathode plate having a top edge, a bottom edge, and first and second side edges extending therebetween, said side edges including a plurality of plate apertures arranged in spaced relation therealong; 
 b. a first side edge strip and a second side edge strip, each of said side edge strips having an upper end and a lower end, and an inner, open side portion extending therebetween, said open side portion including an inner cavity having a volume, and said lower end having a bevel termination, said first side edge of said cathode plate filling a portion of said volume of said inner cavity of said first side edge strip, and said open side portion of said first side edge strip enclosing said apertures along said first side edge, said second side edge of said cathode plate filling a portion of said volume of said inner cavity of said second side edge strip, and said open side portion of said second side edge strip enclosing said apertures along said second side edge; 
 c. a bottom edge strip having an a first end with a bevel termination in mating engagement with said bevel termination of said first side edge strip forming a first juncture, and having a second end with a bevel termination in mating engagement with said bevel termination of said second side edge strip forming a second juncture, said bottom edge strip having an inner, open side portion extending between said first end and said second end, said open side portion including an inner cavity having a volume, said bottom edge of said cathode plate filling a portion of said volume of said inner cavity of said bottom edge strip; 
 d. a first molded corner piece, said first corner piece being molded over said first juncture; 
 e. a second molded corner piece, said second corner piece being molded over said second juncture, forming a unitary structure; and, 
 f. a locking body formed from a fluid curable into a hardened form, said locking body being injected in a fluid form into the remaining unfilled portion of each of said volumes and into each of said apertures, said fluid thereafter curing into a hardened form to secure said cathode plate together with each of said first and said second side edge strips and said bottom edge strip. 
 
     
     
       15. A method for making a U-shaped edge protector system for a cathode plate, comprising the steps of:
 a. providing a first side edge strip and a second side edge strip, each of said side edge strips having an upper end and a lower end, and an inner, open side portion extending therebetween, said lower end having a bevel termination; 
 b. providing a bottom edge strip having an a first end with a bevel termination and a second end with a bevel termination; 
 c. maintaining said bevel termination of said first end of said bottom edge strip in mating engagement with said bevel termination of said first side edge strip, forming a first juncture; 
 d. molding a first corner piece over said first juncture; 
 e. maintaining said bevel termination of said second end of said bottom edge strip in mating engagement with said bevel termination of said second side edge strip, forming a second juncture; and, 
 f. molding a second corner piece over said second juncture. 
 
     
     
       16. A method for making a cathode plate provided with an edge protector system, comprising the steps of:
 a. providing a cathode plate, said cathode plate having a top edge, a bottom edge, and a side edge extending therebetween, said side edge including a plurality of plate apertures extending through said plate and arranged in spaced relation therealong, 
 b. providing a side edge strip having an upper end and a lower end, and an inner, open side portion extending therebetween, said open side portion including an inner cavity having a volume; 
 c. inserting said side edge of said cathode plate into said open side portion, filling a portion of said volume of said inner cavity and enclosing said apertures within said open side portion; 
 d. forming a locking body from a fluid curable into a hardened form, by injecting said fluid into the remaining unfilled portion of said volume and into said apertures; and, 
 e. allowing said fluid to cure into a hardened form, thereby securing said cathode plate and said side edge strip together. 
 
     
     
       17. A U-shaped edge protector system for a cathode plate, comprising:
 a. a first side edge stip and a second side edge strip, each of said side edge strips having an upper end and a lower end, and an inner, open side portion extending therebetween, said lower end having a bevel termination;   b. a bottom edge strip having a first end with a bevel termination in mating engagement with said bevel termination of said first side edge strip forming a first juncture, such that said bevel termination of said first side edge strip and said bevel termination of said bottom edge strip are in parallel relation, and having a second end with a bevel termination in mating engagement with said bevel termination of said second side edge strip forming a second juncture, such that said bevel termination of said second side edge strip and said bevel termination of said bottom edge strip are in parallel relation, said bottom edge strip having an inner, open side portion extending between said first end and said second end;   c. a first molded corner piece, said first corner piece being molded over said first juncture; and,   d. a second molded corner piece, said second corner piece being molded over said second juncture, forming a unitary structure.    
     
     
       18. An edge protector system as in claim 17, including a cathode plate, said cathode plate having a top edge, a bottom edge, and first and second side edges extending therebetween, said side edges including a plurality of plate apertures arranged in spaced relation, and further including first and second retainer strips, said retainer strips each including a plurality of registration pins depending from the underside thereof, said registration pins being arranged in spaced relation for insertion into said plate apertures, whereby said open side portions of said first edge strip and said second edge strip are respectively slip installed over said first retainer strip and said second retainer strip until said bottom edge of said cathode plate is inserted into said open side portion of said bottom edge strip.  
     
     
       19. An edge protector system as in claim 18, in which said cathode plate includes a hanger bar attached along said top edge, and further including a pair of hook holes extending through said cathode plate adjacent said top edge.  
     
     
       20. An edge protector system as in claim 18, in which said cathode plate is made from stainless steel.  
     
     
       21. An edge protector system as in claim 17 in which said first and second corner pieces are molded from liquid plastic.