Edge protector systems for cathode plates and methods of making same

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.

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 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.

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 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.

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.