Water is fuel for Next Generation
NextGen Engineering Auto Systems Pvt Limited
DIY - Mold
Do it yourself - Molding
Most of the people in the world are replicating series cells. In all the designs people are using PVC / Rubber gaskit as spacer between the plateS. These plates are sandwitched and tight between acrylic sheets using 12 to 14 volts.
However this is a good design, but we feel it has potential for leakage due to loss of strength of Rubber / PVC gas kit and unequal pressure on the bolts. At the same time covering the front and back side of the electrode plate does not allow us to take the advantage of engine heat to heat up the electrolyte to most productive range i.e. 50-60 Deg Centigrade.
Hence to take the advantage of engine heat and to avoid any possiblity of leakage, the best way is to Sandwich the plates using plastic injection molding. But for such molding, the die is very costly and requires lot of skills.
For making it simple, we have researched on various products and found that Polyester Resin will be a good stuff for construction of series dry cell. With the polyester resin, you can mold the steel plate at your own and will not require expensive molds. Following are the details of our first trail:
1. Making the mold base : Prepare the mold base using wound board.
Picture - 1
2. Araanging the plates : Use the rubber pads for arranging the plates at desired spacing. Please ensure that the size of the rubber is smaller then the size of the plate. Also the rubber pads and plates should be flat otherwise the resin will enter into the gap to spoil the plate.
Picture - 2
3. Hold them tightly : Use the strong thread to hold the plates and rubber tightly. Please make sure that there is no gap between the rubber and plate.
Picture - 3
4. Bottom spacer : Use the rubber cut pieces to place at the bottom to leave a blank space at the bottom.
Picture - 4
5. Place the Plates into base : Please ensure that you leave equal distance form all the side.
Picture - 5
6. Cover the base : Cover the base using wound board and seal it properly from all the side using adhesive and tape. Please ensure that there is no leakage point.
Picture - 6
Picture - 7
7. Mixing the resin : Take the sufficient quantity of Polyester resin and mix it throughly with hardner (suggested by resin manufacturer).
Picture - 8
Picture - 9
8. Pour the resin : Pour the resin slowly inside the gap between the outer box and set of plates.Please ensure that this activity completes within 10 minutes of mixing the resin with hardner because in 15 minutes the resin forms the jelly as shown in picture 11.
Picture - 10
Picture - 11
9. Cleaning : Remove the tape as shwon in picture 12. Wash out the wound board from water as shwon in picture 13. Break the unwanted edges as shown in figure 14. Finally pull out the rubber as shown in the picture 15.
Picture - 12
Picture - 13
Picture - 14
Picture - 15
10. Final product : Congrates your mold is ready. The look of the final mold is as shown below:
Picture - 16
Picture - 17
Picture - 18
So it is all easy to mold the plate at your own within 5-6 hours. This mold holds plate tightly and no leakage between cells. We have tested this material inside KOH solution for 8 hour and have not seen any adverse reaction to the Ployester base mold. In the same way, the plates can be sealed from all the four side.
We are working on this currently and will post our progess.
Do it yourself - Molding
Most of the people in the world are replicating series cells. In all the designs people are using PVC / Rubber gaskit as spacer between the plateS. These plates are sandwitched and tight between acrylic sheets using 12 to 14 volts.
However this is a good design, but we feel it has potential for leakage due to loss of strength of Rubber / PVC gas kit and unequal pressure on the bolts. At the same time covering the front and back side of the electrode plate does not allow us to take the advantage of engine heat to heat up the electrolyte to most productive range i.e. 50-60 Deg Centigrade.
Hence to take the advantage of engine heat and to avoid any possiblity of leakage, the best way is to Sandwich the plates using plastic injection molding. But for such molding, the die is very costly and requires lot of skills.
For making it simple, we have researched on various products and found that Polyester Resin will be a good stuff for construction of series dry cell. With the polyester resin, you can mold the steel plate at your own and will not require expensive molds. Following are the details of our first trail:
1. Making the mold base : Prepare the mold base using wound board.
2. Araanging the plates : Use the rubber pads for arranging the plates at desired spacing. Please ensure that the size of the rubber is smaller then the size of the plate. Also the rubber pads and plates should be flat otherwise the resin will enter into the gap to spoil the plate.
3. Hold them tightly : Use the strong thread to hold the plates and rubber tightly. Please make sure that there is no gap between the rubber and plate.
4. Bottom spacer : Use the rubber cut pieces to place at the bottom to leave a blank space at the bottom.
5. Place the Plates into base : Please ensure that you leave equal distance form all the side.
6. Cover the base : Cover the base using wound board and seal it properly from all the side using adhesive and tape. Please ensure that there is no leakage point.
7. Mixing the resin : Take the sufficient quantity of Polyester resin and mix it throughly with hardner (suggested by resin manufacturer).
8. Pour the resin : Pour the resin slowly inside the gap between the outer box and set of plates.Please ensure that this activity completes within 10 minutes of mixing the resin with hardner because in 15 minutes the resin forms the jelly as shown in picture 11.
9. Cleaning : Remove the tape as shwon in picture 12. Wash out the wound board from water as shwon in picture 13. Break the unwanted edges as shown in figure 14. Finally pull out the rubber as shown in the picture 15.
10. Final product : Congrates your mold is ready. The look of the final mold is as shown below:
So it is all easy to mold the plate at your own within 5-6 hours. This mold holds plate tightly and no leakage between cells. We have tested this material inside KOH solution for 8 hour and have not seen any adverse reaction to the Ployester base mold. In the same way, the plates can be sealed from all the four side.
We are working on this currently and will post our progess.