Additive Coating Tooling With Cantilevered Plate for Stable Contact

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Solution Overview

Problem

Existing tools for electrically driven aqueous coating processes, such as those used in the aviation industry for gas turbine blades, suffer from deformation and damage due to manual fabrication techniques, leading to reduced coating efficacy and increased costs due to component discard.

Innovation Solution

Additively manufactured tools with a cantilevered plate and asymmetrical channel design, integrated with a support bar and polymer cover, ensure secure and consistent contact during the coating process, preventing deformation and damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual fabrication techniques are used to create tools for coating processes, then the initial manufacturing cost and complexity are reduced, but the tools suffer from deformation and damage during use, leading to reduced reliability and increased loss of time

Engineering Contradiction:

ImproveInitial manufacturing easeVSAvoidTool durability during coating process

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the manufacturing method from manual fabrication to additive manufacturing, fundamentally altering how the tool is created. This parameter change enables complex geometries and integrated structures that prevent deformation during use, while maintaining manufacturing efficiency through automated processes.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs tools with integrated multi-material construction, combining different materials with complementary properties within a single additively manufactured component. This allows the tool to have regions with different mechanical properties optimized for specific functions, improving overall durability and resistance to deformation.

Inventive Principle:

Principle #40Composite materials

2Device complexity

If conventional tools are used for securing components, then the device complexity is lower, but the coating efficacy is reduced due to inconsistent contact and deformation

Engineering Contradiction:

ImproveTool structure simplicityVSAvoidCoating application consistency

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent divides the tool into distinct functional segments including a support bar, bracket, adapter, and cantilevered plate. Each segment is optimized for its specific function while being integrated through additive manufacturing, allowing precise control over contact geometry and positioning for consistent coating application.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a cantilevered plate that extends from the adapter, creating a new dimensional element that provides consistent contact with the component surface. This additional structural dimension ensures uniform positioning and contact pressure, improving coating consistency without significantly increasing overall complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of manufacture

If tools deform during the coating process, then the initial manufacturing is simpler, but component damage increases and productivity decreases

Engineering Contradiction:

ImproveInitial tool fabricationVSAvoidCoating process efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent changes the manufacturing approach to additive manufacturing, which enables creation of tools with optimized structural parameters that resist deformation. The additive process allows for integrated reinforcement features and optimized material distribution that prevent tool deformation while maintaining manufacturing efficiency.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent designs the tool with built-in structural features that prevent deformation before it can occur during the coating process. The additively manufactured tool includes reinforced geometries and stress-distributing features that cushion against applied loads, preventing both tool deformation and component damage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 additively manufactured tools provide durable and efficient coating processes with reduced component damage and increased longevity, allowing for more consistent and effective application of coatings on aerospace components.

Implementation Method 1

securing the component to the tool such that the cantilevered plate is in contact with the component

Methodology Applied

Scientific EffectMechanical contact: Mechanical Force

Implementation Method 2

lowering the support bar and the component secured to the tool in an aqueous solution to coat the component using an electrically driven aqueous process

Methodology Applied

Scientific EffectElectrically driven aqueous process: Electrodeposition

Data Source

PatentEP4488426A1Additively manufactured tooling for coating components using electrically driven aqueous processes

Publication Date: 2025.01.08 CHROMALLOY GAS TURBINE LLC

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AI summary

A tool for securing a component for a treatment process and methods of making and using same. A method for securing a component for a treatment process includes obtaining a tool for retaining the component during the treatment process. The tool includes a cantilevered plate. The method includes associating the tool with a support bar and securing the component to the tool such that the cantilevered plate is in contact with the component.