Articulated Operator Device Lightweight Coating

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Solution Overview

Problem

Existing articulated automatic operator devices used in the pharmaceutical sector are heavy due to their solid stainless steel construction, making them difficult to move quickly and precisely while also being subjected to intensive decontamination and sterilization treatments.

Innovation Solution

A method for producing articulated automatic operator devices using casings made from lightweight materials such as aluminum, magnesium, or titanium, which are then coated with a corrosion-resistant material using thermal spraying techniques to protect against CIP and SIP treatments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If solid stainless steel is used for articulated components, then resistance to decontamination and sterilization treatments is improved, but weight increases making high-speed movement and precise positioning difficult

Engineering Contradiction:

Improveresistance to decontamination and sterilization treatmentsVSAvoidweight of articulated components

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by combining a lightweight substrate (aluminum, magnesium, or titanium) with a protective coating layer (polymer, ceramic, or metal). This composite structure provides both the weight reduction benefits of lightweight materials and the treatment resistance of durable coatings, resolving the contradiction between weight and treatment resistance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies protective coatings only to the external surfaces of articulated components that are exposed to decontamination and sterilization treatments, while internal surfaces remain uncoated. This localized approach provides treatment resistance where needed while minimizing the amount of coating material and maintaining lightweight properties.

Inventive Principle:

Principle #3Local quality

2Speed

If lightweight materials are used for articulated components, then ease of movement and positioning is improved, but resistance to decontamination and sterilization treatments deteriorates

Engineering Contradiction:

Improvespeed of movement and positioningVSAvoidresistance to decontamination and sterilization treatments

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The patent uses composite materials combining lightweight substrates (aluminum, magnesium, or titanium) with protective coating layers. This allows the components to achieve high speed and precise positioning due to reduced weight, while the coating layer simultaneously provides the necessary resistance to decontamination and sterilization treatments.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The protective coating is applied selectively to external surfaces exposed to treatments, allowing lightweight materials to be used throughout the component structure while providing treatment resistance only where required for protection.

Inventive Principle:

Principle #3Local quality

3Reliability

If coating is applied to internal surfaces of components, then protection against treatments is improved, but quantity of coating material required increases

Engineering Contradiction:

Improveprotection against decontamination and sterilization treatmentsVSAvoidquantity of coating material

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent applies protective coatings only to external surfaces of articulated components that are exposed to decontamination and sterilization treatments during normal operation. Internal surfaces that are not exposed to these treatments remain uncoated, significantly reducing the quantity of coating material required while maintaining adequate protection.

Inventive Principle:

Principle #3Local quality

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 method results in articulated operator devices that are lightweight yet resistant to intensive treatments, allowing for efficient movement and precise positioning while maintaining surface integrity and reducing material costs.

Implementation Method 1

subjecting each casing to a thermal spray process by means of powders of a second material accelerated in a supersonic gaseous jet, to deposit a coating of the second material at least on the external surface of each component

Methodology Applied

Scientific EffectThermal spray: Plasma Spray

Data Source

PatentUS12221706B2Method to produce an articulated automatic operator device and corresponding articulated automatic operator device

Publication Date: 2025.02.11 IMA IND MASCH AUTOMATICHE SPA

AI summary

A method to produce an articulated automatic operator device treated on the surface with a corrosion-resistant material and/or to obtain surface properties resistant to CIP/SIP treatments, in particular in the field of the production and packaging of pharmaceutical products, where the device includes a plurality of articulated components rotatably connected to one another in correspondence with respective coupling interfaces, such that the method provides to make available casings suitable to be assembled together to make the articulated components, wherein the casings are made of a first material and subject each casing to a thermal spray treatment using solid powders of a second material accelerated in a supersonic gaseous jet to deposit a coating of said second material at least on the external surface of each of said casings.