Hand-Held Cathode Structure for Selective Electrolytic Polishing

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Solution Overview

Problem

Existing electrolytic polishing methods face challenges in polishing complex shapes and materials like steel, stainless steel, and Inconel, as well as in performing partial or complete polishing on large, immovable objects like tanks and pipes, due to the limitations of immersion-based techniques which lead to unnecessary polishing and potential damage.

Innovation Solution

A hand-held cathode structure with a movable cathode plate and insulating fiber film layers that allow for precise electrolytic polishing of specific areas, using vertical and horizontal perforations for electrolyte supply and bubble discharge, enabling selective and efficient polishing of complex shapes and immovable objects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If immersion-based electrolytic polishing is used for complex shapes and large objects, then polishing coverage is improved, but unnecessary polishing of sensitive areas occurs and damage is caused

Engineering Contradiction:

Improvepolishing coverage areaVSAvoidunnecessary polishing damage

Core Design Contradiction:

Area of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The cathode is divided into multiple independent segments or sections, each capable of being positioned and controlled separately. This allows the polishing process to be applied selectively to specific areas of the workpiece, avoiding unnecessary polishing of sensitive regions while maintaining coverage of required areas.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the cathode are designed with different properties or configurations to match the specific polishing requirements of different areas on the workpiece. This enables localized control over polishing intensity and coverage, preventing damage to sensitive areas while effectively polishing required surfaces.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If cathode plate is placed close to polishing surface for uniform polishing, then polishing quality is improved, but electrical short circuit risk increases

Engineering Contradiction:

Improvepolishing uniformityVSAvoidelectrical short circuit prevention

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

An insulating medium or barrier is introduced between the cathode plate and the workpiece surface. This intermediary maintains the necessary close proximity for uniform polishing while preventing direct electrical contact that would cause short circuits, thus preserving both polishing quality and electrical safety.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

A thin insulating film or coating is applied to the cathode plate surface. This film is thin enough to allow effective polishing close to the workpiece surface while providing sufficient electrical insulation to prevent short circuits, resolving the contradiction between polishing quality and electrical safety.

Inventive Principle:

Principle #30Flexible shells and thin films

3Area of stationary object

If conventional electrolytic polishing is used for multi-material objects, then complete surface treatment is achieved, but selective polishing of specific locations is not possible

Engineering Contradiction:

Improvetotal surface coverageVSAvoidselective area polishing capability

Core Design Contradiction:

Area of stationary objectVSAdaptability or versatility

Solution Approach 1:

The cathode is segmented into multiple independently controllable sections, allowing selective activation of specific segments to polish only desired areas of multi-material objects. This enables precise control over which materials and locations receive polishing treatment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of applying polishing to the entire surface, the method selectively applies polishing action only to specific required locations on multi-material objects. This partial action approach prevents unnecessary treatment of sensitive or incompatible materials while effectively polishing required areas.

Inventive Principle:

Principle #16Partial or excessive action

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

Enables precise and efficient electrolytic polishing of difficult-to-reach areas and large, immovable objects by maintaining electrolyte containment and facilitating bubble discharge, improving polishing performance and preventing unnecessary damage.

Implementation Method 1

an insulating fiber film layer disposed between the electrolytic polishing target material and the cathode plate and capable of absorbing an electrolyte

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 2

a high viscosity liquid layer (viscous layer) containing a large amount of dissolved metal ions from the anode surrounds the electrolytic polishing target material, which is the anode

Methodology Applied

Scientific EffectElectrolysis: Electrolysis

Data Source

PatentUS11332846B2Hand-held cathode structure and electrolytic-polishing apparatus including the same

Publication Date: 2022.05.17 HWANG JAE SANG

AI summary

The embodiment relates to a hand-held cathode structure and an electrolytic polishing apparatus including the same.The hand-held cathode structure according to the embodiment has a cathode plate structure that is disposed adjacent to an electrolytic polishing target material for an electrolytic polishing, a cathode plate movable with respect to the electrolytic polishing target material, and an insulating fiber coating layer capable of absorbing the electrolyte disposed between the electrolytic polishing target material and the cathode plate.