Self-Adjusting Masking Plug with Wishbone Spring
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Solution Overview
Problem
Conventional masking plugs for complex parts with varying tolerances often fail to fit properly, leading to gaps and unintended coating, which increases manual labor costs and reduces masking quality due to reliance on precise dimensions.
Innovation Solution
A self-adjusting masking plug with a wishbone spring design that allows expansion and contraction, formed from NYLON 12 or NYLON 11 using selective laser sintering, featuring interconnected body halves and a common rib to adapt to varying tolerances, ensuring secure fit and effective masking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional masking plug with fixed dimensions is used, then the masking process is simple and quick, but the plug does not fit properly when part tolerances vary, leading to gaps and unintended coating
Solution Approach 1:
The masking plug transitions from a fixed rigid structure to a dynamic structure with an adjustable seam that allows movement between body halves. This enables the plug to adapt its internal volume and shape to match variations in part dimensions within tolerance ranges, eliminating gaps while maintaining quick installation
Solution Approach 2:
The plug body is divided into two separable halves connected by an adjustable seam with a wishbone spring mechanism. This segmentation allows each half to move independently, enabling the plug to conform to dimensional variations in the masked area while maintaining structural integrity and ease of installation
2Manufacturing precision
If a masking plug is made to fit the smallest tolerance dimension, then it fits tightly, but it creates excessive friction and difficulty in insertion and removal
Solution Approach 1:
The adjustable seam with wishbone spring creates a dynamic fit that provides tight sealing when needed while allowing movement during insertion and removal. The spring mechanism stores mechanical energy to facilitate easy insertion and provides controlled expansion for tight masking contact
3Strength
If the masking plug is made from rigid materials for durability, then it maintains shape and protects surfaces, but it cannot adapt to varying part tolerances
Solution Approach 1:
Dividing the rigid plug body into two halves connected by a flexible seam mechanism allows the overall structure to maintain durability while gaining adaptability. The rigid body halves provide structural strength and surface protection, while the segmented connection enables dimensional adjustment
Solution Approach 2:
The wishbone spring mechanism changes the physical parameters of the plug by allowing expansion and contraction of the internal volume. This enables the same durable plug structure to adapt to varying part tolerances through controlled dimensional changes rather than requiring different materials
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 self-adjusting masking plug effectively eliminates gaps by expanding or compressing to fit complex part dimensions, maintaining secure positioning without additional masking materials, thus improving masking quality and reducing manual labor costs in large production runs.
Implementation Method 1
a self-adjusting feature which allows the size the masking plug to expand and contract
Implementation Method 2
formed from NYLON 12 or NYLON 11 using selective laser sintering
Data Source
AI summary
A self-adjusting masking plug is provided which is adapted to be received in a region of a complex part intended to be masked. The plug has a body adapted to be received within a region of the part intended to be masked. The body includes a first body half having at least one first perimeter wall conforming to a first portion of the intended region to be masked; a second body half having at least one second perimeter wall conforming to a second portion of the intended region to be masked; and a wishbone spring formed internally within the body such that it interconnects the first and second body halves. The wishbone spring includes a first half inner wall transversely spanning and interconnecting portions of the at least one first perimeter wall; a second half inner wall transversely spanning and interconnecting portions of the at least one second perimeter wall; and a common rib interconnecting the first and second inner walls. The plug is adapted to expand or compress depending on the tolerances of the part within the part.