Compartmentalized Mesh Enclosure for Mass Finishing
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Solution Overview
Problem
Mass finishing processes often result in damage to large or brittle components due to collisions within the enclosure, leading to fracture, chipping, and degradation, especially when polishing medical device components like hip or shoulder implants.
Innovation Solution
The use of a compartmentalized enclosure system with mesh containers and flexible spider bands allows for simultaneous polishing of multiple components without direct contact, using fenestrations to allow media flow while preventing component collisions, and the containers are designed to absorb collision energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple components are polished simultaneously in a shared enclosure, then productivity increases, but components collide causing damage and manufacturing precision deteriorates
Solution Approach 1:
The enclosure is segmented into multiple separate containers, each holding individual components. This segmentation prevents components from colliding with each other while still allowing simultaneous polishing of multiple components within the same enclosure, thus maintaining both productivity and component integrity
Solution Approach 2:
Polishing media act as an intermediary substance that can flow freely between containers through fenestrations. The media transmit polishing action to components in separate containers without causing direct component-to-component contact, enabling simultaneous polishing while preventing damage
2Adaptability or versatility
If component size is increased to polish larger components, then adaptability improves, but collision damage risk increases leading to manufacturing precision deterioration
Solution Approach 1:
Each component is isolated in its own container regardless of size. This allows large components to be polished without risk of collision with other components, while still enabling simultaneous polishing of multiple components of varying sizes within the same enclosure system
Solution Approach 2:
Containers of different sizes can be nested or arranged within the enclosure to accommodate components of various dimensions. Smaller containers can fit within or alongside larger ones, providing adaptability for different component sizes while maintaining isolation and preventing collision damage
3Productivity
If enclosure capacity is increased to hold more components, then productivity improves, but component density increases leading to more collisions and manufacturing precision deterioration
Solution Approach 1:
The enclosure capacity is increased by adding more separate containers rather than increasing component density within a single container. Each container maintains low component density (typically one component per container), preventing collisions while allowing the overall enclosure to accommodate many components simultaneously for high productivity
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
This solution reduces in-process scrap rates and enables efficient polishing of larger components by preventing collisions and ensuring uniform media exposure, increasing throughput and maintaining component integrity.
Implementation Method 1
The mesh container allows media flow through its fenestrations while containing the component
Implementation Method 2
the containers are designed to absorb collision energy
Data Source
AI summary
An embodiment comprises a container to include a substrate during processing (e.g., centrifugal or vibratory processing) and protect the substrate from other substrates (e.g., medical implants) that are simultaneously being processed and/or from the polishing environment (e.g. vibratory tub sidewalls) during processing. Other embodiments are described herein.