Integrated forming production method of shading sleep-aiding eyeshade based on PVC (polyvinyl chloride) material

Abstract

The invention belongs to the technical field of plastic forming and processing, and particularly relates to a PVC (polyvinyl chloride) material-based shading sleep-aiding eyeshade integral forming production method which comprises the following steps: S1, precise preparation of a PVC multifunctional composite modified material: taking medical grade PVC resin as a base material, adding the composite modified material according to a mass ratio, then putting the material into a double-screw mixer, and mixing uniformly to obtain the PVC multifunctional composite modified material; forming a modified PVC composite raw material; by introducing a performance contribution coefficient () and a process compatibility coefficient (), the multi-target performance demand quantity is converted into a computable parameter, and the datamation decision of the modifier proportion is realized; compared with empirical proportioning, the method has the advantages that the proportion coordination among the reagents can be accurately balanced, and meanwhile, material defects caused by insufficient mixing capacity are avoided, so that the standard reaching rate of the comprehensive performance of the modified PVC is improved, and the trial and error cost and raw material waste are reduced.

Description

Technical Field

[0001] This invention belongs to the field of plastic molding and processing technology, specifically a method for producing a one-piece molded sleep-aiding eye mask based on PVC material. Background Technology

[0002] Light-blocking sleep masks are practical tools that improve sleep quality by physically blocking light. Their core function is achieved through high-density materials (such as multi-layer composite fabrics and nano-electronic cloud coatings) that block light from inhibiting melatonin secretion, helping people quickly enter deep sleep.

[0003] PVC light-blocking sleep aid eye masks are a type of functional sleep aid product with polyvinyl chloride (PVC) as the core material. Through the material's opaque properties and ergonomic design, they can block light and create a dark sleep environment, and are widely used in daily rest, travel commuting, and post-medical surgery scenarios.

[0004] In the existing technology, traditional PVC light-blocking sleep aid eye masks have difficulty balancing environmental protection and performance in terms of materials during the production process. The phthalate additives they rely on pose compliance risks, and their skin-friendliness, elasticity, and light-blocking sealing are insufficient. At the production level, they are limited by fixed molds and single processes, resulting in high changeover costs, low molding efficiency, and poor product structure consistency. Quality control relies on extensive post-processing and manual inspection, making it difficult to guarantee the precision of details and the stability of core functions.

[0005] Therefore, the present invention provides a method for producing a one-piece molded light-blocking and sleep-aiding eye mask based on PVC material. Summary of the Invention

[0006] In order to overcome the shortcomings of the prior art, at least one technical problem raised in the background art is solved.

[0007] The technical solution adopted by this invention to solve its technical problem is: a one-piece molding production method for a PVC-based light-blocking and sleep-aiding eye mask, comprising the following steps: S1. Precise formulation of PVC multifunctional composite modified material: Using medical-grade PVC resin as the base material, composite modified material is added according to the mass ratio: The material is then fed into a twin-screw mixer to form modified PVC composite raw material; S2. Modular Dynamic Cavity Mold Design and Fabrication: A switchable cavity + intelligent sensing integrated mold structure is adopted, with a three-module design: body cavity module, ear loop dynamic module, and nose bridge fitting intelligent module; enabling rapid switching between multiple specifications in one mold for production. S3. Implementation of dynamic gradient injection molding process: A horizontal injection molding machine equipped with a servo motor is selected, and an injection strategy of zoned temperature control + real-time feedback is adopted. The injection process is dynamically controlled in four stages: filling stage, transition stage, holding pressure stage, and cooling stage. S4. Post-treatment and precision finishing after directional modification: The molded eye mask is first sent into a low-temperature directional annealing furnace, and the surface stress is eliminated by a stepped cooling annealing process. Then, laser and ultrasonic composite finishing is carried out to complete the surface treatment of the eye mask. S5. Comprehensive Intelligent Testing and Performance Calibration: Constructing a three-in-one testing system based on physical performance, functional characteristics, and environmental indicators; the testing is divided into four steps: light-blocking performance testing, mechanical performance testing, breathability performance testing, and environmental protection testing; S6. Closed-loop recycling and functional aseptic packaging: Establish a closed-loop recycling system from waste to raw materials: Non-conforming products and flow channel waste are pulverized at low temperature and re-granulated by a twin-screw granulator; qualified goggles are sent to a Class 100 cleanroom to await packaging.

[0008] Preferably, the composite modified material added in S1 adopts a ternary composite modification system of "light-shielding-elasticity-breathability", which includes: 28% environmentally friendly tributyl citrate (replacing traditional DOP plasticizer), 6% nano-grade titanium dioxide-carbon black composite light-shielding agent (particle size 50-80nm, light-shielding efficiency improved by 40%), 4% ethylene-vinyl acetate copolymer (EVA) elastic modifier, 3% porous diatomaceous earth breathable modifier, supplemented with 2% calcium zinc stabilizer and 0.8% antioxidant 1010; the integrated mold structure in S2 is made of S136 corrosion-resistant stainless steel, and the cavity surface is mirror polished and nitrided; the barrel temperature of the horizontal injection molding machine in S3 is set in stages. Preferably, the precise formulation of the PVC multifunctional composite modified material in S1 adopts the following formula: Formula for calculating the optimal blending ratio of composite modifier: ; In the formula, For the first The mass percentage of the modifier; This is the contribution coefficient of the modifier to the target performance; This is the process compatibility coefficient of the modifier; This refers to the total number of types of modifiers.

[0009] Preferably, the design and fabrication of the modular dynamic cavity mold in S2 adopts the following formula: Formula for controlling temperature field distribution in the mold cavity: ; In the formula, For any point in the mold cavity at time Temperature; This refers to the initial mold temperature. For the first Temperature influence coefficient of each cooling loop; This is the cooling rate coefficient; , The first The length and width of each cooling circuit; This represents the total number of cooling circuits.

[0010] Preferably, the dynamic gradient injection molding process in S2 is implemented using the following formula: Injection pressure dynamic adjustment formula: ; In the formula, For a moment Injection pressure; Base pressure value; This refers to the amplitude of pressure fluctuations. For injection molding cycle; This is the segmented adjustment coefficient.

[0011] Preferably, the directional modification post-treatment and precision trimming in S2 adopt the following formula: Formula for controlling the skin affinity of plasma surface modification: ; In the formula, The contact angle of the modified PVC surface; The material response coefficient; This refers to the plasma processing power. For processing time; The distance between the plasma nozzle and the material surface; This is the initial contact angle before treatment.

[0012] Preferably, the full-dimensional intelligent detection and performance calibration in S2 adopts the following formula: Formula for comprehensive evaluation of shading performance: ; In the formula, This refers to the shading rate; For incident light at wavelength The light intensity at that location; The light intensity after passing through the goggles; This represents the visual sensitivity coefficient.

[0013] Preferably, the closed-loop recycling and functional aseptic packaging in S2 adopt the following formula: Formula for calculating the performance retention rate of recycled materials: ; In the formula, The performance retention rate of recycled materials; The compatibilizer modification efficiency coefficient; The proportion of recycled materials to be blended; This represents the maximum permissible blending ratio.

[0014] The beneficial effects of this invention are as follows: 1. The present invention discloses a one-piece molding production method for a light-blocking and sleep-aiding eye mask based on PVC material, which introduces a "performance contribution coefficient (...)" ")" and "process compatibility coefficient" This method quantifies multi-objective performance requirements into calculable parameters, enabling "data-driven decision-making" of modifier ratios. Compared to empirical ratios, it can accurately balance the proportions of various reagents while avoiding material defects caused by insufficient compatibility, thereby improving the overall performance compliance rate of modified PVC and reducing trial-and-error costs and raw material waste.

[0015] 2. The method for producing a one-piece molded sleep-aid eye mask based on PVC material described in this invention constructs a three-dimensional temperature field model in space and time, which can dynamically calculate the real-time temperature at any point in the cavity. Combined with the independent control of multiple cooling circuits, it achieves "zoned precise temperature control". Compared with a fixed temperature mode, it can control the temperature difference between different areas within a very small range, avoiding molding defects caused by uneven temperature. The mold's adaptability to multiple specifications of products is improved by 60%, while the cooling time is shortened by 15%-20%, thus improving production efficiency.

[0016] 3. The present invention describes a one-piece molding production method for a PVC-based light-blocking and sleep-aiding eye mask, which introduces "time period sinusoidal fluctuation" and "segmented adjustment coefficient (…). This system dynamically adapts injection pressure according to the filling progress: high pressure for rapid material replenishment during the filling stage, low pressure to prevent shrinkage during the holding stage, and low pressure for shape stabilization during the cooling stage. Compared to constant pressure mode, it can improve the density uniformity of the product by more than 25%, reduce the defect rate such as flash and short material by 80%, and shorten the injection cycle through precise pressure matching, increasing single-mold capacity by 10%-15%. Attached Figure Description

[0017] The invention will now be further described with reference to the accompanying drawings.

[0018] Figure 1 This is a perspective view of the present invention; Figure 2 This is a schematic diagram of the structure of the plastic molding and processing body in this invention; Figure 3 This is a structural schematic diagram of shaft No. 1, shaft No. 2, and shaft No. 3 in this invention; Figure 4 This is a schematic diagram of the bottom structure of the plastic molding and processing body in this invention; Figure 5 This is a schematic diagram of the structure of the second shaft in this invention; Figure 6 In this invention Figure 4 Enlarged view of point A. Detailed Implementation

[0019] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0020] like Figures 1 to 6 As shown in the embodiment of the present invention, a one-piece molding production method for a light-blocking and sleep-aiding eye mask based on PVC material includes the following steps: S1. Precise Formulation of PVC Multifunctional Composite Modified Material: Using medical-grade PVC resin as the base material, a "light-shielding-elasticity-breathability" ternary composite modification system is introduced: Composite modified materials are added according to the following mass ratio: 28% environmentally friendly tributyl citrate (replacing traditional DOP plasticizer), 6% nano-grade titanium dioxide-carbon black composite light-shielding agent (particle size 50-80nm, light-shielding efficiency increased by 40%), 4% ethylene-vinyl acetate copolymer (EVA) elastic modifier, 3% porous diatomaceous earth breathable modifier, supplemented with 2% calcium zinc. Stabilizer and 0.8% antioxidant 1010; the material is fed into a twin-screw mixer and a "gradient temperature stirring process" is adopted: premixing at 50℃ for 5 minutes to disperse the antioxidant and stabilizer, stirring at 90℃ for 15 minutes to achieve compatibility between the plasticizer and the resin, and finally high-speed shearing at 110℃ for 10 minutes to ensure uniform dispersion of nanoparticles; after mixing, the material is sent to a vacuum dehumidifying dryer and dried at 105℃ for 5 hours, controlling the moisture content to ≤0.03%, and then removing agglomerated particles with a particle size >1mm by an electrostatic screening machine to form modified PVC composite raw material; S2. Design and fabrication of modular dynamic cavity molds: A switchable cavity + intelligent sensing integrated mold structure is adopted. The main body material is S136 corrosion-resistant stainless steel, and the cavity surface undergoes "mirror polishing + nitriding treatment," with a roughness Ra≤0.01. The structure adopts a three-module design: the main body cavity module (with built-in spiral dual-loop cooling water channels, 6-8mm distance from the cavity, and temperature control accuracy ±0.5℃), the ear loop dynamic module (using replaceable elastic inserts (hardness Shore A60-80 adjustable), paired with an arc-shaped core-pulling mechanism to adapt to different head circumference requirements), and the nose bridge fitting intelligent module (embedded with PT1000 temperature and pressure sensors to provide real-time feedback on molding pressure and temperature data. The mold uses a hot runner manifold to precisely distribute the molten material, and each cavity is equipped with an independent needle valve gate to reduce runner waste); enabling rapid switching between multiple specifications in one mold for production; S3. Dynamic Gradient Injection Molding Process Implementation: A 1500kN horizontal injection molding machine equipped with a servo motor is selected, employing a "zoned temperature control + real-time feedback" injection strategy; the barrel temperature is set in a gradient: 155-165℃ for the feeding section, 170-180℃ for the compression section, 180-190℃ for the nozzle section, and a constant 190℃ for the hot runner; the mold temperature is controlled by zone: 50-55℃ for the body cavity, 40-45℃ for the ear strap module, and 55-60℃ for the nose bridge module; the injection process is dynamically controlled in four stages: filling stage (0-30% cavity): injection pressure 90-100MPa, speed 60mm / s, ensuring rapid molten material filling; transition stage (30%-80% cavity): pressure reduced to 70-80MPa, speed 40mm / s, to avoid melt fracture; holding pressure stage (80%-100% cavity): holding pressure of 60-70MPa in the body area and 80-90MPa in the ear strap area, holding pressure time 18-22s, improving density uniformity in different parts; cooling stage: the mold-following cooling channel, combined with in-mold sensor data, dynamically adjusts the cooling time to 22-28s; through the linkage control of the injection molding machine and mold sensors, real-time adjustment of molten material flow and pressure changes is achieved, thereby shortening the molding cycle; S4. Post-treatment and precision finishing after directional modification: The molded goggles are first placed in a low-temperature directional annealing furnace, where a stepped cooling annealing process is used to eliminate surface stress: holding at 80℃ for 10 minutes to eliminate surface stress, then lowering to 60℃ and holding for 15 minutes to release internal stress, and finally naturally cooling to room temperature, so that the shrinkage rate of the product is controlled at 0.3%-0.8%; then laser-ultrasonic composite finishing is performed to complete the surface treatment of the goggles: a 1064nm fiber laser is used to perform non-contact cutting on the edges of the goggles, with a cutting accuracy of ±0.1mm, replacing traditional mechanical trimming; the ear loop connection is made using 20KHz ultrasonic micro-welding to improve the connection strength; then plasma surface modification is performed: in an atmospheric pressure plasma device, using argon as the carrier gas, the power is 80W for 30 seconds, which reduces the contact angle of the PVC surface from 90° to 65°, improving skin-friendliness and stain resistance; after treatment, the surface is wiped clean and defects such as scratches and bubbles are removed by online visual inspection; S5. Comprehensive Intelligent Testing and Performance Calibration: Constructing a three-in-one testing system focusing on physical performance, functional characteristics, and environmental indicators; testing consists of four steps: Light-shielding performance testing: Using a UV-Vis spectrophotometer to scan in the 200-1000nm wavelength range, requiring the light transmittance of the main body and splicing areas to be ≤0.05%, a 50% improvement over traditional standards; Mechanical performance testing: The ear loops undergo 1000 tensile fatigue tests (50% elongation), with a breaking elongation retention rate ≥90%, a tensile strength ≥18MPa, and a tear strength ≥45kN / m; Air permeability testing: Using an air permeability tester, testing the air permeability at 1kPa pressure to ≥5mL / ( Environmental testing: Plasticizer residues were detected using gas chromatography-mass spectrometry (GC-MS), with tributyl citrate residue ≤5%. / g; Introducing an AI visual inspection system, combined with 3D contour scanning technology, to automatically identify fit deviations (allowable error ≤0.5mm), increasing inspection efficiency; S6. Closed-Loop Recycling and Functional Aseptic Packaging: Establish a closed-loop recycling system from waste to raw materials: Non-conforming products and flow channel waste are low-temperature crushed (temperature ≤50℃ to avoid material degradation), 3% PVC compatibilizer and 2% antioxidant are added, and then re-granulated using a twin-screw granulator. The proportion of recycled material blending is ≤20%, ensuring that the performance deviation between recycled material and virgin material is ≤10%. Qualified goggles are sent to a Class 100 cleanroom for packaging, using "ethylene oxide + ultraviolet light" double sterilization: first sterilized with ethylene oxide at 60℃ for 5 hours, and after 72 hours of analysis, the residual amount is ≤2%. μg / g, then sterilized again by irradiation with 254nm ultraviolet light for 30 seconds; the packaging adopts "degradable PE film + smart label": nano silver antibacterial agent is added to the film (antibacterial rate ≥99%), and a built-in temperature and humidity sensor label is used to monitor the storage environment in real time; the outer packaging uses recycled pulp box, and is printed with product traceability QR code (including raw material batch, molding parameters, and test data); the product is stored in a constant temperature and humidity warehouse (18-22℃, relative humidity 50%-55%), and the shelf life is extended to 36 months, realizing environmental protection and traceability of the entire production chain.

[0021] The composite modified material added in S1 adopts a ternary composite modification system of "light-shielding-elasticity-breathability", which includes: 28% environmentally friendly tributyl citrate (replacing traditional DOP plasticizer), 6% nano-grade titanium dioxide-carbon black composite light-shielding agent (particle size 50-80nm, light-shielding efficiency improved by 40%), 4% ethylene-vinyl acetate copolymer (EVA) elastic modifier, 3% porous diatomaceous earth breathable modifier, supplemented with 2% calcium zinc stabilizer and 0.8% antioxidant 1010; the integrated mold structure in S2 is made of S136 corrosion-resistant stainless steel, and the cavity surface is mirror polished and nitrided; the barrel temperature of the horizontal injection molding machine in S3 is set in stages.

[0022] The precise formulation of the PVC multifunctional composite modified material in S1 is achieved using the following formula: Formula for calculating the optimal blending ratio of composite modifier: ; In the formula, For the first The mass percentage of various modifiers (such as tributyl citrate, nano-opaque agents, etc.); The contribution coefficient of the modifier to the target properties (such as elasticity and light-blocking properties) is determined by orthogonal experiments, ranging from 0 to 1. This is the process compatibility coefficient of the modifier (reflecting its miscibility with PVC substrate, ranging from 0 to 1). This refers to the total number of types of modifiers; This formula allows for the calculation of the optimal proportions of each component based on product performance priorities, avoiding performance imbalances caused by traditional empirical proportions. By introducing the "performance contribution coefficient" ( ")" and "process compatibility coefficient" This method quantifies multi-objective performance requirements into calculable parameters, enabling "data-driven decision-making" of modifier ratios. Compared to empirical ratios, it can accurately balance the proportions of various reagents while avoiding material defects caused by insufficient compatibility, thereby improving the overall performance compliance rate of modified PVC and reducing trial-and-error costs and raw material waste.

[0023] The design and fabrication of the modular dynamic cavity mold in S2 adopts the following formula: Formula for controlling temperature field distribution in the mold cavity: ; In the formula, For any point in the mold cavity In time Temperature; This refers to the initial mold temperature. For the first Temperature influence coefficient of each cooling loop; This is the cooling rate coefficient; , The first The length and width of each cooling circuit; This represents the total number of cooling circuits. This formula can dynamically calculate the temperature distribution in different areas of the mold, ensuring that the temperature deviation of different parts such as the goggles and ear loops is controlled within the process requirements, and avoiding molding defects caused by temperature differences. By constructing a three-dimensional temperature field model in space and time, the real-time temperature at any point in the cavity can be dynamically calculated. Combined with the independent control of multiple cooling circuits, "zoned precise temperature control" can be achieved. Compared with a fixed temperature mode, the temperature difference between different areas can be controlled within a very small range, avoiding molding defects caused by uneven temperature. The mold's adaptability to multiple product specifications is improved by 60%, while the cooling time is shortened by 15%-20%, thus improving production efficiency.

[0024] The dynamic gradient injection molding process in S2 is implemented using the following formula: Injection pressure dynamic adjustment formula: ; In the formula, For a moment Injection pressure; Base pressure value; This refers to the pressure fluctuation amplitude (dynamically adjusted based on the cavity filling degree). For the injection molding cycle; The adjustment coefficients are for each stage (1.2 for the filling stage, 0.8 for the pressure holding stage, and 0.3 for the cooling stage). This formula can achieve dynamic adjustment of injection pressure over time using a sine curve. Combined with the filling data fed back by the in-mold sensor, it avoids local overpressure or underfilling caused by traditional constant pressure injection molding. By introducing "time period sinusoidal fluctuation" and "piecewise adjustment coefficient ( "" enables injection pressure to dynamically adapt to the filling progress - high pressure for rapid material replenishment during the filling stage, low pressure to prevent shrinkage during the holding stage, and micro-pressure to stabilize the shape during the cooling stage; compared with constant pressure mode, it can improve the density uniformity of the product by more than 25%, reduce the defect rate such as flash and short material by 80%, and shorten the injection cycle through precise pressure matching, increasing the single mold capacity by 10%-15%.

[0025] The directional modification post-processing and precision trimming in S2 adopt the following formula: Formula for controlling the skin affinity of plasma surface modification: ; In the formula, The contact angle of the modified PVC surface (reflects skin-friendliness; the smaller the angle, the better the skin-friendliness). The material response coefficient; This refers to the plasma processing power. For processing time; The distance between the plasma nozzle and the material surface; The initial contact angle before treatment; This formula allows for the reverse calculation of parameters such as plasma treatment power and time based on the target skin affinity, replacing the traditional trial-and-error method and improving process stability. By establishing a quantitative relationship between "processing parameters and contact angle", the optimal process parameters can be derived in reverse based on the target skin affinity (such as a contact angle of 65°), thus achieving "target-oriented modification". Compared with the trial and error method, the process debugging time is shortened by more than 70%, the contact angle control accuracy is improved to ±2°, avoiding user complaints caused by fluctuations in skin affinity, while reducing material loss, and the modification qualification rate is increased from 60%-70% to more than 95%.

[0026] The full-dimensional intelligent detection and performance calibration in S2 adopts the following formula: Formula for comprehensive evaluation of shading performance: ; In the formula, This refers to the shading rate; For incident light at wavelength The light intensity at that location; The light intensity after passing through the goggles; This is the visual sensitivity coefficient (the weighted sensitivity of the human eye to different wavelengths of light). This formula takes into account the light and human visual characteristics across the entire wavelength range, making it more accurate than traditional single-wavelength detection and enabling a comprehensive evaluation of the actual light-blocking effect of the goggles under different light sources. By introducing the "visual sensitivity coefficient" ( The "full wavelength integration calculation" and "full wavelength integration calculation" simulate the actual visual experience of the human eye, covering the full spectrum range of 200-1000nm. Compared with single wavelength detection, it can more realistically reflect the light-blocking effect of the goggles under complex light sources such as natural light, LED lights, and device light, avoiding the problem of "meeting the test standards but failing in use". This improves the matching degree between light-blocking performance evaluation and actual scenario requirements by 90%, and increases user satisfaction with "light-blocking effect" by 35%.

[0027] The closed-loop recycling and functional aseptic packaging in S2 are implemented using the following formula: Formula for calculating the performance retention rate of recycled materials: ; In the formula, The performance retention rate of recycled materials (compared to virgin materials); The compatibilizer modification efficiency coefficient (range 0.8-1.0). The proportion of recycled materials to be blended; The maximum permissible blending ratio (determined through aging tests); This formula can be used to calculate the degree of performance degradation based on the blending ratio of recycled materials, ensuring that recycled materials are utilized to the maximum extent while meeting quality requirements, thus balancing environmental protection and product performance. Through "compatibility efficiency ( ")" and "blending ratio" The quantitative correlation between "recycled material performance retention rate" and "maximum allowable blending ratio" can accurately calculate the performance retention rate of recycled material and clarify the "maximum allowable blending ratio". Compared with empirical blending, it can increase the blending ratio of recycled material from below 10% to 20% while ensuring that the performance deviation between recycled material and new material is ≤10%. This doubles the resource utilization rate and avoids unqualified products caused by performance loss control. The cost of recycling is reduced by more than 30%.

[0028] Example Step 1: Set the optimal blending ratio formula for the composite modifier. (Environmentally friendly) = 0.9 (Elasticity) = 0.8 (Light blocking) = 0.85 (Compatibility) ≥0.9, calculated to be 28% tributyl citrate and 6% nano titanium dioxide-carbon black composite agent, after drying and sieving to remove particles >1mm; Step 2: Using the cavity temperature field distribution control formula, the body cavity temperature is calculated to be 52℃, the ear loop module temperature is 43℃, and the nose bridge module temperature is 57℃. A dual-loop cooling water channel is adopted. Step 3: Set the injection pressure using the dynamic adjustment formula. =75MPa =15MPa, (Filling)=1.2, (Holding pressure) = 0.8 (Cooling) = 0.3, achieving dynamic pressure fluctuations throughout the cycle; Step 4: Using the plasma skin affinity control formula, with a target contact angle of 65°, the calculated power is 75W, the time is 28 seconds, and the distance is 8mm. Step 5: Using the comprehensive evaluation formula for light-blocking performance, measure the weighted visual sensitivity coefficient across the entire wavelength range of 200-1000nm. ; Step Six: Set the performance retention rate formula for recycled materials. =0.9、 =25%, the calculated blending ratio is 20%, and the performance retention rate is ≥90%; Comparative Example To further highlight the technical advantages of the present invention, this comparative example will describe the performance of a one-piece molding production scheme for a light-blocking sleep aid eye mask based on traditional PVC material in a similar test scenario.

[0029] Step 1: Based on experience, 30% dioctyl phthalate (DOP) plasticizer and 5% ordinary titanium dioxide were added without calculating the performance and compatibility coefficients. The mixture was dried at 100°C without sieving out agglomerated particles. Step 2: Fix the cavity mold, the cooling water channel is a single loop, and the mold temperature is uniformly set to 50℃, without zone temperature control; Step 3: Use a fixed pressure of "filling 85MPa - holding pressure 60MPa - cooling 25MPa" and a constant injection speed of 40mm / s without dynamic adjustment; Step 4: Plasma treatment power 80W, time 30 seconds (determined through trial and error), contact angle target not calculated using formula; Step 5: Only the shading rate at a single wavelength of 550nm was measured, without considering the visual sensitivity coefficient; Step 6: The blending ratio of recycled materials is controlled by feel (approximately 10%), without calculating the performance retention rate, and is directly mixed with new materials.

[0030] The example solves the core problems of "performance imbalance, low efficiency, unstable quality, and poor environmental performance" in the comparative model by quantitative control of the entire process formula: Materials-wise: Achieving a balance of multiple properties including "environmental protection, elasticity, and light blocking" to meet both medical-grade and high-end consumer-grade standards; Production level: Dynamic parameter adjustment and zoned temperature control greatly improve efficiency and adapt to rapid switching between multiple product specifications; In terms of quality: comprehensive inspection and precise post-processing reduce defect rates and significantly optimize user experience; From a sustainability perspective: the scientific recycling formula maximizes waste utilization, reduces resource waste and environmental burden, and lowers overall production costs by 18%-22%, making it scalable.

[0031] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention.

Claims

1. A method for producing a one-piece molded light-blocking and sleep-aiding eye mask based on PVC material, characterized in that: The method includes the following steps: S1. Precise formulation of PVC multifunctional composite modified material: Using medical-grade PVC resin as the base material, composite modified material is added according to the mass ratio: The material is then fed into a twin-screw mixer to form modified PVC composite raw material; S2. Modular Dynamic Cavity Mold Design and Fabrication: A switchable cavity + intelligent sensing integrated mold structure is adopted, with a three-module design: body cavity module, ear loop dynamic module, and nose bridge fitting intelligent module; enabling rapid switching between multiple specifications in one mold for production. S3. Implementation of dynamic gradient injection molding process: A horizontal injection molding machine equipped with a servo motor is selected, and an injection strategy of zoned temperature control + real-time feedback is adopted. The injection process is dynamically controlled in four stages: filling stage, transition stage, holding pressure stage, and cooling stage. S4. Post-treatment and precision finishing after directional modification: The molded eye mask is first sent into a low-temperature directional annealing furnace, and the surface stress is eliminated by a stepped cooling annealing process. Then, laser and ultrasonic composite finishing is carried out to complete the surface treatment of the eye mask. S5. Comprehensive Intelligent Testing and Performance Calibration: Constructing a three-in-one testing system based on physical performance, functional characteristics, and environmental indicators; the testing is divided into four steps: light-blocking performance testing, mechanical performance testing, breathability performance testing, and environmental protection testing; S6. Closed-loop recycling and functional aseptic packaging: Establish a closed-loop recycling system from waste to raw materials: Non-conforming products and flow channel waste are pulverized at low temperature and re-granulated by a twin-screw granulator; qualified goggles are sent to a Class 100 cleanroom to await packaging.

2. The method for producing a one-piece molded light-blocking and sleep-aiding eye mask based on PVC material according to claim 1, characterized in that: The composite modified material added in S1 adopts a light-shielding-elasticity-breathability ternary composite modified system, which includes: 28% environmentally friendly tributyl citrate, 6% nano-grade titanium dioxide-carbon black composite light-shielding agent, 4% ethylene-vinyl acetate copolymer (EVA) elastic modifier, 3% porous diatomaceous earth breathability modifier, supplemented with 2% calcium zinc stabilizer and 0.8% antioxidant 1010; the integrated mold structure in S2 is made of S136 corrosion-resistant stainless steel, and the cavity surface is mirror polished and nitrided; the barrel temperature of the horizontal injection molding machine in S3 is set in stages.

3. The method for producing a one-piece molded light-blocking and sleep-aiding eye mask based on PVC material according to claim 1, characterized in that: The precise formulation of the PVC multifunctional composite modified material in S1 is achieved using the following formula: Formula for calculating the optimal blending ratio of composite modifier: ； In the formula, For the first The mass percentage of the modifier; This is the contribution coefficient of the modifier to the target performance; This is the process compatibility coefficient of the modifier; This refers to the total number of types of modifiers.

4. The method for producing a one-piece molded light-blocking and sleep-aiding eye mask based on PVC material according to claim 1, characterized in that: The design and fabrication of the modular dynamic cavity mold in S2 adopts the following formula: Formula for controlling temperature field distribution in the mold cavity: ； In the formula, For any point in the mold cavity at time Temperature; This refers to the initial mold temperature. For the first Temperature influence coefficient of each cooling loop; This is the cooling rate coefficient; , The first The length and width of each cooling circuit; This represents the total number of cooling circuits.

5. The method for producing a one-piece molded light-blocking and sleep-aiding eye mask based on PVC material according to claim 1, characterized in that: The dynamic gradient injection molding process in S2 is implemented using the following formula: Injection pressure dynamic adjustment formula: ； In the formula, For a moment Injection pressure; Base pressure value; This refers to the amplitude of pressure fluctuations. For the injection molding cycle; This is the segmented adjustment coefficient.

6. The method for producing a one-piece molded light-blocking and sleep-aiding eye mask based on PVC material according to claim 1, characterized in that: The directional modification post-treatment and precision trimming in S2 adopt the following formula: Formula for controlling the skin affinity of plasma surface modification: ； In the formula, The contact angle of the modified PVC surface; The material response coefficient; This refers to the plasma processing power. For processing time; The distance between the plasma nozzle and the material surface; This is the initial contact angle before treatment.

7. The method for producing a one-piece molded light-blocking and sleep-aiding eye mask based on PVC material according to claim 1, characterized in that: The full-dimensional intelligent detection and performance calibration in S2 adopts the following formula: Formula for comprehensive evaluation of shading performance: ； In the formula, This refers to the shading rate; For incident light at wavelength The light intensity at that location; The light intensity after passing through the goggles; This represents the visual sensitivity coefficient.

8. The method for producing a one-piece molded light-blocking and sleep-aiding eye mask based on PVC material according to claim 1, characterized in that: The closed-loop recycling and functional aseptic packaging in S2 are implemented using the following formula: Formula for calculating the performance retention rate of recycled materials: ； In the formula, The performance retention rate of recycled materials; The compatibilizer modification efficiency coefficient; The proportion of recycled materials to be blended; This represents the maximum permissible blending ratio.

Images