Adapter Frame Assembly for Extra-Large ADF Welding Helmet
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Solution Overview
Problem
Welding helmets often lack the capability to accommodate extra-large auto darkening filters (ADFs) and diopters, requiring the removal of existing components for replacement or installation, which is inconvenient and inefficient.
Innovation Solution
An adapter frame assembly is designed to support an extra-large 110 mm×110 mm ADF, safety lens, and diopter within the welding helmet's viewing window, allowing for the replacement of the safety lens without removing the ADF and the installation/removal of the diopter without disturbing the ADF or safety lens, utilizing a frame body with retention tabs and seats for secure and flexible mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If the welding helmet uses a standard viewing window design, then the existing components (ADF, safety lens, diopter) can be accommodated, but the helmet cannot accommodate extra-large ADFs (110mm×110mm) or additional components like diopters
Solution Approach 1:
The adapter frame is divided into multiple functional zones: an inner seat for the ADF, an outer seat for the safety lens, and a diopter seat for the diopter. This segmentation allows each component to be independently positioned and secured within the adapter frame, enabling the helmet to accommodate extra-large ADFs while maintaining compatibility with other components
Solution Approach 2:
The adapter frame is nested within the existing viewing window opening of the welding helmet. The inner seat, outer seat, and diopter seat are nested within the adapter frame structure. This nested arrangement allows the extra-large ADF to be accommodated within the existing helmet dimensions while maintaining adaptability for other components
2Ease of manufacture
If the safety lens and ADF are permanently fixed together, then the structure is simple, but replacement of the safety lens requires removal of the ADF which is inconvenient and inefficient
Solution Approach 1:
The adapter frame is segmented into distinct seating areas with independent retention mechanisms: the inner seat for ADF, outer seat for safety lens, and diopter seat for diopter. This segmentation allows the safety lens to be replaced by simply removing the outer seat, without affecting the ADF in the inner seat, thereby improving ease of operation while maintaining assembly simplicity
Solution Approach 2:
The retention tabs and retention mechanisms are designed to be dynamically adjustable, allowing components to be easily inserted and removed. The retention tabs can engage or disengage from the helmet shell, and the retention mechanisms in each seat can independently secure or release components, enabling quick replacement of the safety lens without removing the ADF
3Device complexity
If the diopter is integrated into the ADF assembly, then the structure is compact, but installation and removal of the diopter requires disassembly of the entire ADF and safety lens assembly which is time-consuming
Solution Approach 1:
The adapter frame is segmented to include a dedicated diopter seat that is separate from the ADF inner seat and the safety lens outer seat. This segmentation allows the diopter to be independently installed and removed from the diopter seat without disassembling the ADF or safety lens, significantly reducing installation time while maintaining a compact overall structure
Solution Approach 2:
The diopter seat is pre-configured within the adapter frame structure during manufacturing, with retention mechanisms already in place. This preliminary preparation allows the diopter to be quickly installed or removed without requiring disassembly of other components, reducing installation time while maintaining device compactness
Data Source
AI summary
An adapter frame assembly is provided to receive and support an extra-large 110 mm×110 mm ADF, safety lens and diopter within the viewing window of an existing welding helmet. The adapter frame assembly provides for replacement of the safety lens without removing the ADF and installation or removal of a diopter without removing the safety lens or diopter. The ADF, safety lens and diopter are all easy to install and change.