Co-molded Thermoplastic Elastomer Diving Mask for Sealing and Stiffness
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Solution Overview
Problem
Current diving masks face challenges with sealing issues, high manufacturing costs, fragility, and weight due to the use of tempered glass for transparent elements, and lack of materials that provide both necessary flexibility and stiffness for effective sealing and clear vision.
Innovation Solution
A diving mask made from co-molded thermoplastic elastomers with different hardness levels, where the transparent elements have a higher Shore A hardness (75-95) and the facial body has a lower Shore A hardness (35-55), and a stiffer frame is co-molded with these components to provide adequate stiffness and flexibility, using copolymers like styrene/ethene-butene/styrene and ethylene/propylene/propylene for optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tempered glass is used for transparent elements, then stiffness and transparency are improved, but sealing problems, manufacturing costs, and fragility increase
Solution Approach 1:
The patent changes the material parameter from traditional tempered glass to thermoplastic elastomer with controlled hardness (Shore A 70-95). This parameter change maintains sufficient optical clarity and stiffness while eliminating sealing problems and reducing fragility, as the elastomeric material can deform to conform to the facial body seal surfaces.
Solution Approach 2:
The patent uses a composite approach by integrating the transparent element directly with the facial body through co-molding, creating a unified structure where the thermoplastic elastomer material provides both optical and sealing functions simultaneously, eliminating the need for separate sealing components.
2Device complexity
If a single material is used for both transparent elements and facial body, then manufacturing complexity is reduced, but it is difficult to achieve both adequate flexibility for sealing and adequate stiffness for clear vision
Solution Approach 1:
The patent applies local quality by creating different hardness zones within the same material structure - the transparent element region has higher hardness (Shore A 70-95) for optical clarity and stiffness, while the facial body region has lower hardness for sealing flexibility. This is achieved through controlled variations in material composition and molding parameters during the co-molding process.
3Strength
If the transparent element is made stiffer to avoid deformations, then vision clarity is improved, but image deformations occur due to divergence between transparent elements when strap is pulled
Solution Approach 1:
The patent merges the transparent elements with the facial body into a single co-molded structure, ensuring that both elements are rigidly positioned relative to each other. This integration prevents relative movement and divergence between the transparent elements when the strap is pulled, maintaining proper alignment and preventing image deformations.
Data Source
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AI summary
Diving mask, comprising a facial body and at least one transparent element which allows viewing and intended to overlap the eye area, made by co-molding at least two different thermoplastic elastomers, said transparent element being formed by a thermoplastic elastomer provided with a relatively greater degree of hardness, and said facial body being formed by a thermoplastic elastomer provided with a relatively lower degree of hardness.