Dual-Hardness Visor via Two-Step Injection Molding
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Solution Overview
Problem
Cap visors are either uniformly hard, causing discomfort and potential skin damage due to resistance, or uniformly soft, leading to drooping and obstructed vision due to lack of structural support.
Innovation Solution
A method involving primary and secondary injection molding using distinct molds and temperature control to create visors with varying hardness, where the part in contact with the cap is soft and the rest is hard, preventing resistance and drooping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the whole visor is made hard, then the visor maintains structural support and prevents drooping, but the visor creates resistance against the head causing discomfort and potential skin damage
Solution Approach 1:
The visor is divided into two distinct parts with different hardness properties: a first part (front end) made soft to be gentle on the head, and a second part (rear end) made hard to provide structural support and prevent drooping. This local differentiation of material properties resolves the contradiction between comfort and structural integrity.
Solution Approach 2:
The visor is segmented into two separately molded parts that are subsequently bonded together. The first part and second part are manufactured independently using different molding conditions, allowing each segment to have optimized properties for its specific function while working together as a unified structure.
2Object-affected harmful factors
If the whole visor is made soft, then the visor does not create resistance against the head, but the front ends of the visor droop due to gravity obstructing vision
Solution Approach 1:
Different regions of the visor are assigned different material hardness properties: the first part contacting the head is soft to eliminate resistance and discomfort, while the second part providing structural support is hard to prevent gravity-induced drooping and maintain proper visor orientation.
Solution Approach 2:
The visor structure is divided into two functional segments manufactured through separate injection molding processes. The first part handles the comfort function with soft material, while the second part handles the structural support function with harder material, and the two are bonded to form the complete visor.
3Object-affected harmful factors
If the visor is made with different hardness parts, then both comfort and structural support are achieved, but the manufacturing process becomes more complex requiring multiple injection molding steps
Solution Approach 1:
The manufacturing process merges multiple injection molding operations into an integrated multi-step process. The first injection molding creates the first part, then the same or a second injection molding machine performs the second injection molding to create the second part, which is then bonded to the first part. This combining of operations achieves differentiated hardness requirements while maintaining manufacturing efficiency.
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 method allows for a comfortable fit without obstructing vision, as the visor is designed to be soft against the head and structurally sound to prevent drooping, enhancing both usability and appearance.
Implementation Method 1
heating and melting the molding material
Implementation Method 2
heating and melting the molding material
Implementation Method 3
injecting the molten molding material into the injection mold through an injection molding machine
Implementation Method 4
The molten molding material is injected into the first injection mold... and the second injection mold... so as to obtain the needed visor
Data Source
AI summary
Disclosed are a visor and a method of making the same. The method includes 1) preparing molds and molding material, 2) performing a primary injection molding, and 3) performing a secondary injection molding. According to the method, the first part and the second part are independently made on an injection mold, therefore the hardness of the first part and the second part can be made to be different so that the visor body consisting of the first part and the second part has different hardness at different positions. The disclosure further includes a visor, comprising a visor body which is composed of a first part and a second part, where the hardness of the first part is less than that of the second part.