Eyeglass Frame Decorative Lamination via Injection Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for producing eyeglass frames with decorative patterns are costly, time-consuming, and limited to two-dimensional designs, with complex manufacturing processes that result in low productivity, high costs, and poor aesthetic quality due to instability and dimensional control issues.
Innovation Solution
A thermoplastic sheet laminate with transfer printing decorative patterns and covering layers, where core layers can include three-dimensional articles or immiscible fluids, bonded together using heat, pressure, or adhesives, allowing for polychromatic designs and improved stability, and a manufacturing process involving bending and bonding under controlled temperature and pressure to ensure uniformity and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional silk screen printing method is used to produce decorative patterns on eyeglass frames, then decorative patterns can be applied, but the manufacturing process becomes complex and time-consuming with low productivity
Solution Approach 1:
The patent combines multiple manufacturing steps into a single injection molding process. The decorative patterns are integrated directly into the mold cavity, allowing the frame and decorative elements to be formed in one operation rather than through separate printing and assembly steps. This merging of operations eliminates the complexity of silk screen printing while maintaining high productivity through automated injection molding.
Solution Approach 2:
The decorative patterns are prepared in advance by creating precision cavities and features directly in the injection mold. This preliminary action embeds the decorative design into the manufacturing tooling itself, so that each production cycle automatically reproduces the pattern without requiring separate printing operations. The mold cavities are pre-configured with the exact decorative geometry needed.
2Adaptability or versatility
If multiple silk screens are used for different patterns, then pattern variety is achieved, but manufacturing cost increases and productivity decreases
Solution Approach 1:
The injection mold is designed as a universal tool that can produce multiple different decorative patterns. By changing the mold cavity design or inserting different patterned inserts into the mold, the same injection molding machine can produce frames with various decorative styles. This multi-functional mold eliminates the need for separate silk screen equipment for each pattern type.
Solution Approach 2:
The patent achieves pattern variety by changing the geometric parameters of the mold cavity rather than changing the entire manufacturing system. Different cavity shapes, depths, and surface textures can be incorporated into the mold to produce different decorative effects. This parameter-based approach allows flexible pattern variation without adding equipment complexity.
3Reliability
If conventional protective coating is applied over transferred patterns, then pattern protection is achieved, but the coating wears out and patterns become depleted over time
Solution Approach 1:
Instead of applying a protective coating over the pattern (conventional approach), the patent inverts the sequence by embedding the pattern within the frame material itself through the injection molding process. The decorative cavities are formed as integral parts of the frame structure, so the pattern becomes the substrate rather than the coating. This eliminates the wear issue because there is no separate protective layer to deteriorate.
Solution Approach 2:
The patent creates a composite structure where the decorative pattern and the frame material are combined into a single integrated component through injection molding. The patterned cavities are formed within the thermoplastic material, creating a composite structure where the decorative element and structural element are unified. This integration ensures the pattern withstands the full service life of the frame without separate coating degradation.
4Manufacturing precision
If manual manufacturing process is used for thermoplastic sheet laminate, then decorative patterns can be produced, but production cycle is lengthy and stability is limited
Solution Approach 1:
The patent replaces the manual mechanical lamination process with an automated injection molding system. The injection molding machine automatically injects thermoplastic material into the mold cavity, applies pressure and heat, and forms the decorative frame in one automated cycle. This mechanical substitution eliminates manual handling steps, reduces production time, and ensures consistent dimensional precision through automated process control.
Solution Approach 2:
The injection molding process utilizes phase transitions of the thermoplastic material to achieve rapid forming. The material is heated to a molten state, injected into the mold cavity under pressure, then cooled and solidified to form the finished frame. This controlled phase change (solid-liquid-solid) enables rapid production cycles with high dimensional accuracy, replacing slow manual lamination processes.
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 solution provides eyeglass frames with durable, high-density, and aesthetically pleasing decorative patterns that maintain stability and uniformity, reducing production costs and time while enabling three-dimensional designs and improved dimensional control.
Implementation Method 1
bonded together using heat, pressure, or adhesives
Implementation Method 2
bonded together using heat, pressure, or adhesives
Implementation Method 3
bonded together using heat, pressure, or adhesives
Implementation Method 4
wherein the covering layers bond to the thermoplastic sheet laminate incorporating transfer printing eyeglass decorative patterns
Data Source
AI summary
An eyeglass frame including a thermoplastic sheet laminate incorporating transfer printing eyeglass decorative patterns and a one or more covering layers bonded thereto. A process for manufacturing an eyeglass frame including: preparing a thermoplastic sheet laminate incorporating eyeglass decorative patterns; bending said thermoplastic sheet laminate under heat and pressure forming a one or more intermediate products in a first mold; and bonding a one or more covering layers to the intermediate products from the bending step in a second mold.