Eyewear Lens Molding with Retaining Elements
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Solution Overview
Problem
Conventional plastic molding processes for eyewear frames struggle to produce a variety of designs that meet consumer needs for both fashion and functionality, as they cannot effectively secure lenses as a central part of the eyewear.
Innovation Solution
A method involving multiple molding procedures to integrate retaining elements with lenses and support structures, where the lenses are permanently attached to both front and rear support structures through a series of molding steps, ensuring a secure and integral eyewear design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional plastic molding process is used to manufacture frame structure, then the manufacturing process is simple, but the ability to produce variety of molded eyewear designs and securely attach lenses is limited
Solution Approach 1:
The molding process is divided into multiple sequential procedures: first molding the lens with integrated retaining elements, then molding the front support structure around the lens, and finally molding the rear support structure. This segmentation allows each component to be optimized independently while achieving complex integrated designs that satisfy both fashion and functionality requirements.
Solution Approach 2:
The retaining elements are pre-formed as integral parts of the lens during the first molding procedure, before the support structures are created. This preliminary action ensures that the lens is ready for secure attachment and allows subsequent molding steps to focus on creating the support structures that engage with these pre-formed elements.
2Reliability
If lenses are permanently secured to frame structure using conventional molding, then lens attachment is achieved, but the lens cannot be securely integrated as a central part of the eyewear
Solution Approach 1:
The lens and retaining elements are merged into a single integrated component through co-molding, where the retaining elements protrude rearwardly from the lens and are permanently attached to it. This merging ensures that the lens assembly acts as a unified central part of the eyewear, securely integrated with the support structures.
Solution Approach 2:
The molding process employs nested molding where the front support structure is molded with the lens already in place, and then the rear support structure is molded with the front support structure and lens assembly already positioned. This nested approach creates multiple layers of secure integration, with each molding step adding another level of permanent attachment.
3Reliability
If multiple molding procedures are used to integrate retaining elements with lenses and support structures, then secure permanent attachment is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The complex manufacturing process is segmented into three distinct but sequential molding procedures, each with a specific function: creating the lens with retaining elements, forming the front support structure, and forming the rear support structure. This segmentation makes the overall complex process manageable and repeatable.
Solution Approach 2:
Each molding procedure performs preliminary actions that prepare for the next step: the first molding creates pre-formed retaining elements on the lens, the second molding positions the lens assembly and creates engagement features, and the third molding completes the integration. These preliminary actions ensure that each subsequent step builds upon a prepared foundation, reducing overall process complexity.
Data Source
AI summary
A method of making eyewear includes molding procedures using different molding materials to produce the lenses and support structures in a sequence to permanently attach the lenses to the support structure. The lenses are formed with retaining elements to engage with the support structure.