Frameless Diving Mask Lens Adhesion via Dual Silica Gel Layers
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Solution Overview
Problem
Frameless diving masks face challenges in maintaining optical properties and field-of-view due to the lack of a rigid frame, and their manufacturing process is hindered by thermal expansion issues during high-temperature molding, leading to potential detachment of the first silica gel layer.
Innovation Solution
A method involving a two-layered structure where the first flexible layer is formed with protrusions and a spacing means to prevent direct contact with the high-temperature mold, allowing for a second flexible layer to be molded without detaching the first layer, enhancing adhesion and design variability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid frame is used to support the lens, then the lens is protected, but the distance between the lens and the user's eyes increases, negatively affecting optical properties and field-of-view
Solution Approach 1:
The patent removes the rigid frame structure from the diving mask design, extracting the harmful element that caused the contradiction. By eliminating the frame entirely and using a frameless design with the lens directly mounted on the flexible mask, the solution maintains lens protection through alternative means while restoring optimal optical properties and field-of-view by minimizing the distance between lens and eyes.
Solution Approach 2:
The patent replaces the rigid frame with a flexible mask structure made of elastic materials. The lens is secured through the flexibility and elasticity of the mask material itself, which can conform to the user's face while providing support. This flexible approach eliminates the need for a rigid frame that compromised optical properties.
2Ease of manufacture
If two layers of silica gel are injection-molded twice on the lens to provide color variation, then the appearance is enriched, but the high-temperature mold causes thermal expansion that makes the first layer fall off
Solution Approach 1:
The patent applies a heat-resistant coating to the lens before the injection molding process. This preliminary action prepares the lens surface to withstand the high temperatures of the molding process without causing thermal expansion that would lead to detachment. The coating is applied in advance, allowing the subsequent molding process to proceed without compromising adhesion.
Solution Approach 2:
The patent uses a disposable or replaceable first layer of silica gel that is specifically designed to be heat-resistant. This layer acts as a protective interface between the lens and the high-temperature mold, and if it does detach or degrade, it can be replaced without affecting the lens or the overall mask structure.
3Manufacturing precision
If the lens is directly combined with the facial mask without a rigid frame, then the distance between the lens and eyes is shortened improving optical properties, but the difficulty of combining silica gel to other materials increases
Solution Approach 1:
The patent employs composite material construction by combining the lens (made of optical material) with the facial mask (made of elastic material such as silicone or rubber). The lens is securely attached to the mask through adhesive bonding or mechanical integration, creating a composite structure that leverages the strengths of each material. This approach enables direct combination of dissimilar materials while maintaining both optical performance and manufacturing feasibility.
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 effectively prevents thermal detachment of the first flexible layer and allows for varied designs and colors, improving the mask's appearance and consumer appeal by maintaining the optical benefits of a frameless design.
Implementation Method 1
the first flexible layer is formed with protrusions and a spacing means to prevent direct contact with the high-temperature mold... prevent the heat energy from being directly transferred from the high-temperature second mold to the lens
Implementation Method 2
an adhesive is coated on the edge of the lens to assist the lens to be combined with other articles
Data Source
AI summary
A method for fabricating a frameless diving includes the following steps. First, providing a lens; next, coating an adhesive on an edge of the lens; then, forming a first flexible layer made of a silica gel on the edge of the lens; thereafter, forming a second flexible layer made of another silica gel on the first flexible layer. The first flexible layer has a plurality of protrusions and may enables the lens covered with the first flexible layer to be spaced apart from a high-temperature mold for a proper distance, so as to prevent the first flexible layer from falling off from the lens due to the high temperature when molding the silica gel. The protrusions are exposed out of the second flexible layer, so as to vary the design and shape of the frameless diving mask abundantly.