Lens Molding Assembly With Gasket Ridge Film Retention
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Solution Overview
Problem
The conventional process of molding polarized lenses is complex, dependent on operator skill, and prone to deformation or damage of the polarizing film due to manual handling and gasket expansion, leading to inconsistent quality.
Innovation Solution
An assembly featuring a peripheral gasket member with internal circumferential ridges and an annular member to securely hold the polarizing film, allowing for automated insertion and sealing without gasket expansion, using mold parts to define a molding cavity filled with liquid material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling and gasket expansion are used to place the polarizing film, then the film can be inserted into the molding cavity, but the film may be deformed or damaged
Solution Approach 1:
The patent introduces an intermediary structure (the ridge with controlled clearance) between the gasket and the polarizing film. This intermediary mechanism allows the film to be retained without direct contact forces from gasket expansion, eliminating the harmful interaction while maintaining the film in position during molding.
Solution Approach 2:
The patent utilizes the flexibility of the polarizing film to allow it to conform to the ridge structure and be retained by the clearance space. The film's inherent flexibility enables it to be held in place without rigid constraints that could cause damage, resolving the contradiction between ease of insertion and film integrity.
2Reliability
If the gasket is expanded to hold the polarizing film, then the film can be retained in the molding cavity, but the gasket may be deformed
Solution Approach 1:
The ridge structure acts as an intermediary that provides film retention without requiring gasket expansion. The clearance between the ridge and film creates a retention mechanism that is independent of gasket deformation, ensuring both film retention and gasket stability simultaneously.
3Productivity
If manual placement of the polarizing film is performed, then the film can be positioned in the molding cavity, but the quality and time taken are dependent on operator skill
Solution Approach 1:
The ridge structure with clearance enables self-retention of the polarizing film during the molding process. The film automatically maintains its position through the mechanical clearance design without requiring continuous manual adjustment or monitoring, achieving both high productivity and consistent placement quality independent of operator skill.
Data Source
AI summary
An assembly for molding a lens including a peripheral gasket member having a surrounding wall around an axis to define a through-cavity, the surrounding wall having an internal circumferential ridge portion protruding inwardly towards the axis and partitioning the surrounding wall into an upper wall portion and a lower wall portion, wherein the internal circumferential ridge portion includes a first ridge-flank and a second ridge-flank; a film disposed at the first ridge-flank; an annular member disposed over the film to retain the film between the annular member and the first ridge-flank; a first mold part disposed with a circumferential edge in abutment with the upper wall portion; and a second mold part disposed opposite the first mold part and with a circumferential edge in abutment with the lower wall portion, wherein the peripheral gasket member, the first mold part and the second mold part define a molding cavity therebetween.