3D Metal Eyeglass Frame for Lightweight AR Heat Dissipation
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Solution Overview
Problem
Head-mounted computing devices, especially those with glasses form factors, face challenges such as weight discomfort, lack of rigidity leading to distortion in augmented reality configurations, and low thermal conductivity causing heat buildup and performance issues.
Innovation Solution
The method involves additively manufacturing a metal frame for the head-mounted computing device using laser sintering on aluminum or titanium powder, followed by a reductive process to smooth the surface and improve thermal conductivity and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional manufacturing methods are used for the metal frame, then the frame may have sufficient strength, but the device weight increases causing user discomfort
Solution Approach 1:
The patent changes the manufacturing parameters by using additive manufacturing with laser sintering of metal powders (aluminum or titanium) instead of conventional subtractive manufacturing. This allows creating frames with optimized internal structures that maintain strength while reducing weight through controlled material distribution.
Solution Approach 2:
The patent employs composite material approaches by combining metal powders with binding agents during additive manufacturing, creating a composite structure that achieves both strength and weight reduction. The subsequent reductive process removes excess binding materials to reveal the optimized metal structure.
2Ease of operation
If the metal frame has complex geometry for ergonomic design, then comfort improves, but manufacturing complexity increases
Solution Approach 1:
The patent segments the manufacturing process into distinct stages: additive manufacturing of the base structure, application of binding agent, and reductive processing. This segmentation allows complex geometries to be created through automated additive processes while simplifying each individual manufacturing step.
Solution Approach 2:
The patent replaces traditional mechanical manufacturing methods (maching, molding) with additive manufacturing technology. This substitution enables complex ergonomic geometries to be created directly from digital models without requiring complex tooling or multiple assembly steps.
3Reliability
If the frame material has high thermal conductivity to prevent heat buildup, then performance stability improves, but the frame may become more prone to heat-related manufacturing defects
Solution Approach 1:
The patent uses periodic laser sintering cycles during additive manufacturing, where the laser selectively heats and fuses metal powder layers. This periodic thermal action allows precise control of heat distribution, preventing thermal defects while achieving the desired thermal conductivity in the final product.
Solution Approach 2:
The patent changes material parameters by selecting specific metal powders (aluminum or titanium) with controlled particle size, shape, and composition. These parameter changes optimize both the thermal conductivity for heat dissipation and the manufacturability through laser sintering 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
This approach results in a lightweight, rigid, and thermally conductive metal frame, reducing discomfort, image distortion, and heat-related issues, while also lowering manufacturing costs and enhancing the cosmetic appeal of the device.
Implementation Method 1
additively manufacturing the metal frame of the head-mounted computing device by performing laser sintering on aluminum powder or titanium powder
Implementation Method 2
performing laser sintering on aluminum powder or titanium powder
Implementation Method 3
removing an outer surface of the metal frame via a reductive process
Data Source
AI summary
A method of manufacturing is provided, including forming a metal frame of a head-mounted computing device shaped as a pair of eyeglasses. Forming the metal frame may include additively manufacturing the metal frame of the head-mounted computing device by performing laser sintering on aluminum powder or titanium powder. Forming the metal frame may further include removing an outer surface of the metal frame via a reductive process.