Nylon Polarized Lens Buffer Grooves and Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional polarized lenses made of polycarbonate (PC) material face issues such as stress concentration when assembled with metal frames, inability to be drilled, and incompatibility with acidic environments, leading to potential breakage and quality issues, particularly for thin and expensive lenses like nylon polarized lenses, where existing manufacturing methods result in material wastage and reduced product quality.
Innovation Solution
A nylon polarized lens design featuring buffer grooves and positioning portions at the corners, paired with a moulding mold having buffer flanges and positioning needles, which prevents adhesive glue from being flushed during injection molding, allowing for direct adhesive application without a protective plastic layer, enabling the production of thin, high-quality, and expensive lenses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plastic layer is attached to protect adhesive glue during injection molding, then adhesive glue displacement is prevented, but lens thickness increases and material usage increases
Solution Approach 1:
The invention divides the protective function into two parts: positioning portions that prevent adhesive glue displacement during injection molding, and buffer grooves that absorb injection pressure. This segmentation eliminates the need for an additional protective plastic layer while maintaining adhesive glue retention.
Solution Approach 2:
The positioning portions are pre-formed on the lens surface before injection molding. These positioning portions preliminarily secure the adhesive glue in place, preventing displacement during the subsequent injection molding process without requiring additional protective layers.
2Ease of manufacture
If conventional injection molding is used without positioning portions, then manufacturing process is simpler, but adhesive glue is flushed away during injection causing quality issues
Solution Approach 1:
Positioning portions are pre-formed on the lens surface before the injection molding process. This preliminary action secures the adhesive glue in the correct position, preventing it from being flushed away during injection while maintaining a relatively simple manufacturing process.
Solution Approach 2:
The positioning portions act as an intermediary structure between the adhesive glue and the injection molding process. They provide a physical barrier and anchoring mechanism that prevents adhesive glue displacement without requiring complex manufacturing processes.
3Strength
If PC material is used for polarized lenses, then lenses are light and durable, but stress concentration occurs when assembled with metal frames
Solution Approach 1:
The invention changes the material parameter from PC (polycarbonate) to nylon. Nylon material has different mechanical properties including lower internal stress and better compatibility with metal frames, eliminating the stress concentration issue while maintaining lens durability.
Solution Approach 2:
The invention uses nylon as a composite material alternative to PC. Nylon provides the necessary strength and durability for polarized lenses while having superior stress distribution characteristics when assembled with metal frames, resolving the stress concentration problem.
Data Source
AI summary
A nylon polarized lens includes a nylon material layer and a polarized film. The nylon material layer has four corners formed with positioning portions to position the polarized film. The nylon material layer has buffer grooves at two opposing end surfaces thereof. A moulding mold to manufacture a nylon polarized lens includes an upper die and a lower die. The lower die has a top surface which is an arc concave surface. Two opposing sides of the top surface of the lower die are formed with buffer flanges which are adapted to form buffer grooves of the nylon polarized lens. The top surface of the lower die is further formed with positioning portions to position the polarized film. The upper die has a bottom surface which is an arc convex surface. The upper die cooperates with the lower die to form a chamber for shaping the lens.