One-Piece Silicone Eyewear via Two-Material Molding
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Solution Overview
Problem
Conventional eyewear manufacturing is labor-intensive, costly, and results in products that are prone to slipping, breaking, and limited resistance to heat and cold, making them unsuitable for occupational use.
Innovation Solution
A one-piece composite eyewear article is created using a two-material molding process with a frame and lens made from cured liquid silicone rubber, which auto-adheres during curing, reducing manufacturing steps and enhancing durability and temperature resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing processes are used with multiple separate components, then manufacturing flexibility is maintained, but manufacturing complexity and labor intensity increase significantly
Solution Approach 1:
The patent merges the frame and lens into a single integrated component manufactured through one continuous injection molding process. The frame portion is molded first, then the lens material is injected into the frame's cavity without removing the frame from the mold, creating a unified one-piece eyewear article that eliminates assembly steps and reduces manufacturing complexity
Solution Approach 2:
The injection molding process is designed to perform multiple functions sequentially: first forming the frame structure, then creating the lens within the same mold and manufacturing cycle. This multi-functional approach allows a single manufacturing process to produce both structural and optical components simultaneously
2Reliability
If standard smooth plastic is used for the frame, then manufacturing is simple, but the eyewear slips off the user's nose when sweating or oily
Solution Approach 1:
The patent applies a specific surface texture treatment to the portions of the frame that contact the user's skin (nose and ears), while keeping other portions smooth. This localized texturing increases friction and grip stability in critical areas without affecting the overall manufacturing process or aesthetic portions of the frame
3Strength
If conventional plastic or glass materials are used, then manufacturing is straightforward, but the eyewear scratches and breaks easily
Solution Approach 1:
The patent uses a thermoplastic elastomer material that combines the flexibility and impact resistance of rubber with the moldability of plastic. This composite material properties enable the frame to resist breaking and scratching while still being manufacturable through standard injection molding processes, eliminating the need for fragile glass or complex multi-material assemblies
4Temperature
If conventional materials are used, then manufacturing is simple, but resistance to heat and cold is limited
Solution Approach 1:
The patent selects a thermoplastic elastomer with specific thermal properties that maintain flexibility and structural integrity across a wide temperature range. By changing the material parameters (choosing a polymer with appropriate glass transition temperature and melting point), the eyewear achieves resistance to both heat and cold while remaining manufacturable through injection molding
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 reduces manufacturing costs, prevents slipping, and provides high-quality eye protection resistant to impact, water, heat, and cold, making it suitable for occupational use.
Implementation Method 1
a single integral piece of cured liquid silicone rubber consisting of a liquid dimethyl polysiloxane polymer thermoset
Implementation Method 2
the frame auto-adheres to the lens during curing
Data Source
AI summary
A one-piece, composite eyewear article including a frame having two temples, two eye wires, a bridge and two hinges, the entire frame composed of a single integral piece of cured liquid silicone rubber consisting of a liquid dimethyl polysiloxane polymer thermoset, a lens situated within the two eye wires and extending across the bridge, the lens composed of a single integral piece of optical grade cured liquid silicone rubber consisting of a liquid dimethyl polysiloxane polymer thermoset, and wherein the frame and lens are molded via a two-material molding process, such that the frame auto-adheres to the lens during curing.