Single-Lens Wrap-Around Spectacles Integral Molding

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for manufacturing single-lens wrap-around spectacles are complex and require separate production of lens structures and supporting arms, leading to increased assembly complexity and potential optical distortions due to prismatic effects.

Innovation Solution

A method where a semi-finished lens is produced using injection molding, thermo-forming, or compression molding, with integral lateral arms and a single-piece design, allowing for simplified assembly and shaping to maintain optimal optical properties by varying the curvature and thickness of lens surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If separate production of lens structures and supporting arms is used, then manufacturing flexibility is improved, but assembly complexity increases

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidassembly complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the lens structure and supporting arms into a single integrated component produced by injection molding. The lens holder and arms are formed as one piece, eliminating separate assembly steps while maintaining manufacturing flexibility through the molding process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single-piece lens holder structure performs multiple functions: it holds the lens, provides structural support, and forms the supporting arms all in one component. This multi-functionality reduces assembly complexity while maintaining ease of manufacture through integrated production.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Shape

If marked lateral curvature is increased for wrap-around design, then aesthetic impact is improved, but optical properties deteriorate due to prismatic effects

Engineering Contradiction:

Improvelateral curvatureVSAvoidoptical properties

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The patent applies different curvature characteristics to different regions of the lens. The lateral regions have marked curvature for wrap-around aesthetic impact, while the central visual regions maintain optimal curvature for clear vision. This local differentiation resolves the conflict between shape and optical properties.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The lens is effectively segmented into different functional zones: lateral wrap-around regions with high curvature for aesthetic impact, and central visual regions with controlled curvature for optimal optics. This segmentation allows each region to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If multiple components are used for lens and arms, then adaptability is improved, but production time increases

Engineering Contradiction:

Improvecomponent adaptabilityVSAvoidproduction time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The lens holder and supporting arms are combined into a single injection-molded component, reducing the number of parts and assembly steps. This merging significantly reduces production time while the modular lens insertion maintains adaptability for different lens configurations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The lens holder is pre-formed with integrated arm structures during injection molding, preparing the complete assembly structure in advance. This preliminary formation of the complete framework eliminates subsequent assembly operations, reducing production time while maintaining design adaptability.

Inventive Principle:

Principle #10Preliminary action

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

Simplifies production, reduces assembly components, minimizes prismatic effects, and enhances aesthetic appeal while ensuring comfortable wear by maintaining optimal optical properties and reducing distortions.

Implementation Method 1

a first step provides for the production of a semi-finished lens 5 (FIGS. 3 and 4) by the forming of a plastics material by an injection process or alternatively by casting. Further techniques that can be used to produce the semi-finished lens 5 are thermo-forming and compression moulding.

Methodology Applied

Scientific EffectThermo-forming:

Implementation Method 2

Methodology Applied

Scientific EffectCompression moulding:

Implementation Method 3

shaping machining with the removal of material, during which both the arms 4a, 4b and the lens structure 2 are shaped to the final shape in accordance with the preselected style

Methodology Applied

Scientific EffectCurvature variation: Geometry

Data Source

PatentUS8061836B2Method of manufacturing spectacles of the single-lens, wrap-around type and spectacles produced by the method

Publication Date: 2011.11.22 SAFILO SPA

AI summary

In a method of manufacturing spectacles of the type which does not have a lens-holding frame and which has a single, wrap-around front lens structure that can extend laterally beyond the main visual regions, and which also has respective arms for the lateral support of the spectacles, predominant portions of the respective lateral arms of the spectacles are produced integrally with the front lens structure by a process for the forming of plastics material with which a semi-finished lens is produced, so that the spectacles are consequently produced in a single piece.