Abstract:
A method for making spectacle arms from composite material with differentiated rigidity, the arms defining a first portion and an adjacent second portion which is less rigid than the first portion. The method includes: providing a first layer of non-cross-linked fiber-reinforced polymer material in the first and second portions; providing a separating element in the first portion, and superimposing a second layer of non-cross-linked fiber-reinforced polymer material on the first layer so as to cover the separating element at the first portion and contact the first layer at the second portion; subjecting the first layer, the second layer, and the separating element interposed between them to a molding process at predetermined pressure and temperature levels so as to cross-link the polymer of the composite material, thus obtaining a thickness and rigidity of the arm at the first portion which are greater than the thickness and rigidity at the second portion.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to a method for making arms for spectacles from composite material with differentiated rigidity, having the characteristics stated in the preamble of the principal claim. 
         [0002]    The invention also concerns an arm for spectacles obtained according to this method. 
       BACKGROUND ART 
       [0003]    There are known arms for spectacles made of composite material formed from a polymer matrix, generally epoxide-based, reinforced with fibres, typically of carbon. 
         [0004]    Arms of this type, described for example in WO 2009/080444, are particularly valued not only for their distinctive appearance but also for their mechanical characteristics and the lightness imparted to them by the material from which they are made. 
         [0005]    This material is formed by long fibres, present in the polymer matrix in a high percentage by weight of at least 50% and possibly as much as 70%, which can be processed so as to be substantially unidirectional, or so as to be intertwined or woven, embedded in a polymer matrix to form a layer of pre-impregnated material, also known as “pre-preg”. 
         [0006]    It should be noted that these composite materials are clearly different, in terms of both their production and their mechanical characteristics, from composite materials comprising a polymer matrix in which reinforcing fibres of reduced length (known as “short fibres”) are embedded in proportions of up to 40% by weight, these fibres generally being dispersed in a random way in the matrix. 
         [0007]    Arms of the aforementioned type are generally made by successively superimposing a suitable number of these layers, which are subjected, within a suitable mould, to temperature and pressure conditions which result in a process of consolidation and cross-linking of the composite material forming the superimposed layers. On completion of the cross-linking phase of the composite material, a sheet-like intermediate product is obtained, from which the arms are produced by appropriate cutting and edge trimming. 
         [0008]    The resulting arms have substantially uniform mechanical properties along their longitudinal extension, particularly in terms of flexibility, elasticity and percentage elongation. 
         [0009]    EP 2051108 describes an arm for spectacles made of composite material and capable of retaining over time the form imparted by manual deformation carried out to adjust the shape of the arm. The arm described in EP 2051108 has this advantageous characteristic because of the provision of a metallic core of constant thickness in the arm, surrounded by a coating of fibre-reinforced polymer-based composite material. The metallic core extends from a first longitudinal end of the arm, where it can act as a hinge element with the front frame, to the opposite longitudinal end. The arm described in EP 2051108 has a substantially constant thickness along the longitudinal extension of the arm, at least in its regions made of composite material. 
         [0010]    The Applicant has observed that, in some cases, spectacle arms should be provided with characteristics of flexural rigidity that are suitably differentiated along their longitudinal extension, in order to meet all the aesthetic and functional requirements of designers. 
         [0011]    For example, in order to enable the spectacles to be worn comfortably and to be kept in a position adhering to the user&#39;s head, the arm preferably has regions of differentiated flexibility, with greater flexibility in the region near the hinge (so as to replace, possibly, the conventional but costly elastic hinges), followed by a greater flexural rigidity in the median region corresponding approximately to the temple of the user wearing the spectacles. Alternatively, or additionally, it may be preferable to have an arm with a more flexible region in the area above the ear and a more rigid adjacent region in the area behind the ear, allowing the spectacles to “grip” the user&#39;s head more effectively. 
         [0012]    The Applicant has also observed that this differentiation in the rigidity characteristics is obtained in spectacle arms made of other types of material, for example metal or polymer, by providing regions of increased thickness (thickening) in the regions where greater flexural rigidity is desired. 
         [0013]    However, the specific composition and layered structure of the composite material used is unsuitable for creating variations of thickness. 
         [0014]    This is because, in order to keep the mechanical and aesthetic characteristics of the composite material unaltered, the ratio between the polymer and the reinforcing fibres must be kept within a well defined range in every portion of the arm. This characteristic makes it inherently impossible to form regions of greater thickness in a structure of simple superimposed layers by shaping the mould cavity in a suitable way (for example, by forming a recess with cavities of different depth). In fact, it has been observed that, in the first phase of moulding, owing to the high temperature and the newly initiated cross-linking reaction, the polymer matrix becomes particularly fluid and tends to flow from regions of higher pressure towards regions of lower pressure. Consequently, if the mould impression has varying cross sections, the greater space available in the areas of larger cross section is substantially occupied by the polymer component, so that a composite material having a high percentage of polymer is produced in these regions, whereas, in the adjacent regions, a composite material with an excessively high percentage of fibres is obtained. 
         [0015]    To avoid such kind of drawbacks, variations of thickness are usually created by superimposing successive portions of layers in the areas concerned, with progressively reduced sizes if necessary, so that, when placed in the mould, the various areas of the layered structure are substantially subjected to the same pressure and there is no significant displacement of polymer within the material. 
         [0016]    This operation has the drawback of requiring a considerable labour load in terms of time and human resources. Moreover, in this type of arm the edge, formed by the trimmed edges of the layers forming the arm, does not have the typical aesthetic effect of the texture of composite carbon materials (known as the “carbon look”), which is visible only on the principal surfaces of the layers. Although this limitation is less significant in very limited thicknesses, it may be negatively affect the arm at the regions of greater thickness and may be aesthetically displeasing. 
         [0017]    It should be noted that, in the context of the present description and the subsequent claims, the term “rigidity” or “flexural rigidity” denotes the resistance of the arm or a region thereof to bending about an axis perpendicular to the longitudinal direction of the arm and substantially parallel to an axis about which the arm is hinged to a front frame of the spectacles to which the arm is intended to be fixed in a hinged arrangement. Similarly, in the context of the present description and the subsequent claims, the contrary term “flexibility” denotes the capacity of the arm or a region thereof to be deformed when subjected to bending of the same type. 
       DESCRIPTION OF THE INVENTION 
       [0018]    The problem underlying the present invention is that of providing a method for producing arms for spectacles from composite material with differentiated rigidity, as well as an arm for spectacles which is structurally and functionally designed to overcome the limitations described above with reference to the cited prior art. 
         [0019]    This problem is resolved and these objects are achieved by the present invention by means of a method of production and an arm for spectacles realised in accordance with the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]    The characteristics and advantages of the invention will be made clearer by the following detailed description of a preferred embodiment thereof, illustrated, for the purpose of guidance and in a non-limiting way, with reference to the attached drawings, in which: 
           [0021]      FIG. 1  is a view in side elevation of an arm for spectacles with differentiated rigidity, obtained by a production method according to the present invention, 
           [0022]      FIG. 2  is a plan view from above of the arm of  FIG. 1 , 
           [0023]      FIG. 3  is a longitudinal sectional view taken along the plane III-III of a portion of the arm of  FIG. 1  shown on an enlarged scale, 
           [0024]      FIG. 4  is a longitudinal sectional view taken along the plane IV-IV of a portion of the arm of  FIG. 2  shown on an enlarged scale. 
       
    
    
     PREFERRED EMBODIMENT OF THE INVENTION 
       [0025]    In the figures, with  1  is indicated, as a whole, an arm for spectacles with differentiated rigidity, obtained by a production method according to the present invention. 
         [0026]    The arm  1  extends in a predominant longitudinal direction X, and respective longitudinally opposed end regions  3   a  and  3   b  are defined on it. 
         [0027]    The end region  3   a  is intended to be connected to a front frame of the spectacles, while the opposed end region  3   b,  forming a terminal region of the arm  1 , is intended to be supported on the user&#39;s head. The end region  3   a  is connected to the front frame by means of a suitable pivoting element, typically a hinge, to allow the arm  1  to swing relative to the front frame about a hinge axis Y, substantially perpendicular to the longitudinal axis X. 
         [0028]    The arm  1  has a thickness, defined as the dimension perpendicular to the longitudinal direction X and to the hinge axis Y, which is variable along the longitudinal extension X. 
         [0029]    In particular, there are defined on the arm  1  a first portion  2   a,  a second portion  2   b  longitudinally adjacent to the first portion  2   a,  and, preferably, a third portion  2   c  which is also adjacent to the first portion  2   a  and is positioned on the longitudinally opposite side from the second portion  2   b.    
         [0030]    The first portion  2   a  has a greater thickness than the second and third portions  2   b  and  2   c,  and consequently the rigidity of the first portion  2   a  is also greater than the rigidity of the second and third portions  2   b  and  2   c.    
         [0031]    In a preferred version, the second and third portions  2   b,    2   c  have substantially the same thickness. 
         [0032]    In the preferred example described and illustrated herein, the first portion  2   a  is formed by a median region  4  of the arm  1  which, when the spectacles are worn, is positioned substantially facing one of the user&#39;s temples, while the second and third portions  2   b  and  2   c  are formed on the longitudinally opposite sides of the first portion. 
         [0033]    The median region  4  preferably has a longitudinal extension in the range from 15 mm to 40 mm, and is positioned at about 40 mm to about 80 mm from the end of the arm included in the end region  3   a.    
         [0034]    In the preferred embodiment illustrated and described herein, the median region  4  has a cross section (along a plane on which the thickness of the arm is measured, and which is substantially horizontal when the spectacles are worn in the normal way) of generally triangular shape (see  FIGS. 2 and 3 ), such that the thickness of the arm increases progressively from the second and third portions  2   b  and  2   c,  adjacent to the median region  4 , towards a peak point  5 . At this point, the thickness is preferably approximately in the range from 2 to 5 mm, while in the second and third portions  2   b  and  2   c,  adjacent to the median region  4 , the thickness of the arm  1  is approximately in the range from 0.5 to 2 mm, and is preferably about 1.2 mm. 
         [0035]    In the preferred example described and illustrated herein, the end region  3   b  forms a first portion  2   a,  whose thickness and rigidity are greater than those of a region immediately adjacent to it forming a second portion  2   b.    
         [0036]    For example, the thickness of the end region  3   b  may be in the range from 1.5 to 4 mm, while the area of the arm  1  immediately adjacent to it may have a thickness in the range from 0.5 to 2 mm. 
         [0037]    Clearly, the arm may have regions of differentiated rigidity that differ in position, number and extension from those described in relation to the arm  1 , according to the functional or aesthetic requirements that may be required. It should therefore be understood that the principles described above in relation to the first, second and third portions  2   a,    2   b  and  2   c  may easily be applied to any other region of the arm. 
         [0038]    The arm  1  is made by superimposing layers of composite material formed by a polymer matrix in which continuous reinforcing fibres are embedded, in a unidirectional or woven form, and in a percentage by weight ranging from about 50% to about 70%. 
         [0039]    Preferably, the reinforcing fibres are woven carbon fibres embedded in a polymer matrix of the epoxide type. 
         [0040]    However, it is also specified that the fibres may be of different types, whether inorganic, such as glass fibre or mineral fibre, or organic. 
         [0041]    In the same way, it is also specified that the polymer matrix may be made from other thermosetting polymers, for example polymers of polyester or polyurethane basis. 
         [0042]    As stated previously, the arm  1  is formed from a plurality of superimposed layers of composite material, and in particular it comprises at least a first layer  11  and at least a second layer  12  which are superimposed on one another so as to be in mutual contact over a large part of the surface extension of the arm  1 . In particular, the first layer  11  and the second layer  12  are in mutual contact in the second portion  2   b,  and in the third portion  2   c  when present, whereas the first layer  11  is separated and spaced apart from the second layer  12  at the first portion  2   a.    
         [0043]    Preferably, the first layer  11  and the second layer  12  are in mutual contact along the entire edges  7   a  and  7   b  of the arm  1 , including the edges corresponding to the first portion  2   a,  so that in this portion the layers  11  and  12  are in contact at the two opposed edges  7   a,    7   b  and are separated in their internal region, as explained more fully below. 
         [0044]    In a first embodiment of the present invention, a separating element formed by an insert  13  is interposed between the first layer  11  and the second layer  12  at the first portion (or first portions)  2   a.    
         [0045]    The insert  13  is preferably a solid body, shaped so as to determine the shape in cross section of the first portion  2   a,  thus defining the thickening of the arm  1  at this first portion. 
         [0046]    The insert  13  may have any suitable shape, and, in the preferred example described herein with reference to the median region  4 , it has a substantially parallelepipedal shape with a triangular cross section, the vertex of which (forming the peak point  5 ) faces towards the outside of the arm  1 , on the opposite side from the user&#39;s head (see  FIG. 3 ). 
         [0047]    The insert  13  has a longitudinal dimension which is smaller than that of the first layer  11  and is approximately in the range from 15 to 40 mm, with a variable thickness which increases between the longitudinal ends and the vertex, this thickness being approximately in the range from 0.2 to 4 mm. 
         [0048]    With reference to  FIG. 4 , the insert may have two points  6   a,    6   b,  extending towards the upper edge  7   a  and the lower edge  7   b  of the arm  1  respectively, at its vertex. In an alternative preferred embodiment, a single point  6   b,  extending towards the lower edge  7   b  of the arm  1 , is provided. 
         [0049]    Advantageously, the dimensions of the insert  13  are also such that the first layer  11  and the second layer  12  are also in mutual contact in the first portion  2   a  at the upper and lower edges  7   a  and  7   b  of the arm  1 . 
         [0050]    The insert  13  can be made of any suitable material, and preferably of a material such that its shape is not substantially modified by the moulding phase which the arm undergoes during processing. For example, the insert  13  may be made of metallic material, wood or MDF, or, more preferably, of a polymer material based on thermoplastic polyurethane (TPU) which provides better attachment to the epoxy resin. 
         [0051]    According to another aspect of the invention, the insert  13  may be made of expanded material of either closed cell or open cell type, so as to preserve the characteristics of great lightness of the arm  1 . Examples of materials of this type may include polyurethane- or polyvinyl-based expanded foams or structural foams based on polymethacrylimide (PMI), available on the market under the trade name of Rohacell®. 
         [0052]    In a second preferred embodiment of the invention, the separating element that keeps the first layer  11  and the second layer  12  apart in the first portion  2   a  is formed during the moulding phase. 
         [0053]    In this case, the separation between the first and the second layer  11 ,  12  results from an expansion action brought about by an expanding agent of the separating element, which pushes these layers against the opposed walls of an recess formed in the mould, which, at the first portion  2   a,  will be shaped according to the desired final shape. 
         [0054]    In a first example of this second embodiment, the insert  13  is formed by a polymer that expands during the moulding phase, forming a polymer foam. 
         [0055]    More particularly, it is possible to use a thermoplastic material, preferably a thermoplastic polyurethane (TPU), in which a suitable amount of expanding agent, such as azodicarbonamide, is dispersed, this agent evolving large amounts of gas such as nitrogen and carbon dioxide at the temperatures reached during the moulding phase, thus expanding the thermoplastic material (and consequently the layers of the composite material) against the walls of the mould. The amount of expanding agent used is suitably adjusted to exert a correct pressure which does not give rise to significant displacements of polymer forming the matrix of the composite material. 
         [0056]    In a second variant of this second embodiment, the insert  13  is formed from an amorphous polymer paste in which are dispersed microspheres (closed cells) containing a gas which, as a result of the temperature reached during the moulding phase, expands and causes the volume of the microspheres to be increased up to 3 or 4 times. The polymer paste therefore expands, compressing the layers of the composite material against the walls of the mould. A material of this type suitable for use according to the procedures described above is known on the market under the trade name of Expancel®. 
         [0057]    In a third variant of this second embodiment, the insert  13  is formed by one or more sealed bag-like envelopes containing a gas (typically air) which expands as a result of the temperature reached in the moulding phase. 
         [0058]    Envelopes of this type are preferably made of thermoplastic polyurethane (TPU) filled with air and having suitable dimensions, according to the size of the first portion  2   a  (for example, they may have a length of several tens of millimetres with a width and thickness of several millimetres). 
         [0059]    The first layer  11  is preferably included in a first plurality of layers, indicated as a whole by  20  in  FIG. 3 , which are superimposed on one another on the same side of the insert  13 . The layers of the first plurality  20 , preferably between 2 and 4 in number, may all be made of the composite material of the first layer  11 , or, in a preferred embodiment, may be made of different composite materials, so as to differentiate the characteristics of elongation and elasticity of the arm  1  in a suitable way. 
         [0060]    For example, the first layer  11  may be formed by using a composite material based on unidirectional carbon fibres, while the outer layer, visible in the finished arm, may advantageously be formed by using a composite material whose reinforcing fibres are interwoven in the form of a textile. 
         [0061]    These reinforcing fibres may be carbon-based, or may be made of glass fibre which is suitably metallized (with aluminium, for example) so as to impart the desired aesthetic effect, known as “carbon look”, to the arm  1 . 
         [0062]    Similarly, the second layer  12  is preferably included in a second plurality of layers, indicated as a whole by  21  in  FIG. 3 , preferably comprising 2 to 4 layers superimposed on one another on the same side of the insert  13 , opposite the first plurality of layers  20 . 
         [0063]    In this case also, the layers of the second plurality  21  may all be made of the composite material of the second layer  12 , or, in a preferred embodiment, may be made of different composite materials. Additionally, the outer layer of the second plurality  21  may be identical to the outer layer of the first plurality  20 , or may be different. 
         [0064]    For example, the outer layer of the second plurality  21  may be made of carbon fibre, while the outer layer of the first plurality  20  may be made of metallized glass fibre, so as to provide an arm having an inner surface (in the sense of the surface facing towards the user&#39;s head) with a more conventional “carbon look” and having an outer surface (in the sense of the surface facing away from the user&#39;s head) with a metallized “carbon look”. 
         [0065]    Because of its shape with variable thickness, the arm  1  has values of rigidity differentiated along its longitudinal extension, being more flexible and elastic in the second and third portions  2   b  and  2   c  and more rigid in the first portion  2   a.    
         [0066]    The arm  1  is produced by the following method. 
         [0067]    A suitable number of layers of composite material, for example 3, in which the polymer material has not yet been cross-linked, are superimposed on one another so as to form the first plurality of layers  20 . The separating element is placed on the final layer of the first plurality  20 , forming the first layer  11 , in the first portion (or first portions)  2   a,  and the second layer  12 , followed by any further layers forming the second plurality of layers  21 , for example another 2 layers, are then placed on top of the separating element. 
         [0068]    The separating element interposed between the first and second layers  11  and  12  may be an insert  13  having a previously defined shape, or may comprise an expanding agent capable of moving the layers  11  and  12  away from one another during the moulding phase which may or may not form the insert  13 , as explained in detail in the preceding paragraphs. 
         [0069]    The separating element is interposed between the first and the second layer  11  and  12  in the first portion  2   a  only, while the second layer  12  is in contact with the first layer  11  in the remaining regions, particularly in the second portion  2   b,  in the third portion  2   c  if present, and along the whole perimetric edge of the arm  1 . 
         [0070]    Preferably, the layers used for the pluralities of layers  20  and  21  have surface dimensions such that many arms can be produced, and therefore many separating elements are provided on the first layer  11 , in predefined positions which are suitably spaced apart, each of these elements being provided in one or more corresponding first portions  2   a  of respective arms  1 . 
         [0071]    The intermediate product formed in this way is then subjected to a process of consolidation and cross-linking of the composite material forming the first and second plurality of layers  20  and  21 , by being placed in a mould which is suitably heated to a predetermined temperature for a predefined time. 
         [0072]    Suitable impressions are formed in the mould, each having the final shape of the arm  1 , so that the intermediate product, when properly centred in the mould, has each separating element in the correct position to produce arms  1  in which the layers  11  and  12  are spaced apart in the respective first portions  2   a.    
         [0073]    The mould is closed and subjected to a predefined pressure and temperature, according to the appropriate instructions for the type of composite material used. 
         [0074]    In this phase, if the separating element comprises an expanding agent, the latter releases the gas which expands the pluralities of layers  20  and  21  against the opposed walls of the mould, with sufficient pressure to consolidate the layers of cross-linked polymer material in the desired shape, imparted by the impression of the mould suitably shaped in the form of the first portion  2   a.    
         [0075]    After a predetermined time, the mould is opened and the intermediate product is extracted. 
         [0076]    In this phase, the intermediate product has a thin sheet-like shape, with the shapes of the arms  1  in relief, these arms then being cut away from the portion of intermediate product linking them to the other arms. 
         [0077]    Advantageously, the edges of the impressions of the mould are made to be slightly rounded, so as to create a link between the edge of the relief defining the arm and the remaining sheet portion of the intermediate product. 
         [0078]    The insert  13 , if any, is also smaller than the impression of the mould, so that the first layer  11  and the second layer  12 , as mentioned above, are directly in contact at the edges  7   a  and  7   b.  Thus the thickness of the edge portion that is to be trimmed is reduced, even in the first portion  2   a.  This enables the appearance of the composite material to be preserved, so that the texture of the weave (the “carbon look”) can be appreciated even at the edges  7   a  and  7   b  of the arm, thus imparting a three-dimensional effect to the texture of the arm and thereby enhancing the overall aesthetic value. 
         [0079]    After being trimmed, the arm  1  is ground and painted by procedures which are conventional in this field. 
         [0080]    Thus the present invention resolves the problem of the prior art identified above, while also offering numerous other benefits, including the possibility of producing arms for spectacles of variable thickness by the superimposition of successive layers in the form of whole sheets of composite material, using established production processes which are relatively simple and inexpensive. 
         [0081]    It also becomes possible to provide an arm of composite material with differentiated rigidity in which the thickness of the edge is kept low, in a way which is substantially independent of the thickness of the arm in its various regions.