Eyewear article with changeable temples

A one-piece, composite eyewear article including a frame having two temples, a top bar and two hinges, the entire frame composed of a single integral piece of solidified thermoplastic consisting of a polymer, a lens situated against, and extending across, the top bar, the lens composed of a single integral piece of optical grade cured liquid silicone rubber consisting of a dimethyl polysiloxane polymer thermoset, and wherein the frame and lens are molded via a two-material molding process, such that the lens auto-adheres to the frame during curing.

Not Applicable.

Not Applicable.

TECHNICAL FIELD

The technical field relates generally to the field of eyewear and, more specifically, relates to eyewear manufactured using novel processes and materials.

BACKGROUND

Eyewear consists of items and accessories worn on or over the eyes, for fashion or adornment, protection against the environment, and to improve or enhance visual acuity. Common forms of eyewear include glasses (also called eyeglasses or spectacles), sunglasses, and the like. Eyewear can also include more utilitarian forms of eye protection, such as goggles. A standard eyewear article comprises a single lens or two lenses, a frame, and two temples. The temples are the arms that are placed over a wearer's ears and the hinges rotationally attach the frame to the temples.

One of the drawbacks associated with the conventional process for manufacturing eyewear is the large amount of manpower, tooling and fabrication involved. The conventional process for manufacturing eyewear typically involves the following. The temples are manufactured, often using an injection molding process or a metal stamping process. The frame is separately manufactured, also using an injection molding process or a metal stamping process. Then, the hinges are attached to the frame and temples, often using manpower, machining or some combination of the two. Lastly, the lens or lenses are attached to the frame, also often using manpower, machining or some combination of the two. Thus, there is a significant number and variation of steps involved in the conventional process for manufacturing eyewear. This can be costly, time consuming and tedious for manufacturers of eyewear.

Furthermore, conventional eyewear suffers certain drawbacks related to its constitution and its usage. Conventional eyewear is often made of standard, smooth plastic which has a tendency of slipping off a user's nose, especially when the user is sweating or has natural oils on his face. Also, conventional eyewear is known to scratch and break easily, as it is typically made of plastic and glass. Further, conventional eyewear is not known to be highly resistant to heat or cold, which limits its usability among individuals who require eyewear in their occupations, such as welders. Lastly, purchasers of conventional eyewear are stuck with the color and design of the purchased eyewear, which limits the versatility of its use for fashion purposes.

Therefore, a need exists to overcome the problems with the prior art as discussed above, and particularly for improved eyewear and a more efficient way of manufacturing said improved eyewear.

SUMMARY

A composite eyewear article is provided. This Summary is provided to introduce a selection of disclosed concepts in a simplified form that are further described below in the Detailed Description including the drawings provided. This Summary is not intended to identify key features or essential features of the claimed subject matter. Nor is this Summary intended to be used to limit the claimed subject matter's scope.

In one embodiment, an article is provided that solves the above-described problems. A one-piece, composite eyewear article includes a frame having two temples, a top bar and two hinges, the entire frame composed of a single integral piece of solidified thermoplastic consisting of a polymer, a lens situated against, and extending across, the top bar, the lens composed of a single integral piece of optical grade cured liquid silicone rubber consisting of a dimethyl polysiloxane polymer thermoset, and wherein the frame and lens are molded via a two-material molding process, such that the lens auto-adheres to the frame during curing.

In another embodiment, a composite eyewear article includes an eyewear frame comprising of two temple stubs, a top bar, a nosepiece and two hinges, the entire frame composed of a single integral piece of solidified thermoplastic consisting of a polymer, a lens situated against, and extending across, the top bar, the lens composed of a single integral piece of optical grade cured liquid silicone rubber consisting of a dimethyl polysiloxane polymer thermoset, wherein the frame and lens are molded via a two-material molding process, such that the lens auto-adheres to the frame during curing, and a pair of separately molded temple arms configured for removable coupling with the two temple stubs.

In another embodiment, a one-piece, composite eyewear article is prepared by a process comprising the steps of: providing a mold having a first void defining an eyewear frame comprising of two temple stubs, a top bar and two hinges, and a second void defining a lens situated against the top bar and extending across the top bar, injecting the first void in the mold with a thermoplastic consisting of a liquid polymer, so as to produce said frame as a single integral piece, injecting the second void in the mold with optical grade silicone rubber consisting of a liquid dimethyl polysiloxane polymer thermoset, so as to produce said lens as a single integral piece, allowing a predefined period of time to pass, wherein during said period of time, the lens auto-adheres to the frame during curing, and removing the one-piece, composite eyewear article from the mold.

In another embodiment, a composite eyewear article includes an eyewear frame comprising of two temple stubs, a top bar, a nosepiece and two hinges, the entire frame composed of a single integral piece of cured liquid silicone rubber consisting of a dimethyl polysiloxane polymer thermoset, a lens situated against, and extending across, the top bar, the lens composed of a single integral piece of optical grade cured liquid silicone rubber consisting of a dimethyl polysiloxane polymer thermoset, wherein the frame and lens are molded via a two-material molding process, such that the lens auto-adheres to the frame during curing, and a pair of temple arms configured for removable coupling with the two temple stubs, each temple arm composed of a single integral piece of solidified thermoplastic consisting of a polymer.

DETAILED DESCRIPTION

The following detailed description refers to the accompanying drawings. While embodiments of the claimed subject matter may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Accordingly, the following detailed description does not limit the claimed subject matter. Instead, the proper scope of the claimed subject matter is defined by the appended claims.

The claimed subject matter improves over the prior art by providing a one-piece, composite eyewear article that is manufactured using a reduced number of passes in the manufacturing process. The claimed subject matter presents an inexpensively manufactured article that provide high quality eye protection, resists impact and can be immersed in water. The claimed subject matter accomplishes the objectives of conventional eyewear while also reducing manufacturing costs and providing utility to the consumer. Additionally, the material of the claimed subject matter reduces slipping of the eyewear off a user's nose, especially when the user is sweating or has natural oils on his face and reduces or eliminates scratching and breaking of the frame and lens(es). Further, the material of the claimed subject matter is highly resistant to heat and cold, which increases usability among individuals who require eyewear in their occupations, such as welders and athletes. Lastly, purchasers of the claimed subject matter are not stuck with the color and design of the purchased eyewear, since interchangeable temples allow the user to change the color and design of the eyewear for fashion purposes, which increases the versatility of the claimed subject matter's use for fashion purposes.

Eyewear or eyeglasses are worn on or over the eyes, for fashion or adornment, protection against the environment, and to improve or enhance visual acuity. Eyewear consists of a lens or lenses mounted in a frame that holds them in front of a person's eyes, using a bridge over the nose and temples or arms which rest over the ears. Eyewear is typically used for vision correction, such as with reading glasses and glasses used for nearsightedness, for safety in providing eye protection against flying debris or radiation, for glare or bright daylight, for high levels of ultraviolet light, for viewing specific visual information (such as stereoscopy) or three-dimensional movies, or simply for aesthetic or fashion purposes.

Many eyewear articles include one or more of the following known elements: a top bar or brow bar (a bar just above the lens providing structural support and/or style enhancement), two nose pads that allow a comfortable resting of the frame on the nose, two hinges connecting the top bar to the temples and allowing a swivel movement, two temples (or earpieces) on either side of the skull, and two temple tips at the end of each temple.

FIG. 1depicts a front perspective view of a one-piece, composite eyewear article100, according to an example embodiment.FIG. 1shows that the one-piece, composite eyewear article100includes a frame101comprising of temples120,122, top bar110, nose piece150and hinges130,132, the frame101composed of a single integral piece of solidified thermoplastic consisting of a polymer. A thermoplastic, or thermosoftening plastic, is a plastic polymer material that becomes pliable or moldable at a certain elevated temperature and solidifies upon cooling. Thermoplastic has high stability and ability to resist extreme temperatures of heat and cold, ideally suitable for production of parts, where high quality is desired. Thermoplastic is also resistant to breaking, cracking and scratching. Thermoplastic also reduces slippage when placed against human skin, even when the skin is wet or oily.

The top bar110is an elongated piece that extends horizontally a long a top of the article100. The top bar110is curved to match the curve of the wearer's forehead. A nosepiece150is coupled to a midpoint of the top bar, wherein the nosepiece comprises a planar piece302extending downwards from the top bar, and a pair of nose-pads304coupled to the planar piece.

FIG. 1shows that the one-piece, composite eyewear article100includes a lens102located below the top bar110, the lens composed of optical grade cured liquid silicone rubber consisting of a dimethyl polysiloxane polymer thermoset. Optical-grade silicones offer high temperature resistance along with optical clarity. Optical liquid silicone rubber does not discolor or lose transparency with age or with exposure to heat or UV light; it is significantly lighter than glass and most other plastics; and it is scratch and crack resistant, among many other advantages. The lens102(or a top portion thereof) contacts, and is coupled with, the forward-facing surface of the top bar110. The lens102(or a top portion thereof) auto-adheres to the forward-facing surface of the top bar110during curing. The lens102(or a top portion thereof) also contacts, and is coupled with, the forward-facing surfaces of the planar piece302and pair of nose-pads304of the nosepiece150. The lens102(or a top portion thereof) auto-adheres to the forward-facing surfaces of the planar piece302and pair of nose-pads304of the nosepiece150during curing.

FIG. 1shows that the right temple120is attached via right hinge130to the top bar110, and the top bar110is connected to the nosepiece150. The left hinge132is connected to the left temple122. Each temple may bend down behind the ears, follow the contour of the skull and rest evenly against the skull.

In an alternative embodiment, the frame101comprising of temples120,122, top bar110, nose piece150and hinges130,132, is also composed of cured liquid silicone rubber consisting of a dimethyl polysiloxane polymer thermoset.

FIG. 2depicts a top perspective view of the one-piece, composite eyewear article100, according to an example embodiment.FIG. 2shows a better view of the contours of the left temple122and the lens102.

FIG. 3depicts a front view of the one-piece, composite eyewear article100, according to an example embodiment.FIG. 3shows the location of the vertical cross section802taken on a plane perpendicular to the view ofFIG. 3and through the nosepiece150.FIG. 3also shows the location of the horizontal cross section1002taken on a plane perpendicular to the view ofFIG. 3and through the lens102, wherein said plane is also perpendicular to the plan of the cross section802.

FIG. 4depicts a left side view of the one-piece, composite eyewear article100, according to an example embodiment.FIG. 4shows a better view of the contours of the left temple122and the curved nature of the lens102.FIG. 3also shows the location of the horizontal cross section1002taken on a plane perpendicular to the view ofFIG. 3and through the lens102, wherein said plane is also perpendicular to the plan of the cross section802.

FIG. 4also shows the location of a possible vertical separation point450through the temple122, which is described in greater detail below. In an alternative embodiment, the frame101is manufactured so as to include the top bar110, hinges130,132and temple stubs402(in lieu of entire temples120,122). In said alternative embodiment, temple arms404are manufactured or molded separately from the lens102and frame101and attached to the temple stubs402at a later time. When a temple arm404is removably coupled to a temple stub402, at the separation point450,FIG. 4shows the temple arm404extending from the temple stub402, as described more fully below. This feature allows purchasers of the article100to obtain interchangeable temple arms to change the color and design of the article100for fashion purposes, which increases the versatility of the article100for fashion purposes.

FIG. 5depicts a rear view of the one-piece, composite eyewear article100, according to an example embodiment.FIG. 5shows a better view of the contours of the top bar110and the nosepiece150.

FIG. 6depicts a top view of the one-piece, composite eyewear article100, according to an example embodiment.FIG. 6shows the location of the vertical cross section802taken on a plane perpendicular to the view ofFIG. 6and through the nosepiece150.FIG. 6further shows the close-up1102taken of the left hinge130.FIG. 7depicts a bottom view of the one-piece, composite eyewear article, according to an example embodiment.

FIG. 8depicts a cross sectional view802of the top bar110and lens102of the one-piece, composite eyewear article100, according to an example embodiment.FIG. 8shows that the cross section802depicts an approximate L-shaped element810, wherein810is the top of the lens102. Cross section802also depicts an approximate step shaped element representing the interior surface of the top bar110at the top end812, into which the lens102is located. The step shape is depicted in shape820, and comprises a vertical line connected at a top end to a first horizontal line that extends to the right, and the vertical line connected at a bottom end to a second horizontal line that extends to the left. The cross section802of the lens102is shown as having a step shape at the top end810(which matches the step shape of the top part810of the top bar110).

FIG. 10depicts a cross sectional view1002of the top bar110and lens102of the one-piece, composite eyewear article100, according to an example embodiment.FIG. 10shows that the cross section1002top bar110and lens102is shown as two approximate L-shaped elements1010and1012, wherein1010is the interior or proximal part of top bar110and1012is the exterior or distal part of top bar110. Cross section1002depicts an approximate step shaped element representing the interior surface of the top bar110at the proximal and distal elements1010and1012, against which the lens102(or a portion thereof) is situated. During the manufacturing process, the lens102(or a portion thereof) auto-adheres to the step shaped elements of the interior surface of the top bar110. A cross section of the lens102is shown as having a step shape at the proximal end1050(which matches the step shape of the proximal part1010of the top bar110) and having a step shape at the distal end1052(which matches the step shape of the distal part1012of the top bar110).

Note also that the lens102(or a portion thereof) contacts a forward-facing side of the planar piece302and pair of nose-pads304of the nosepiece150. During the manufacturing process, the lens102(or a portion thereof) auto-adheres to the forward-facing side of the planar piece302and pair of nose-pads304of the nosepiece150.

FIG. 11depicts a close-up1102of a top view taken of the right hinge130of the one-piece, composite eyewear article100, according to an example embodiment.FIG. 11shows that the right temple120has a uniform thickness that, as it approaches hinge130, includes a détente or depression114, which acts as a pivot point about which the temple120rotates.

FIG. 9Adepicts a temple stub402and temple arm404including a protruding insert906that is configured for removable insertion into a complementing cavity (not shown) in the temple stub402(using a friction fit), so as to removably couple the temple arm with the temple stub. The complementing cavity in the temple stub402is a negative void that matches the shape and size of the protruding insert906, such that the protruding insert fits securely within the complementing cavity, thereby removably coupling the temple stub402to the temple arm404. The protruding insert906may be inserted into the complementing cavity in stub402using finger strength.FIG. 9Bis a cross section of another connection point between a temple stub402and temple arm404including a protruding insert913that is configured for removable insertion into a complementing cavity910in the temple stub402(using a friction fit), so as to removably couple the temple arm with the temple stub.

FIG. 9Cdepicts another temple stub402and temple arm404including a protruding insert922that is configured for removable insertion into a complementing cavity (not shown) in the temple stub402(using a friction fit), so as to removably couple the temple arm with the temple stub.FIG. 9Dis a cross section of another connection point between a temple stub402and temple arm404including a protruding insert930that is configured for removable insertion into a complementing cavity933in the temple stub402(using a friction fit), so as to removably couple the temple arm with the temple stub.

In one embodiment, each temple arm404is composed of a single integral piece of solidified thermoplastic consisting of a polymer, as described herein. Each temple arm may be manufactured or molded separately from the frame101and/or the lens102. In another embodiment, the frame101and/or the lens102are composed of cured liquid silicone rubber consisting of a dimethyl polysiloxane polymer thermoset, while each temple arm404is composed of a single integral piece of solidified thermoplastic consisting of a polymer.

Returning to manufacturing, the frame101and the lens102may be molded via a two-material molding process, such that the frame and the lens auto-adhere to each other during curing. Two material or multi-material injection molding is the process of molding two or more different materials into one part (or in one injection mold) at one time. As is the case in traditional injection molding, multi material injection molding uses materials that are at or near their melting point so that the semi-liquidous (viscous) material can fill voids and cavities within a pre-machined mold, thus taking on the desired shape of designed tooling. In general, advantages of multi-material injection molding over other production techniques include, but are not limited to, creating parts that have an elastic modulus that varies with location on the part (different regional polymer hardness), creating a single-structure part with different regional materials (similar to the previous advantage, but more focused on joining different types of polymers like rubber and plastic), and also creating a single part with multiple independent polymer colors. Injection molding of liquid silicone rubber is a process to produce pliable, durable parts.

An insert over molding process, which is a form of two-material molding processes, may be used. Insert molding involves molding material around a core or “insert”. The insert in this case may be the frame, around which the lens is molded. Insert molding is often used to join the insert and secondary material together more securely than assembly allows. Moreover, it often eliminates post-molding assembly and saves the additional cost incurred in a secondary operation.

Injection molding consists of high-pressure injection of raw material into a mold which shapes the polymer into the desired shape. Molds can be of a single cavity or multiple cavities. In multiple cavity molds, each cavity can be identical and form the same parts or can be unique and form multiple different geometries during a single cycle. For thermosets, two different chemical components may be injected into the mold. These components immediately begin irreversible chemical reactions which eventually crosslinks the material into a single connected network of molecules. After the part has solidified, valves close to isolate the injection system and chemical precursors, and the mold opens to eject the molded part(s). Then, the mold closes and the process repeats.

In one embodiment, any of the components of the composite eyewear article described above may comprise other materials, such as any thermoset elastomer, any plastic, polyethylene, PVC, or the like. In another embodiment, the frame101and/or lens102is tinted with any one of: carbon nano tint, soluble organic dye, metallic oxide pigments or any dye known in the art for use with thermoset elastomers. A thermoset is a material that is irreversibly cured from a soft solid or viscous liquid prepolymer or resin. The process of curing changes the resin into an infusible, insoluble polymer network, and is induced by the action of heat or suitable radiation often under high pressure, or by mixing with a catalyst. Thermoset resins are usually malleable or liquid prior to curing and are often designed to be molded into their final shape.

In one embodiment, the entire frame101is composed of a single integral piece of cured thermoplastic consisting of a liquid polymer. A thermoplastic, or thermosoftening plastic, is a plastic polymer material that becomes pliable or moldable at a certain elevated temperature and solidifies upon cooling. Examples of a thermoplastic include acrylic, acrylonitrile butadiene styrene, nylon, PLA, polybenzimidazole, polycarbonate, polyether sulfone, polyoxymethylene, polyetherether ketone, polyetherimide, polyethylene, polyphenylene oxide, polyphenylene sulfide, polypropylene, polystyrene, polyvinyl chloride, polyvinylidene fluoride, and Teflon. In another embodiment, the entire frame101is composed of a single integral piece of cured liquid silicone rubber consisting of a liquid dimethyl polysiloxane polymer thermoset.

Similarly, in one embodiment, the entire lens102is composed of a single integral piece of optical grade cured liquid silicone rubber consisting of a liquid dimethyl polysiloxane polymer thermoset. The term “single, integral piece” refers to one piece or part that is formed of a continuous volume of a polymer material that is injected all at once, and that cures all at once. For example, the lens102may be a single, integral piece of optical grade cured liquid silicone rubber that is injected into a mold all at once, and that cures all at once. In yet another embodiment, in lieu of a single lens102, the article100may comprise two separate lenses.

The one-piece, composite eyewear article100may be prepared by a two-material molding process comprising the steps of providing a mold having: 1) a first void defining an eyewear frame101comprising of two temples120,122(or two temple stubs), a top bar110, a nosepiece150and two hinges130,132, and 2) a second void defining a lens102situated against the top bar and extending across the top bar. The process continues by injecting the first void in the mold with a thermoplastic consisting of a liquid polymer, so as to produce said frame as a single integral piece and injecting the second void in the mold with optical grade liquid silicone rubber consisting of a dimethyl polysiloxane polymer thermoset, so as to produce said lens as a single integral piece. The process continues by allowing a predefined period of time to pass, wherein during said period of time, the lens auto-adheres to the frame during curing. Thereafter, the one-piece, composite eyewear article is removed from the mold. In parallel to the manufacturing of the frame and lens above, in one embodiment, temple arms404are manufactured or molded separately from the lens102and frame101and removably attached to the temple stubs402at a later time. The temple arms may be composed of a solidified thermoplastic consisting of a polymer, wherein said temple arms may be injection molded similarly to the frame101above. In one alternative to the process described above, the first void in the mold is injected with a liquid silicone rubber consisting of a dimethyl polysiloxane polymer thermoset (instead of a thermoplastic consisting of a liquid polymer), so as to produce said frame as a single integral piece.

The term “auto-adhere” refers to the process by which a first material in a liquid or semi-liquid state cures or cools down into a solid or near solid state while contacting a second material, wherein the first material adheres to, or forms a bond with, the second material. The second material may also be in a liquid or semi-liquid state, and the second material may cure or cool down into a solid or near solid state while contacting the first material.

Liquid dimethyl polysiloxane polymer thermoset belongs to a group of polymeric organosilicon compounds that are commonly referred to as silicones. It is the most widely used silicon-based organic polymer and is particularly known for its unusual rheological (or flow) properties. It is optically clear, and, in general, inert, non-toxic, and non-flammable.

Embodiments may be described above with reference to functions or acts, which comprise methods. The functions/acts noted above may occur out of the order as shown or described. For example, two functions/acts shown or described in succession may in fact be executed substantially concurrently or the functions/acts may sometimes be executed in the reverse order, depending upon the functionality/acts involved. While certain embodiments have been described, other embodiments may exist. Further, the disclosed methods' functions/acts may be modified in any manner, including by reordering functions/acts and/or inserting or deleting functions/acts, without departing from the spirit of the claimed subject matter.