METHOD OF MANUFACTURING EYEWEAR FRAMES

Abstract: A method of manufacturing an eye (12, 14) having an integral side shield for use in a front eyewear frame (10) employing a pair of such eyes comprises the steps of providing a sheet of frame material (e.g., metal, plastic or composite) and cutting a stamping with a die having an outline which replicates the outline in the stamping. The outline has opposite side edges which extend in a non-parallel, curved manner to form a maximum width near the center portion of the stamping. In a preferred embodiment, a coining operation is performed on the stamping to create the groove for receiving the lens edge. The stamping is bent into a looped configuration with the lens edge in the groove, with the opposite end portions of the stamping secured together.

Description: Title: Method of Manufacturing Eyewear Frames Background of the Invention The present invention generally relates to eyewear manufacturing. More particularly, the present invention relates to a novel method of manufacturing eyewear frames. Eyewear frames (including, e.g., spectacle frames, sunglass frames, and goggle frames) are made in many different styles using many different materials and manufacturing techniques. For example, metal frames are typically made by bending profiled wire into a pair of looped eyewires which extend around a respective lens and are secured at opposite ends of the eyewire with a screw. A bridge element interconnects the pair of eyewires and lenses to form the front frame. While this method is very common in the industry, there are limits as to the frame styles which may be achieved with this method. Another approach disclosed in U.S. Pat. No. 3,758,203 is stamping of a unitary- front frame out of aluminum. In this method, the entire front frame is stamped in the configuration shown in Fig. 1 thereof, with a series of cuts being made at the bridge portion to facilitate insertion and removal of the lenses. A first horizontal cut divides the bridge into upper and lower halves 27,28 to form a horizontal gap 29 which allows the bridge to be expanded to insert the lenses into lens rim portions 12,13. (See Col. 3, Lns. 26-36 thereof). A vertical cut is made in the lower segment 28 of the bridge to facilitate independent insertion and removal of each lens. (See Col. 3, Lns 37-45 thereof). This method of manufacture is specifically directed toward an aluminum front frame which, although lightweight and aesthetically pleasing, presents difficulties in soldering and brazing. Furthermore, the configuration of the stamped front frame requires a very specific bridge configuration and is therefore not amenable to a wide variety of frame styles. Plastic eyewear frames are typically molded as a unitary piece, although some are cut and formed from a slab of thermoplastic material (see, e.g., U.S. Patent No. 3,868,438). In unitary plastic frames, lenses are inserted into respective eye openings of the frame by stretching the eye openings to the point where the lenses can be "popped" into place. Stretching the frame is assisted with the application of heat which temporarily expands the plastic to allow insertion of the lenses. After the lenses are in place in the eye openings of the frame, the frame is allowed to cool whereupon the frame shrinks back to its pre-stretched shape, securing the frame around the lenses. Other eyewear frame styles include "frameless" designs, where the temples attach directly to the lateral side edges of one (unitary) lens, or to a pair of lenses, respectively. Still other eyewear frame styles include a combination of materials, including both plastic and metal in a single frame (see, e.g., U.S. Patent No. 4,707,089). One presently popular eyewear frame style includes the provision of "side shields" located at the opposite lateral sides of the front frame. Side shields may be used to prevent or reduce light from entering at the lateral areas of the wearer's field of view, or to provide an aesthetic component to the eyewear frame, or both. Side shields may be made as a separate attachment for an eyewear frame (see, e.g., WIPO DM/039,455 Figs. 2.1-3.7, Bulletin Des Designs Et Modeles Internationaux, 3/97), or may be integrally formed with the eyewear frame (see, e.g., U.S. Patent No. 4,877,320). Side shields which are separately attached to an eyewear frame are necessarily of complex construction in that a side shield manufacturing operation, distinct from the frame manufacturing operation, must take place, and cooperative attachment means must be included on the side shields and frame. In styles where the side shield is an integral part of the frame, the sole manufacture method practiced to date is to mold the frame with the mold cavity being configured to form the side shields during the molding operation. This method is not satisfactory, however, in that the mold configuration is necessarily complex to form the side shields which, in turn, increases costs. Additionally, further post-molding finishing operations must typically occur, e.g., cutting away of excess material, which further add to the cost of the product. There therefore remains a need for a simple and inexpensive method for manufacturing eyewear frames which allows for a wide variety of frame styles and materials, including particularly side shields. Summary of the Invention The present invention successfully fills the above need by providing a novel method for manufacturing eyewear frames with integral side shields. More particularly, the inventive method basically comprises the steps of: a) providing a sheet of frame material; b) providing a die having an elongated outline for forming a stamping, said outline having a pair of opposite, non-parallel side edges, and a pair of opposite end portions; c) cutting said frame material with said die; and d) bending said cut frame material into a looped configuration with said opposite end portions positioned adjacent one another. The basic method outlined above forms a single "eye" in which a lens is secured. Two such eyes would be joined with a bridge element therebetween to form a basic frame front. The provision of non-parallel opposite side edges in the stamping provides the ability to define a "side-shield" portion to the eye once the stamping is bent into the intended, looped configuration for holding a lens. Additional features may also be easily incorporated into the stamping which will form the eye, e.g., a nose rest or other features allowing for attachment of other frame elements, etc. An additional coining operation may be implemented to form the groove in the stamping wherein the edge of the lens would reside. This coining operation may be performed concurrently with or following the stamping operation. Additionally, multiple grooves may be formed to accommodate more than one lens in a single eye, if desired. It will be appreciated that the inventive method may be carried out on a variety of materials, including plastics, metals, and composites, and that the drawbacks associated with prior methods of manufacture discussed above are overcome by the present method of manufacture. Furthermore, the inventive method is very accommodating to other frame treatments. For example, aesthetic surface treatments may be easily formed in the sheet of frame material prior to stamping and forming. Also, apertures may be easily stamped within the boundary of the stamped outline to receive a variety of frame attachments such as temples, decorative roping, detachable visor and brow bars, for example. Brief Description of the Drawings Figure 1 is a front, elevational view of an eyewear front employing the present method of manufacture; Figure 2 is a side, elevational view thereof; Figure 3 is a bottom, plan view thereof; Figure 4 is a top, plan view of a stamping according to the present method of manufacture; Figure 5 is a cross-sectional view taken along the line 5-5 in Fig. 4; Figure 6 is a cross-sectional view taken along the line 6-6 in Fig. 4; Figure 7 is a cross-sectional view taken along the line 7-7 in Fig. 4; Figure 8 is a cross-sectional view taken along the line 8-8 in Fig. 4; Figure 9 is a perspective view of an eyewear incorporating a pair of eyes manufactured according to the inventive method; Figure 10a is a perspective view of a second embodiment of an eyewear which utilizes a removable, auxiliary side shield; Figure 10b is a plan view of the stamping used to form the eyes of the frame of Fig. 10a; Figure 11a is a perspective view of a front frame of a third embodiment of an eyewear which incorporates decorative roping about the frame; Figure 1 lb is a plan view of the stamping used to form the eyes of the frame of Fig. 1 la; Figure 12a is a perspective view of a front frame and temple of a fourth embodiment of an eyewear which incorporates a decorative surface treatment about the frame eyes; Figure 12 b is a plan view of the stamping used to form the eyes of the frame of Fig. 12a; Figure 13a is a perspective view of an eyewear front frame of a fifth embodiment of an eyewear which incorporates a removable visor; Figure 13b is a plan view of the stamping used to form the eyes of the frame of Fig. 13a; Figure 14a is a perspective view of an eyewear front frame of a sixth embodiment of an eyewear which incorporates a pair of lenses in each eye of the frame; Figure 14b is a plan view of the stamping used to form the eyes of the frame of Fig. 14a; Figure 15a is a perspective view of an eyewear front frame of a seventh embodiment of an eyewear which incorporates a pair of brow bars in each eye of the frame; Figure 15b is a plan view of the stamping used to form the eyes of the frame of Fig. 15a; Figure 16a is a perspective view of an eyewear of an eighth embodiment of an eyewear which incorporates a temple hinge mechanism; Figure 16b is a plan view of the stamping used to form the eyes of Fig. 16a; and Figures 17a-17d are plan views of four different embodiments of a stamping. Detailed Description Referring to the drawing, there is seen in Figs. 1-3 an eyewear front frame 10 having a pair of looped eyes 12,14 with a pair of lenses 16,18 secured therein, respectively. Eyes 12,14 have opposite inner and outer portions 12a, 12b and 14a, 14b, respectively, with a bridge element 16 interconnecting eyes 12,14 at the inner portions 12a, 14a thereof. Bridge element 16 may be secured to eyes 12,14 using any known means (e.g., brazing). As seen best in Figs. 2-8, the outer portions 12b, 14b of eyes 12,14 are of a width Wi (as measured from front eye edges 12c, 14c to rear eye edges 12d,14d) which is larger than the corresponding width W 2 at the inner portions 12a, 14a, thereby forming what is known in the art as a "side shield". Side shields are useful to reduce light entering from the lateral side edges of the wearer's head, and is also considered a decorative detail of the eyewear itself. The present invention provides a method of manufacturing eyes 12,14 with integral side shields in a simple and cost-effective manner as discussed more fully below. Turning discussion now to the method of manufacturing eyes 12,14, reference is made to Figs. 4-8 which show a planar stamping 20, a pair of which are used to form eyes 12,14, respectively. More particularly, eyewear frame material (e.g., metal, plastic or a composite) is provided in sheet form which is cut with a die (not shown) to form a stamping 20. The outline of the die replicates the outline of the stamping 20 as seen in the plan view of Fig. 4. Stamping 20 thus includes opposite side edges which ultimately form the front and rear eye edges 12c, 14c and 12d,14d of eyes 12,14, respectively. Stamping 20 further includes opposite end portions 20', 20" which are brought together when forming eyes 12,14 from a pair of stampings 20. As seen in Fig. 1, opposite end portions 20', 20" are secured together using a barrel and screw 22, although other attachment means may be used as desired. Prior to bending stamping 20 into an eye 12,14, a groove 24 is formed in what will ultimately become the inside surface 12e,14e of the eye 12,14 (Fig. 1). Groove 24 completely traverses stamping 20 in substantially parallel relationship to front edge 12c, 14c thereof. Groove 24 is provided to receive the outer edge of lenses 16,18 immediately prior to securing end portions 20'20" together which thus secures the lenses 16,18 in eyes 12,14, respectively. It is noted that lens-securing means other than a groove may be provided. For example, the front edge 12c, 14c of stamping 20 may be crimped to form a surface extending radially inwardly toward the center of the formed eye 12,14. The lens would then be inserted into the eye from the back, and an adhesive and/or other securing elements (e.g., tabs) would be used to secure the lens edge to this surface. Referring still to Figs. 4-8, it is seen the opposite side edges 12c, 14c and 12d,14d of the stamping are non-linear and non-parallel. The exact configuration chosen for the outline may vary from that seen in Fig. 4, although the width Wi at about the center of the stamping (which ultimately form the outer portions 12b, 14b of eyes 12,14), is preferably larger than the width Wi at the end portions 20',20" (which ultimately form the inner portions 12a, 14a of eyes 12,14), which creates the side shields at the outer portions 12b, 14b upon bending a pair of stampings 20 into eyes 12, 14, respectively. The variation in width along the length of stamping 20 is seen clearly in the cross-sectional views of Figs. 5-8. It will also be noticed that the front edge 12c, 14 of stamping 20 curves in the same direction as the outer edge 12d,14d thereof, most notably at approximately the center of the stamping. This curving of the opposite side edges dictates the degree of "wrapping" the eye 12,14 will have when formed. The more extreme the bend, the more extreme the wrap of the ultimate eyewear frame 10. Having thus discussed the basic method of manufacture of eyes 12,14, discussion is now turned to Figs. 9-16 which illustrate several variations in eyewear styles which may be achieved with the inventive method of manufacture. Fig. 9 illustrates eyewear having the front frame 10 of Figs. 1-3 (lenses not shown in Figs. 9-16) with a pair of temples 26,28 pivotally connected to the outer portions 12b,14b of eyes 12,14, respectively. Bridge element 16 interconnects eyes 12,14 at the inner portions 12a, 14a thereof, and a pair of nose rests 30a,30b are attached (e.g., by brazing) at the rear edges 12d,14d of eyes 12,14 adjacent bridge element 16, respectively. As seen in Fig. 10a, a generally U-shaped, auxiliary side shield 32 may be provided for removable attachment to the outer portions 12b, 14b of eyes 12,14. Attachment means may easily provided in the form of one or more apertures 36 cut in stamping 20 (Fig. 10b). This cutting operation may take place at any time during the manufacture of stamping 20, i.e., before, during or after either one or both of the stamping and coining operations. Cooperative attachment means are provided on auxiliary side shield 32 in the form of flanged bosses 38 which are aligned with the locations of the apertures 36 in eyes 12,14. Auxiliary side shield 32 has a forward portion 32', on which bosses 38 are formed, and a rear portion 32" which preferably flares outwardly with respect to forward portion 32'. To attach auxiliary side shield 32 to eyes 12,14, the opposite end portions 32a,32b of shield 32 are urged toward one another in accordance with the directional arrows, and forward surface 32' is inserted into the eye 12,14 from the rear until bosses 38 on shield 32 pop into apertures 36 in eye 12,14. Once attached to eye 12,14, auxiliary side shield 32 provides an added degree of protection from light entering from the sides of the eyewear, in addition to providing another decorative detail to the overall appearance of the eyewear. Should it be desired to remove the auxiliary side shield 32, the end portions 32a,32b thereof are simply pressed toward one another until the bosses 38 disengage from apertures 36, at which time the side shield 32 may be simply withdrawn from the rear of the eyes 12,14. As seen in Fig. 1 la, a decorative roping may be applied to eyes 12, 14 by cutting a plurality of apertures 42 in spaced relation along the length of stamping 20, again at any desired step in the manufacturing process. The roping 40 is threaded back and forth through successive apertures 42 in each eye 12,14 to achieve the desired appearance. As seen in Fig. 12a and 12b, stamping 20 may be provided with a decorative surface treatment 44. This may be easily done either prior to or after cutting of stamping 20. As seen in Fig. 13a, 13b, a detachable visor 46 may be provided for removable attachment to eyes 12,14. Attachment means may be provided, for example, by an elongated aperture 48 cut in stamping 20 into which a flange 50 formed on the bottom surface of visor 46 may be inserted. As seen in Fig. 14a, 14b, more than one groove 24a,24b may be provided in stamping 20 to accommodate more than one lens 16a, 16b (e.g., lenses having different coatings, different prescriptions, different materials, etc.). As seen in Fig. 15a, 15b, a pair of removable brow bars 52a, 15b may be provided which are flanged on opposite surfaces of each to fit within an elongated notch 54 formed in each eye 12,14. As seen in Figs. 16a, 16b, pivotal attachment means may be provided in the form of a pair of apertures 56a,56b formed in each stamping 20. A pair of temples 58 are provided with a pair of bosses 60 located at the front end 58' of each temple 58, which front end 58' is preferably somewhat flexible and curved outwardly as shown such that bosses 60a,60b may be squeezed toward one another in the direction of the arrows, at which time the temple end 58' may be inserted into the eye 12,14 form the rear until bosses 60a,60b pop into apertures 56a,56b. Figures 17a-d illustrate four additional embodiments of stampings 200-204, respectively, each of which are of substantially the same outline as stamping 20, but each also including a different element 201 '-204' integrally stamped along the inside edges 201'-204' thereof adjacent the end portions 201"-204" thereof, respectively. Elements 201 ' and 202' are configured to provide attachment points for separate nose pads. Since elements 201'-202' are formed integrally in the stamping, no separate brazing operation is required. Elements 203 ',204' are configured to provide integral nose rests once the stamping is bent into the finished eye. Since these elements are formed integrally with the stamping operation, it will be appreciated that the present method of manufacture allows for variations in frame design/features without the additional and expensive processing steps previously required.

Claims: What Is Claimed Is: 1. A method for manufacturing an eye for use in an eyewear frame front having a pair of said eyes, said method comprising the steps of: a) providing a substantially planar sheet of frame material; b) providing a die having an outline; c) cutting a stamping from said frame material with said die, said stamping having said outline, said outline having opposite, non-parallel side edges and opposite end portions; and d) bending said stamping into a looped configuration with said end portions lying adjacent one another, thereby forming said eye. 2. The method of claim 1, and further comprising the step of forming a first groove in said stamping, said first groove completely traversing said stamping between said end portions. 3. The method of claim 2 wherein said first groove is formed after said cutting operation, and before said bending operation. 4. The method of claim 3 wherein said first groove is formed with a coining operation. 5. The method of claim 2, and further comprising the steps of: a) positioning the edge of a lens in said first groove; and b) attaching said opposite ends of said stamping together, thereby securing said lens in said eye. 6. The method of claim 2, and further comprising the step of forming a second groove in said stamping, substantially parallel to said first groove, and further comprising the steps of: a) positioning the edges of a pair of lenses into said first and second grooves, respectively; and b) attaching said opposite ends of said stamping together, thereby securing said pair of lenses in said eye. 7. The method of claim 6 wherein said pair of lenses have different optical properties. 8. The method of claim 1, wherein said stamping has a center portion located approximately mid-way between said opposite end portions, said center portion having a first width Wi, and said end portions having a second width W 2 , and wherein Wi is greater than W 2 . 9. The method of claim 8, wherein said opposite side edges curve in the same direction along at least said center portion. 10. The method of claim 8, wherein Wi and W 2 are the maximum and minimum widths of said stamping, respectively. 11. The method of claim 10, wherein said opposite side edges smoothly taper from W ! to W 2 . 12. The method of claim 1, wherein said frame material is plastic. 13. The method of claim 1, wherein said frame material is metal. 14. The method of claim 1, and further comprising the step of applying a surface finish to said frame material prior to said cutting operation. 15. The method of claim 1, and further comprising the step of applying a surface finish to said stamping following said cutting operation. 16. The method of claim 1, and further comprising the step of cutting one or more apertures in said frame material within the boundary of said outline. 17. The method of claim 16, wherein said apertures are cut prior to said cutting of said stamping. 18. The method of claim 16, wherein said apertures are cut during said cutting of said stamping. 19. The method of claim 16, wherein said apertures are cut after said cutting of said stamping. 20. The method of claim 16, and further comprising the step of threading a length of decorative material through said apertures. 21. The method of claim 16, wherein said apertures are located adjacent a center portion of said stamping located approximately mid-way between said opposite end portions thereof, and further comprising an auxiliary side shield for attaching to said eye, said auxiliary side shield including one or more attachment means for cooperatively engaging said apertures in said stamping. 22. The method of claim 21, wherein said auxiliary side shield is removably attachable to said eye. 23. The method of claim 1, and further comprising a visor for attaching to said eyes, and further comprising the step of forming cooperative engagement means on said eyes and said visor. 24. The method of claim 23, wherein said cooperative engagement means comprises an aperture formed in said eye, and a flange formed on said visor. 25. The method of claim 1, and further comprising a pair of brow bars for attaching to said eyes, and further comprising the step of forming cooperative engagement means on said brow bars and said eyes. 26. The method of claim 25 wherein said cooperative engagement means comprises a notch formed in each said eye, and a flange formed on each said brow bar. 27. The method of claim 1, and further comprising a pair of temples each having a front end portion for attaching to said pair of eyes, respectively, and further comprising the step of forming cooperative, pivotal engagement means on said temples and said eyes. 28. The method according to claim 27, wherein said cooperative engagement means comprises a pair of apertures formed in each said eye, and a pair of bosses formed on the front end portion of each of said temples, said pair of bosses alignable with said pair of apertures. 29. The method of claim 28 wherein said front end portion of each of said temples is flexible and curves outwardly. 30. The method of claim 1, and further comprising the step of interconnecting said pair of eyes with a bridge element. 31. The method of claim 1, wherein said stamping includes an element providing an attachment point. 32. The method of claim 1, wherein said stamping includes an element providing an integral nose rest.

Inventors: DAMIN MARCO, SIMIONI LUCIANO, DAMIN, MARCO, SIMIONI, LUCIANO
Applicants: BAUSCH & LOMB, DAMIN MARCO, SIMIONI LUCIANO, BAUSCH & LOMB INCORPORATED, DAMIN, MARCO, SIMIONI, LUCIANO
Application year: 1998
Main classification: B29D12
IPC codes: B29D12, G02C5