Abstract:
A brow bar and lens assembly for eyeglasses is provided wherein a flexible brow bar member is attached to a lens assembly only along a central region. By attaching the lens and brow bar in this manner, the brow bar is allowed to flex relative to the lens thereby providing additional means for adjusting the width of the eyeglasses and increasing the comfort for the wearer. Further, the lens construction may include channels along its top edge thereby creating voids that provide a space into which the two ends of the brow bar can travel when deflected relative to the central region.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is related to and claims priority from earlier filed provisional patent application No. 60/576,367, filed Jun. 2, 2004. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates generally to eyewear assemblies and methods of manufacturing eyewear assemblies. More specifically, the present invention relates to safety eyewear assemblies that are manufactured utilizing multi-shot molding techniques to achieve unique manufacturing and assembly advantages.  
         [0003]     In the prior art, there are a large variety of different types of protective eyeglasses that are available for protecting a user&#39;s eyes when engaging in hazardous activities. Generally, however, most of these protective eyeglasses are not adapted to be both comfortably worn and adjustable to fit different wearers. Accordingly, wearers have been forced to wear uncomfortable, poorly fitting protective eyewear, resulting in wearers that disregard proper safety procedures and fail to wear protective eyewear.  
         [0004]     Several prior attempts have been made to manufacture protective eyeglasses that include various degrees of adjustability and the use of multiple material types to enhance the wearability of the eyeglasses. For background, reference is generally made to U.S. Pat. No. 5,457,505, issued to Canavan, U.S. patent to Wiedner et al U.S. Pat. No. 5,890,235, and U.S. patent to Canavan U.S. Pat. No. 6,196,681 each of which describe a safety eyewear construction, the collective specifications of which are incorporated herein by reference. U.S. Pat. No. 5,457,505, issued to Canavan, for example, provides one type of adjustable protective eyeglasses that is adjustable to fit various wearers, wherein the temple frame pieces are angularly adjustable about substantially horizontal pivot axes relative to the lens frame piece and longitudinally adjustable to different lengths. As can be seen however, when manufacturing this type of adjustable protective eyeglasses, a large number of separate pieces are required to provide the necessary joints and degrees of freedom needed within structure of the eyeglasses in order to provide the stated adjustability.  
         [0005]     Similarly, U.S. Pat. No. 5,890,235 provides an eyeglass construction that provides for adjustable length temple frame pieces and the ability to angularly adjust the temple frame pieces relative to the brow bar. However, the lens in this construction does not provide for free floating ends, instead, it is pinned at notches  10  (see  FIG. 7 ). Further, several separate pieces must be molded and subsequently assembled thereby increasing the complexity of the assembly process.  
         [0006]     U.S. Pat. No. 6,196,681, issued to Canavan discloses a unitary structure made by a two-shot process in a single mold wherein a hard frame member is molded to which a secondary soft material is molded and chemically bonded to form soft contact areas along the inner portion of the brow bar and at the nose portions. In this manner, a soft material is provided to contact the wearer while hard material is provided to engage ratchet adjustment pieces as well as a transparent lens structure adapted to cover the eyes of a wearer.  
         [0007]     The difficulty with these prior art protective eyeglasses is that each one is only an incremental improvement and none of them provide a comprehensive solution for manufacturing protective eyeglass that are universally adjustable for individual users while also being comfortable to wear and have a reduced number of individual parts to facilitate assembly.  
         [0008]     There is therefore a need for a protective eyeglass construction that facilitates comfort for the user thereby increasing the likelihood that the protective eyeglasses will be worn by the user. Further, there is a need for a highly adjustable protective eyeglass construction that allows the eyeglasses to be universally adjustable for all users while also having a reduced number of individually formed parts to enhance the manufacturability of the assembly.  
       BRIEF SUMMARY OF THE INVENTION  
       [0009]     In this regard, the present invention provides a novel construction for protective eyeglasses that includes numerous points of articulation thereby allowing the eyeglasses to be highly adjustable to suit the needs of virtually all users of the eyeglasses. Further, the present invention utilizes complex, multi-step injection molding techniques to form in-mold-assembly (IMA) components that are then incorporated into the finished eyeglasses thereby reducing complexity and overall assembly steps.  
         [0010]     Briefly, the protective eyewear comprises a brow bar adapted to receive and support a lens, a noise piece adapted to be snap received into the nose bridge of the lens, and two temple bar assemblies that are snap received into the terminal ends of the brow bar. Among the unique features of the eyewear of the present invention is a centrally anchored lens which allows the terminal ends of the brow bar to free float relative to the lens and to flex outwardly. This ability to flex allows the brow to deflect as the temple bar assemblies are moved outwardly further allowing the eyewear to adjust to larger heads.  
         [0011]     Additionally, the present invention utilizes novel multi-shot molding techniques to provide various hinge connections and telescoping parts that are all sequentially formed inside the mold cavity during molding to create IMA subassemblies that do not require any additional assembly steps once removed from the mold cavity. In the preferred embodiment disclosed herein, the molding techniques are particularly important in the formation of adjustable elastomeric nose pads on the nose-piece of the inventive eyewear, as well as in the formation of the temple bar assemblies that include a ratchet adjustment, hinge, and telescoping cables. Additionally, the multi-shot molding techniques are effective for providing soft cushion materials on the inner side of the brow bar, and lens bumpers on the outer side of the brow bar.  
         [0012]     Accordingly, it is an object of the present invention to provide safety eyewear products that are at least partially assembled in-the-mold using novel multi-shot molding techniques. It is a further object of the present invention to provide safety eyewear having a flexible brow bar to accommodate different size heads. It is yet a further object of the present invention to provide protective eyewear that includes multiple articulated joints that increase the overall adjustability of the eyewear to enhance comfort and wearability of the eyeglasses.  
         [0013]     Other objects, features and advantages of the invention shall become apparent as the description thereof proceeds when considered in connection with the accompanying illustrative drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     In the drawings which illustrate the best mode presently contemplated for carrying out the present invention:  
         [0015]      FIG. 1  is a front perspective view of the safety eyewear of the present invention with the lens shown as transparent;  
         [0016]      FIG. 2  is a top view thereof illustration temples in normal and flexed positions;  
         [0017]      FIG. 3  is an exploded front perspective view thereof;  
         [0018]      FIG. 4  is an exploded rear perspective view thereof;  
         [0019]      FIG. 5  is an exploded view of one of the temple bar assemblies;  
         [0020]      FIG. 6  is cross sectional view of the brow bar;  
         [0021]      FIG. 6A  is a cross-sectional view of the brow bar showing an alternative construction having reduced thickness areas beneath the soft elastomeric overmold to provide greater flex of the brow bar;  
         [0022]      FIG. 7A  is an exploded perspective view of the nose pad assembly;  
         [0023]      FIG. 7B  is a cross-sectional view of the nose piece showing the nose pad and support molded in a two shot molding process;  
         [0024]      FIG. 7C  is an exploded perspective view of an alternative construction of the nose pad assembly;  
         [0025]      FIGS. 8A and 8B  are perspective views of an alternate ball and socket connection between the temple bar and the brow bar;  
         [0026]      FIGS. 9A and 9B  are another alternate perspective of a ball and socket connection between the temple bar and the brow bar;  
         [0027]      FIG. 10  is a perspective view of an alternate embodiment of the safety eyewear having a two part brow bar with snap in sockets on bridge of lens;  
         [0028]      FIGS. 11-14  are perspective views of alternate embodiments of the safety eyewear having a telescoping brow bar configurations;  
         [0029]      FIGS. 15-17  are plan views of alternate angular ratchet adjustment configurations that are formed using the in-mold-assembly techniques of the present invention;  
         [0030]      FIG. 18  is a plan view of an alternate telescoping temple length adjustment;  
         [0031]      FIG. 18A  is a plan view of a second alternate telescoping temple length adjustment; and  
         [0032]      FIG. 19  is a perspective view of an alternate nose pad configuration that provides only for rotation of the nose pads.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0033]     Now referring to the drawings, a preferred embodiment of the safety eyewear of the instant invention is illustrated and generally indicated at  10  in  FIGS. 1-9 . As will hereinafter be more fully described, the safety eyewear  10  includes a brow bar  12  that is adapted to receive and support a lens  14 , a nose piece  16  that is adapted to be snap received into the nose bridge of the lens  14 , and two temple bar assemblies  18  that are snap received into the terminal ends of the brow bar  12 .  
         [0034]     The invention utilizes novel multi-shot molding techniques to provide hinge connections and telescoping parts that are formed inside the mold cavity during molding (In-Mold-Assembly or IMA) and thus do not require any additional assembly once the part is removed from the mold cavity. In the preferred embodiment disclosed herein, the molding techniques are particularly important in the formation of adjustable elastomeric nose pads on the nose piece of the eyewear as well as in the integral formation of the temple bar assemblies including a ratchet body, hinge body, and telescoping cables.  
         [0035]     Turning to  FIG. 1  in combination with  FIG. 6 , the brow bar  12  is the central structural element of the eyewear assembly  10 . The brow bar  12  is formed using a two shot molding process wherein a hard portion  20  is first molded to provide rigidity and strength and thereafter a soft elastomeric portion  22  is molded over and bonded to the hard portion  20  to provide a soft cushion on the inside surface of the brow bar  12 . The soft elastomeric material also wraps around the front surface of the brow bar  12  in selected locations to form soft bumpers  24  between the inner surface of the lens and the outer surface of the brow bar  12 , thereby cushioning the brow bar  12  as it flexes forward and preventing a rattling sound as it contacts the lens  14 . In addition to wrapping around the brow bar  12 , through holes (not shown) may be provided through the brow bar to allow the elastomeric material to flow through the brow bar  12  as a means to assist in forming the soft bumpers  24  on the face of the brow bar  12  and to provide additional means for retaining the soft bumpers  24  on the brow bar  12 .  
         [0036]     Turning now to  FIGS. 1-5 , one of the unique features of the safety eyewear  10  of the present invention is the ability of the brow bar  12  to flex outwardly (see arrows  26  in  FIGS. 1 and 2 ) thereby allowing the eyewear  10  to adapt to different brow width of the wearer. The functionality of this feature is further enhanced by the manner in which the brow bar  12  receives and retains the lens  14 . The lens  14  comprises a single piece lens shield having left and right lens portions integrally connected by a nose bridge, which is secured to the brow bar  12  by two spaced detents  28  located on the top edge of the lens  14 . The detents  28  are received into corresponding notches  30  on the front surface of the brow bar  12 . Similarly, the detents  28  may also be formed on the brow bar  12  and the notches  30  may be formed on the lens  14  wherein the detents  28  are received into corresponding notches  30  formed in the back surface of the lens  14 . A channel arm  32  extends forward from the brow bar  12  and downwardly over the front surface of the lens  14  to capture the lens  14  against the front surface of the brow bar  12  thereby retaining the lens  14  in assembled relation with the brow bar  14 . This center anchoring arrangement allows the outer ends of the lens  14  to float relative to the outer ends of the brow bar  12 . While the general concept of a centrally anchored lens  14  is not entirely new, it is noted that the brow bar  12  of the present invention is preferably molded from a plastic material that is sufficiently flexible so as to movable through at least a range of motion as illustrated in  FIG. 2 . Specifically, the brow bar  12  is sufficiently flexible to allow the temples  18  to be flexed from a static width W to a stretched width of W′ allowing the eyeglasses  10  to accommodate a large range of wearers. While some of the prior art shows central anchoring of a lens for sunglasses, the brow bar and frame of these prior art sunglasses are generally stiff, and while allowing some degree of flexibility, do not allow the broad range of motion as illustrated in  FIG. 2 . More specifically, the materials selected for the present invention permit a range of motion of the temple bar of about 40-50 degrees measured from the anchor point  33  on the lens  14  as illustrated in  FIG. 2 .  
         [0037]     As can best be seen in  FIG. 2 , when the eyewear is worn by a person with a large head, the terminal ends of the brow bar  12  can freely flex outwardly from W to W′ as indicated by arrows  26  allowing the eyewear  10  to adapt to the proper size. To provide clearance to facilitate the outward flex of the brow bar  12 , the upper edges of the left and right lens portions are provided with channels  34  or nests into which the brow bar  12  is guided during outward flexing. In addition to providing a cushioning effect, the soft bumpers  24  extend around on the front of the brow bar  12  also serve to prevent the brow bar  12  from fully deflecting into the nests  34  at the top of the lens  14 . In this manner, the bumpers  24  act a s stand-offs maintaining the brow bar  12  in a slightly spaced relation to the wall of the nests  34  allowing free airflow out the top of the lens  14  and allowing continued venting even when the brow bar  12  ins in a fully flexed position.  
         [0038]     To further enhance the ability of the brow bar  12  to flex outwardly, an alternate embodiment brow bar  12 A is shown in  FIG. 6A  wherein the brow bar  12 A includes periodic weakened or narrowed regions  23  in the hard plastic material that facilitate deflection of the brow bar  12 A. These weakened regions  24  may be arranges such that the elastomeric wrap around material  24  covers and conceals the weakened regions  23  while filling them with a softer more flexible elastomeric material.  
         [0039]     The novel nose piece  16  of the present invention comprises a v-shaped rigid support portion  36  and two nose pads  38 . The rigid support  36  is formed with a groove  40  that mates with the corresponding peripheral edges of the nose bridge on the lens  14  so that the nose piece support  16  is snap received onto the lens  14 . The nose pads  38  are connected to the support by a unique ball and socket arrangement that allows 360 degree freedom of movement of the nose pad  38  relative to the support  36  as well as rotational movement of the nose pad  38 . This greatly enhanced range of motion is an improvement in the present invention over the prior art and facilitates a nose piece that has increased comfort and adjustability for the wearer of the eyewear  10 . While the ball and socket joint provides an enhanced range of adjustment, it is equally important to understand that the ball and socket joint must have some minimal level of friction as well so that the nose pad  38 , once adjusted to a desired position, remains in the desired position. In the preferred embodiment as depicted in  FIGS. 7A and 7B , the rigid support portion  36  is first molded to include the ball portion  42  of the ball and socket joint. Thereafter, the nose pad  38  is molded over the ball  42  to form the uniquely adjustable ball and socket assembly. This molding process could be completed as part of an insert molding process, or as preferred for the present invention, the molding process is completed within the same mold using retractable mold sections to mold the nose pad  38  directly over the ball element  42  without removing the support  36  from the mold, and thus create an assembled part directly within the mold. As described above, since the ball and socket joint must have some minimal level of friction between the parts, the molding process and the selection of materials becomes important to creating a functional part. In an alternative embodiment, the ball and socket formations can be reversed, with the nose pad  38  first being formed with the ball  42  and the support  36  being molded over the ball  42  on the nose pad  38 . Further, in the context of using an insert molding technique, it is possible that the ball element  42  be comprised of a metal material and insert molded within the rigid plastic support  36 . The plastic nose pads  38  could then be molded over the metal ball elements  42 . Further still, the entire rigid nose support  16  could be constructed from metal and the plastic nose pads  38  molded over the ball elements  42 . Additionally, while the rigid support portion  36  may be made from a hard polymer and the nose pads  38  may be made from an elastomer, the present invention also provides for both members to be formed of hard polymer or elastomer. An alternate embodiment as depicted in  FIGS. 13, 17  and  19  further provides that the nose piece  16  snap into a central portion of the eyeglass frame rather than be received by the lens. Still further, it is possible that the nose pads  38  could be molded separately and then assembled by pushing them onto the ball  42 .  
         [0040]     Other constructions of the ball and socket joint for the nose pad  38  are also contemplated. For example,  FIG. 7C  illustrates that the nose support  16  and the ball element  42  of the joint could be integrally molded as part of the lens  14 , and the nose pads  38  could be molded over the ball elements  42 . It is also possible to form a ball and socket joint by forming a plastic ball element, and slotting the ball element to provide relief slots. The slotted ball element could then be press fit into a cylindrical bore of slightly smaller dimensions formed within the nose pad  38 . The slotted ball would be compressed providing a friction fit within the bore, retaining the ball in place and providing the required friction to allow adjustment but also retain the nose pad  38  in position once moved to the desired position. In yet other embodiments, the ball would not be slotted, but would be retained within the bore by an insert or a rod extending perpendicular to the bore.  
         [0041]     Even further still, it is alternately contemplated that the nose pad  38  could be formed with a metallic insert at the upper end thereof. For example, a U-shaped metallic insert plate with two relief apertures could be insert molded within the nose pad  38 . The ball element is then press fit between the plates and received in seated relation between the two relief apertures. In yet another construction, a metal ring could be molded into the nose pad  38  and the ball pressed through the ring for retention. While numerous different constructions have been described herein, these descriptions are not intended to limit the possibility of other ball and socket type constructions. The general inventive concept to be conveyed is that the ball and socket type joint provided between the nose pad  38  and the supporting structure  16  of the nose pad  38  provides a superior range of motion, adjustability and comfort not obtained with prior art constructions.  
         [0042]     Turning back to  FIGS. 1-3  in combination with  FIG. 5 , the temple bar assemblies  18  include three separate elements, namely a ratchet body  44 , a hinge body  46  and a cable portion  48 . The temple bar assemblies  18  are configured so as to provide both an angular ratchet adjustment for adjusting the angle of inclination of the temple bars  18  relative to the brow bar  12  as well as a hinge for folding the temple bars  18  flat relative to the brow bar. In addition, the cable portion  48  of the temple bar assemblies  18  is adapted for telescoping adjustment relative to the hinge body  46 . Generally speaking, the physical construction of the three part temple assemblies  18  is within the prior art. For example, an almost identical structure is illustrated in the U.S. Pat. No. 5,457,505 discussed hereinabove. In this prior art construction, the three components were molded separately and then assembled together to form a temple bar assembly. More specifically, the hinge connection had to be aligned and a hinge pin inserted to form the hinge point. Additionally, the cable had to be pressed onto the end of the temple body.  
         [0043]     For purposes of the present invention, the novelty resides in a unique method of construction the temple bar assembly  18  as a single integrated unit which is formed and assembled directly within the mold. In this regard, the three-part temple bar assembly  18  is formed using a novel three shot molding process wherein the ratchet body  44  is first molded from first rigid plastic material. The ratchet body  44  includes a ratchet formation  50  at the front end thereof and a hinge pin forming a vertical pivot axis  52  at the rear end. In a second shot of the molding process, the hinge body  46  is integrally molded (from a slightly different plastic material) over the rear end of the ratchet body  44  wherein the hinge eye  54  is integrally formed over the hinge pin within the mold. The rear end of the hinge body  46  is provided with an elongated neck  56  that will become part of the telescoping cable structure. Finally, in a third step, a third (softer) elastomeric/plastic material is injected over the neck  56  to form the soft curved cable portion  48  of the temple bar. While in the preferred embodiment a soft elastomeric cable portion  48  is disclosed, clearly the cable portion  48  may also be formed from a hard polymer. To provide selected positioning of the cable  48  relative to the neck  56 , the neck is provided with a detent  58 , and the cable is provided with a series of positioning apertures  60 . Alternately, the positioning aperture  60  may be a single elongated aperture. Similarly, in  FIG. 18 , another alternate cable  90  positioning aperture  88  is shown.  FIG. 18A  shows yet another alternate cable  90  positioning arrangement wherein instead of providing a single aperture, a plurality of apertures  61  are provided to allow the detent  58  to positively engage in one of the selected apertures  61 . Because of the differences in the plastic materials used in the molding process, when the temple bar assembly  18  is removed from the mold, the hinge body  46  is pivotable with respect to the ratchet body  44 , and the cable portion  48  is slidably movable relative to the neck  56  of the hinge body  46 . No assembly is required once removed from the mold. To insure the proper operation and the required movement of each of the elements relative to one another after the molding process is completed, upon removal from the mold each of the joints of the temple bar  18  may be articulated to prevent the different polymers from bonding to one another.  
         [0044]     The temple bar assemblies  18  are then assembled with the brow bar  12  by snapping the respective ratchet body  44  of the left and right temple bar assemblies into mating slots  62  on the terminal ends of the brow bar  12 . The ratchet body  44  includes a pivot post  64  received in a pivot aperture  66  to form a pivot point similar to those ratchet assemblies found in the &#39;681 and &#39;235 patents referenced hereinabove. Alternate configurations of the ratchet body  44  and formations  50  can be found in  FIGS. 15, 16  and  17 . It is important to note that the functional elements of the ratchet body  44  may be formed in a position either ahead of the hinge pivot  52  positioned between the brow bar  12  and the hinge pivot  52  or in a position behind the hinge pivot  52  between the reduced neck  56  and the hinge pivot  52 . This flexible placement of the ratchet body  44  allows flexibility in design as well as facilitating the ability to also form the entire ratchet assembly (body  44  and ratchet receiver  62 ) utilizing IMA techniques and methodology.  
         [0045]     Referring to  FIGS. 8 and 9 , further disclosed embodiments of the invention include a novel brow bar  12 A and temple bar assembly  18 A that is molded in a two shot process with a ball  68  and socket  70  connection rather than a ratchet and hinge. In the embodiment shown in  FIGS. 8A and 8B , the temple bar neck and rear portion  73  are preferably molded in a first molding step wherein the front end of the rear portion  73  includes a ball formation  68 . Thereafter, the front portion  71  is molded over the ball  68  to form a socket formation  70  surrounding the ball  68 . The facing surfaces of the temple bar  18 A and brow bar  12 A are curved on selected surface to allow relative rotation and movement, and in addition, the front portion  71  is provided with a slot  74  on the inner side thereof to permit a hinge/pivot movement of the temple bar  18 A similar to a conventional hinge. The particular arrangement as shown includes a curved side surface  73   a  on the rear portion  73  which permits pivoting movement along a vertical axis. It should be noted that the upper and lower surfaces at the front edges of the rear portion are also somewhat rounded to generally permit pivoting of the rear portion as a true ball and socket joint. This two shot process would eliminate the separate formation of the hinge body and would thus reduce cost and simplify manufacture. Similarly, as disclosed above, the cable ends  48  may be molded over the temple bar  18  to form telescoping temple adjustment. The reverse arrangement of the ball and socket joint is shown in  FIGS. 9A and 9B  wherein the ball formation  68  is formed on the front portion  71  and the rear portion  73  is molded the ball  68  to create a socket  70 .  
         [0046]     Referring to  FIG. 10 , a second alternate embodiment brow bar  12   c  is shown wherein the brow bar  12   c  is made in two pieces. The lens  14  is formed to include a receiver channel  32   c  along the top edge thereof wherein the receiver channel  32   c  includes openings  32   d  in its ends that are configured and arranged to receive and frictionally retain the terminal ends  12   d  of the two brow bar segments  12   c.    
         [0047]     In another alternate embodiment as depicted in  FIG. 11 , the brow bar  12   e  is formed as a continuous member and the lens  14   a  is formed as a two piece lens. The two lenses  14   a  are centrally supported along the central portion of the brow bar  12   e  by any known support means such as the support clip  32   d  shown. The terminal ends  14   b  are free floating and not restrained or connected to the brow bar  12   e  thereby allowing the free flexing of the brow bar  12   e  in accordance with the teachings of the present invention. Additionally, the lenses  14   a  may include nests  34  along their top edges to allow room for the flexing of the brow bar  12   e  or may simply stop short at a point beneath the brow bar  12   e.    
         [0048]     Turning now to  FIGS. 12-14 , several additional embodiments are disclosed wherein the brow bar  12 B telescopingly adjusts for length. In this regard, a central bridge portion  74  of the brow bar  12 B includes left and right temple extensions  76 . Each temple extension  76  includes notches or slots  78  for receiving a mating pin formation  80  provided on a mating temple extension  82  of the temple bar assemblies  18 . It is noted that the temple bar assemblies  18  in this embodiment are formed in a four part molding processes wherein the mating temple extension  82  is formed first having a hinge pin  84  formed at the rear end, followed by a hinge body  86 , the temple bar  88  as depicted in the detail in  FIG. 6  includes a ratchet formation at the front end, and a telescoping cable end  90 .  
         [0049]     It can therefore be seen that the present invention discloses a novel and creative use of multi-shot molding techniques to provide integrally molded yet movable parts, as well as to provide both decorative and functional cushioned areas. For these reasons, the instant invention is believed to represent a significant advancement in the art that has substantial commercial merit.