Abstract:
Eyeglass frame hinges are replaced by flexures made of hyperelastic single-crystal shape memory alloy. These flexures exhibit more than 8 percent recoverable strain. Eyeglass frames with these flexures can be distorted repeatedly in ways that would destroy ordinary hinges, and recover without damage. Flexures may be incorporated in eyeglass frames in ways that make them attractive as fashion items, thus enhancing the value of a commodity consumer product.

Description:
CROSS-REFERENCE TO PRIOR APPLICATION 
   This application claims the benefit under 35 USC §119(e) of U.S. provisional application Ser. No. 60/678,921 filed May 9, 2005. 

   FIELD OF THE INVENTION 
   The present invention relates to frames for eyeglasses, and more particularly to eyeglass frames with improved flexures joining the bows with the foreframes. 
   BACKGROUND OF THE INVENTION 
   Frames to support eyeglasses on the face of the user probably developed soon after the first eyeglasses, at least several hundred years ago. Historically, they have been made of a large variety of materials, including bone, horn, metal, plastic etc. The making and marketing of eyeglasses is a worldwide trade involving hundreds of individual companies and totaling billions of dollars each year. The industry is stratified: certain companies make only components, others assemble components into frames, others are solely marketing. A very large component of customer satisfaction involves fashion. Eyeglass fashions change every few months. 
   An enhancement in satisfaction with the product can worth hundreds of millions of dollars per year. The introduction of prior art superelastic Nitinol eyeglass frames has led to growth of a highly competitive and litigious segment of the industry. Nitinol (also known as NiTi or TiNi) is an alloy of titanium nickel that undergoes an energetic crystalline phase change at near-ambient temperatures: these different phases have distinctly different mechanical characteristics giving rise to shape memory and superelasticity, which is the ability to recover more than 3-4 percent strain. 
   To date nearly all eyeglass frames have employed hinges to join the temple with the rim. Existing eyeglasses that do not have hinges and use ordinary material or superelastic nitinol are limited in the permitted flexure. These may suffer from stiffness, making them difficult to store in a compact space, and are subject to permanent distortion due to plastic deformation if elastic limit of the frame material is exceeded. To diminish this limitation, superelastic eyeglass frames and components have been known for more than a decade of years, and are a major selling item in eyeglass manufacturing and retail. 
   Superelastic SMA 
   Shape memory alloy materials (also termed SMA) are well known. One common SMA material is TiNi (also known as nitinol), which is an alloy of nearly equal atomic content of the elements Ti and Ni. Such an SMA material will undergo a crystalline phase transformation from martensite to austenite when heated through the material□s phase change temperature. When below that temperature the material can be plastically deformed from a “memory shape” responsive to stress. When heated through the transformation temperature, it reverts to the memory shape while exerting considerable force. 
   In the prior art many different useful devices employing SMA have been developed and commercialized. The typical SMAs used in the prior art devices are of polycrystalline form. Polycrystalline SMA exhibits both: 1) shape memory recovery (when cycled through the material&#39;s transformation temperature) and 2) superelasticity. The term superelasticity as used herein applies to a polycrystal SMA material which, when above the transformation temperature (in the austenite crystalline phase), exhibits a strain recovery of several percent. This is in comparison to a strain recovery on the order of only about 0.5 percent for non-SMA metals and metal alloys. Polycrystalline alloys, including Nitinol, cannot achieve the maximum theoretical strain recovery because not all of the crystal grains are optimally aligned. 
   Superelasticity in a polycrystal SMA material results from stress-induced conversion from austenite to martensite as stress is increased beyond a critical level, and reversion from martensite to austenite as stress is reduced below a second (lower) critical level. These phenomena produce a pair of plateaus of constant stress in the plot of stress versus strain at a particular temperature. Single crystal superelasticity is characterized by an abrupt change in slope of the stress strain plot at a combination of stress, strain, and temperature characteristic of that particular alloy. 
   Hyperelastic SMA 
   Shape memory copper-aluminum based alloys grown as single crystals have been experimentally made in laboratories, typically in combination with about 5 percent Ni, Fe, Co, or Mn. The most common such CuAl-based alloy is CuAlNi, which is used throughout this description as the primary example; others are CuAlFe, CuAlCo, and CuAlMn. Single crystal SMA materials when stressed have the property of enabling a shape memory strain recovery much greater than polycrystalline SMA, and resulting shape recovery from about 9% to as great as 24% when above the phase change transition temperature. Because such strain recovery is so far beyond the maximum strain recovery of both convention polycrystal SMA materials and non-SMA metals and alloys, the strain recovery property of single crystal SMA will be referred to herein as “hyperelastic.” 
   OBJECTS OF THE INVENTION 
   A general object of the present invention is to provide an improved eyeglass frame which is a more satisfactory consumer product. 
   It is another object of the invention to provide eyeglass frames in which components, such as the hinges, have greater flexibility than prior art eyeglass frames. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIGS. 1A and 1B  are diagrams showing stress/strain isotherms for SMA materials demonstrating hyperelasticity over a wide temperature range, and enhanced strain compared to Nitinol. 
       FIG. 2  is an isometric view of eyeglasses in accordance with one embodiment having separate hyperelastic hinge/flexures with the bows shown bent into outward positions. 
       FIG. 3  is an isometric view of eyeglasses in accordance with another embodiment having hyperelastic hinge/flexures integral with the frame and with the bows shown bent into three different positions. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Many of the limitations in prior art eyeglasses using superelastic SMA (polycrystalline alloys) material are obviated in the present invention through the use of single crystal hyperelastic shape memory alloys which provide an improved material for making flexures enabling extreme distortions, i.e. strain recovery from about 9% to as great as 24% when above the phase change transition temperature. One preferred hyperelastic SMA for use in the invention is single crystal CuAlNi. 
   One advantage of CuAlNi is its extended temperature range of hyperelasticity. Krumme U.S. Pat. No. 4,772,112 describes a method of making Nitinol superelastic over a temperature range from −20 to +40 deg. C. However, strain of these specially created superelastic materials is limited to about 3%, not enough to make a compact flexure strength to make a satisfactory substitute for a pin hinge. 
   Hyperelastic single crystal CuAlNi SMA provides an even greater temperature range, from cryogenic temperature to +200 deg. C., and a larger hyperelastic region, up to 9% or 10% and in certain instances as much as 20%. 
   The stress-strain diagram of  FIG. 1A  shows curves  2  and  3  representing superelastic SMA. Both curves demonstrate the SMA&#39;s superelastic properties. 
   In comparison, the stress-strain diagram of  FIG. 1B  shows curves  4  and  5  representing hyperelastic SMA. The curves represent temperatures that differ by 90 deg. C., and both demonstrate the SMA&#39;s hyperelastic properties. In  FIG. 1B  the two stress-strain diagrams for hyperelastic SMA each showing a plateau up to 9% with a small hysteresis. 
   In the existing eyeglasses containing Nitinol, superelasticity is enhanced by cold work. 
   This requires significant pre-processing of the material. Enhanced superelasticity of CuAlNi is an intrinsic property of single crystal CuAlNi and is achieved without extra processing steps. The as-quenched single crystal provides recoverable strains that are larger than can be achieved in Nitinol under optimal conditions. 
   Hyperelastic single crystal CuAlNi is produced by the Stepanov method, described elsewhere. In this method, one or several crystals are pulled from melt, generally in vacuum. The environment must be very low oxygen content, less than 10e-5, to prevent oxidation of Al as it migrates to the surface. Particles of Al2O3 adhering to the surface of the meniscus as it solidifies initiates formation of multiple crystals. It is important to maintain the cooled such that the crystallization zone is independent of the die through which the melt is pulled so that crystallization takes place without being affected by the die. The region between the die and the crystallization zone is supported and contained by surface tension so that crystal growth is solely in the (100) direction. The mechanical properties of single crystal CuAlNi are not isotropic, and the direction that tolerates the greatest recoverable strain is in this preferred direction. 
   Superelasticity in single crystal CuAlNi is inherent in the material: it originates from the conversion of austenite (high temperature phase) to stress-induced martensite (low temperature phase) that takes place at constant stress. The material is strong enough, (or the conversion takes place at a small enough stress) that, without damage to the material, this conversion can take place in material that has a transformation temperature far below room temperature and reaches to high above room temperature. 
   Shape-setting in nitinol amounts to deforming, constraining, &amp; annealing. One cannot do this with single crystal: it will degenerate. So a different method is employed. Material is deformed, constrained, rapidly heated and rapidly cooled so that precipitation does not occur. 
   Other methods are known for shape-setting CuAlNi alloys. For example the German patent WO03052150. These methods are limited to small deformations, less than 4%. Our method allows up to 9% deformation after shape-setting: the original crystal is not changed, but has a new shape. 
   There is no need to do the kind of sophisticated heat treatment and cold work required in TiNi. And the superelastic region is greater. 
     FIG. 2  illustrates an embodiment providing eyeglass frame  10 . The frame comprises a foreframe  12  for holding a pair of lenses  14 ,  16  and a pair of bows  18 ,  20 . The bows are of sufficient length for passing alongside the user&#39;s temple and over the user&#39;s ear. The frame further comprises separate flexures  22 .  23  which join together the bows with the foreframe. Each flexure is made of hyperelastic material. 
   The embodiment of  FIG. 3  provides an eyeglass frame  26  in which the flexures comprise portions  28 ,  30  of hyperelastic material and in which the flexures are integral with bow  32 ,  34  and foreframe  36  of which both are also formed of hyperelastic material. As used herein, the phrase “integral with the bow and foreframe” in relation to the flexure means that the bow, flexure and foreframe are uniformly joined as one piece of hyperelastic material and not as separate pieces. 
   In both embodiments the flexures, being made of hyperelastic SMA such as CuAlNi, enable the bows to be bent through 180 degrees without damage. Thus, in  FIG. 3  the solid lines shown at  32 ,  34  depict the bows bent into the plane of the foreframe, broken lines  32 ′,  34 ′ depict the bows at right angles to the foreframe, and broken lines  32 ″,  34 ″ depict the bows bent inwardly inot the foreframe plane. 
   The flexure may be shaped to fit the configuration of the frame. It may be attached to the rim and to the temple piece by any convenient means. Methods include bolting, pinning, riveting, swaging, threading, bonding by means of adhesives, soldering, and welding. Some of these methods require special equipment and materials. In particular, ordinary fluxes do not clean the surface of CuAlNi. Brazing with TiCuSil or other flash bonding agents will remove the native oxide and enable suitable bonds with adequate strength. 
   Eyeglass products made with the hyperelastic material will be more durable and consequently more tolerant of errors in handling. It is also possible to incorporate features that protect the lens from breakage by providing a constant-force frame. 
   Method of Fabricating Flexures of the Invention 
   A flexure for use in the invention is fabricated by these steps: a rod or wire is drawn from a melted ingot of CuAlNi of nominal composition Cu(85)Al(11)Ni(4) (atomic percent) in a furnace with an inert atmosphere or vacuum. Pulling rates, compensation, temperatures. Boules up to 1 cm diameter have been made. Multiple wires may be pulled simultaneously from the same melted ingot. 
   The furnace is cooled. The rod or wire is removed from the furnace. The rod is heated in a resistance-heater oven up to nominally 950 deg. C. The rod is plunged into salt water to quench by rapid cooling and thereby preserve the alloy with copper, aluminum, and nickel dissolved in each other. 
   Alternatively, the rod or wire is heated while being constantly moved through a heat source, such as an induction heater, and quenched, for example with a salt-water spray, for rapid cooling. 
   The rod is centerless ground to a fixed consistent dimension. It is inspected to determine that it is single crystal. The rod is cut into slices by electron discharge machining (EDM). Abrasive machining is used for further shaping to size and configuration to produce a flexure. 
   The flexure may be altered in shape by a shape-setting process that includes deforming to form induced martensite, heating rapidly to release stress, and cooling rapidly to preserve the solution of copper-aluminum-nickel. 
   The thickness of the flexure is made such that it has adequate strength but in bending straight either inward or outward its maximum strain does not exceed 10%. A variety of shapes, cross-sections, lengths, widths, and thicknesses are possible to fit various styles of glasses. 
   Other variations are possible that may be desirable. The hyperelastic hinge flexure may be curved like a carpenterâ??s tape so that it snaps into position. Carbon fiber may be used to make the bridge and the temple pieces.