Flexible eyewear with embedded partial frame portions

Abstract

Flexible eyewear comprising a first rigid frame portion and a second rigid frame portion embedded in flexible material and separated from each other, when embedded, to form a flexible bridge portion therebetween; a pair of arms, each arm connected to a corresponding one of the rigid frame portions; and a pair of lenses, each lens connected to an exposed surface of the corresponding rigid frame portion.

Description

FLEXIBLE EYEWEAR WITH EMBEDDED PARTIAL FRAME PORTIONSCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims priority to U.S. Provisional Patent Application No.63 / 773,799 filed on March 18, 2026, the contents of which are incorporated herein by reference in their entirety.TECHNICAL FIELD

[0002] The following generally relates to flexible eyewear and, in particular, to flexible eyewear with embedded partial frame portions that can flex relative to each other, for example, via a flexible bridge portion therebetween.BACKGROUND

[0003] Eyewear such as eyeglasses generally include a frame that supports one or more lenses. Such eyewear may include a variety of eyeglasses, such as sunglasses, protective / work / safety glasses, sport goggles, prescription eyewear, etc. The frame typically includes a nose bridge or nose pieces that engage the user’s nose to support the eyewear on the user’s head. Eyeglasses also typically include a pair of arms attached to (or integral with) the frame, to further support the eyeglasses, e.g. by resting the arms on the user’s ears or engaging their head in the temple region. Other eyewear may include other support elements such as straps or bands (e.g., in sports goggles).

[0004] Eyeglasses have traditionally utilized frames or frame components made from substantially rigid materials such as plastics, metals, or composite materials. The rigidity of these materials supports the lenses in the frames and substantially maintains the shape of the eyeglasses such that they consistently fit on a user’s head as intended. However, when the eyeglasses are subject to a physical impact, they can break or deform. Additionally, frames made of rigid materials may not be capable of flexing or being flexed.SUMMARY

[0005] In one aspect, there is provided flexible eyewear comprising a first rigid frame portion and a second rigid frame portion embedded in flexible material and separated from each other, when embedded, to form a flexible bridge portion1CPST Doc: 1385-4088-3229.1therebetween; a pair of arms, each arm connected to a corresponding one of the rigid frame portions; and a pair of lenses, each lens connected to an exposed surface of the corresponding rigid frame portion.

[0006] In certain example embodiments, the rigid frame portions each extend from the flexible bridge portion to connection points with the corresponding arm.

[0007] In certain example embodiments, the connection points include hinges.

[0008] In certain example embodiments, a first part of the hinge is provided at a distal end of the rigid frame portion and a second part of the hinge is coupled to the corresponding arm.

[0009] In certain example embodiments, the second part of the hinge is coupled to a flexible arm portion, the flexible arm portion being connected at a distal end to a rigid arm portion.

[0010] In certain example embodiments, each rigid frame portion includes at least one surface detail to interface with the flexible material.

[0011] In certain example embodiments, the surface detail includes contouring.

[0012] In certain example embodiments, the surface detail includes at least one aperture through the rigid frame portion.

[0013] In certain example embodiments, the eyewear further includes a nose piece.

[0014] In certain example embodiments, the nose piece includes a pair of nose pads each coupled to a respective one of the rigid frame portions and coupled to each other via a flexible connector.

[0015] In certain example embodiments, each lens comprises a notch, a protrusion, or a notch and a protrusion to secure the lens into a channel in the exposed surface.

[0016] In certain example embodiments, the eyewear includes a flexible bar extending between the frame portions and being embedded in the flexible bridge portion.2CPST Doc: 1385-4088-3229.1

[0017] In certain example embodiments, the eyewear includes at least one notch or groove in one or more of the rigid frame portion or the lens to provide venting. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Embodiments will now be described with reference to the appended drawings wherein:

[0019] FIG. 1 is a perspective view of flexible eyewear having embedded partial frame portions that can flex relative to each other.

[0020] FIG. 2 is a front view of the flexible eyewear.

[0021] FIG. 3 is a side view of the flexible eyewear.

[0022] FIG. 4 is a partial top view of the flexible eyewear.

[0023] FIGS. 5 and 6 are partial perspective views of the flexible eyewear showing insertion of a lens.

[0024] FIG. 7 is a partial perspective view of the flexible eyewear showing an interface between a lens and an embedded rigid frame portion.

[0025] FIG. 8 is an enlarged cross-sectional view of the interface between the lens and the embedded rigid frame portion.

[0026] FIGS. 9a, 9b, 9c, and 9d are schematic cross-sectional views of overmolded interfaces between flexible and rigid materials.

[0027] FIG. 10 is a perspective view of the flexible eyewear being flexed in one direction.

[0028] FIG. 11 is a perspective view of the flexible eyewear being flexed in another direction.

[0029] FIG. 12 is an enlarged perspective view of a flexible bridge portion having a flexible connector piece extending between the embedded rigid frame portions.

[0030] FIGS. 13-16 are views of flexible eyewear that includes venting in embedded rigid frame portions.3CPST Doc: 1385-4088-3229.1DETAILED DESCRIPTION

[0031] For simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the examples described herein. However, it will be understood by those of ordinary skill in the art that the examples described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the examples described herein. Also, the description is not to be considered as limiting the scope of the examples described herein.

[0032] The present disclosure describes flexible eyewear, which may include any type of eyewear such as sunglasses, prescription eyewear, safety eyewear, etc. The principles discussed herein are applicable to any such eyewear and the examples provided are purely illustrative. The flexible eyewear embeds partial frame portions in flexible material to not only join portions of the overall assembly together, but also to provide flexibility in selection portions. For example, as described further below, the flexible material can couple or join a pair of embedded frame portions that are configured to hold respective lenses with the frame portions extending towards and providing the rigidity to hinges that are used to couple arms to the eyewear. The hinge may be coupled to another portion of flexible material to additionally provide flexibility to the arms. The flexible material additionally provides a layer of comfort to engage a user’s face while holding the embedded rigid portions therewithin.

[0033] Referring now to the figures, FIG. 1 illustrates a perspective view of flexible eyewear 10. The flexible eyewear 10 includes a pair of rigid embedded frame portions 12, denoted by 12a and 12b in FIG. 1. The frame portions 12a, 12b are connected to each other using flexible material that is applied (e.g., via overmolding) to the rigid embedded frame portions 12a, 12b. In this example, the flexible material extends over and at least partially around the frame portions 12a, 12b to form first and second portions 24a, 24b and a connecting flexible bridge portion 26. The flexible bridge portion 26 adheres to and embeds, at opposite ends thereof, to central portions of the embedded frame portions 12a, 12b. In this way, the frame portions 12a, 12b are separated from each other by a suitable distance according to 4CPST Doc: 1385-4088-3229.1the size and fit of the eyewear 10 while enabling the rigid embedded frame portions 12a, 12b to flex relative to each other.

[0034] The frame portions 12a, 12b provide a base into which a pair of respective lenses 28a, 28b can be inserted as discussed further below. The frame portions 12a, 12b are embedded through the flexible material and extend outwardly and around towards respective hinge mechanisms 16a, 16b. As seen in FIG. 1, a first portion of the hinge mechanism 16 is embedded in the same flexible material that embeds the frame portion 12 and a second portion of the hinge mechanism 16 is embedded in a separate flexible arm portion 18. The flexible arm portions 18a, 18b are coupled to respective rigid arm portions 20a, 20b of corresponding arms 14a, 14b. The arms 14a, 14b thus provide rigidity at the point of contact with the user (e.g., against head, over ears, etc.) while providing some flexibility that is independent of the flexibility provided by the flexible bridge portion 26 and connecting the arms 14a, 14b to the hinges 16a, 16b. A nose piece 30 may also be integrated into the eyewear 10.

[0035] Referring now to FIGS. 2 and 3, the nose piece 30 may include a pair of nose pads connected via a flexible nose bridge 32. The flexible nose bridge 32 may be bendable such that the nose pads can flex with the frame portions 12a, 12b as shown, for example, in FIGS. 10 and 11 described below. Also shown in FIGS. 2 and 3 are a series of bonding apertures 34, by way of example. The apertures 34 are one example of a way to promote adhesion of the flexible material in flexible portions 24a, 24b to the respective embedded frame portion 12a, 12b. For example, the material may be substantially flexible that is constructed from an elastomer such as thermoplastic polyurethane (TPU), rubber or thermoplastic rubber (TRP), soft plastic, or any other suitable material. The apertures 34 allow the flexible material to flow into and / or through the apertures 34 to surround and hold areas of the embedded frame portions 12a, 12b.

[0036] For instance, the flexible material may flow through the apertures 34 during an overmolding process and fill those passages to provide additional gripping and encapsulation of the rigid frame portions 12a, 12b, forming a stronger hold between the overmolded portions 24a, 24b and bridge portion 26 and the frame portions 12a, 12b. It can be appreciated that any number of elongated passages,5CPST Doc: 1385-4088-3229.1slots or holes of any geometry can be used, e.g., as shown in FIGS. 9a-9d described below.

[0037] The construction of the flexible material with the rigid frame portions 12a, 12b can be done using any suitable overmolding process. Overmolding, sometimes referred to as two times injection molding, is a process where a single part is created using two or more different materials in combination. Typically, the first material (or substrate) is partially or fully covered by overmolded material during the manufacturing process. In this case, a portion of the frame portions 12a, 12b may act as the substrate that is overmolded with the material used to create the flexible eyewear 10. The overmolded material is generally an elastomer such as thermoplastic TPU, rubber or TRP, soft plastic, or any other suitable material. The flexible portions 24a, 24b and flexible bridge portion 26 can be overmolded to the frame portions 12a, 12b prior to attaching the arms 14 and a separate overmolding process may be applied to adhere the flexible arm portions 18a, 18b to the hinges 16a, 16b.

[0038] FIG. 4 provides a top view that illustrates the hinge connections. As shown, the flexible portion 24a ends prior to the moveable portion of the hinge 16a that is coupled to the flexible arm portion 18a of the arm 14a. The flexible arm portion 18a is coupled at its other end to the rigid portion 20a of the arm 14a. This allows both rigidity for a secure fitment with the user’s head while permitting flexure of the arm 14a itself separately and independently from the rest of the flexible eyewear 10. This allows the user to, for example, slightly flex the arms 14a, 14b when placing the arms 14a, 14b on their ears or against their head. This also accommodates different sized users and head proportions while maintaining a good fit and comfort. The flexible bridge portion 26, also seen in FIG. 4, can provide additional flexibility for fitting on a user’s head while also permitting exaggerated flexure to avoid breakage of the eyewear 10. The flexibility provided by the flexible material in selected portions as seen in FIG. 4 enables flexing of the eyewear 10 that is much more than inherent flexibility of regular plastic or metal frames, which can eventually deform, snap or otherwise degrade over time when flexing occurs.Instead, the flexible material used in the eyewear 10 permits repeated and even6CPST Doc: 1385-4088-3229.1significant or drastic flexing of the portions of the eyewear 10 in normal use to prolong the life and ensure comfortable fit and stable placement over time.

[0039] Referring now to FIGS. 5 and 6, the manner in which the rigid embedded frame portions 12a, 12b are held in the flexible material additionally provides a rigid attachment edge for securing the lenses 28a, 28b. For example, as shown in FIG. 5, the lens 28b may include a notch 36b and a protrusion 38b that can snap into an exposed edge or surface of the frame portion 12b. In this way, the flexible portion 24b that embeds the frame portion 12b can substantially hide the rigid material while enabling the lens 28b to be detachably coupled to the eyewear 10 permitting lenses 28 to be changed or replaced. The inserted lens 28b is shown in FIG. 6 in which it can be appreciated that the notch 36b grips an indented portion of the exposed ridge, slot or channel 44 (see FIG. 7) in the frame portion 12b while the protrusion 38b likewise engages with a slot (not shown) in the same ridge or channel allowing a “snap-in” type configuration. It can be appreciated that this snap-in configuration is only one example and various other mechanisms such as friction fits or couplings using different numbers of protruding elements or complementary contours may be used.

[0040] FIGS. 7 and 8 provide partial cross-sectional views in which the channel 44b is seen with the lens 28b secured therein. The notch 36b can also be seen secured against a portion of the channel 44b having complementary contouring. The cross-section also illustrates the flow of flexible material in the flexible portion 24b through an aperture 34. As illustrated in FIG. 8, the flexible material is thus capable of surrounding areas of the frame portion 12b to maintain adherence of the flexible material to the embedded frame portion 12b.

[0041] Referring to FIGS. 9a-9d, the flexible material may be coupled to the embedded frame portions 12a, 12b in various ways. For example, FIG. 9a illustrates coupling via adhesive or other fusing of the flexible material to the outer surfaces of the frame portion 12 without the need for apertures 34 or other mechanisms. In each of FIGS. 9a-9d, the lens 28 is shown coupled to the embedded frame portion 12 via the respective channel 44 with the flexible portion 24 surrounding substantial exposed surfaces of the frame portion 12. FIG. 9b illustrates the example described above, wherein at least one aperture 34 is used to permit the flexible material to flow 7CPST Doc: 1385-4088-3229.1through the frame portion 12 to provide an encapsulating grip between the flexible portion 24 and the frame portion 12. In another example, shown in FIG. 9c, the frame portion 12 includes a pair of notches 50 which increase the surface contact area between the flexible portion 24 and the frame portion 12. Similarly, as shown in FIG.9d, other contours can be incorporated into the frame portion 12 to increase the surface contact area, in this case a T-shaped detail 52 that includes opposing notches 50. It may be noted that in the configuration shown in FIG. 9d, the upper surface of the T-shaped detail 52 allows an exposed surface of the material used for the frame portion 12 to show, which may be used to provide contrasting colors or other aesthetic details. In the example shown in FIG. 9d, this would provide a stripe or strip of material that would be exposed at the top of the flexible portion 24.

[0042] FIGS. 10 and 11 illustrate the extent to which the flexible eyewear 10 may be flexed by incorporating the flexible bridge portion 26. This permits the eyewear 10 to be folded, be sat upon, or be otherwise deformed between items without losing its ability to return to its normal usage and without breaking. As illustrated in FIG. 11 , extreme flexure outwardly wherein the arms 14a, 14b are pushed away from each other is also accommodated, well beyond normal inherent flexibility provided by plastic and metal materials without the use of flexible material 24, 26.

[0043] Referring now to FIG. 12, the flexible bridge portion 26 can also embed a deformable rigid bar 60 extending between the rigid embedded frame portions 12a, 12b. Including such a deformable rigid bar 60 adds to or otherwise customizes the resistance to flexure of the flexible eyewear 10. Similarly, the deformable rigid bar 60, via its inherent elastic deformability and resilience, further encourages a return to rest for the overall assembly after being flexed. The deformable rigid bar 60 can also connect to the frame portions 12a, 12b to connect otherwise separate parts and facilitate aligning and holding them in place during assembly (e.g., during an overmolding process) to further assist in the accuracy and efficiency of such a process. Moreover, shape memory and other alloys can be used to enable a user to customize or otherwise adjust the rest position of the flexible bridge portion 60, e.g., by including a slight bend to accommodate the specific user.

[0044] The embedded rigid frame portions 12 can additionally be adapted to include other features, such as venting as shown in FIGS. 13-16. In this example,8CPST Doc: 1385-4088-3229.1the embedded rigid frame portion 12a includes a number of multi-directional venting notches 70 and / or lens grooves, which may additionally or alternatively be provided using apertures or other contouring. The flexible portion 24a is adapted to adhere to the frame portion 12a while permitting passageways at / through the venting notches 70. It can be appreciated that the venting notches 70 may themselves include or provide suitable surface area(s) to promote adhesive or gripping of the flexible portion 24a to the frame portion 12a. As can be appreciated from FIG. 16, the back wall redirects the air coming from the injection-molded TPU portion of the frame 12.

[0045] For example, the multidirectional venting can be provided by lens grooves 72 which can be angled in different directions. This increases airflow throughout the eyewear in many directions and permits multidirectional venting. In this embodiment, a first lens groove (not pictured) angles the airflow downwards toward the bottom of the lens, a second lens groove (not pictured) angles the airflow towards the middle of the lens and a third lens groove (not pictured) angles the airflow towards the nose portion. The multi-directional airflow permits air to travel and vent the bottom of the lens, the middle of the lens and the inner portion of the lens equally.

[0046] It can be appreciated that the multi-directional vents preferably do not allow air to enter the area behind the lens in a straight path. The airflow is channeled through the grooves and may not follow a straight path. For example, the vents allow air to enter the grooves via a horizontal path, the air is then channeled vertically upwards towards the frame groove, and finally vertically downwards into the area behind the lens. This allows the air to be directed in a specific manner. Furthermore, the grooves can be angled such that the airflow is directed to a region behind the lens which needs more ventilation. For example, the grooves can be angled sharply towards the nose to ventilate the area near the nose more than other areas. Thus, the angle of the grooves provided can alter and guide the airflow as needed. It can be appreciated that by using a greater number of grooves, the ability to redirect air in multiple different directions increases.

[0047] It will be appreciated that the examples and corresponding diagrams used herein are for illustrative purposes only. Different configurations and terminology can be used without departing from the principles expressed herein. For instance,9CPST Doc: 1385-4088-3229.1components and modules can be added, deleted, modified, or arranged with differing connections without departing from these principles.

[0048] Although the above principles have been described with reference to certain specific examples, various modifications thereof will be apparent to those skilled in the art as having regard to the appended claims in view of the specification as a whole.10CPST Doc: 1385-4088-3229.1

Claims

Claims:

1. Flexible eyewear comprising:a first rigid frame portion and a second rigid frame portion embedded in flexible material and separated from each other, when embedded, to form a flexible bridge portion therebetween;a pair of arms, each arm connected to a corresponding one of the rigid frame portions; anda pair of lenses, each lens connected to an exposed surface of the corresponding rigid frame portion.

2. The flexible eyewear of claim 1 , wherein the rigid frame portions each extend from the flexible bridge portion to connection points with the corresponding arm.

3. The flexible eyewear of claim 2, wherein the connection points include hinges.

4. The flexible eyewear of claim 3, wherein a first part of the hinge is provided at a distal end of the rigid frame portion and a second part of the hinge is coupled to the corresponding arm.

5. The flexible eyewear of claim 4, wherein the second part of the hinge is coupled to a flexible arm portion, the flexible arm portion being connected at a distal end to a rigid arm portion.

6. The flexible eyewear of claim 1 , wherein each rigid frame portion includes at least one surface detail to interface with the flexible material.

7. The flexible eyewear of claim 6, wherein the surface detail includes contouring.

8. The flexible eyewear of claim 6, wherein the surface detail includes at least one aperture through the rigid frame portion.11CPST Doc: 1385-4088-3229.

19. The flexible eyewear of claim 1 , further comprising a nose piece.

10. The flexible eyewear of claim 9, wherein the nose piece includes a pair of nose pads each coupled to a respective one of the rigid frame portions and coupled to each other via a flexible connector.

11. The flexible eyewear of claim 1 , wherein each lens comprises a notch, a protrusion, or a notch and a protrusion to secure the lens into a channel in the exposed surface.

12. The flexible eyewear of claim 1 , further comprising a flexible bar extending between the frame portions and being embedded in the flexible bridge portion.

13. The flexible eyewear of claim 1 , further comprising at least one notch or groove in one or more of the rigid frame portion or the lens to provide venting.12CPST Doc: 1385-4088-3229.1

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