CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Application No. 63/155548, filed on March 2, 2021, which is incorporated herein by reference in its entirety.

BACKGROUND

[0002] Embodiments of the disclosure relate to materials formed from renewable resources, and more particularly, to goods that are formed using these renewable materials.

[0003] Polyesters such as polyethylene terephthalate (PET) and polyolefins such as polypropylene (PP) are two commonly used classes of petroleum based polymers in the commercial production of textile fibers, packaging films, beverage bottles, and injection molded goods. The manufacture of such materials and the goods formed from such materials has a detrimental affect on the environment. The manufacture of such synthetic materials is responsible for global greenhouse gas emissions, and decomposition of synthetic material in a landfill can take up to 200 years while leaching toxins into the adjacent soil and groundwater.

[0004] Accordingly, there is a need to develop and manufacture goods using a renewable eco-friendly material.

BRIEF DESCRIPTION

[0005] According to an embodiment, a block of a set of toy building blocks has a solid body including at least one planar exterior surface. The body is formed from a non- woven material including natural occurring fibers.

[0006] In addition to one or more of the features described above, or as an alternative, in further embodiments the non-woven material is formed solely from naturally occurring fibers.

[0007] In addition to one or more of the features described above, or as an alternative, in further embodiments the non-woven material includes a filler material.

[0008] In addition to one or more of the features described above, or as an alternative, in further embodiments the non-woven material includes a single type of naturally occurring fibers.

[0009] In addition to one or more of the features described above, or as an alternative, in further embodiments the naturally occurring fibers are wool from a sheep. [0010] In addition to one or more of the features described above, or as an alternative, in further embodiments the non-woven material includes a plurality of layers of naturally occurring fibers, wherein the plurality of layers are stacked on top of one another and compressed.

[0011] In addition to one or more of the features described above, or as an alternative, in further embodiments the non-woven material includes a plurality of layers of naturally occurring fibers, wherein the plurality of layers are mechanically bonded.

[0012] In addition to one or more of the features described above, or as an alternative, in further embodiments the solid body formed from the non-woven material is semi-rigid.

[0013] According to another embodiment, a pair of eyeglasses includes a body including a frame having a first rim, a second rim connected to the first rim, and two arms extending from opposite ends of the frame. Each of the first rim and the second rim is configured to receive a lens. At least a portion of the body is formed from a non-woven material including solely naturally occurring fibers.

[0014] In addition to one or more of the features described above, or as an alternative, in further embodiments at least a portion of the frame is formed form the non-woven material.

[0015] In addition to one or more of the features described above, or as an alternative, in further embodiments at least a portion of one off the arms is formed form the non-woven material.

[0016] In addition to one or more of the features described above, or as an alternative, in further embodiments the non-woven material includes a single type of naturally occurring fibers.

[0017] In addition to one or more of the features described above, or as an alternative, in further embodiments the naturally occurring fibers are wool from a sheep.

[0018] In addition to one or more of the features described above, or as an alternative, in further embodiments the non-woven material includes a plurality of layers of naturally occurring fibers, wherein the plurality of layers are stacked on top of one another and compressed.

[0019] In addition to one or more of the features described above, or as an alternative, in further embodiments the non-woven material includes a plurality of layers of naturally occurring fibers, wherein the plurality of layers are mechanically bonded.

[0020] In addition to one or more of the features described above, or as an alternative, in further embodiments the solid body formed from the non-woven material is semi-rigid. [0021] In addition to one or more of the features described above, or as an alternative, in further embodiments the solid body formed from the non-woven material is rigid.

[0022] In addition to one or more of the features described above, or as an alternative, in further embodiments a structural rigidity of the non-woven material is about equal to or greater than a rigidity of a plastic selected from polyamide, nylon, polycarbonate, carbon, Optyl, zylonite, acetate, and cellulose acetate.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The following descriptions should not be considered limiting in any way.

With reference to the accompanying drawings, like elements are numbered alike:

[0024] FIGS. 1 A- 1C are perspective views of various toy building according to an embodiment; and

[0025] FIG. 2 is a plan view of a piece of non-woven material and the building blocks to be formed therefrom according to an embodiment; and

[0026] FIG. 3 is a perspective view of a pair of glasses according to an embodiment.

DETAILED DESCRIPTION

[0027] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

[0028] Renewable resources, such as naturally occurring fibers for example, may be used to form an ecologically conscious material. In an embodiment, such a material formed solely from naturally occurring fibers or fur/hair may be manufactured to form a variety of products including, toys, personal accessories, and housewares. As a result, such an eco- friendly material would also be bio-degradable. However, it should be understood that embodiments where the eco-friendly material includes one or more filler materials that are not naturally occurring, and therefore the material may not be bio-degradable, are also within the scope of the disclosure. Examples of naturally occurring fibers used to form an eco- friendly material include but are not limited to animal fibers (such as wool or silk), mineral fibers, and vegetative or plant-based fibers (such as rubber, cotton, and sisal). The material may consist of a single type of fiber, or alternatively, of a mixture of types of fibers.

[0029] When a mixture of fibers is used, the fibers may have similar or different characteristics. In an embodiment, the material described herein is formed entirely from animal fibers, and more specifically from wool. The wool may be derived from a single type of animal, such as sheep, or may be from a variety of animals, such as sheep, goats, and alpaca. In an embodiment, the wool is taken from sheep located in the United States, such as sheep local or native to New England or the north eastern region of the United States. In another embodiment, the wool is taken from sheep local or native to Australia or New Zealand. Further, the fibers may be provided from a single breed of each type of animal, or alternatively, from a variety of breeds within each species. However, it should be understood that embodiments where the material is a mixture or combination of different types of naturally occurring fibers, such as including both animal and plant fibers, animal and mineral fibers, plant and mineral fibers, or animal, plant, and mineral fibers are also within the scope of the disclosure.

[0030] The eco-friendly material described herein may be considered a “non-woven” material because the fibers within the material are mechanically bonded to one another. Accordingly, no additional material, such as an interlocking thread or resin for example, is required to affix the fibers to one another. To form the material, the plurality of fibers are arranged in sheets or layers. These individual layers are then arranged in an overlapping relationship, such as stacked on top of one another for example. In an embodiment, to mechanically bond the fibers of the multiple fiber layers together to form a single unitary body of material, the fiber layers may be compressed, such as via the application of one or more of pressure, heat, and moisture. When compressed, the fibers within the different layers penetrate and entangle with one another. Alternatively, or in addition, the fibers may be mechanically bonded by penetrating the one or more of the fiber layers with one or more barbed needles. The repeated insertion of these needles causes the fibers of the different layers to intertwine or entangle, thereby creating a nonwoven fabric or material.

[0031] The total number and the configuration of the stacked fiber layers may be customized to achieve an eco-friendly material having a specific size and shape. Alternatively, or in addition, the properties associated with the mechanical bonding process, such as the temperature or the pressure applied for example, may be adjusted to achieve a material having a specific size, shape, density, weight, structural rigidity or other property. The properties of the fiber layers, such as density and weight for example, may be generally uniform or may vary between layers, or alternatively, may be generally uniform or constant within a layer or may vary within a layer. In an embodiment, the formed eco-friendly material is semi-rigid or rigid and therefore limited or no movement or deformation of the material occurs when a force is applied thereto. At least one of the density and weight of the fibers used to form the eco-friendly material is selected to achieve a desired hardness. In an embodiment, the hardness or structural rigidity of the eco-friendly material formed from the natural fibers is comparable to a wood, such as a hard wood for example, or a plastic material. For example, the structural rigidity of the eco-friendly material may be about 32 pounds per square yard at a one-inch thickness. In addition, prior to or after formation of the material, a dye may be applied to the fibers to achieve a material having a desired color.

[0032] In an embodiment, the eco-friendly material described herein may be used to manufacture one or more toy building blocks, such as a collection or set of building blocks for example. The toy building blocks within the set may be substantially identical in size and/or shape, or alternatively, may vary in size and shape. With reference to FIGS. 1A-1C, examples of various building blocks 20 that may be formed from the eco-friendly material are illustrated. The body of each of the one or more blocks 20 may be cubic, rectangular, conical, frustoconical, pyramidic, rhomboid, triangular, spherical, cylindrical, arcuate, or polygonal in shape. In an embodiment, each of the plurality of blocks 20 is a polyhedron. However, a building block 20 having any suitable shape is within the scope of the disclosure. Further, each of the plurality of blocks is connectable or stackable with another of the blocks of the set. In such embodiments, each of the plurality of blocks may have at least one generally planar surface arrangeable in contact with a planar surface of another of the plurality of blocks. However, blocks having other features, such as projections and grooves for example, for forming connections between adjacent blocks are also contemplated herein.

[0033] In an embodiment, each of the building blocks is formed from a substantially solid body of compressed eco-friendly material as described herein. To form each of the toy building blocks, the eco-friendly material may be formed via compression into a substantially final shape of one of the blocks. For example, the stacked fiber layers may vary in size such that when compressed, the fibers are formed into a generally conical or triangular shape. Alternatively, as shown in FIG. 2, the eco-friendly material may be formed into a large three dimensional shape, such as a rectangular slab 30. In an embodiment, the slab or piece 30 of formed eco-friendly material has at least one dimension greater than a corresponding dimension of one of the toy building blocks 20. In such embodiments, one or more building blocks 20 may be formed via a cutting operation, for example via punching or stamping, applied to a single piece or slab 30 of material. In embodiments where several building blocks 20 are formed from a single piece of eco-friendly material 30, the plurality of blocks may be the same, or alternatively, may be different, as shown in FIG. 2. In an embodiment, an entire set of building blocks 20 may be formed from a single piece 30 of the formed eco- friendly material. The eco-friendly material used to fabricate the blocks 20 is sufficiently rigid to support the weight of several additional blocks 20 stacked thereon without deforming.

[0034] In another embodiment, the eco-friendly material may be used to form at least a portion of a pair of eyeglass. With reference to FIG. 3, an example of a pair of eyeglasses 40 is illustrated. Although the glasses illustrated in FIG. 3 are eyeglasses, it should be understood that any suitable form of optical glasses or eyewear, such as a sunglasses for example are also contemplated herein. As shown, a body of the eyeglasses 40 includes a frame 42 having two rims 44, each configured to receive a lens therein, and a bridge 46 connecting the two rims 44 to one another. Two arms or temples 48 extend in the same direction from opposite ends of the frame 42. The temples 48 are hingedly connected to a respective endpiece of the frame 42 via a screw or other fastener. In an embodiment, at least a portion of the frame 42, such as a rim 44 or the bridge 46 for example, is formed from the eco-friendly material. In an embodiment, the frame 42 is formed as a single unitary body made of the eco-friendly material. Alternatively, or in addition, one or more of the temples 48 may be formed the eco-friendly material. In such embodiments, the eco-friendly material used to form at least a portion of the glasses 40 has a structural strength or rigidity comparable to the typical materials used to form glasses, such as thin metal, wood, or plastic, such as polyamide, nylon, polycarbonate, carbon, Optyl, zylonite, acetate, and cellulose acetate for example.

[0035] The various goods described herein that are formed from a sustainable non- woven material of naturally occurring fibers. As a result, the goods are both non-toxic and eco-conscious.

[0036] The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application.

[0037] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof. [0038] While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.